Film and method for molding

Abstract

To provide a membrane and a method for molding.SOLUTION: There is provided a reusable molding membrane (100) that forms an external mold during a process of encapsulating a target object (102) in a material. The membrane includes a cylindrical membrane body (104) including an elastically deformable material and an inner diameter (202) of the cylindrical membrane body (104) is smaller than an outer diameter (302) of the target object provided on an outer surface (106) of a cylindrical carrier body (108) when the membrane body (104) is in an undeformed state. The membrane further includes a plurality of manipulation structures (110, 910) provided on an outer portion (112) of the membrane body (104), and each of the manipulation structures (110, 910) is configured to be manipulated by applying mechanical force. A space inside the membrane body (104) can be controlled by controlling the amount of deformation of the membrane body (104), There is also provided a method for use during a process to encapsulate a target object in a material.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present application relates to membranes used in molding and methods used during the process of encapsulating a target object. [Background technology]

[0002] A variety of techniques can be used to mold the target object. In some instances, a rigid molding tool (or mold tool) can be used. For example, a molding tool can be used that defines an interior space to provide the desired space for the object to be molded. In some instances, molding techniques can be used to coat or encapsulate the target object in a substance, such as a resin. In these applications, it may be desirable for the molding tool to fit tightly around the target object.

[0003] In some instances, a portion of the forming tool may be formed from a flexible material to achieve a tight fit. For example, the target object may be placed on a rigid surface. The rigid surface may provide a platform for the forming process. The flexible material may then be deployed to fit tightly over the target object and conform to the shape of the target object. However, those skilled in the art will appreciate that achieving a tight fit that matches the shape of the target object may be difficult to achieve and / or deploying the flexible material may be labor intensive, time consuming, and / or may need to be done manually. The flexible material may be difficult to remove without affecting the material encapsulating the target object. Typically, the flexible material is discarded after the encapsulation process. Summary of the Invention [Problem to be solved by the invention]

[0004] It is an object of the present application to provide a convenient and efficient structure and method for molding encapsulation of a target object within a substance. [Means for solving the problem]

[0005] In a first aspect of the present invention, a reusable molding membrane for forming an external mold during a process of encapsulating a target object in a substance is provided. The molding membrane includes a cylindrical membrane body including an elastically deformable material, and when the membrane body is in a non-deformed state, the inner diameter of the cylindrical membrane body is smaller than the outer diameter of the target object provided on the outer surface of a cylindrical carrier body. The molding membrane further includes a plurality of control structures provided on an outer portion of the membrane body, and each of the control structures is configured to be controlled by applying a mechanical force, so that the amount of deformation of the membrane body can be controlled to control the internal space of the membrane body.

[0006] Optionally, one or more of the plurality of manipulation structures include an elongated through-hole configured to receive an elongated manipulation member and exert a force on an end of the elongated manipulation member in a direction perpendicular to the central longitudinal axis, thereby deforming the membrane body proximate the respective manipulation structure.

[0007] Optionally, one or more of the plurality of operating structures include: an embedded operating member embedded within the membrane body; and one or more mounting structures attached to the embedded operating member so as to protrude from the membrane body in a direction away from the central longitudinal axis of the membrane body.

[0008] Optionally, one or more of the multiple operating structures having embedded operating members are each configured to exert a force on one or more mounting structures of each embedded operating member in a direction perpendicular to the central longitudinal axis to deform the membrane body adjacent the respective operating structure.

[0009] Optionally, a first seal structure (or seal arrangement) is provided toward a first end of the molding membrane, the first seal structure being configured to form a seal against a carrier body disposed within the membrane body.

[0010] Optionally, a second seal structure is provided towards a second end of the forming membrane, the second seal structure being configured to form a seal against a carrier body disposed within the membrane body.

[0011] Optionally, the membrane body includes a flange towards the first end, the flange extending inwardly within the membrane body, the first seal formation being provided on the flange.

[0012] Optionally, towards an innermost end of the flange, there is included a rigid base structure connected with the flange.

[0013] Optionally, a first alignment feature is provided configured to engage with a second alignment feature such that a rotational positioning of the shaping film is fixed about the central longitudinal axis relative to the carrier body.

[0014] Optionally, it includes a reservoir structure provided towards the second end of the molding membrane for introducing a substance for encapsulation.

[0015] Optionally, each of the plurality of handling structures includes a handling structure fiber reinforcement, the handling structure fiber reinforcement being molded into each handling structure.

[0016] Optionally, the membrane body includes fiber reinforcement of the membrane body to limit the amount of deformation of the membrane body.

[0017] In a second aspect of the present invention, a method for use during a process of encapsulating a target object in a substance is provided, the method comprising a reusable molding film for forming an outer mold, the reusable molding film comprising a cylindrically shaped film body comprising an elastically deformable material, the inner diameter of the cylindrically shaped film body being smaller than the outer diameter of the target object provided on the outer surface of a cylindrically shaped carrier body when the film body is in a non-deformed state, and a plurality of manipulation structures provided on an outer portion of the film body, each of the plurality of manipulation structures being configured to be manipulated by applying a mechanical force, such that the amount of deformation of the film body can be controlled to control the internal space of the film body. The method includes providing a target object on an outer surface of a carrier body; manipulating a plurality of operating structures to deform the cylindrically-shaped membrane body to increase an internal space of the cylindrically-shaped membrane body so that the target object provided on the carrier body is accommodated within the internal space of the cylindrically-shaped membrane body; inserting the target object provided on the carrier body into the internal space of the cylindrically-shaped membrane body; and manipulating the plurality of operating structures to shrink the membrane body onto the target object so that an external mold that fits closely onto the target object is formed.

[0018] Optionally, manipulating a given one of the plurality of manipulating structures to adjust an external molding on the target object proximate the given manipulating structure.

[0019] Optionally, introducing a substance between the outer mold formed by the molding film and the inner mold formed by the carrier body; and applying a vacuum to seal the molding film to the carrier body, thereby sealing the target object between the molding film and the carrier body. Hereinafter, embodiments related to the present invention will be described with reference to the accompanying drawings. [Brief description of the drawings]

[0020] [Figure 1] FIG. 1 is a first schematic perspective view of a reusable molding membrane according to a first set of embodiments. [Diagram 2]FIG. 2 is a schematic plan view of a reusable molding membrane according to a first set of embodiments in a first state according to the embodiment. [Diagram 3] FIG. 3 is a schematic plan view of a reusable molding membrane according to a first set of embodiments in a second state according to the embodiment. [Figure 4] FIG. 4 is a second schematic perspective view of a reusable molding membrane according to the first set of embodiments. [Diagram 5] FIG. 5 is a side cross-sectional view of a first main part of a first operating structure according to an embodiment. [Figure 6] FIG. 6 is a schematic plan view of a main part of a first operating structure according to the embodiment. [Figure 7] FIG. 7 is a side cross-sectional view of a second main portion of the first operating structure according to the embodiment. [Figure 8] FIG. 8 is a side cross-sectional view of a third main portion of the first operating structure according to the embodiment. [Figure 9] FIG. 9 is a schematic cross-sectional side view of a main part of a second operating structure according to the first combination of embodiments. [Figure 10] FIG. 10 is a schematic front cross-sectional view of a first main part of a second operating structure according to a first combination of embodiments. [Figure 11] FIG. 11 is a schematic plan cross-sectional view of a second main part of a second operating structure according to the first combination of embodiments. [Figure 12] FIG. 12 is a schematic cross-sectional plan view of a portion of a reusable molding membrane according to a first combination of embodiments. [Figure 13] FIG. 13 is a schematic perspective view of a reusable molding membrane according to a second combination of embodiments. [Figure 14] FIG. 14 is a flow diagram illustrating a method used during the process of encapsulating a target object. [Figure 15] FIG. 15 is a schematic perspective view of a reusable molding membrane according to a third combination of embodiments. [Figure 16] FIG. 16 is a schematic perspective view of a reusable molding membrane according to a fourth combination of embodiments. [Figure 17] FIG. 17 is a schematic perspective cross-sectional view of a reusable molding membrane according to a fifth combination of embodiments. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] This application relates to a reusable molding membrane, e.g., a mold membrane that is reusable so that it can be applied to multiple molding processes for which it is intended to be used.

