Mold production and molding system and method for carbon fiber products

Abstract

The invention relates to a system for creating a mold for mass production of products intended to be produced using composite materials, in particular carbon fiber, and for producing the product with this mold, as well as a method suitable with this system.

Description

[0001] MOLD PRODUCTION AND MOLDING SYSTEM AND METHOD FOR CARBON FIBER PRODUCTS

[0002] Technical Field of the Invention

[0003] The invention relates to a system for creating a mold for mass production of products intended to be produced using composite materials, in particular carbon fiber, and for producing the product with this mold, as well as a method suitable with this system.

[0004] State of the Art of the Invention

[0005] It is a known application in the art to obtain various objects using molding methods using carbon fiber. In this application, the quality of the product is highly dependent on the qualification and luck of the technician carrying out the production. For these reasons, the margin of error in the products obtained by these methods is high and a product with such a margin of error cannot be classified as an engineered product.

[0006] Document with publication no. CN116572564A discloses a resin transfer molding (RTM) based device for forming a carbon fiber based composite material. The present invention comprises a fixed lower mold at the base and a movable upper mold compatible with the lower mold. There is an injection pipe at the top of said upper mold towards the bottom. A carbon fiber material is deposited between the two molds. Heating elements are used for the material to take the form of the lower mold. After the material takes its form, resin is discharged from the injection pipes between the two molds.

[0007] Document with publication no. US2008105996A1 describes a method for providing prototype parts. Here, a heated plate is placed on top of a model to replicate it (to create a kind of mold) and a vacuum is applied from the base in the process.

[0008] Document with publication no. JPH01224137A describes a method of creating a mold. Here, a polyurethane layer is formed on a master model and then a retaining frame is placed around the model, a material, which can also be chosen as polyurethane, is poured on top and the model is removed after cooling As a result all the above-mentioned problems have made it imperative to make an innovation in the relevant field.

[0009] Objects and Summary of the Invention

[0010] The main object of the invention is to create a mold for mass production of products intended to be produced using composite materials, in particular carbon fiber, and to reduce user errors in a system that produces the product with this mold and to ensure that production can be carried out within acceptable ranges.

[0011] Accordingly, the present invention proposes a system as a solution, comprising a vacuum plate having vacuum openings on its surface, on which the object is to be placed, and a vacuum source for generating vacuum through said vacuum openings, a mold plate frame for holding a plate made of a thermoplastic material, and a first movement arm for moving said mold plate frame towards the vacuum plate, a second movement arm for moving an injector plate having at least one injector opening on its surface and an injector placed in said injector opening towards the vacuum plate, at least two feed tanks connected to said injector, and at least one control unit for controlling the flow from the feed tanks to said injector, the movement of the primary movement arm and the secondary movement arm, and the vacuum source.

[0012] In connection with this system, the invention also proposes a method comprising the steps of laying a plate made of a heated thermoplastic material that is at least capable of being shaped on an object and applying vacuum towards the object, after said plate has solidified, pouring another molding material in a fluid state on top and waiting until it dries to form a mold part, turning the obtained mold part upside down, laying a plate made of a heated thermoplastic material that is at least capable of being shaped on the object and pouring another mold material in fluid form on said plate after it solidifies and waiting until it dries to form another mold part, punching holes that allow the transfer of fluids necessary for forming the part to be obtained from the mold into the mold parts and feeding at least one fluid necessary for forming the part to be obtained from the mold into the mold through the punched holes. In addition, the present invention offers a significant advantage in terms of space utilization, depending on the positioning and shape of the mold plate frame and the injector plate.

[0013] Descriptions of the Figures Describing the Invention

[0014] The figures and the related descriptions used in order to better describe the device designed with this invention are as follows.

[0015] Fig- 1- A schematic of the system of the invention.

[0016] Fig- 2. Isometric view of the system of the invention before the start of the mold making process.

[0017] Fig. 2a. Isometric view of the system of the invention during plate placement for mold making.

