High rate fabrication of compression molded components

Matsen, Marc R.; Negley, Mark A.; Dykstra, William C.; Smith, Glen L.; Miller, Robert J.

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A - human necessities
A01 - agriculture
A21 - baking
A22 - butchering
A23 - foods or foodstuffs
A24 - tobacco
A41 - wearing apparel
A42 - headwear
A43 - footwear
A44 - haberdashery
A45 - hand or travelling articles
A46 - brushware
A47 - furniture
A61 - medical or veterinary science
A62 - life-saving
A63 - sports
A99 - subject matter not otherwise provided for in this section
B - performing operations
B01 - physical or chemical processes or apparatus in general
B02 - crushing, pulverising, or disintegrating
B03 - separation of solid materials using liquids or using pneumatic tables or jigs
B04 - centrifugal apparatus or machines for carrying-out physical or chemical processes
B05 - spraying or atomising in general
B06 - generating or transmitting mechanical vibrations in general
B07 - separating solids from solids
B08 - cleaning
B09 - disposal of solid waste
B21 - mechanical metal-working without essentially removing material
B22 - casting
B23 - machine tools
B24 - grinding
B25 - hand tools
B26 - hand cutting tools
B27 - working or preserving wood or similar material
B28 - working cement, clay, or stone
B29 - working of plastics
B30 - presses
B31 - making articles of paper, cardboard or material worked in a manner analogous to paper
B32 - layered products
B33 - additive manufacturing technology
B41 - printing
B42 - bookbinding
B43 - writing or drawing implements
B44 - decorative arts
B60 - vehicles in general
B61 - railways
B62 - land vehicles for travelling otherwise than on rails
B63 - ships or other waterborne vessels
B64 - aircraft
B65 - conveying
B66 - hoisting
B67 - opening, closing {or cleaning} bottles, jars or similar containers
B68 - saddlery
B81 - microstructural technology
B82 - nanotechnology
B99 - subject matter not otherwise provided for in this section
C - chemistry
C01 - inorganic chemistry
C02 - treatment of water, waste water, sewage, or sludge
C03 - glass
C04 - cements
C05 - fertilisers
C06 - explosives
C07 - organic chemistry
C08 - organic macromolecular compounds
C09 - dyes
C10 - petroleum, gas or coke industries
C11 - animal or vegetable oils, fats, fatty substances or waxes
C12 - biochemistry
C13 - sugar industry
C14 - skins
C21 - metallurgy of iron
C22 - metallurgy
C23 - coating metallic material
C25 - electrolytic or electrophoretic processes
C30 - crystal growth
C40 - combinatorial technology
C99 - subject matter not otherwise provided for in this section
D - textiles
D01 - natural or man-made threads or fibres
D02 - yarns
D03 - weaving
D04 - braiding
D05 - sewing
D06 - treatment of textiles or the like
D07 - ropes
D10 - indexing scheme associated with sublasses of section d, relating to textiles
D21 - paper-making
D99 - subject matter not otherwise provided for in this section
E - fixed constructions
E01 - construction of roads, railways, or bridges
E02 - hydraulic engineering
E03 - water supply
E04 - building
E05 - locks
E06 - doors, windows, shutters, or roller blinds in general
E21 - earth drilling
E99 - subject matter not otherwise provided for in this section
F - mechanical engineering
F01 - machines or engines in general
F02 - combustion engines
F03 - machines or engines for liquids
F04 - positive - displacement machines for liquids
F05 - indexing schemes relating to engines or pumps in various subclasses of classes f01-f04
F15 - fluid-pressure actuators
F16 - engineering elements and units
F17 - storing or distributing gases or liquids
F21 - lighting
F22 - steam generation
F23 - combustion apparatus
F24 - heating
F25 - refrigeration or cooling
F26 - drying
F27 - furnaces
F28 - heat exchange in general
F41 - weapons
F42 - ammunition
F99 - subject matter not otherwise provided for in this section
G - physics
G01 - measuring
G02 - optics
G03 - photography
G04 - horology
G05 - controlling
G06 - computing
G07 - checking-devices
G08 - signalling
G09 - education
G10 - musical instruments
G11 - information storage
G12 - instrument details
G16 - information and communication technology [ict] specially adapted for specific application fields
G21 - nuclear physics
G99 - subject matter not otherwise provided for in this section
H - electricity
H01 - basic electric elements
H02 - generation
H03 - basic electronic circuitry
H04 - electric communication technique
H05 - electric techniques not otherwise provided for
H99 - subject matter not otherwise provided for in this section
Y - new / cross sectional technologies
Y02 - technologies or applications for mitigation or adaptation against climate change
Y04 - information or communication technologies having an impact on other technology areas
Y10 - technical subjects covered by former uspc

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Title: High rate fabrication of compression molded components

Abstract

A method for fabricating a thermoplastic composite component comprises inductively heating a thermoplastic pre-form with a first induction coil by inducing current to flow in susceptor wires disposed throughout the pre-form, inductively heating smart susceptors in a molding tool to a leveling temperature with a second induction coil by applying a high-strength magnetic field having a magnetic flux that passes through surfaces of the smart susceptors, shaping the magnetic flux that passes through surfaces of the smart susceptors to flow substantially parallel to a molding surface of the smart susceptors, placing the heated pre-form between the heated smart susceptors; and applying molding pressure to the pre-form to form the composite component.