[0022] With reference to the attached figures, in these embodiments a reusable shaping film 100 is provided to form an external mould during the process of encapsulating a target object 102 in a substance. The shaping film 100 comprises a cylindrical (or columnar) shaped film body 104. The cylindrical shaped film body 104 (hereinafter also simply referred to as film body for the sake of simplicity) comprises an elastically deformable material, whereby when the film body 104 is in a non-deformed state, an inner diameter 202 of the cylindrical shaped film body 104 is smaller than an outer diameter 302 of a target object provided on an outer surface 106 of a cylindrical shaped carrier body (or carrier body) 108. In this example, the molding membrane can have a plurality of control structures 110, 910 provided on the outer portion 112 of the membrane body 104, each of which is configured to be controlled by applying a mechanical force, thereby controlling the amount of deformation of the membrane body 104 and thereby controlling the internal space of the membrane body 104.

[0023] 1-13 and 15-17 show examples of molding membranes 100 that illustrate various different features. However, molding membranes 100, including examples that provide the above features, are not limited to the specific examples shown and described below. Those skilled in the art will appreciate other various ways in which the above features may be specifically applied. It should be noted that for ease of illustration, not all features are shown and / or numbered in each of the figures. Rather, the figures are simplified and schematic, and specific figures may be used to illustrate examples of features.

[0024] FIG. 1 is a schematic perspective view illustrating a reusable molding film 100 according to some embodiments. In these embodiments, the reusable molding film 100 allows for the formation of an external mold during a process of encapsulating a target object 102. In these embodiments, a target object 102 is provided on an outer surface 106 of a cylindrical carrier body 108. For example, the cylindrical carrier body 108 serves as an internal mold during the encapsulation process. In some embodiments, the encapsulation process is a process in which a substance is molded between the internal and external moldings and the surface of the target object 102 to encapsulate the target object 102. For example, the encapsulation process may include fitting the external mold onto the target object 102, introducing a substance to cover the target object 102, and a curing process to, for example, harden the substance on the target object 102.

[0025] The outer surface 106 of the carrier body 108 refers to, for example, the cylindrical outwardly facing surface defined by the cylindrically shaped carrier body 108. In other words, the outer surface 106 is the surface of the carrier body 108 that faces away from the central longitudinal axis (or central longitudinal axis) of the cylindrically shaped carrier body 108. It should be noted that when the carrier body is inserted into the molding film, the central longitudinal axes of the molding film and the carrier body will be more or less aligned. Thus, reference may be made herein to the position and orientation of components of the carrier body relative to the central longitudinal axis 114 of the molding film.

[0026] The target object may be any type of object that can be placed on the cylindrical carrier body 108 for encapsulation during the molding process. In some examples, the target object is a coil, which can be used as a magnet, wrapped around the cylindrical carrier body 108. In some examples, the target object is a coil for a rotor winding of a motor or generator.

[0027] It should be noted that the material encapsulating the target object 102 may be, for example, a resin. For example, a thermosetting resin such as polyester, polyurethane, vinyl ester, or epoxy may be used. For example, depending on the application, it may be desirable to encapsulate a coil that can be used as a magnet in the resin. In some examples, the encapsulated coil may be large, for example, having a size suitable for use in magnetic resonance imaging (MRI). In other examples, the reusable molding film 100 may be used as an external molding in connection with other target objects. For example, the molding film examples disclosed herein may be used when a tight-fitting external molding is desired for any target object that can be provided on a cylindrical carrier body.

[0028] It may be desirable to provide a coating of a material on the target object having a relatively consistent thickness while avoiding material-rich regions. In embodiments involving a resin encapsulating a coil, it may be desirable to have a consistent coating of resin on the coil and avoid resin-rich regions. For example, a resin-rich region may be an area where there is more resin than other areas of the surface of the target object 102. For example, it may be desirable for the coating from the encapsulation process to have a relatively consistent thickness (within acceptable or practical tolerances) on all surfaces of the target object 102. For example, when the coil is energized to generate a magnetic field, the resin-rich regions may crack and / or rob the coil of energy, which may have undesirable effects on the application in which the coil is being used. Also, for example, by providing a coating with a relatively consistent thickness while avoiding material-rich regions, consumption of the material may be reduced. This reduced consumption may be significant depending on the application. Also, for example, avoiding material-rich areas can reduce the time required to complete the encapsulation process by eliminating the need to remove excess amounts of material from the encapsulated target object after curing.

[0029] To achieve a consistent coating of material (e.g., resin) onto the target object (e.g., coil) 102 while avoiding material-rich regions, the mold (or form) used may be required to fit closely onto the target object. Thus, in the embodiments described herein, a tight-fitting external mold is advantageously provided.

[0030] The term "cylindrical" is used herein. A component described as cylindrical may have a circular cross-section in cross section. However, the cross-section is not limited to this shape. In some embodiments, the cross-section may be elliptical. For example, a cross-section taken perpendicular to the central longitudinal axis of the described cylindrical shape may be elliptical. As described herein, a cylindrical shape having a circular cross-section may be a special case of a general cylindrical shape, and is not limited to a circular cross-section.

[0031] In some embodiments, the membrane body 104 has an open cylindrical shape. In some embodiments, the membrane body 104 includes one or more flanges, as described below. In the described embodiments, the membrane body 104 includes an elastically deformable material. For example, the membrane body 104 can include an elastomer, such as silicone. In some embodiments, the membrane body 104 can include latex, nitrile rubber, polyurethane, or vinyl. FIG. 2 is a schematic plan view of a molding membrane 100 according to an embodiment. In the orientation shown in FIG. 2, the central longitudinal axis 114 of the molding membrane 100 is oriented into the page and is represented by a cross at the end of the arrow to indicate the direction. In these embodiments, the inner surface of the membrane body 104 has a circular cross section. In the embodiment of FIG. 2, the membrane body 104 is in an undeformed state (or non-deformed state). The inner diameter of the membrane body 104 in the non-deformed state is illustrated by a double arrow 202. In these embodiments, the inner diameter 202 is smaller than the outer diameter of the target object 102 disposed on the outer surface 106 of the carrier body 108. Thus, in these embodiments, the target object 102 disposed on the outer surface 106 of the carrier body 108 does not fit within the inner space (defined by the inner diameter 202) of the membrane body 104 in its non-deformed state. However, for example, a target object 102 provided as described may be fitted into the membrane body 104 if deformation occurs in the membrane body 104 such that the space therein is increased.

[0032] Fig. 3 is a schematic plan view of a molding film 100 and a target object 102 according to an embodiment. Fig. 3 illustrates the target object 102 on the outer surface 106 of a cylindrical carrier body 108, which is inserted into the inner space of the film body 104 in a deformed state according to an embodiment. For simplicity, in Fig. 3, the target object 102 and the carrier body 108 are illustrated diagrammatically as a circle with the reference number 102. As is obvious, the target object 102 is held on the outer surface 106 of the carrier body 108. The schematic perspective view of Figure 4 shows a target object 102 mounted on the outer surface 106 of a cylindrical carrier body 108 according to the embodiment when it is inserted into the internal space of the membrane body 104, where the membrane body 104 is maintained in a deformed state according to the embodiment.

[0033] The outer diameter of the target object 102 disposed on the outer surface 106 of the carrier body 108 is illustrated by the double-headed arrow at reference numeral 302. For example, the membrane body 104 may be deformed to increase the space therein, as described below, to allow for the accommodation of a target object 102 having a larger outer diameter 302.