[0018] Fig. 2b. Isometric view of the system of the invention while feeding material to the periphery of the mold-making mold.

[0019] Fig. 2c. Isometric view of the system of the invention after the mold-making mold is formed.

[0020] Definitions of the Elements / Parts / Features of the Invention

[0021] In order to better describe the device developed with this invention, the features and parts in the figures are numbered and the equivalent of each number is given below.

[0022] 10. Vacuum plate

[0023] 11. Vacuum opening

[0024] 12. Vacuum source

[0025] 13. Retaining Frame

[0026] 20. Mold plate frame

[0027] 21. Primary movement arm

[0028] 22. Heating element

[0029] 30. Ejector plate 31. Secondary movement arm

[0030] 32. Injector opening

[0031] 33. Injector

[0032] 40. Feed tank

[0033] 41. Feed connection

[0034] 50. Roll holder

[0035] 51. Tertiary movement arm

[0036] 60. Storage tank

[0037] 100. Chassis

[0038] 110. Separating wall

[0039] 111. Through-opening

[0040] K. Control unit

[0041] R. Roll

[0042] P. Plate

[0043] M. Mold

[0044] Detailed Description of the Invention

[0045] The subject of the invention relates to a system for creating a mold (M) for mass production of products intended to be produced using composite materials, in particular carbon fiber, and for producing the product with this mold, as well as a method suitable with this system.

[0046] Referring to Fig. 1, the current system comprises a vacuum plate (10). The size of the vacuum plate (10) should be chosen to be at least large enough to accommodate the object (N) to be molded (M), preferably larger. On the surface of said vacuum plate (10), vacuum openings (11) are arranged in the form of a channel extending between both sides of the plate. The vacuum openings (11) help to create a vacuum force at the top of the vacuum plate (10).

[0047] A vacuum source (13) is arranged at the bottom of the vacuum plate (10) and, as will be described later, provides vacuum force during mold making and molding through vacuum openings (11).

[0048] The system of the invention comprises a mold plate frame (20) for carrying a plate (P) made of thermoplastic material towards said vacuum plate (10). The mold plate frame (20) is configured to hold and deposit the plate (P) onto the vacuum plate (10). Here, the form of the mold frame (20) is preferably rectangular or square, but this geometric preference should not be considered as limiting. This form preference can change according to different areas and needs.

[0049] Preferably, the system may also include a retaining frame (13). The retaining frame (13) can be part of the system or it can also be an element placed in the system during molding. The retaining frame (13) can be arranged as a rising structure around the vacuum plate (10), for example on the side of a drive element (not shown in the figures).

[0050] Said mold plate frame (20) is connected to a primary movement arm (21). The primary movement arm (21) is preferably coupled to the periphery of the mold plate frame (20). The primary movement arm (21) moves said mold plate frame (20) towards the vacuum plate (10). Here, the primary movement arm (21) is preferably an element that provides telescopic movement. Preferably, piston or linear drive elements can be selected as the primary movement arm (21).

[0051] In the preferred embodiment, said primary moving arm (21) is configured to move perpendicularly to the surface of the vacuum plate (10) on which the object (N) is placed.

[0052] In order to carry out the mold making process, said plate (P) must be heated sufficiently to allow a change of form. This heating process is preferably carried out by a heating element (22). Said heating element (22) may be provided coupled to the mold plate frame (20), or may be provided independently of the mold plate frame (20). Alternatively, said system may not comprise a heating element (22) and accordingly the plate (P) may be heated by the operator.

[0053] The system of the invention further comprises an injector plate (30). The injector plate (30) comprises at least one and preferably multiple injector openings (32). Said injector openings

[0054] (32) allow the injectors (33) to be positioned according to user preference. Here the injectors

[0055] (33) are connected to the feed tanks (40). At least one injector (33), preferably multiple injectors (33) are used here. Injectors (33) are connected to different feed tanks (40). Here, the feed tanks (40) comprise different fluids from each other. At least two feeding tanks (40) are provided, but more feeding tanks (40) can be used in preferred embodiments since the number of input types will vary depending on the mold (M) to be obtained and the product to be obtained from the mold (M).

