US4940563A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Molding method and apparatus using a solid flowable, polymer medium
Assignee: RTX Corp
•
Filing: 1988-05-26
•
Granted: 1990-07-10
•
Expires: 2008-05-26
Abstract
Abstract An article is molded by contacting it with a solid polymer medium, such as an especially low strength unfilled silicone rubber which is solid and able to flow readily. Thermal expansion of the medium or mechanical force is used to create molding pressure and thereby provides a substantially uniform pressure on the article precursor. Various temperature and pressure cycles can be attained; constant high pressures can be maintained on the article precursor during cooldown, optionally aided by flowing of medium to and from a vessel in which the article precursor is being molded. The method is particularly adapted to molding filler or fiber reinforced thermosetting polymer composite articles.
Inventors
- 👤 Robert V. Kromrey
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 15:55
CPC Classifications
B; B29; B29C; B29C43/00; B29C43/32; B22; B22F; B22F3/00; B22F3/12; B22F3/14; B22F3/15; B29C43/02; B29C43/10; B29K; B29K2101/00; B29K2101/10; B29K2105/00; B29K2105/06; B29K2105/12; B29K2105/16
Claims Analysis
Total Claims: 46
Claim 1
Independent Claim
75 words
The method of forming an article from an article precursor comprising, placing the article precursor within a pressure vessel, substantially filling the vessel with a solid, flowable, polymer medium and causing said medium to produce a substantially uniform, predetermined medium pressure on the surface of said article precursor by applying heat or pressure to the medium, wherein the temperature of the article precursor and pressure to which the article precursor is subjected are independently controlled.
Claim 2
Independent Claim
75 words
The method of forming an article from an article precursor comprising, placing the article precursor within a pressure vessel, substantially filling the vessel with a solid, flowable, polymer medium and causing said medium to produce a substantially uniform, predetermined medium pressure on the surface of said article precursor by applying heat or pressure to the medium, wherein the temperature of the article precursor and pressure to which the article precursor is subjected are independently controlled.
Claim 3
Dependent Claim
17 words
The method of claim 1 wherein the medium has a low Young's modulus and low shear strength.
Claim 4
Dependent Claim
15 words
The method of claim 2 wherein the medium has a positive coefficient of thermal expansion.
Claim 5
Dependent Claim
24 words
The method of claim 2 wherein at least part of the uniform predetermined medium pressure on said article precursor is produced by mechanical means.
Claim 6
Dependent Claim
25 words
The method of claim 2 wherein at least part of the uniform predetermined medium pressure on said article precursor is produced by heating the medium.
Claim 7
Dependent Claim
28 words
The method of claim 2 wherein said forming additionally comprises heating the article precursor to a predetermined temperature after placement of the article precursor within the pressure vessel.
Claim 8
Dependent Claim
19 words
The method of claim 6 wherein said heating incidentally heats the medium in the vicinity of the article precursor.
Claim 9
Dependent Claim
22 words
The method of claim 7 wherein said heating produces at least part of the uniform, predetermined medium pressure on said article precursor.
Claim 10
Independent Claim
48 words
The method of claims 4 or 5 wherein the medium is heated primarily to expand the medium in at least one selected area not at or near that occupied by the article precursor to produce at least part of the uniform predetermined medium pressure on said article precursor.
Claim 11
Independent Claim
25 words
The method of claims 4, 5, or 6 wherein the medium pressure is additionally controlled by cooling the medium in at least one selected area.
Claim 12
Independent Claim
25 words
The method of claims 1, 2, 3, 4, 5, 6, 7 or 8 wherein the article is a filler or fiber reinforced resin matrix composite.
Claim 13
Independent Claim
20 words
The method of claims 1, 2, 3, 4, 5, 6, 7 or 8 wherein the article is a powder-metal preform.
Claim 14
Dependent Claim
17 words
The method of claim 9 wherein the article is a filler or fiber reinforced resin matrix composite.
Claim 15
Dependent Claim
12 words
The method of claim 9 wherein the article is a powder-metal preform.
Claim 16
Dependent Claim
17 words
The method of claim 10 wherein the article is a filler or fiber reinforced resin matrix composite.
Claim 17
Independent Claim
12 words
The method of claims 10 wherein the article is a powder-metal preform.