[0034] In these embodiments, the forming membrane 100 includes a plurality of first control structures 110. The first control structures 110 are specific examples of applicable control structures, and further examples are described below. The first control structures 110 are provided on the outer portion 112 of the membrane body 104. For example, the outer portion 112 is a cylindrical outer surface defined by the cylindrical membrane body 104. In other words, the outer portion 112 is a surface of the membrane body 104 facing away from the central longitudinal axis 114. In these figures, only a portion of the first control structures 110 are labeled with reference numbers. However, in these embodiments, it is clear that a plurality of first control structures 110 are provided around the outer portion 112. In these embodiments, the number of control structures can be varied. In some embodiments, three or more first control structures 110 may be provided. For example, eight first control structures 110 may be provided around the outer portion 112.

[0035] The first manipulation structure 110 may comprise a resiliently deformable material that is integral with the remainder of the membrane body 104 and protrudes from the outer portion 112 in a direction away from the central longitudinal axis 114 .

[0036] In these embodiments, each of the plurality of first manipulation structures 110 is configured to be manipulated by applying a mechanical force (or load) to control the amount of deformation of the membrane body 104, and thus the volume within the membrane body 104. For example, the first manipulation structures 110 provide a structure that can exert a force on the membrane body 104 to deform the membrane body 104. For example, the first manipulation structures 110 are locations where a mechanical force is applied to the manipulation structure 110 in question to deform a local membrane body 104 region.

[0037] 3, in these embodiments, a force is applied to each of the first manipulation structures 110 in a direction perpendicular to and away from the central longitudinal axis 114 (see arrows originating from each of the first manipulation structures 110 in FIG. 3). As a result of the force being applied to each of the first manipulation structures 110, the membrane body 104 is deformed, increasing the space within the membrane body 104. The creation of more space within the membrane body 104 allows the target object 102 having the outer diameter 302 to be accommodated therein.

[0038] The first manipulation structure 110 may take on a variety of different configurations to deform the membrane body 104 in the manner described herein. Some exemplary manipulation structures (e.g., the first manipulation structure 110 of several examples) are described below. However, one of ordinary skill in the art will recognize other types of structures that enable the described functionality.

[0039] In some embodiments, one or more of the plurality of control structures are provided with an elongated through hole. In the illustrated example of the through hole, the through hole extends in a direction substantially parallel to the central longitudinal axis 114 of the cylindrical shaped membrane body 104 in the undeformed state. For example, the first control structure 110 includes an elongated through hole. Other examples of control structures may not include a through hole, as described below with respect to Figures 9-11. 1-8 relate to embodiments of the first manipulation structure 110 with a through hole. In these embodiments, the first manipulation structure 110 includes an elongated through hole 204 as shown. In other words, in these embodiments, the elongated through hole extends in the same direction as the central longitudinal axis 114 in the undeformed state. It should be understood that the term "substantially parallel" as used herein includes the elongated through hole generally (e.g., to some extent) extending in the same direction as the central longitudinal axis 114, but does not require the elongated through hole to be strictly parallel to the central longitudinal axis 114. In other embodiments, not all of the manipulation structures of the forming membrane 100 need to be first manipulation structures 110 with a through hole. 5 is a side cross-sectional view of a main part of the first operating structure 110 according to the embodiment. In the embodiment of FIG. 5, a cross section across the through hole 204 of the first operating structure 110 is illustrated.

[0040] In some embodiments, the through-hole 204 is configured to receive the elongated operating member 502 therein such that application of a force to an end of the elongated operating member 502 in a direction perpendicular to the central longitudinal axis 114 causes a deformation of the membrane body 104 adjacent to the corresponding first operating structure 110. Note that application of the force to a component parallel to the central longitudinal axis 114 is not excluded. During the uses described herein, the component of the force perpendicular to the central longitudinal axis 114 is associated with a deformation that affects the internal space of the membrane body 104. Thus, the present description focuses on forces perpendicular to the central longitudinal axis 114.

[0041] In the embodiment of FIG. 5, the elongated operating member 502 includes an operating member first end 502a and an operating member second end 502b. In these embodiments, the elongated operating member 502 extends beyond the through-hole 204. For example, the elongated operating member 502 may be received within the through-hole 204 such that the operating member first end 502a and the operating member second end 502b protrude from the through-hole 204. In these embodiments, each of the ends 502a, 502b is connected to an actuation mechanism 504. For simplicity, the actuation mechanism 504 is illustrated simply as a component that connects with the operating member first and second ends 502a, 502b. For example, the elongated operating member 502 may be provided in the form of a pin. The pin ends 502a, 502b may be connected to the actuation mechanism 504 using a variety of different means, as would be understood by one of ordinary skill in the art.

[0042] The actuation mechanism 504 may be any actuation mechanism capable of providing a mechanical force that can act on the elongated manipulation member 502. For example, the actuation mechanism may include an electronic actuation system (e.g., an electric motor). The actuation mechanism may include a pneumatic actuation system. The actuation mechanism may include a hydraulic system. The actuation mechanism may include a mechanical actuation system, and the like. In some embodiments, the actuation mechanism 504 may include a combination of these systems. For example, a mechanical system may be used to open and close the molding membrane as a whole (e.g., to form a space inside the molding membrane for inserting the target object 102 and the carrier body 108), and pneumatic actuators may be applied to individual manipulation structures (e.g., to manipulate localized areas of the membrane body 104). It should be understood that the type of actuation mechanism used may be based on the size of the membrane body 104, the amount of force required to deform the membrane body 104, and the like. For example, one embodiment of the membrane body 104 suitable for use in enclosing a magnetic coil for MRI imaging may be large and may require a relatively large force to produce the desired amount of deformation, and in some such embodiments, a hydraulic actuation system may be appropriate.

[0043] The actuation mechanism 504 may be automatically controlled. For example, the actuation mechanism 504 may be controlled without manual intervention from a user (e.g., other than a user inputting control commands to a control system of the actuation mechanism 504). For example, the actuation mechanism 504 may be computer controlled, with control signals input from the computer to the actuation mechanism 504. In some embodiments, the actuation mechanism 504 may be configured to exert a mechanical force on all associated control structures. In such examples, the actuation mechanism 504 may be configured to apply forces independently to each of the control structures, such that each control structure is independently controllable. In some embodiments, a separate actuation mechanism is provided for each control structure for independent control.

[0044] Thus, the various manipulation structures may be automatically controlled. The various manipulation structures may be independently manipulated and may deform localized areas of the membrane body 104. This advantageously allows a high level of control over the membrane body 104 and how it forms an external mold on the target object 102. Furthermore, automating the manipulation of the membrane body 104 allows for more efficient savings (e.g., in terms of time and effort required by the user) compared to, for example, using a flexible mold with manual manipulation. For example, avoiding manual manipulation allows for consistent and repeatable results. The automation also allows manipulation at different stages of the encapsulation process, for example, allowing things that would not be possible if manual manipulation was relied upon. For example, the automation using the manipulation structures may be applied inside a chamber (e.g., an autoclave or autoclave) that would not be possible with manual manipulation. The manipulation structures also allow the shaped membrane 100 to be removed after the molding process is completed to encapsulate the target object 102. For example, the controlled manipulation enabled by the above-described molding film 100 allows for the molding film 100 to be removed in a controlled manner without undesirably significantly disturbing the encapsulated target object 102. Additionally, controlled removal may avoid damage to the molding film, the cured material, and / or the target object. The above-described embodiments of the molding film 100 provide a molding film 100 that is reusable.

[0045] Returning to the embodiments of the first control structure 110, in these embodiments, the membrane body 104 is deformed by applying forces to the ends 502a, 502b of the elongated control member 502 in a direction perpendicular to the central longitudinal axis 114 and away from the central longitudinal axis 114, so that a layer of space is created in the membrane body 104. For example, the portion of the membrane body 104 near the first control structure 110 in question is deformed when the elongated control member 502 pulls the first control structure 110 away from the central longitudinal axis 114. See, for example, Figures 3 and 4. In the orientation illustrated in Figure 5, the central longitudinal axis is located to the right of the first control structure 110.