Inventors:: Matsen, Marc R.; Negley, Mark A.; Dykstra, William C.; Smith, Glen L.; Miller, Robert J.

Issue Date:: Tue Apr 19 00:00:00 EDT 2016

Research Org.:: The Boeing Company, Chicago, IL (United States)

Sponsoring Org.:: USDOE

OSTI Identifier:: 1248017

Patent Number(s):: 9314975

Application Number:: 13/870,111

Assignee:: The Boeing Company (Chicago, IL)

Patent Classifications (CPCs):: B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29C - SHAPING OR JOINING OF PLASTICS

B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29K - INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS

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B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29C - SHAPING OR JOINING OF PLASTICS
B29C2035/0811 - {using induction}
B29C2043/568 - {in a magnetic or electric field}
B29C2043/5816 - {temperature}
B29C33/06 - using radiation {, e.g. electro-magnetic waves, induction heating}
B29C35/0805 - {using electromagnetic radiation}
B29C43/18 - incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles {
B29C43/52 - Heating or cooling
B29C51/082 - {by shaping between complementary mould parts}
B29C51/421 - {of preforms, specially adapted for thermoforming
B29C70/345 - {using matched moulds}
B29C70/42 - for producing articles of definite length, i.e. discrete articles
B29C70/46 - using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
B29C70/54 - Component parts, details or accessories

B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29K - INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
B29K2105/06 - containing reinforcements, fillers or inserts
B29K2105/0872 - {Prepregs}

Show less

DOE Contract Number:: FG36-08GO18135

Resource Type:: Patent

Resource Relation:: Patent File Date: 2013 Apr 25

Country of Publication:: United States

Language:: English

Subject:: 36 MATERIALS SCIENCE; 32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION

Citation Formats


                    Matsen, Marc R., Negley, Mark A., Dykstra, William C., Smith, Glen L., and Miller, Robert J. High rate fabrication of compression molded components.  United States: N. p., 2016. 
        Web.

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                    Matsen, Marc R., Negley, Mark A., Dykstra, William C., Smith, Glen L., & Miller, Robert J. High rate fabrication of compression molded components.  United States.

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                    Matsen, Marc R., Negley, Mark A., Dykstra, William C., Smith, Glen L., and Miller, Robert J. Tue .  
        "High rate fabrication of compression molded components".  United States.  https://www.osti.gov/servlets/purl/1248017.

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@article{osti_1248017,

  title        = {High rate fabrication of compression molded components},

  author       = {Matsen, Marc R. and Negley, Mark A. and Dykstra, William C. and Smith, Glen L. and Miller, Robert J.},

  abstractNote = {A method for fabricating a thermoplastic composite component comprises inductively heating a thermoplastic pre-form with a first induction coil by inducing current to flow in susceptor wires disposed throughout the pre-form, inductively heating smart susceptors in a molding tool to a leveling temperature with a second induction coil by applying a high-strength magnetic field having a magnetic flux that passes through surfaces of the smart susceptors, shaping the magnetic flux that passes through surfaces of the smart susceptors to flow substantially parallel to a molding surface of the smart susceptors, placing the heated pre-form between the heated smart susceptors; and applying molding pressure to the pre-form to form the composite component.},

  doi          = {},

  journal      = {},
number       = ,

  volume       = ,

  place        = {United States},

  year         = {Tue Apr 19 00:00:00 EDT 2016},

  month        = {Tue Apr 19 00:00:00 EDT 2016}

}

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Works referenced in this record:

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Cattanach, James B.; Barnes, Anthony
US Patent Document 4,657,717
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Consolidation of thermoplastic panels
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Gap filling for thermoplastic welds
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Anderson, Robert C.; Christensen, Stephen; Peterson, Todd R.
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Structural susceptor for thermoplastic welding
patent, February 1998

Christensen, Stephen; Gosse, Jonathan H.
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Method for achieving thermal uniformity in induction processing of organic matrix composites or metals
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Matsen, Marc R.; Woods, Edward J.; Hansen, Karl A.
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Barbed susceptor for improviing pulloff strength in welded thermoplastic composite structures
patent, May 1998

Kirkwood, Brad L.; Patt, Paul
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Monitoring the bond line temperature in thermoplastic welds
patent, June 1998