[0056] Said injector frame (30) is connected to a secondary movement arm (31). The secondary movement arm (31) is preferably connected to the periphery of the injector plate (30). The secondary movement arm (31) moves said injector plate (30) towards the vacuum plate (10). Here, the secondary movement arm (31) is preferably an element that provides telescopic movement. Preferably, piston or linear drive elements can be selected as the secondary movement arm (31).

[0057] In the preferred embodiment, said secondary moving arm (31) is configured to move perpendicularly to the surface of the vacuum plate (10) on which the object (N) is placed.

[0058] In a preferred embodiment of the invention, the area of said mold plate frame (20) is larger than the injector plate (30) provided within the frame. Thus, the injector plate (30) can reach the laid plate (P) by passing through said mold plate frame (20) after the mold plate frame (20) has deposited / laid the plate (P) on the object. Thus, the mold plate frame (20) and the injector plate (30) can be used in the same volume, resulting in a large space saving.

[0059] Preferably, the mold plate frame (20) and the injector plate (30) are rectangular in shape, but the injector plate is smaller and said injector plate (30) can pass through the cavity of the frame after the plate (P) is deposited onto the object (N).

[0060] In a preferred embodiment, a turning element (not shown in the figures) is provided for holding and turning said mold (M) after the mold (M) has been formed. This process can also be performed manually by operators.

[0061] Also, in another embodiment, there is also a punching element (not shown in the figures) to allow fluid entry into the mold (M). This process can also be performed manually by operators.

[0062] A preferred embodiment of the invention uses fabric, in particular carbon fiber fabric, in the manufacture of parts. A roll holder (50) is used here. Said roll holder (50) comprises a tertiary movement element (51) for conveying the roll (R) placed thereon to the molds (M) to be obtained. Said tertiary movement element (51) is arranged to hold and pull the fabric towards the molds (M). Preferably, piston or linear drive elements can be selected as the tertiary movement arm (51). This process can be performed by the operator without a tertiary movement arm (51), but the use of the tertiary movement arm (51) is crucial to automate the system.

[0063] The current system includes at least one control unit (K) to control these elements. It is also possible to use multiple control units (K) to control different elements. Here, the control unit (K) can control the system according to predetermined parameters, or it can include a user input element, such as a keyboard or touch screen, to receive parameters directly from the user.

[0064] The control unit (K) and its units control at least the flow from the feed tanks (40) to the injector (33), the movement of the primary moving arm (21) and the secondary moving arm (31), and the vacuum source (13). Here, the flow between the feed tanks (40) and the injector can be regulated by controlling a valve, or the drive elements of the moving arms can be controlled, or the output of the vacuum source (13) can be regulated.

[0065] In addition, if there is a control unit (K), it can also control the tertiary movement arm (51) or the heating element (22).

[0066] Accordingly, said system in its most basic form comprises, a vacuum plate (10) having vacuum openings (11) on its surface on which the object (N) is to be placed, and a vacuum source (12) for generating vacuum through said vacuum openings (11), a mold plate frame (20) for holding a plate (P) made of a thermoplastic material, and a first movement arm (21) for moving said mold plate frame (20) towards the vacuum plate (10), a second movement arm (31) for moving an injector plate (30) having at least one injector opening (32) on its surface and an injector (34) placed in said injector opening (32) towards the vacuum plate (10), at least two feed tanks (40) connected to said injector (33), and at least one control unit (K) for controlling the flow from the feed tanks (40) to said injector (33), the movement of the primary movement arm (21) and the secondary movement arm (31), and the vacuum source (13).

[0067] Referring to Fig. 2, the present system is configured on a chassis (100). The chassis (100) is divided into two compartments by the separating wall (110) that separates the feed tanks (40) and the roll holder (50) from the vacuum plate (10), the mold plate frame (20), and the injector plate (30). A fabric opening can be provided on said separating wall (110) through which the fabric in the roll (R) can pass.