[0046] In these embodiments, for example as illustrated in Figs. 3 and 4, a force is applied to the respective first manipulation structure 110 to stretch the membrane body 104, allowing the insertion of the target object 102 disposed on the carrier body 108 into the internal space of the membrane body 104. Once the target object 102 is positioned within the membrane body 104 as desired, the manipulation structure can be manipulated (e.g., the force applied to the elongated manipulation member 502 is reduced) to cause the membrane body 104 to contract on the target object 102. In these embodiments, when stretched, an elastic force is generated that urges the membrane body 104 to return to its undeformed state. For example, when the force applied by the actuation means 504 is reduced or removed in a direction away from the central longitudinal axis 114, this results in the membrane body 104 contracting. This elastic force causes the membrane body 104 to fit tightly on the target object. In these embodiments, the inner diameter of the membrane body in its undeformed state may be selected to provide an appropriate elastic force to allow the membrane body 104 to fit closely against the desired target object 102 .

[0047] In some embodiments, a force may be applied to the first manipulation structure 110 in a direction toward the central longitudinal axis 114. Such a force may aid in forming a tight fit with the desired target object 102. In some embodiments, a combination of forces away from and toward the central longitudinal axis 114 may be used to adjust the membrane body 104 as desired.

[0048] Providing a membrane that is elastically deformable to form a tight fit is advantageous because, for example, it allows the tight fit to be achieved independently of variations in the size of the target object 102. For example, if a molding membrane having a particular outer diameter 302 is intended for use with the target object 102, the exact outer diameter 302 may vary depending on the procedure for mounting the target object 102 on the carrier body 108. For example, in some embodiments, the target object 102 may have a larger or smaller outer diameter compared to other embodiments. In embodiments in which the target object 102 is a coil, there may be some variation in the outer diameter as the coil is wrapped around the carrier body. However, the inner diameter 202 and deformation characteristics of the membrane body 104 may be selected to accommodate such variations. In this way, the same membrane body 104 may be used to consistently form a tight fit on multiple target objects of some variation in size. A rigid / hard external molding cannot accommodate such variations, whereas the flexible molding membrane described herein can accommodate a tight fitting external molding despite such variations in outer diameter 302.

[0049] In some embodiments, a given embodiment of the reusable molding membrane 100 can be used to form molds on target objects of different desired sizes (e.g., may have a variety of different outer diameters 302 by design) because the membrane body 104 can deform and then shrink onto the target object to form a tight-fitting external mold within the outer diameter 302 (e.g., within a reasonable range based on the elasticity and other parameters of the reputable deformable material).

[0050] Moreover, the membrane body 104 described above can advantageously form a tight fit in all relevant areas of the target object, regardless of local variations in its size and shape. For example, when the membrane body 104 contracts, the elastically deformable material of the membrane body 104 can reach into local gaps in the target object 102. This is particularly advantageous in embodiments in which the coil is wound around the carrier body 108.

[0051] The above are examples of some of the many advantages of these embodiments.

[0052] Returning to the embodiment of FIG. 5, in some embodiments, a force may be applied differently to one end of the elongated operating member 502 compared to the other end. For example, more force may be applied by the actuation mechanism 504 to the first end 502a of the operating member compared to the second end 502b of the operating member. FIGS. 7 and 8 are schematic cross-sectional views of a portion of the first operating structure 110 according to an embodiment. FIG. 7 illustrates the membrane body 104 in an undeformed state. In this case, arrow 602 illustrates a force applied to the first end 502a of the elongated operating member 502 to move the membrane body 104 from the undeformed state illustrated in FIG. 7 to the deformed state illustrated in FIG. 8. In these embodiments, for simplicity, the actuation mechanism 504 is not illustrated. In these embodiments, no force is applied to the second end 502b of the elongated operating member 502. Thus, in these embodiments, the second end 502b of the manipulation member acts as a fulcrum so that the elongated manipulation member 502 pivots at an angle relative to the central longitudinal axis 114 as shown. This is an example of another way in which the membrane body 104 can be manipulated. Those skilled in the art will appreciate that, based on the application, the membrane body 104 can be manipulated in various ways in the vicinity of the first manipulation structure 110 in question by applying different mechanical forces at the first end 502a of the manipulation member and / or the second end 502b of the manipulation member.

[0053] In some embodiments, one or more of the plurality of control structures includes a control member embedded in the membrane body 104. In such embodiments, the control structure includes one or more mounting structures (930) attached to the embedded control member such that the embedded control member (or embedded control member) protrudes from the membrane body (104) in a direction away from the central longitudinal axis 114 of the membrane body 104. The control structure of such embodiments differs from the first control structure 110 described above in that an embedded control member is provided instead of a through hole 204 for receiving the elongated control member 502.

[0054] FIG. 9 is a schematic main plan side cross-sectional view illustrating a second control structure 910 according to several embodiments. The second control structure 910 is another example of a control structure that is configured to be controlled by applying a mechanical force to control the amount of deformation of the membrane body 104 and thereby the space inside the membrane body 104. In FIG. 9, components corresponding to those described with respect to the first control structure 110 are given the same reference numbers as in the previous figures. The outer portion of the membrane body 104 can include multiple control structures as described in connection with FIGS. 1 to 8 or multiple control structures as described below in connection with FIG. 9. Alternatively, the membrane body 104 can include multiple control structures, including one or more first control structures as described in connection with FIGS. 1 to 8 and one or more second control structures as described in connection with FIG. 9. It should be noted that other embodiments of the control structure are also possible. For example, if the disclosure herein is configured to be operable by applying a mechanical force, thereby controlling the amount of deformation of the membrane body 104 and thereby controlling the space inside the membrane body 104, a person skilled in the art will understand that there are various ways to provide such an operating structure.

[0055] In these illustrative examples, the second operating structure 910 includes an embedding operating member 920, as illustrated in FIG. 9 . In these illustrative examples, the second operating structure 910 includes one or more mounting structures 930 attached to the embedding operating member 920. In some illustrative examples, the mounting structures 930 are integral with the embedding operating member 920. In other embodiments, the mounting structures 930 and the embedding operating member 920 are provided together as a single piece. In other illustrative examples, the mounting structures 930 are separate pieces that are attached onto the embedding operating member 920.

[0056] In these embodiments, the attachment structures 930 protrude from the membrane body 104 in a direction away from the central longitudinal axis 114 of the membrane body 104. For example, the attachment structures 930 extend outwardly relative to the outer portion 112 of the membrane body 104. For example, the attachment structures 930 are partially embedded within the material of the membrane body 104. In the embodiment of FIG. 9, two attachment structures 930 are provided. However, any number of attachment structures 930 may be provided, as desired. In some embodiments, the number of attachment structures 930 may be based on the shape and / or size of the embedding manipulation member 920.

[0057] For example, the embedded operating member 920 may be configured to deform the membrane body 104 in the vicinity of the second operating structure 910 by applying a force to the attachment feature 930 in a direction perpendicular to the central longitudinal axis 114. In these embodiments, the embedded operating member 920 may be a rigid plate (e.g., may include metal or other material to form a rigid plate having suitable dimensions). In some embodiments, the embedded operating member 920 is a rigid rectangular plate (or rectangular plate) or a rigid circular plate. For example, the rigid plate may be embedded in the sense that it is molded into the elastically deformable material of the second operating structure 910. For example, the plate may be oriented to face substantially in the same direction as the outer portion 112 (i.e., the outer surface of the membrane body 104).

[0058] In the embodiment of Figure 9, the rigid plate 920 is fully embedded within the material of the membrane body 104. Figure 10 is a schematic partial side cross-sectional view of a second manipulation structure 910 according to an embodiment. The horizontal dashed lines indicate that this structure continues beyond what is illustrated in Figure 10. In these embodiments, the embedded manipulation member 920 is a rectangular plate.

[0059] In some embodiments, the embedded operating member 920 may be partially embedded in the elastically deformable material at the location of the second operating structure 910, e.g., such that two ends of the embedded operating member 920 protrude, as described below.

