US2014159267A1PendingUtilityA1

System and method for forming composite articles

Individually held — no corporate assignee on recordPriority: Jul 28, 2011Filed: Jul 30, 2012Published: Jun 12, 2014

Est. expiryJul 28, 2031(~4.9 yrs left)· nominal 20-yr term from priority

Inventors:Robert W. Murch Gary R. Lownsdale Douglas L. Bartolotti

B29C 35/0294B29C 35/007

PatentIndex Score

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References

Claims

Abstract

A thermal system ( 20 ) for rapidly heating and cooling a mold surface ( 24 ) of a tool ( 26 ) comprises a heater-subsystem ( 40 ) in fluid communication with the tool ( 26 ). The heater-subsystem ( 40 ) comprises a heater ( 42 ), a tank ( 44 ), and a three-way valve ( 46 ). The tank ( 44 ) contains a mass of heated thermal fluid. The system ( 20 ) further comprises an exchanger-subsystem ( 49 ) in fluid communication with the heater-sub system ( 40 ) and the tool ( 26 ). The exchanger-subsystem ( 49 ) comprises an exchanger ( 51 ) and a three-way valve ( 53 ). The system ( 20 ) further comprises a chiller-sub system ( 48 ) in fluid communication with the exchanger-subsystem ( 49 ). The chiller-subsystem ( 48 ) comprises a chiller ( 50 ), a tank ( 52 ), and a three-way valve ( 54 ). The tank ( 52 ) contains a mass of cooled thermal fluid. A controller ( 56 ) can be used to control and/or instruct the subsystems ( 40,48,49 ). The system ( 20 ) and tool ( 26 ) can be used for forming a composite article ( 22 ), such as a carbon fiber composite (CFC) article ( 22 ). A method utilizing the system ( 20 ) is also provided.

Claims

exact text as granted — not AI-modified

1 . A thermal system ( 20 ) for rapidly heating and cooling a mold surface ( 24 ) of a tool ( 26 ) used for forming a composite article ( 22 ), said thermal system ( 20 ) comprising:
 I) a heater-subsystem ( 40 ) in fluid communication with the tool ( 26 ) and comprising;
 a heater ( 42 ) for heating a first thermal fluid, 
 a tank ( 44 ) in fluid communication with said heater ( 42 ) and containing a mass of heated first thermal fluid, and 
 a three-way valve ( 46 ) in fluid communication i) between said tank ( 44 ) and said heater ( 42 ) for re-circulating the first thermal fluid from said tank ( 44 ) to said heater ( 42 ) and ii) between said tank ( 44 ) and the tool ( 26 ) for directing the first thermal fluid from said tank ( 44 ) to the tool ( 26 ); 
   II) an exchanger-subsystem ( 49 ) in fluid communication with said heater-subsystem ( 40 ) and the tool ( 26 ) and comprising;
 an exchanger ( 51 ) for cooling the first thermal fluid returning from the tool ( 26 ), and 
 a three-way valve ( 53 ) in fluid communication i) between said exchanger ( 51 ) and said heater-subsystem ( 40 ) for sending the first thermal fluid from the tool ( 26 ) back to the heater-subsystem ( 40 ) and ii) between said exchanger ( 51 ) and the tool ( 26 ) for directing the first thermal fluid from the tool ( 26 ) to said exchanger ( 51 ); and 
   III) a chiller-subsystem ( 48 ) in fluid communication with said exchanger-subsystem ( 49 ) and comprising;
 a chiller ( 50 ) to cool a second thermal fluid, 
 a tank ( 52 ) in fluid communication with said chiller ( 50 ) and containing a mass of cooled second thermal fluid, and 
 a three-way valve ( 54 ) in fluid communication i) between said tank ( 52 ) and said chiller ( 50 ) for re-circulating the second thermal fluid from said tank ( 52 ) to said chiller ( 50 ) and ii) between said tank ( 52 ) and said exchanger-subsystem ( 49 ) for directing the second thermal fluid from said tank ( 52 ) to said exchanger ( 51 ). 
   
     
     
         2 . The thermal system ( 20 ) as set forth in  claim 1  further comprising a controller ( 56 ) in communication with said subsystems ( 40 , 48 , 49 ) and the tool ( 26 ) for directing the thermal fluids within the thermal system ( 20 ) via control of the three-way valves ( 46 , 53 , 54 ). 
     