Claim 18
Independent Claim
109 words
A method of forming a filler or fiber reinforced resin article from a filler or fiber reinforced resin article precursor comprising placing the article precursor within a pressure vessel, substantially filly the vessel with a solid, flowable, polymer medium having a low Young's modulus, positive coefficient of thermal expansion and a low shear strength, heating the article precursor to a predetermined temperature, causing said medium to produce a substantially uniform, predetermined medium pressure on the surface of said article precursor, at least part of said medium pressure produced by said heating, and independently controlling the temperature of the article precursor and pressure to which the article precursor is subjected.
Claim 19
Independent Claim
109 words
A method of forming a filler or fiber reinforced resin article from a filler or fiber reinforced resin article precursor comprising placing the article precursor within a pressure vessel, substantially filly the vessel with a solid, flowable, polymer medium having a low Young's modulus, positive coefficient of thermal expansion and a low shear strength, heating the article precursor to a predetermined temperature, causing said medium to produce a substantially uniform, predetermined medium pressure on the surface of said article precursor, at least part of said medium pressure produced by said heating, and independently controlling the temperature of the article precursor and pressure to which the article precursor is subjected.
Claim 20
Dependent Claim
33 words
The method of claim 17 wherein said pressure is additionally controlled by heating primarily to expand the medium in at least one area not at or near that occupied by the article precursor.
Claim 21
Independent Claim
27 words
The method of claims 17 or 18 wherein said pressure is additionally controlled by cooling the medium in at least one area remote from the article precursor.
Claim 22
Dependent Claim
14 words
The method of claim 19 wherein said pressure is additionally controlled by mechanical means.
Claim 23
Dependent Claim
21 words
The method of claim 19 wherein the resin is a thermosetting resin and said heating is sufficient to cure the resin.
Claim 24
Dependent Claim
21 words
The method of claim 19 wherein said heating is produced by resistance heating, induction coil heating, steam heating, or fluid transfer.
Claim 25
Dependent Claim
18 words
The method of claim 18 wherein the vessel, medium and article precursor are heated as a single unit.
Claim 26
Dependent Claim
14 words
The method of claim 23 wherein the pressure is additionally controlled by mechanical means.
Claim 27
Dependent Claim
97 words
Apparatus for forming an article from an article precursor comprising: (a) an essentially closed pressure vessel for containing the article and a mass of pressurized solid flowable polymer medium within the vessel; (b) means for independently controlling the temperature of the article precursor and pressure to which the article precursor is subjected; and (c) said vessel substantially filled with said solid flowable polymer medium, the medium substantially filling interstices within the vessel not otherwise occupied by the article precursor, said medium capable of producing a substantially uniform, predetermined medium pressure on the surface of the article precursor.
Claim 28
Dependent Claim
97 words
Apparatus for forming an article from an article precursor comprising: (a) an essentially closed pressure vessel for containing the article and a mass of pressurized solid flowable polymer medium within the vessel; (b) means for independently controlling the temperature of the article precursor and pressure to which the article precursor is subjected; and (c) said vessel substantially filled with said solid flowable polymer medium, the medium substantially filling interstices within the vessel not otherwise occupied by the article precursor, said medium capable of producing a substantially uniform, predetermined medium pressure on the surface of the article precursor.
Claim 29
Dependent Claim
17 words
The apparatus of claim 25 wherein the medium has a low Young's modulus and low shear strength.
Claim 30
Dependent Claim
15 words
The apparatus of claim 26 wherein the medium has a positive coefficient of thermal expansion.
Claim 31
Dependent Claim
16 words
The apparatus of claim 26 additionally containing mechanical means for producing pressure on said polymer medium.
Claim 32
Dependent Claim
13 words
The apparatus of claim 26 including heating means to heat said polymer medium.
Claim 33
Dependent Claim
13 words
The apparatus of claim 26 including heating means to heat the article precursor.
Claim 34
Dependent Claim
24 words
The apparatus of claim 30 including heating means to heat the polymer medium an area at or near that occupied by the article precursor.
Claim 35
Dependent Claim
21 words
The apparatus of claim 29 wherein the heating means is not at or near the area occupied by the article precursor.
Claim 36
Independent Claim
16 words
The apparatus of claims 28, 29 or 30 including cooling means to cool the polymer medium.
Claim 37
Dependent Claim
40 words
The method as recited in claim 1 wherein said solid, flowable, polymer medium has a nominal flow rate of at least 0.6 g/s through a 1.1 cm diameter by 7.5 cm long pipe under an applied pressure of 10.34 MPa.