[0060] FIG. 11 is a schematic partial side cross-sectional view of the second operating structure 910 according to an embodiment. The embodiment of FIG. 11 differs from the embodiment of FIGS. 9 and 10 in that the embedded operating member 920 is partially embedded. In the embodiment of FIG. 11, the two ends of the embedded operating member 920 protrude from the elastically deformable material (e.g., protrude from the remainder of the second operating structure 910). For example, the two ends of the embedded operating member 920 protrude at different positions relative to the central longitudinal axis 114 (see FIG. 11). In these embodiments, the embedded operating member 920 comprises a first embedded operating end 920a and a second embedded operating end 920b, each of which is provided at a different end of the protruding embedded operating member 920, as described. In the orientation shown in FIG. 11, the first embedded operating end 920a is the top (or upper) operating end of the embedded member, and the second embedded operating end 920b is the bottom (or lower) operating end of the embedded member.

[0061] The manipulation ends 920a, 920b of the implantable members can include a mounting structure 930. For example, the mounting structure 930 is configured to engage with the actuation mechanism 504 (not shown in FIGS. 9, 10, and 11). Those skilled in the art will appreciate that there are various ways to couple the manipulation ends 920a, 920b of the implantable members to the actuation mechanism. As a simple example, the mounting structure 930 can take the form of a mounting ring, a mounting through hole, a mounting threaded hole, or any other type of structure that allows for mechanical coupling with the actuation mechanism.

[0062] The second manipulation structure 910 can function in a manner similar to that described above in relation to the first manipulation structure 110. Accordingly, a description of their common features, functions, advantages, etc. will be omitted for the sake of brevity. The described manipulation structure provides a way to apply mechanical forces at given locations on the membrane body 104, thereby manipulating the membrane body 104 to take advantage of the elastic advantages of the elastically deformable material.

[0063] In some embodiments, the forming film 100 includes a first seal structure disposed toward a first end of the forming film 100. In these embodiments, the first seal structure is configured to form a seal with the carrier body 108. In these embodiments, the first end of the forming film 100 is at a particular location relative to the central longitudinal axis 114. For example, a second end of the forming film 100 opposite the first end is at a different location relative to the central longitudinal axis 114.

[0064] For example, in the embodiments of Figures 1, 4 and 5, the first end 116 of the molding membrane 100 is labeled with a reference number. In the orientation shown in these figures, the first end 116 of the molding membrane 100 is the bottom end of the molding membrane 100. For example, the first seal structure is provided in a position where the membrane body 104 does not abut the target object 102 during use.

[0065] The first seal structure can take any form or structure capable of providing a seal to be formed. In some embodiments, the seal formed by the first seal structure is a seal capable of preventing or significantly inhibiting the flow of liquid material out between the molding film 100 and the carrier body 108. In some embodiments, the seal formed by the first seal structure is a vacuum seal (in other words, prevents or significantly inhibits the flow of air / gas molecules). The air tightness of the seal formed by the first seal structure (and thus the particular example of the first seal structure to be applied) may be selected according to the application. In some applications, only a seal that prevents the flow of liquid may be desired. In other applications, a vacuum seal may be desired.

[0066] In some embodiments, the membrane body 104 is provided with a flange 118 toward the first end 116. In these embodiments, the flange 118 extends into the interior of the membrane body 104. For example, the flange 118 extends toward the central longitudinal axis 114. In these embodiments, the flange 118 is provided to surround the cylindrically shaped membrane body 104, for example, as shown in FIG. 1. The flange 118 is part of the membrane body 104 and, therefore, comprises an elastically deformable material.

[0067] In the embodiment of FIG. 1, the first seal structure is indicated by reference numeral 120. In some embodiments, the first seal structure 120 is provided on the flange 118, as illustrated in FIG. 1. However, in some embodiments, the flange can be omitted and the first seal structure 120 can be provided on another portion of the membrane body 104. In such an embodiment, the membrane body 104 can have a ring-like structure. In some embodiments, the flange 118 is provided, but the first seal structure 120 can be provided on a portion of the membrane body 104 other than the flange 118.

[0068] For example, the flange 118 abuts an end surface (e.g., a bottom surface) of the carrier body 108 relative to the central axis 114. In the orientation illustrated in Figure 1, the flange 118 abuts a bottom surface (not illustrated) of the carrier body 108.

[0069] In some embodiments, the first seal structure 120 takes the form of a channel formed in the flange 118, where the elastically deformable material does not abut the carrier body 108. For example, the area forming the channel has more air or space between the elastically deformable material and the carrier body 108 than other areas. Referring again to FIG. 5, in these embodiments, the first seal structure 120 has the form of a channel as described above. For example, the first seal structure 120 may extend circumferentially around the flange 118 to form a ring-shaped channel that surrounds the central axis 114.

[0070] The first seal structure 120 in these embodiments functions to form a seal, for example, under a vacuum. For example, when a vacuum is applied, the air within the channel that forms the first seal structure 120 is evacuated. This causes the flange 118 to be forced (depending on the strength of the vacuum, the exact configuration of the channel, etc.) against the carrier body 108 forming a seal.

[0071] 5 embodiment is spaced a predetermined distance from where the cylindrical portion of the membrane body 104 meets the flange 118. For example, the predetermined distance may be selected to ensure that the seal formed by applying a vacuum to the channel is not compromised when the membrane body 104 deforms as described above.

[0072] In some embodiments in which the first seal structure 120 is provided in a portion of the membrane body 104 different from the flange 118 (whether or not a flange 118 is provided), for example, the first seal structure may be in the form of a channel on an inward-facing surface of the membrane body 104 (the surface opposite the central longitudinal axis 114).

[0073] In other embodiments, the first seal structure 120 can provide other means for sealing the flange 118 (or other parts of the membrane body 104, depending on the embodiment applied) to the carrier body 108. For example, various embodiments of a fastening mechanism (as part of the first seal structure 120) can be provided to fasten the flange 118 to the carrier body 108 to form a seal. Those skilled in the art will understand that there are various ways to sufficiently forcefully fasten, attach, or clamp an object to another object to form a desired seal. In some embodiments, the first seal structure 120 includes a suitable type of mechanical clamp. These other embodiments of the first seal may be applied, for example, on the flange 118 or to other parts of the membrane body 104.

[0074] For example, in some embodiments, the first seal structure 120 may comprise a strap disposed around the outer portion 112 of the membrane body 104. The strap may function to tighten around the membrane body 104 to force the membrane body 104 (in the vicinity of the strap) against the carrier body 108.

[0075] In some embodiments, the molding membrane 100 includes a second seal structure that is disposed toward a second end of the molding membrane 100. The second end of the molding membrane 100 is disposed opposite the first end 116 of the molding membrane 100. In the embodiments of Figures 1, 4 and 5, the second end 124 of the molding membrane 100 is labeled with a reference number. In the orientation illustrated in these figures, the second end 124 is the top end of the molding membrane 100. For example, the second seal structure is disposed at a location where the membrane body 104 does not abut against the target object 102 during use.

[0076] 5, an exemplary second seal structure 510 is shown toward the second end 124 of the molding membrane 100. For example, the first seal structure 120 and the second seal structure 510 described above are positioned such that there is an area of ​​the membrane body 104 that abuts the target object 102 between the first seal structure and the second seal structure. In these embodiments, a seal is formed around the perimeter of the target object 102 that abuts the membrane body 104.

