Vortex control in slurry molding applications

Abstract

A molding head is especially adapted for vacuum molding or forming of structures and, in particular, fibrous composite structures in an adjustable, controllable three dimensional orientation before, during and after molding. Such a molding head includes a mold plate with narrow slots in the mold surface thereof and wider channels in the back surface thereof, with such slots and channels intersecting one another. A control system of servomotors or other actuators permits movement and orientation of the mold head during forming, thereby creating the ability to vary the material properties based on gravity and particle or suspension grain, thickness and other now controllable properties.

1 . A molding system comprising:
 a container for holding material to be molded;   a mold head on which material is be molded;   at least one arm attached to said mold head and capable of moving said mold head in three-dimensions within said container.   
     
     
         2 . The molding system of  claim 1  wherein said material is at least one of a pulp, slurry or suspension mixture. 
     
     
         3 . The molding system of  claim 1  wherein said material comprises a fiber. 
     
     
         4 . The molding system of  claim 3  wherein said fiber comprises at least one fiber selected from carbon fibers, Kevlar® fiber, fiberglass, ceramic fibers, ceramic fiber precursors. 
     
     
         5 . The molding system of  claim 1  further comprising a pressure reduction device associated with said mold head capable of drawing material through said mold head. 
     
     
         6 . The molding system of  claim 5  in which said pressure reduction device includes at least one rotary union, such that vacuum pressure may be applied to said mold head while said mold head is in different positions within said container. 
     
     
         7 . The molding system of  claim 6  in which said pressure reduction device varies the vacuum pressure applied to said mold head during the molding operation. 
     
     
         8 . The molding system of  claim 1  in which said arm comprises includes servos for moving said mold head. 
     
     
         9 . The molding system of  claim 8  in which said arm comprises linear servos for moving said mold head within said container. 
     
     
         10 . The molding system of  claim 1  wherein said material drawn through said mold head forms a vortex perpendicular to a portion of said mold head and said portion of said mold head is movable in a direction which is not perpendicular to said vortex. 
     
     
         11 . The molding system of  claim 1  wherein said mold head further comprises a vortex generator. 
     
     
         12 - 23 . (canceled) 
     
     
         24 . A molded part formed by the process of:
 providing a container for holding a material to be molded; placing a molding head into said material wherein said molding head comprises passages therethrough; applying a reduced pressure to said molding head to draw material through said passages;   moving said molded part in three dimensions within said material; and   forming said molded part on said molding head.   
     
     
         25 . The molded part of  claim 24  in which said container holds at least one of a pulp, slurry or suspension mixture. 
     
     
         26 . The molded part of  claim 24  wherein said material comprises a fiber. 
     
     
         27 . The molded part of  claim 26  wherein said fiber comprises at least one fiber selected from carbon fibers, fiberglass, ceramic fibers, ceramic fiber precursors. 
     
     
         28 . The molded part of  claim 27  wherein said depletion of said material comprises depletion of said fiber. 
     
     
         29 . The molded part of  claim 24  further comprising a pressure reduction device associated with said mold head capable of drawing material through said mold head. 
     
     
         30 . The molded part of  claim 29  in which said pressure reduction device includes at least one rotary union, such that vacuum pressure may be applied to said mold head while said mold head is in different positions within said container. 
     
     
         31 . The molded part of  claim 30  in which said pressure reduction device varies the vacuum pressure applied to said mold head during the molding operation. 
     
     
         32 . The molded part of  claim 24  in which said arm comprises includes servos for moving said mold head. 
     
     
         33 . The molded part of  claim 24  in which said arm comprises linear servos for moving said mold head within said container. 
     
     
         34 . The molded part of  claim 24  wherein said material is drawn through said mold head forming a vortex perpendicular to a portion of said mold head and said portion of said mold head is moved in a direction which is not perpendicular to said vortex. 
     
     
         35 . (canceled)