     
         3 . The thermal system ( 20 ) as set forth in  claim 2  wherein said controller ( 56 ) is programmed to instruct said three-way valve ( 46 ) of said heater-subsystem ( 40 ) such that the first thermal fluid:
 i) re-circulates between said heater ( 42 ) and said tank ( 44 ) and bypasses the tool ( 26 ) to maintain the mass of heated first thermal fluid in said heater-subsystem ( 40 ); or 
 ii) is directed from said heater-subsystem ( 40 ) to the tool ( 26 ) to heat the mold surface ( 24 ) of the tool ( 26 ). 
 
     
     
         4 . (canceled) 
     
     
         5 . The thermal system ( 20 ) as set forth in  claim 2  wherein said controller ( 56 ) is programmed to instruct said three-way valve ( 54 ) of said chiller-subsystem ( 48 ) such that the second thermal fluid:
 i) re-circulates between said chiller ( 50 ) and said tank ( 52 ) and bypasses said exchanger-subsystem ( 49 ) to maintain the mass of cooled second thermal fluid in said chiller-subsystem ( 48 ); or 
 ii) is directed from said chiller-subsystem ( 48 ) to said exchanger-subsystem ( 49 ) to cool the first thermal fluid returning from the tool ( 26 ) and entering said exchanger-subsystem ( 49 ). 
 
     
     
         6 . (canceled) 
     
     
         7 . The thermal system ( 20 ) as set forth in  claim 2  wherein said controller ( 56 ) is programmed to instruct said three-way valve ( 53 ) of said exchanger-subsystem ( 49 ) such that the first thermal fluid returning from the tool ( 26 ) is directed to:
 i) said heater-subsystem ( 40 ) and bypasses said exchanger-subsystem ( 49 ) to reheat the first thermal fluid within said heater-subsystem ( 40 ); or 
 ii) said exchanger-subsystem ( 49 ) to cool the first thermal fluid via the second thermal fluid from the chiller-subsystem ( 48 ). 
 
     
     
         8 . (canceled) 
     
     
         9 . The thermal system ( 20 ) as set forth in  claim 1  further comprising:
 i) a pump ( 55 ) in fluid communication between the tool ( 26 ), said heater-subsystem ( 40 ), and said exchanger-subsystem ( 49 ), for directing the first thermal fluid from said subsystems ( 40 , 49 ) to the tool ( 26 ); 
 ii) at least one supplemental valve ( 58 ) in fluid communication a) between said heater-subsystem ( 40 ) and the tool ( 26 ) for directing the first thermal fluid to and from the tool ( 26 ) and said heater-subsystem ( 40 ) and/or b) between said exchanger-subsystem ( 49 ) and the tool ( 26 ) for directing the first thermal fluid to and from the tool ( 26 ) and said exchanger-subsystem ( 49 ); or 
 iii) both i) and ii). 
 
     
     
         10 . (canceled) 
     
     
         11 . The thermal system ( 20 ) as set forth in  claim 1  wherein;
 the first thermal fluid is shared between said heater-subsystem ( 40 ) and said exchanger-subsystem ( 49 ), 
 the second thermal fluid is shared between said chiller-subsystem ( 48 ) and said exchanger-subsystem ( 49 ), and 
 the first thermal fluid is kept separate from the second thermal fluid. 
 
     
     
         12 . The thermal system ( 20 ) as set forth in  claim 1  wherein the first thermal fluid is different from the second thermal fluid. 
     
     
         13 - 14 . (canceled) 
     
     
         15 . The thermal system ( 20 ) as set forth in  claim 1  wherein;
 the mold surface ( 24 ) of the tool ( 26 ) heats at a rate of greater than about 33° C. per minute (60° F./min), alternatively greater than about 39° C. per minute (70° F./min), via the heater-subsystem ( 40 ), and 
 the mold surface ( 24 ) of the tool ( 26 ) cools at a rate of greater than about 22° C. per minute (40° F./min), alternatively greater than about 28° C. per minute (50° F./min), via the exchanger-subsystem ( 49 ) and the chiller-subsystem ( 48 ). 
 
     
     
         16 . (canceled) 
     
     
         17 . The thermal system ( 20 ) as set forth in  claim 1  further comprising:
 a tool-connection system ( 200 ) operatively connected to said tool ( 26 ), and 
 a press-connection system ( 218 ) in fluid communication with said heater-subsystem ( 40 ) and said exchanger-subsystem ( 49 ), 
 wherein said connection systems ( 200 , 218 ) couple together for feeding and receiving the first thermal fluid to and from said tool ( 26 ). 
 