[0077] For example, the second seal structure 510 is configured to form a seal against the carrier body 108 disposed inside the membrane body 104. In the embodiment of FIG. 5, the second seal structure 510 includes a channel disposed in an inner-facing surface (opposite the central longitudinal axis 114) of the membrane body 104. In these embodiments, the second seal structure 510 takes the form of a channel as described above with respect to the first seal structure 120. In other embodiments, the second seal structure 510 may include other means for forming a seal, such as a mechanism for fixing (e.g., clamping) the membrane body 104 against the carrier body 108 toward the second end 124. Those skilled in the art will appreciate that there are various ways to forcefully fix, attach, or clamp an object against another object to form a desired seal. In some embodiments, the second seal structure 510 includes a mechanical clamp of any suitable type. In some embodiments, the second seal structure 510 is configured to form a seal on a surface of the carrier body 108 that is substantially perpendicular to the outer surface 106 (e.g., the top surface of the carrier body 108 in the orientation of Figures 1, 4, and 5).

[0078] For example, in some embodiments, the second seal structure 510 may include a strap disposed around the outer portion 112 of the membrane body 104, which may function to tighten around the membrane body 104 and force an area of ​​the membrane body 104 near the strap against the carrier body 108, thereby tightening around the membrane body 104.

[0079] In some embodiments, a second seal actuation mechanism may be provided that acts to apply a seal against the second seal structure 510. For example, the second seal actuation mechanism may be used to tighten a strap, apply a clamp, or the like, based on the configuration of the second seal structure. For example, the second seal actuation mechanism may act independently of the mechanism that actuates the manipulation structure. In such embodiments, the second seal actuation mechanism may be used, for example, to hold the second seal structure open as the membrane body 104 expands to insert the target object 102.

[0080] In some embodiments, a pressure differential can be exerted across the molding film 100, for example, by evacuating the volume between the molding film 100 and the carrier body 108 and / or by applying external pressure to the molding film 100. For example, the pressure differential can be applied to cause a substance (e.g., resin) to fill the space around the target object 102. In some embodiments, the pressure differential can help press the film body 104 against the target object 102. In some embodiments, a combination of evacuating the volume between the molding film 100 and the carrier body 108 and applying external pressure can be used.

[0081] As described above, some embodiments of the molding membrane 100 include a first seal structure 120. Some embodiments may include both a first seal structure 120 and a second seal structure 510. In some embodiments where a vacuum is desired between the membrane body 104 and the carrier body 108, both a first seal structure 120 and a second seal structure 510 may be included in such a way that a vacuum seal can be formed on either side of the target object. Such embodiments may be applied depending on the desired application.

[0082] For example, there may be an embodiment where the first seal structure 120 and the second seal structure 510 are included and there is no vacuum in the space immediately outside the molding film 100. For example, this is the case when the molding film 100 is not placed in an autoclave that is evacuated. In such an embodiment, a means for evacuating air (e.g., tubes, pipes, etc.) may be provided and configured to create a vacuum between the molding film 100 and the carrier body 108. In such an embodiment, a means for introducing a substance (e.g., resin) into the space between the molding film 100 and the carrier body 108 (e.g., tubes, pipes, etc.) may also be provided.

[0083] In these embodiments, when a vacuum is applied, the material fills the voids left by the displaced air, thus coating the target object 102. In embodiments where the seal structure takes the form of a channel as described above, application of a vacuum forms a corresponding seal.

[0084] In some embodiments where the flange 118 is provided, the molding membrane 100 may include a rigid base structure connected to the flange 118 toward its innermost edge. For example, the rigid base structure may be a rigid ring. For example, the rigid base structure may be a rigid disk. In the embodiment of FIG. 1, a first rigid base structure 122 is provided, which has the form of a rigid disk 122 connected to the flange 118. In the embodiment of FIG. 5, a second rigid base structure 506 is provided, which has the form of a rigid ring 506. The first and second rigid base structures 122, 506 are examples of the rigid base structures described above. The rigid base structures 122, 506 may comprise any suitable rigid material, such as, for example, a metal.

[0085] In some embodiments, the rigid base structure 122, 506 comprises a fastening mechanism for fastening the rigid base structure 122, 506 to the carrier body 108. For example, in the embodiment shown in FIG. 5, the second rigid base structure 506 comprises a rigid ring fastening mechanism 508.

[0086] The fastening mechanism for the rigid base structure 122, 506 can be provided in a variety of forms, such as a clamping mechanism, a mechanism utilizing screws and / or bolts.

[0087] In some embodiments, the forming membrane 100 includes a first alignment feature (or positioning feature) configured to engage with a second alignment feature such that the rotational positioning of the forming membrane relative to the carrier body 108 about the central longitudinal axis 114 is fixed. For example, the first and second alignment features may also help to generally position (but not be limited to rotationally) the carrier body and the target object within the forming membrane 100 as desired. For example, it may be desirable for a particular portion of the target object 102 to be positioned at or near a particular location around the cylindrical membrane body 104. For example, correct positioning may enable correct placement of the first and / or second seal structures so that the seal is not disturbed during manipulation of the membrane body 104. The first and second alignment features may be provided to achieve such positioning.

[0088] 1, the molding membrane 100 includes first alignment features 126 in the form of guide pins. In these particular embodiments, three guide pins are provided at different angular positions about the central longitudinal axis 114. The guide pins 126 are elongated such that they extend in a direction substantially parallel to the central longitudinal axis 114 when the membrane body 104 is in an undeformed state. In embodiments in which guide pins are used, any number of guide pins may be used.

[0089] The guide pins can be provided in the rigid base structure 122, 506. For example, the guide pins can be provided on the rigid disk 122. In some other embodiments, the guide pins can be provided on the rigid ring 506. In some embodiments, the guide pins can be part of the membrane body 104, for example, and can be provided on the flange 118. For example, the guide pins can be molded into the elastically deformable material that forms the flange 118.

[0090] In the embodiment of FIG. 1, the carrier body 108 includes a second alignment feature 128. In these particular embodiments, the second alignment feature 128 has the form of a hole that receives the guide pin 126. In the particular embodiment illustrated in FIG. 1, the carrier body 108 includes an inwardly extending flange 130 that is disposed on a portion of the carrier body 108 that abuts the flange 118. In these embodiments, the inwardly extending flange 130 is positioned toward the first end 116 of the molding membrane 100 during use. The second alignment feature 128 includes a through hole disposed in the inwardly extending flange 130. If necessary, a guide pin is received in the through hole 128 to align the membrane body 104 with the target object 102.

[0091] In other embodiments, different first and second alignment features may be provided. For example, the molding film 100 may include structure that engages with a complementary structure on the carrier body 108, thereby fixing the relative rotational position between the molding film 100 and the carrier body 108. For example, the molding film 100 may include one or more protrusions (or projections) and / or recesses (or grooves) that engage with complementary one or more protrusions (or projections) and / or recesses (or grooves) on the carrier body 108, thereby fixing the relative rotational position. Those skilled in the art will appreciate that there are various ways to fix the relative rotational position with respect to the embodiments described herein.

[0092] In some embodiments, each of the multiple control structures 110, 910 includes control structure fiber reinforcement molded into each control structure 110, 910. In the embodiments of Figures 9, 10, and 11, a control structure fiber reinforcement 940 is provided. In these embodiments, the control structure fiber reinforcement 940 may include, for example, one or more woven layers (or fiber layers) disposed about the embedded control members 920. For example, the control structure fiber reinforcement may be limited to each control structure.

[0093] Providing a textile reinforcement for the actuation structure in conjunction with an embodiment of the actuation structure may advantageously provide structural reinforcement for the actuation structure (e.g., to prevent damage from forces transmitted from the actuation mechanism 504). In some embodiments, providing a textile reinforcement for the actuation structure in conjunction with an embodiment of the actuation structure may allow for control of the amount of deformation experienced by the actuation structure. For example, the fabric (or fibers) used may be such that elastic deformation is not possible.

[0094] 9, 10, and 11 are merely illustrative examples of fiber reinforcement within the manipulation structure. For example, there may be embodiments of the first manipulation structure 110 that include fiber reinforcement. For example, the fiber reinforcement may be provided in one or more layers surrounding the elongated through holes 204. Any configuration and / or number of fiber reinforcement layers may be provided as part of the manipulation structure embodiments depending on the amount of reinforcement desired.