Claim 38
Dependent Claim
27 words
The method as recited in claim 1 wherein the pressure to which the article precursor is subjected to is sustained as the article precursor's temperature is reduced.
Claim 39
Independent Claim
75 words
The method of forming an article from an article precursor comprising, placing the article precursor within a pressure vessel, substantially filled the vessel with a solid, flowable, polymer medium and causing said medium to produce a substantially uniform, predetermined medium pressure on the surface of said article precursor by applying heat or pressure to the medium, wherein at least part of the uniform predetermined medium pressure on said article precursor is produced by mechanical means.
Claim 40
Independent Claim
75 words
The method of forming an article from an article precursor comprising, placing the article precursor within a pressure vessel, substantially filled the vessel with a solid, flowable, polymer medium and causing said medium to produce a substantially uniform, predetermined medium pressure on the surface of said article precursor by applying heat or pressure to the medium, wherein at least part of the uniform predetermined medium pressure on said article precursor is produced by mechanical means.
Claim 41
Independent Claim
97 words
The method of forming an article from an article precursor comprising, placing the article precursor within a pressure vessel, substantially filling the vessel with a solid, flowable, polymer medium and causing said medium to produce a substantially uniformed, predetermined medium pressure on the surface of said article precursor by applying heat or pressure to the medium, wherein the medium is heated primarily to expand the medium in at least one selected area not at or near that occupied by the article precursor to produce at least part of the uniform predetermined medium pressure on said article precursor.
Claim 42
Independent Claim
97 words
The method of forming an article from an article precursor comprising, placing the article precursor within a pressure vessel, substantially filling the vessel with a solid, flowable, polymer medium and causing said medium to produce a substantially uniformed, predetermined medium pressure on the surface of said article precursor by applying heat or pressure to the medium, wherein the medium is heated primarily to expand the medium in at least one selected area not at or near that occupied by the article precursor to produce at least part of the uniform predetermined medium pressure on said article precursor.
Claim 43
Independent Claim
72 words
The method of forming an article from an article precursor comprising, placing the article precursor within a pressure vessel, substantially filling the vessel with a solid, flowable, polymer medium and causing said medium to produce a substantially uniform, predetermined medium pressure on the surface of said article precursor by applying heat or pressure to the medium, wherein the medium pressure is controlled by cooling the medium in at least one selected area.
Claim 44
Independent Claim
72 words
The method of forming an article from an article precursor comprising, placing the article precursor within a pressure vessel, substantially filling the vessel with a solid, flowable, polymer medium and causing said medium to produce a substantially uniform, predetermined medium pressure on the surface of said article precursor by applying heat or pressure to the medium, wherein the medium pressure is controlled by cooling the medium in at least one selected area.
Claim 45
Independent Claim
85 words
The method of forming an article from an article precursor comprising, placing the article precursor within a pressure vessel, substantially filling the vessel with a solid, flowable, polymer medium, said medium having a nominal flow rate of at least 25 g/s through a 1.1 cm diameter by 7.5 cm long pipe under an applied pressure of 10.34 MPa and causing said medium to produce a substantially uniform, predetermined medium pressure on the surface of said article precursor by applying heat or pressure to the medium.
Claim 46
Independent Claim
85 words
The method of forming an article from an article precursor comprising, placing the article precursor within a pressure vessel, substantially filling the vessel with a solid, flowable, polymer medium, said medium having a nominal flow rate of at least 25 g/s through a 1.1 cm diameter by 7.5 cm long pipe under an applied pressure of 10.34 MPa and causing said medium to produce a substantially uniform, predetermined medium pressure on the surface of said article precursor by applying heat or pressure to the medium.
References Cited (Backward Citations)
US31355A
Cited
US3249964A
Cited
US3279917A
Cited
US3363037A
Cited
US3462797A
Cited
US3419935A
Cited
US3556201A
Cited
US4041123A
Cited
DE2134168A1
Cited
US3843601A
Cited
US3968862A
Cited
US4011929A
Cited
USRE31355E
Cited
US4167430A
Cited
US4264556A
Cited
US4388263A
Cited
US4428906A
Cited
US4547337A
Cited
US4504044A
Cited
US4501718A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1993-07-09 | 1994-01-08 | 1994-07-10 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1997-07-09 | 1998-01-08 | 1998-07-10 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2001-07-09 | 2002-01-08 | 2002-07-10 | $7700.00 | Window Closed / Lapsed |