Compression Moulding Composite Process Using Liquid Metal Alloy
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Solution Overview
Problem
Current molding techniques for composite materials with high anisotropy, such as thermoplastic and thermosetting polymers, face challenges in reducing manufacturing cycles due to the thermal inertia of molds, leading to high costs and low productivity, especially when producing hollow parts.
Innovation Solution
A process using a sheet of heat-moldable material with a deformable but resistant membrane, paired with a metal alloy that is introduced in liquid form into a mold to shape and heat the material, eliminating the need for the mold to serve as a heating and cooling source, thereby reducing cycle time and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the mold is used as a thermal means to heat and cool the material, then the material can be transformed into the desired shape, but the significant thermal inertia of the mold considerably increases the duration of the transformation cycle
Solution Approach 1:
The invention separates the thermal functions from the mold structure by introducing a dedicated thermal fluid circulation system. The mold cavity is equipped with channels through which hot and cold fluids circulate, allowing independent control of heating and cooling processes without being constrained by the mold's thermal inertia.
Solution Approach 2:
A thermal fluid acts as an intermediary between the heat sources/sinks and the material being molded. The fluid circulates through channels in the mold, transferring thermal energy efficiently to and from the material, thereby decoupling the mold structure from the thermal transformation process.
2Productivity
If the mass of the mold is reduced while increasing thermal power, then the transformation cycle can be shortened, but the mold becomes deformed during rapid and repeated thermal cycles
Solution Approach 1:
The thermal functions are extracted from the mold structure itself and transferred to a separate fluid circulation system. This allows the mold to maintain its structural integrity and mass for stability while the fluid system provides the rapid thermal response needed for short cycle times.
Solution Approach 2:
The thermal fluid system serves multiple functions: heating the material, cooling the molded part, and can be adjusted for different material types and molding requirements. This multi-functional system replaces the need for the mold structure itself to perform thermal functions.
3Productivity
If a simplified mold with no proper heating means is used, then the thermal inertia is reduced, but significant displacement of the mold during manufacture is required which proves restrictive
Solution Approach 1:
The mold is equipped with self-contained heating and cooling channels that allow it to perform thermal functions independently without requiring external heating devices or significant displacement between heating and molding stages. The thermal fluid system serves the mold's own thermal needs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly shortens manufacturing cycles, reduces energy consumption, and lowers costs by utilizing a metal alloy for both shaping and heating, while maintaining the mold's geometric function without thermal constraints, making it suitable for large series production.
Implementation Method 1
introducing the first metal alloy in liquid form into the mold... said first alloy being carried... at a molding temperature higher than the transformation temperature of the mouldable material
Implementation Method 2
providing a first metal alloy whose melting temperature is lower than the transformation temperature of the moldable material
Data Source
Figure 1~6
Figure 7~13
Figure 9~11
AI summary
The process consists of inserting a layer of a composition material (1) that can be moulded when hot, together with a lining membrane (6) with low thermal insulation and strong but deformable at moulding temperature, in the mould cavity and pressing it against the cavity surfaces by a first metal alloy in liquid form. The alloy is heated to a moulding temperature above the transition temperature of the composition material and raised to a pressure sufficient to force the material against the mould cavity surface so that it adopts the required shape. A second metal alloy with a lower melting point is used to remove the article from the mould. Both metal alloys contain lead, tin, bismuth or cadmium.