[0095] In some embodiments, the membrane body 104 is provided with a membrane body fiber reinforcement to limit the amount of deformation of the membrane body 104. Figure 12 is a top cross-sectional view of a schematic portion of the molding membrane 100, which includes a membrane body fiber reinforcement 1202. In these embodiments, the membrane body fiber reinforcement 1202 includes one or more continuous fiber layers circumscribing the central longitudinal axis 114. The membrane body fiber reinforcement 1202 may extend all or part of the length of the membrane body 104 in a direction along the central longitudinal axis 114.

[0096] Fiber reinforcement 1202 in the membrane body can be used to limit the amount (or extent) that the membrane body 104 moves away from the central longitudinal axis 114 as it deforms to create spaces therein.

[0097] As mentioned above, in some embodiments, both the first and second seal structures may be provided such that a vacuum between the membrane body 104 and the carrier body 108 is desired. In some embodiments, the entire membrane for molding may be placed in a chamber under vacuum (e.g., an autoclave, etc.) according to an embodiment. In such embodiments, the second seal structure may be omitted.

[0098] For example, in some embodiments where the molding membrane is envisioned to be used in a vacuum chamber, the first seal structure may form a seal sufficient to significantly inhibit or prevent the flow of the enclosed material, but need not necessarily be a vacuum seal.

[0099] In some embodiments where the molding membrane is intended to be used in a vacuum chamber, the molding membrane includes a reservoir structure, which is provided toward the second end 124 of the molding membrane. In these embodiments, the reservoir structure is provided for introducing an encapsulating substance. FIG. 13 is a schematic perspective view of a molding membrane 100 according to an embodiment. In the embodiment of FIG. 13, a different embodiment of the molding membrane 100 is illustrated in comparison with the previous figures. In the embodiment of FIG. 13, the molding membrane 100 is similar to that described with respect to FIGS. 1 to 8 and can include any combination of the features described above. For example, the molding membrane 100 of FIG. 13 can include a plurality of the above-described first manipulation structures 110, a plurality of the above-described second manipulation structures 910, or a combination thereof. In the example shown in FIG. 13, a plurality of the first manipulation structures 110 is provided according to an embodiment.

[0100] As can be seen from FIG. 13, the shaping membrane 100 has a larger dimension along the central longitudinal axis 114 compared to the shaping membrane embodiments described above. The dimensions of the shaping membrane can be selected according to the desired application. These embodiments illustrate a target object 102 mounted on a carrier body 108 having an outer surface 106, which differs from the target object and carrier body described above in terms of the dimension along the central longitudinal axis 114, but these are merely examples. For example, the shaping membrane 100 of these embodiments is used to encapsulate a coil corresponding to a cylindrical shape of a larger length. The embodiments of FIG. 13 illustrate different dimensions than the embodiments described above.

[0101] 13, the molding membrane 100 includes a reservoir structure 1302. In these embodiments, the reservoir structure 1302 forms a funnel-like container capable of holding a desired amount of a substance therein. In these embodiments, the reservoir structure 1302 extends circumferentially about the central longitudinal axis 114 at the second end 124.

[0102] In use, the molding film 100 according to these embodiments can be placed in a vacuum chamber. A carrier body 108 holding a target object 302 can be placed in the film body 104. In these embodiments, when a vacuum is applied in the vacuum chamber, the air between the film body 104 and the carrier body 108 is removed and the material held in the reservoir structure 1302 is drawn into the remaining space. In this manner, the entire target object 102 can be covered in the desired material.

[0103] In applications where the encapsulation process is performed inside a closed chamber such as an autoclave, automated manipulation of the membrane body 104 can be particularly advantageous because once a typical mold (or form) is placed inside the vacuum chamber, manual manipulation is not possible. However, the above-described embodiments provide an automated method of manipulation using actuation mechanisms that can be performed inside the vacuum chamber, thus allowing further adjustment of the outer mold during various processes that are performed inside the vacuum chamber.

[0104] It should be noted that in the above-described embodiments, the outer surface of the carrier body corresponds to the outer surface of a simple cylindrical shape. However, in other embodiments, the carrier body may have one or more flanges or protrusions extending away from the central longitudinal axis 114 when the carrier body is positioned in the molding film as described above. For example, the carrier body may have a shape similar to that of a bobbin or the like. FIG. 17 shows a schematic perspective cross-section of a molding film 100 for forming an external mold on a target object 102 according to an embodiment. In these embodiments, the target object is held on a carrier body 108 that includes the flanges illustrated in FIG. 17. For example, the flanges are provided on either side of the channel in which the target object 102 is placed. In these embodiments, the film body 104 shrinks on the target object 102 to form a tight-fitting external mold. Whatever the shape of the carrier body, examples of molding films used with the carrier body have a suitable shape of the film to allow for forming a tight-fitting external mold on the target object.

[0105] Any of the above-mentioned embodiments of the forming membrane can be used in the method used during the process of encapsulating a target object in a substance. It should be noted that in the embodiments in which the first and second seal structures 120, 510 are provided, the forming membrane 100 can be used in any orientation as required. For example, FIG. 15 is a schematic perspective view of an example of the forming membrane 100 oriented horizontally relative to the ground. Also, for example, FIG. 16 is a schematic perspective view of an example of the forming membrane 100 oriented with the first and second ends of the forming membrane 100 swapped. In other words, the forming membrane 100 in FIG. 16 is upside down compared to the orientation illustrated in FIG. 1, for example. In such an embodiment, the forming membrane 100 can be facing downwards on the carrier body. The first and second seal structures can be provided in any orientation used.

[0106] 14 is a flow diagram of a method 1400 used during the process of encapsulating a target object according to an embodiment. More specifically, the method 1400 includes forming a tight-fitting outer mold around the target. In the following description of the method 1400, reference is made to the above-mentioned embodiment.

[0107] In a step 1402 of the method 1400, a reusable molding film (or membrane) is provided to form an exterior mold. The reusable molding film may be a molding film of any of the embodiments described herein. In a step 1404 of the method 1400, a target object 102 is provided on an exterior surface of a carrier body 108.

[0108] In step 1406 of the method 1400, the manipulating structures 110, 910 are manipulated to deform the cylindrical membrane body 104 so that the target object 102 mounted on the carrier body is accommodated in the space inside the cylindrical membrane body 104. For example, as described above, the manipulating structures 110, 910 are used to manipulate and deform the membrane body 104. As described above, the manipulating structures 110, 910 are locations where mechanical forces can be applied to deform a region of the membrane body 104 locally relative to the manipulating structure 110, 910 in question. For example, a mechanical force is applied at each manipulating structure 110, 910 in a direction away from the central longitudinal axis 114 to deform the membrane body 104 and form a space therein, or a mechanical force is applied in a direction toward the central longitudinal axis 114 to push the membrane body 104 toward the central longitudinal axis 114.

[0109] In step 1408 of the method 1400, the target object 102 disposed on the carrier body 108 is inserted into a space within the cylindrically shaped membrane body 104. For example, in step 1406, the target object 102 held on the carrier body 108 is inserted into the space created by manipulating the membrane body 104.

[0110] 13 illustrates the target object 102 partially inserted into the membrane body 104. In these embodiments, upon completion of step 1408, the target object is within the membrane body, but in a position that allows the membrane body to contract over the target object to form a tight-fitting external mold. For example, the embodiment of FIG. 4 illustrates the target object 102 (not shown in FIG. 4) completely within the cylindrical membrane body 104. Note that it is desirable for the membrane body 104 to completely cover the target object 102 to effectively form a tight-fitting external mold.

[0111] In step 1410 of the method 1400, the manipulating structure 110, 910 is manipulated to cause the membrane body 104 to contract on the target object 102 to form a tight-fitting external mold on the target object 102. For example, a force applied to the manipulating structure 110, 910 away from the central longitudinal axis 114 to create a space may be released to cause the membrane body 104 to contract. In these embodiments, the membrane body 104 contracts on the target object 102. For example, the membrane body 104 may fit tightly by conforming to surface variations on the target object 102. For example, the tight fit may avoid spaces where excessive amounts of material may accumulate. For example, the membrane body 104 may form a tight-fitting external mold to facilitate a coating of material having a relatively consistent thickness on all surfaces of the target object 102.