[0068] Said system operates according to a method.

[0069] In said method, the object (N) to be modeled and molded (M) is first placed on the vacuum plate (10). Here the system is in the position in Fig. 2. That is, a mold plate frame (20) is positioned closer to the vacuum plate (10) than the existing injector frame (30).

[0070] At this point, the plate (P) held by the mold plate frame (20) is preheated or heated by the heating elements (22). Said plate (P) is preferably made of thermoplastic material, in particular vinyl. As can be seen in Fig. 2a, the plate (P) is heated and placed on the object (N) on the vacuum plate (10). The hot plate (P) replicates the object, and in the process, a vacuum is preferably applied by the vacuum source (13) to ensure a better fit of the plate (P) on the object (N).

[0071] At this point, the injector plate (30) moves towards the vacuum table (10) while the mold plate frame (20) retracts, as shown in Fig. 2b. Here, a fluidized material, for example polyurethane, which will solidify at room temperature, is poured from the injectors (33) onto the plate (P). At this point, a retaining frame (13) is preferably provided around the vacuum plate (10) to define the boundaries of the mold (M). Here, when the fluid dries, the mold in Fig. 2c is formed and since the object (N) is inside, its form is shaped in the mold (M). Preferably, vacuuming process is also performed during this process. The vacuuming process both evacuates excess liquid and prevents the problem of bubbles. Preferably, the vacuumed material is transferred to the storage tank (60) provided below the system. At this point, holes are punched on the mold (M) and preferably stainless steel open-ended tubes are driven into the holes to prevent sticking and clogging.

[0072] The obtained mold (M) is then turned upside down on the vacuum table (10). At this point, a plate, preferably made of thermoplastic material, especially vinyl, is placed again at the bottom of this mold. Here vacuum is applied by the vacuum source (13) by utilizing the opening on the mold (M).

[0073] Once the plate (P) has obtained the required shape, a fluidized material, for example polyurethane, which will solidify at room temperature, is poured onto the plate (P) from the injectors (33). At this point, a retaining frame (13) is preferably provided around the vacuum plate (10) to define the boundaries of the mold (M). Then, holes are punched on the lower mold (M) and preferably stainless steel open-ended tubes are driven into the holes to prevent sticking and clogging.

[0074] Thus, a two-part (top and bottom) mold (M) is obtained.

[0075] With the obtained mold, product production with carbon fiber fabric method or product production with forged carbon fiber method can be realized.

[0076] In the carbon fiber fabric method, the fabric is placed between molds from a roll (R). Here the fabric is pressed between the molds, preferably with an increasing and repeated force. This allows the fabric to fit the mold (M) better. The molds (M) are then closed and resin and similar fluid material is transferred from the feed tanks (40) through the holes previously punched on the molds (M) by means of said injectors. In this process, vacuum is preferably provided through holes in the lower mold. The vacuum process is extremely important as the vacuum process ensures that the product has maximum strength and is free of air pockets. After the mold is completely filled, injection and vacuuming are continued for some time to reduce or completely eliminate air bubbles.

[0077] As will be understood, at least one of the injectors (33) is connected to the feed tank (40) filled with resin or similar fluid, and at least one other is connected to the feed tank (40) filled with polyurethane or similar fluid. In the forged carbon fiber method, chopped carbon fiber and resin or similar product material are placed in the molds (M). Here the resin can also be delivered through injectors. Preferably a larger amount of material is used here than the cavity of the mold (M). The two molds are opened and closed repeatedly with increasing speed. The pressure force to be applied at this stage is high. At the same time, vacuum is applied to the mold (M) through previously punched holes in the vacuum plate (10) with a very low negative pressure.

[0078] When the curing time of the resin used is over, the mold is opened and the product, which has dried sufficiently, is taken to the predetermined waiting point. The curing time of the resin varies between 3 minutes to 7 days. The type of resin used, the catalysts and additives used can change this time.