     
     
         18 . The thermal system ( 20 ) as set forth in  claim 17 :
 i) wherein said tool ( 26 ) includes tubing ( 28 ) opposite said mold surface ( 24 ) and said press-connection system ( 218 ) is operatively connected to said tubing ( 28 ) for heating and cooling said mold surface ( 24 ) with the first thermal fluid;   ii) further comprising a press ( 64 ) having a platform ( 68 ) and a cover ( 70 ) facing said platform ( 68 ) with said cover ( 70 ) operable to couple with said platform ( 68 ) to define a cavity ( 72 ) operable to maintain a pressurized and/or temperature controlled environment and wherein said press-connection system ( 218 ) is operatively connected through said cover ( 70 ) and/or said platform ( 68 ) into the cavity ( 72 ) for coupling with said tool-connection system ( 200 ) while said tool ( 26 ) is disposed within the cavity ( 70 ) of the press ( 64 ) for heating and cooling said mold surface ( 26 ) with the first thermal fluid; or   iii) both i) and ii).   
     
     
         19 - 20 . (canceled) 
     
     
         21 . A method of rapidly heating and cooling a mold surface ( 24 ) of a tool ( 26 ) used for forming a composite article ( 22 ), said method comprising the steps of:
 providing a heater-subsystem ( 40 ) in fluid communication with the tool ( 26 ) and comprising;
 a heater ( 42 ) for heating a first thermal fluid, 
 a tank ( 44 ) in fluid communication with the heater ( 42 ) and containing a mass of heated first thermal fluid, and 
 a three-way valve ( 46 ) in fluid communication i) between the tank ( 44 ) and the heater ( 42 ) for re-circulating the first thermal fluid from the tank ( 44 ) to the heater ( 42 ) and ii) between the tank ( 44 ) and the tool ( 26 ) for directing the first thermal fluid from the tank ( 44 ) to the tool ( 26 ); 
   providing an exchanger-subsystem ( 49 ) in fluid communication with the heater-subsystem ( 40 ) and the tool ( 26 ) and comprising;
 an exchanger ( 51 ) for cooling the first thermal fluid returning from the tool ( 26 ), and 
 a three-way valve ( 53 ) in fluid communication i) between the exchanger ( 51 ) and the heater-subsystem ( 40 ) for sending the first thermal fluid from the tool ( 26 ) back to the heater-subsystem ( 40 ) and ii) between the exchanger ( 51 ) and the tool ( 26 ) for directing the first thermal fluid from the tool ( 26 ) to the exchanger ( 51 ); and 
   providing a chiller-subsystem ( 48 ) in fluid communication with the exchanger-subsystem ( 49 ) and comprising;
 a chiller ( 50 ) to cool a second thermal fluid, 
 a tank ( 52 ) in fluid communication with the chiller ( 50 ) and containing a mass of cooled second thermal fluid, and 
 a three-way valve ( 54 ) in fluid communication i) between the tank ( 52 ) and the chiller ( 50 ) for re-circulating the second thermal fluid from the tank ( 52 ) to the chiller ( 50 ) and ii) between the tank ( 52 ) and the exchanger-subsystem ( 49 ) for directing the second thermal fluid from the tank ( 52 ) to the exchanger ( 51 ); 
   providing a controller ( 56 ) in communication with the tool ( 26 ) and the subsystems ( 40 , 48 , 49 ) for instructing the subsystems ( 40 , 48 , 49 );   directing the mass of heated first thermal fluid from the tank ( 44 ) of the heater-subsystem ( 40 ) to the tool ( 26 ) via the controller ( 56 ) to heat the mold surface ( 24 ) of the tool ( 26 ) from a first temperature (T 1 ) to a second temperature (T 2 ) within a first period of time (Tt 1 );   directing the mass of heated first thermal fluid from the tank ( 44 ) of the heater-subsystem ( 40 ) to the mold surface ( 24 ) of the tool ( 26 ) via the controller ( 56 ) to maintain the mold surface ( 24 ) at T 2  for a second period of time (Tt 2 ); and   directing the mass of cooled second thermal fluid from the tank ( 52 ) of the chiller-subsystem ( 48 ) to the exchanger-subsystem ( 49 ) via the controller ( 56 ) to cool the mold surface ( 24 ) of the tool ( 26 ) from T 2  to a third temperature (T 3 ) within a third period of time (Tt 3 );   wherein the mold surface ( 24 ) of the tool ( 26 ) heats at a rate of greater than about 33° C. per minute (60° F./min) and cools at a rate of greater than about 22° C. per minute (40° F./min); and   wherein Tt 1 +Tt 2 +Tt 3  is no greater than 20 minutes.   
     