[0112] In some embodiments, the method 1400 includes manipulating a given manipulation structure 110, 910 to adjust the exo-shaping on the target object 102 in the vicinity of the given manipulation structure 110, 910. As described above, the manipulation structure 110, 910 is provided to apply a mechanical force to the membrane body 104 by using a machine (e.g., based on the actuation mechanism 504, as opposed to manually manipulating the membrane body 104 using hands). For example, the manipulation of the membrane body 104 may be controlled in an automated manner (e.g., using a computer-controlled actuation mechanism). In these embodiments, individual manipulation structures may be used to locally manipulate the membrane body 104. In this way, the exo-shaping may be locally adjusted as needed. Advantageously, the use of the molding membranes and methods described herein provides a more efficient method of applying exo-shaping on the target object 102.

[0113] As discussed above, the method 1400 provides an exterior mold that fits closely with the target object 102. In some embodiments, the method 1400 may include further processing with respect to encapsulating the target object in a substance.

[0114] For example, the method 1400 may include introducing a substance (e.g., a resin) between the outer mold formed by the molding film 100 and the inner mold formed by the carrier body 108. For example, the method 1400 may further include applying a vacuum to seal the molding film 100 to the carrier body such that the target object 102 is sealed (or hermetically sealed) between the molding film 100 and the carrier body 108.

[0115] As described above, this vacuum may be applied between the forming film 100 and the carrier body 108, or the forming film 100 and carrier body may be placed in an evacuated chamber, such as an autoclave.

[0116] For example, heat may be applied to harden the material to complete the molding process. Advantageously, a tight-fitting exterior mold can encapsulate the target object 102 in a uniform manner and avoid areas of excess material.

[0117] For example, at the end of the process, the handling structure 110, 910 can be used to remove the molding film 100 away from the encapsulated target object 102. This can be done in an automated and controlled manner, for example, as described above.

[0118] All of the features disclosed in this specification (including the accompanying claims, abstract, and drawings), and / or any method or process steps so disclosed, may be combined in any combination, except combinations in which at least some of the features and / or steps are mutually exclusive.

[0119] Each feature disclosed in this specification (including the accompanying claims, abstract, and drawings) may be replaced by alternative features serving the same, equivalent, or similar purpose, except where expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is only an example in a generic series of equivalent or similar features.

[0120] The invention is not limited to the details of the embodiments described above, but rather extends to any novel, or any novel combination of, features disclosed in this specification (including the accompanying claims, abstract and drawings), and to any novel, or any novel combination of method or process steps so disclosed.

Claims

1. A reusable molding film (100) for forming an external mold during a process of encapsulating a target object (102) in a substance, comprising: a cylindrically shaped membrane body (104) comprising an elastically deformable material; a plurality of operating structures (110, 910) provided on an outer portion (112) of the membrane body (104); When the membrane body (104) is in a non-deformed state, an inner diameter (202) of the cylindrical membrane body (104) is smaller than an outer diameter (302) of the target object provided on the outer surface (106) of a cylindrical carrier body (108); Each of the plurality of operation structures (110, 910) is configured to be operable by applying a mechanical force, and the amount of deformation of the membrane body (104) is controlled to control the internal space of the membrane body (104). A molding membrane (100).

2. One or more of the plurality of operating structures (110) comprises an elongated through hole (204); the elongated through-holes (204) are configured to receive elongated operating members (502) and exert forces on the ends (502a, 502b) of the elongated operating members (502) in a direction perpendicular to the central longitudinal axis (114), thereby deforming the membrane body (104) adjacent the respective operating structures (110); The molding membrane (100) of claim 1.

3. One or more of the plurality of operating structures (910) an embedded operating member (920) embedded in the membrane body (104); and one or more mounting structures (930) attached to the embedding member (920) so as to protrude from the membrane body (104) in a direction away from the central longitudinal axis (114) of the membrane body (104). The molding membrane (100) of claim 1.

4. 4. The molding membrane (100) of claim 3, wherein one or more of the plurality of operating structures (910) having the embedded operating members (920) are each configured to exert a force on one or more of the mounting structures (930) of each of the embedded operating members (920) in a direction perpendicular to the central longitudinal axis (114) to deform the membrane body (104) in the vicinity of each of the operating structures (910).

5. 2. The molding membrane (100) of claim 1, further comprising a first seal structure (120) disposed toward a first end (116) of the molding membrane (100), the first seal structure (120) configured to form a seal against the carrier body (108) disposed within the membrane body (104).

6. 6. The molding membrane (100) of claim 5, further comprising a second seal structure (510) provided toward a second end (124) of the molding membrane (100), the second seal structure (510) configured to form a seal against the carrier body (108) disposed within the membrane body (104).

7. The membrane body (104) includes a flange (118) toward a first end (116), the flange (118) extending inwardly within the membrane body (104); The first seal structure (120) is provided on the flange (118). The molding membrane (100) of claim 5.

8. 8. The forming membrane (100) of claim 7, further comprising a rigid base structure (122, 506) connected with said flange (118) toward an innermost end of said flange (118).

9. 5. The molding film (100) of any one of claims 2, 3 and 4, comprising a first alignment feature (126) configured to engage with a second alignment feature (128) to fix a rotational positioning of the molding film (100) about the central longitudinal axis (114) relative to the carrier body (108).

10. 6. The molding membrane (100) of claim 5, comprising a reservoir structure (1302) provided toward a second end (124) of the molding membrane (100) for introducing a substance for encapsulation.

11. 2. The moldable membrane (100) of claim 1, wherein each of the plurality of manipulation structures (110, 910) includes a manipulation structure fiber reinforcement (940), the manipulation structure fiber reinforcement (940) being molded into each of the manipulation structures (110, 910).

12. 10. The forming membrane (100) of claim 1, wherein the membrane body (104) comprises membrane body fiber reinforcement (1202) for limiting the amount of deformation of the membrane body (104).

13. A method for use during a process of encapsulating a target object (102) in a substance, comprising the steps of: A reusable molding film (100) is used to form an external mold, the reusable molding film (100) comprising: a cylindrically shaped membrane body (104) comprising an elastically deformable material; a plurality of operating structures (110, 910) provided on an outer portion (112) of the membrane body (104); When the membrane body (104) is in a non-deformed state, an inner diameter (202) of the cylindrical membrane body (104) is smaller than an outer diameter (302) of the target object provided on the outer surface (106) of a cylindrical carrier body (108); Each of the plurality of operating structures (110, 910) is configured to be operable by applying a mechanical force, and the amount of deformation of the membrane body (104) is controlled to control the internal space of the membrane body (104); The method comprises: providing a target object (102) on an outer surface (106) of the carrier body (108); Operate the plurality of operation structures (110, 910) to deform the cylindrical membrane body (104) so ​​as to increase an internal space of the cylindrical membrane body (104), so that the target object provided on the carrier body (108) is accommodated within the internal space of the cylindrical membrane body (104); The target object (102) provided on the carrier body (108) is inserted into an internal space of the cylindrical membrane body (104); The method of claim 1, wherein the plurality of manipulation structures (110, 910) are manipulated to contract the membrane body (104) onto the target object (102) to form a tight-fitting external mold onto the target object (102).

14. 14. The method of claim 13, comprising manipulating a given manipulation structure (110, 910) of the plurality of manipulation structures (110, 910) to adjust the external molding on the target object (102) in a vicinity of the given manipulation structure (110, 910).

15. introducing a substance between the outer mold formed by said molding membrane (100) and the inner mold formed by said carrier body (108); 15. The method of claim 13 or 14, comprising applying a vacuum to seal the shaping film (100) against the carrier body (108), thereby sealing the target object (102) between the shaping film (100) and the carrier body (108).

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