Claims

CLAIMS1. A system for making a mold (M) of an object (N) and producing parts with said mold(M), characterized in that it comprises:A vacuum plate (10) having vacuum openings (11) on its surface on which the object(N) is to be placed, and a vacuum source (12) for generating vacuum through said vacuum openings (11), a mold plate frame (20) for holding a plate (P) made of a thermoplastic material, and a first movement arm (21) for moving said mold plate frame (20) towards the vacuum plate (10), a second movement arm (31) for moving an injector plate (30) having at least one injector opening (32) on its surface and an injector (34) placed in said injector opening (32) towards the vacuum plate (10), at least two feed tanks (40) connected to said injector (33), and at least one control unit (K) for controlling the flow from the feed tanks (40) to said injector (33), the movement of the primary movement arm (21) and the secondary movement arm (31), and the vacuum source (13).

2. The system according to claim 1, characterized in that said mold plate frame (20) is wider in area than the injector plate (30) to allow the passage of the injector plate (30).

3. The system according to claim 1 or 2, characterized in that said primary movement arm (21) and secondary movement arm (31) are configured to move the mold plate frame (20) and the injector plate (30) in the same direction.

4. The system according to claim 1, characterized in that the injector plate (30) comprises multiple injector openings (32).

5. The system according to claim 1 or 4, characterized in that the injector plate (30) comprises multiple injectors (33).

6. The system according to any one of claims 1, 4 or 5, characterized in that it comprises multiple injectors (33) coupled to different feed tanks (40).

7. The system according to claim 1, characterized in that the mold plate frame (20) comprises at least one heating element (22) for heating the plate (P).

8. The system according to claim 7, characterized in that said heating element (22) is coupled to the mold plate frame (20).

9. The system according to claim 1, characterized in that it comprises a roll holder (50).

10. The system according to claim 9, characterized in that it comprises a tertiary movement element (51) configured to hold and pull the roll (R) material to pull a roll (R) inserted in said roll holder (50) towards the vacuum plate (10).

11. The system according to claim 1, characterized in that it comprises at least one punching element for punching holes in the obtained mold (M).

12. The system according to claim 1, characterized in that it comprises at least one turning element for turning said obtained mold (M) upside down on the vacuum plate (10).

13. The system according to claim 1, characterized in that it comprises at least one retaining frame (13) arranged to surround said vacuum plate (10).

14. The system according to claim 13, characterized in that it comprises at least one drive element that moves said retaining frame (13).

15. A method for making a mold (M) of an object (N) and producing parts with said mold (M), characterized by: laying a plate (P) made of a heated thermoplastic material that is at least capable of being shaped on an object (N) and applying vacuum towards the object (N), after said plate has solidified, pouring another molding material in a fluid state on top and waiting until it dries to form a mold (M) part, turning the obtained mold (M) part upside down, laying a plate (P) made of a heated thermoplastic material that is at least capable of being shaped on the object (N) and pouring another mold material in fluid form on said plate after it solidifies and waiting until it dries to form another mold (M) part,punching holes that allow the transfer of fluids necessary for forming the part to be obtained from the mold (M) into the mold (M) parts, and feeding at least one fluid necessary for forming the part to be obtained from the mold (M) into the mold through the punched holes.

16. The method according to claim 15, characterized by feeding at least one fluid necessary for forming the part to be obtained from the mold (M) into the mold through the holes of the mold at the top and applying vacuum through the holes of the mold (M) at the bottom.

17. The method according to claim 15 or 16, characterized in that a fabric is placed between the mold (M) and the object before the at least one fluid necessary for forming the part to be obtained is placed in the mold.

18. The method according to any one of claims 15-17, characterized in that said fabric is a fabric made of carbon fiber and said fluid comprises at least resin.

19. The method according to any one of claims 15-18, characterized in that the mold material fluidly poured onto the plate (P) is polyurethane.

20. The method according to any one of claims 15-19, characterized in that said plate (P) is made of vinyl.

21. The method according to claim 15, characterized in that the object (N) is removed from the mold (M) parts and the cavity between the molds (M) is filled with material supplied through the openings.

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