     
         22 . (canceled) 
     
     
         23 . The method as set forth in  claim 21  wherein the controller ( 56 ) instructs the three-way valve ( 46 ) of the heater-subsystem ( 40 ) such that the first thermal fluid:
 i) re-circulates between the heater ( 42 ) and the tank ( 44 ) and bypasses the tool ( 26 ) to maintain the mass of heated first thermal fluid in the heater-subsystem ( 40 ) at a temperature of T 2  or higher; or 
 ii) is directed from the heater-subsystem ( 40 ) to the tool ( 26 ) to heat the mold surface ( 24 ) of the tool ( 26 ) from T 1  to T 2 . 
 
     
     
         24 . (canceled) 
     
     
         25 . The method as set forth in  claim 21  wherein the controller ( 56 ) instructs the three-way valve ( 54 ) of the chiller-subsystem ( 48 ) such that the second thermal fluid:
 i) re-circulates between the chiller ( 50 ) and the tank ( 52 ) and bypasses the exchanger-subsystem ( 49 ) to maintain the mass of cooled second thermal fluid in the chiller-subsystem ( 48 ) at a temperature of T 3  or lower; or 
 ii) is directed from the chiller-subsystem ( 48 ) to the exchanger-subsystem ( 49 ) to cool the first thermal fluid returning from the tool ( 26 ) and entering the exchanger-subsystem ( 49 ) to a temperature lower than T 2 . 
 
     
     
         26 . (canceled) 
     
     
         27 . The method as set forth in  claim 21  wherein the controller ( 56 ) instructs the three-way valve ( 53 ) of the exchanger-subsystem ( 49 ) such that the first thermal fluid returning from the tool ( 26 ) is directed to:
 i) the heater-subsystem ( 40 ) and bypasses the exchanger-subsystem ( 49 ) to reheat the first thermal fluid within the heater-subsystem ( 40 ) to a temperature of T 2  or higher; or 
 ii) the exchanger-subsystem ( 49 ) to cool the first thermal fluid via the second thermal fluid from the chiller-subsystem ( 48 ) to a temperature lower than T 2 . 
 
     
     
         28 . (canceled) 
     
     
         29 . The method as set forth in  claim 21  further comprising the step of maintaining the mold surface ( 24 ) of the tool ( 26 ) at an intermediate temperature (T 1-2 ) of between T 1  and T 2  via the controller ( 56 ) for a portion of Tt 1  (Tt &lt;1 ) prior to heating the mold surface ( 24 ) of the tool ( 26 ) to T 2 . 
     
     
         30 . The method as set forth in  claim 29  wherein:
 i) T 1-2  is from about 38° C. (100° F.) to about 177° C. (350° F.); 
 ii) Tt &lt;1  is from 1 to less than 10 minutes; or 
 iii) both i) and ii). 
 
     
     
         31 . (canceled) 
     
     
         32 . The method as set forth in  claim 21  wherein:
 i) T 1  is from about 10° C. (50° F.) to about 52° C. (125° F.); and/or 
 ii) T 2  is from about 121° C. (250° F.) to about 204° C. (400° F.); and/or 
 iii) T 3  is from about 24° C. (75° F.) to about 66° C. (150° F.). 
 
     
     
         33 - 34 . (canceled) 
     
     
         35 . The method as set forth in  claim 21  wherein Tt 1  is from 1 to 10 minutes, Tt 2  is from 1 to 10 minutes, and Tt 3  is from 1 to 10 minutes, provided that Tt 1 +Tt 2 +Tt 3  is no greater than 20 minutes. 
     
     
         36 - 37 . (canceled) 
     
     
         38 . The method as set forth in  claim 21  wherein:
 i) the mass of heated first thermal fluid in the tank ( 44 ) of the heater-subsystem ( 40 ) is at a temperature of T 2  or higher for heating the mold surface ( 24 ) of the tool ( 26 ) with the mass of heated fluid; 
 ii) the mass of cooled second thermal fluid in the tank ( 52 ) of the chiller-subsystem ( 48 ) is at a temperature of T 3  or lower for cooling the mold surface of the tool ( 26 ); or 
 iii) both i) and ii). 
 
     
     
         39 - 41 . (canceled)

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