Method and material efficient tooling for continuous compression molding

Abstract

Thermoplastic laminates are fabricated in a continuous compression molding production line. A lay-up of laminate plies is placed in a recess on a carrying tool, and the tool is moved through successive forming operations on the line, including preforming and consolidation operations. The tool is separated from the fully formed part at the end of the line and may be reused. Use of the carrying tool reduces material scrap.

1 . Tooling used in a continuous process for forming laminated thermoplastic parts using a lay-up of laminate plies, comprising:
 a rigid body having first and second ends,   the body including a recessed area,   the first and second ends of the rigid body extending beyond the recessed area.   
     
     
         2 . The tooling of  claim 1 , wherein the recess defines first and second shoulders in the body for respectively engaging an end of the part. 
     
     
         3 . The tooling of  claim 1 , wherein the recess has a depth substantially equal to a thickness of the part. 
     
     
         4 . The tooling of  claim 1 , wherein the recess has a depth such that outer surfaces of the tooling are substantially coplanar with outer surfaces of the part. 
     
     
         5 . The tooling of  claim 1 , wherein the body has a cross sectional shape generally matching the cross sectional shape of the consolidated part. 
     
     
         6 . The tooling of  claim 1 , wherein the body is elongate and the recess is formed in the body between the first and second ends of the body. 
     
     
         7 . The tooling of  claim 1 , wherein the first and second ends of the body have an outer surface extending substantially coplanar with an outer surface of the part. 
     
     
         8 . The tooling of  claim 1 , wherein the recessed area has the general shape of a part and the part is carried in the recessed area. 
     
     
         9 . The tooling of  claim 1 , wherein the recessed area has a depth that varies in at least one direction across the recessed area. 
     
     
         10 . The tooling of  claim 1 , wherein the body includes tooling features within the recessed area for forming shapes in a part. 
     
     
         11 . Tooling for carrying a lay-up of laminate plies though a continuous compression molding line used to produce a part, comprising:
 an elongate body having opposite first and second ends,   the body having at least one recess,   the first and second ends of the rigid body extending respectively beyond opposite ends of the at least one recess lay-up and having outside surfaces forming an extension of the profile of the part when the lay-up is compressed into the shape of the part.   
     
     
         12 . The tooling of  claim 11 , wherein the at least one recess has the general shape of the part and the lay-up is received within the at least one recess. 
     
     
         13 . The tooling of  claim 11 , wherein the recess has a depth substantially equal to a thickness of the part. 
     
     
         14 . The tooling of  claim 11 , wherein the outside surfaces of the body are substantially coplanar with exterior surfaces of the compressed part. 
     
     
         15 . The tooling of  claim 11 , wherein the recess defines first and second shoulders in the body, and the first and second shoulders engage opposite ends of the part. 
     
     
         16 . The tooling of  claim 11 , wherein body has a cross sectional shape generally matching the cross sectional shape of the part. 
     
     
         17 . The tooling of  claim 11 , wherein the first end of the body extends beyond the recess a length sufficient such that at least portions of the first end of the body pass through the molding line before the lay-up enters the molding line. 
     
     
         18 . The tooling of  claim 11 , wherein the second end of the body extends beyond the recess a length sufficient such that at least portions of the second end of the body pass remain in the molding line after the lay-up has passed through the molding line. 
     
     
         19 . The tooling of  claim 11 , wherein the at least one recess has a non-uniform depth. 
     
     
         20 . The tooling of  claim 11 , wherein the body includes tooling features within the at least one recess for forming shapes in the part. 
     
     
         21 - 27 . (canceled) 
     
     
         28 . A tool for carrying a lay-up of laminate plies though a continuous compression molding line used to produce a part, comprising:
 an elongate body having a leading end, a central section, and a trailing end, in which a length of the leading end of the tool is greater than or equal to a distance between a pulsating drive mechanism and a pre-forming zone of the continuous compression molding line; and   at least one recess positioned within the central section,   
     
     
         29 . The tool of  claim 28 , wherein the at least one recess has a non-uniform depth. 
     
     
         30 . The tool of  claim 28 , wherein a length of the trailing end of the tool is greater than or equal to a length of a consolidation station of the continuous compression molding line. 
     
     
         31 . The tooling of  claim 1 , wherein a length of the first end of the tooling is greater than or equal to a distance between a pulsating drive mechanism and a pre-forming zone of the continuous compression molding line. 
     
     
         32 . The tooling of  claim 11 , wherein a length of the first end of the tooling is greater than or equal to a distance between a pulsating drive mechanism and a pre-forming zone of the continuous compression molding line. 
     
     
         33 . The tooling of  claim 1 , wherein a length of the second end of the tooling is greater than or equal to a length of a consolidation station of the continuous compression molding line. 
     
     
         34 . The tooling of  claim 11 , wherein a length of the second end of the tooling is greater than or equal to a length of a consolidation station of the continuous compression molding line.