Matsen, Marc R.; Hansen, Karl A.; deJong, executor, John J.
US Patent Document 5,760,379
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Method of shaping susceptor-based polymeric materials
patent, February 2002

Swartz, Henry D.; Magnant, Gary P.; Corey, George
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System and method for controlling an induction heating process
patent, March 2003

Matsen, Marc R.; Mittleider, John A.; Privett, Richard T.
US Patent Document 6,528,771
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Method for alleviating residual tensile strain in thermoplastic welds
patent, August 2003

Christensen, Stephen; Gosse, Jonathan H.
US Patent Document 6,602,810
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Induction processable ceramic die with durable die liner
patent, February 2005

Matsen, Marc R.; Brown, Ronald W.; Fischer, John R.
US Patent Document 6,855,917
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Method of forming a tubular blank into a structural component and die therefor
patent, April 2006

Pfaffmann, George D.; Dykstra, William C.; Matsen, Marc R.
US Patent Document 7,024,897
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Forming method and apparatus and an associated preform having a hydrostatic pressing medium
patent, March 2011

Matsen, Marc R.; Crow, Wesley B.; Firth, Lee C.
US Patent Document 7,905,128
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patent, September 2011

Matsen, Marc R.; Peterson, Kim E.; Dykstra, William C.
US Patent Document 8,017,059
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patent, January 2013

Matsen, Marc R.; Crow, Wesley B.; Kirkwood, Brad L.
US Patent Document 8,343,402
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Matsen, Marc R.; Peterson, Kim E.
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patent, February 2013

Matsen, Marc R.; Dykstra, William C.
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Matsen, Marc R.; Dykstra, William C.
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Method for curing a composite part layup
patent, October 2014

Matsen, Marc R.; Negley, Mark A.; Peterson, Kim E.
US Patent Document 8,865,050
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/8865050

Doubler repair apparatus and method
patent, March 2015

Nigro, Mary Katherine; Matsen, Marc R.; Miller, Robert J.
US Patent Document 8,980,029
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Similar Records

Title: High rate fabrication of compression molded components

Abstract

Citation Formats

Forming fibre-plastics composites patent, April 1987

Consolidation of thermoplastic panels patent, February 1990

Selvaged susceptor for thermoplastic welding by induction heating patent, April 1996

Gap filling for thermoplastic welds patent, January 1998

Structural susceptor for thermoplastic welding patent, February 1998

Method for achieving thermal uniformity in induction processing of organic matrix composites or metals patent, March 1998

Barbed susceptor for improviing pulloff strength in welded thermoplastic composite structures patent, May 1998

Monitoring the bond line temperature in thermoplastic welds patent, June 1998

Method of shaping susceptor-based polymeric materials patent, February 2002

System and method for controlling an induction heating process patent, March 2003

Method for alleviating residual tensile strain in thermoplastic welds patent, August 2003

Induction processable ceramic die with durable die liner patent, February 2005

Method of forming a tubular blank into a structural component and die therefor patent, April 2006

Forming method and apparatus and an associated preform having a hydrostatic pressing medium patent, March 2011

Composite fabrication apparatus and method patent, September 2011

Consolidation of composite material patent, January 2013

Method for resin transfer molding composite parts patent, February 2013

Induction forming of metal components with slotted susceptors patent, February 2013

Induction forming of metal components with integral heat treatment patent, July 2013

Method for curing a composite part layup patent, October 2014

Doubler repair apparatus and method patent, March 2015

Forming fibre-plastics composites
patent, April 1987

Consolidation of thermoplastic panels
patent, February 1990

Selvaged susceptor for thermoplastic welding by induction heating
patent, April 1996

Gap filling for thermoplastic welds
patent, January 1998

Structural susceptor for thermoplastic welding
patent, February 1998

Method for achieving thermal uniformity in induction processing of organic matrix composites or metals
patent, March 1998

Barbed susceptor for improviing pulloff strength in welded thermoplastic composite structures
patent, May 1998

Monitoring the bond line temperature in thermoplastic welds
patent, June 1998

Method of shaping susceptor-based polymeric materials
patent, February 2002

System and method for controlling an induction heating process
patent, March 2003

Method for alleviating residual tensile strain in thermoplastic welds
patent, August 2003

Induction processable ceramic die with durable die liner
patent, February 2005

Method of forming a tubular blank into a structural component and die therefor
patent, April 2006

Forming method and apparatus and an associated preform having a hydrostatic pressing medium
patent, March 2011

Composite fabrication apparatus and method
patent, September 2011

Consolidation of composite material
patent, January 2013

Method for resin transfer molding composite parts
patent, February 2013

Induction forming of metal components with slotted susceptors
patent, February 2013

Induction forming of metal components with integral heat treatment
patent, July 2013

Method for curing a composite part layup
patent, October 2014

Doubler repair apparatus and method
patent, March 2015