U.S. patent application number 11/073119 was filed with the patent office on 2005-09-08 for tool bodies having heated tool faces.
Invention is credited to Lucas, Rick D., Matviya, Thomas M., Merriman, Douglas J., Spradling, Drew M..
Application Number | 20050196481 11/073119 |
Document ID | / |
Family ID | 34964672 |
Filed Date | 2005-09-08 |
United States Patent
Application |
20050196481 |
Kind Code |
A1 |
Spradling, Drew M. ; et
al. |
September 8, 2005 |
Tool bodies having heated tool faces
Abstract
Self-heated tools for the production of composite parts are
described. The tools include a tool body which, at least in part,
includes carbon foam materials that are electrically conductive or
permeable to the passage of fluids. These materials can be both
electrically conductive and permeable to the passage of fluids. The
electrically conductive or fluid permeable carbon foam materials
are an intrinsic part of the construction of these tool bodies and
are not add-on devices. Electricity may be used to heat the
electrically conductive carbon foam material and transfer heat to
the tool face. In other embodiments, heated fluid may be passed
through and used to heat the fluid permeable carbon foam material
and transfer heat to tool body. The electrically conductive or
permeable carbon foam materials may define the tool face of the
tool body. The tool bodies may comprise carbon foam, which is both
electrically conductive and permeable. The electrically conductive
carbon foam material and the fluid permeable carbon foam material
may be constructed and/or configured to apply relatively uniform
heating across the surface of the tool face or in certain
circumstances non-uniform heating across the surface of the tool
face.
Inventors: |
Spradling, Drew M.;
(Wheeling, WV) ; Merriman, Douglas J.; (Wheeling,
WV) ; Matviya, Thomas M.; (McKees Rocks, PA) ;
Lucas, Rick D.; (St. Clairsville, OH) |
Correspondence
Address: |
PHILIP DOUGLAS LANE
P.O. BOX 651295
POTOMAC FALLS
VA
20165-1295
US
|
Family ID: |
34964672 |
Appl. No.: |
11/073119 |
Filed: |
March 4, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60549563 |
Mar 4, 2004 |
|
|
|
Current U.S.
Class: |
425/174 |
Current CPC
Class: |
B29C 35/04 20130101;
B29C 2035/0211 20130101; H05B 3/141 20130101; B29C 33/02 20130101;
B29C 33/38 20130101; B29K 2907/04 20130101; B29K 2995/0068
20130101; B29K 2995/0005 20130101; B29C 70/42 20130101 |
Class at
Publication: |
425/174 |
International
Class: |
E21B 043/22 |
Claims
What is claimed is:
1. A tool comprising: a tool body defining a tool face and
comprising an electrically conductive carbon foam material; and
electrical connections connected to one portion of the electrically
conductive carbon foam material and a second portion of the
electrically conductive carbon foam material.
2. The tool of claim 1, further comprising a power source adapted
to be connected to the electrical connections.
3. The tool of claim 1, wherein the electrically conductive carbon
foam material provides substantially even heating of the tool face
when current flow through the carbon foam is produced by the power
source.
4. The tool of claim 1, wherein a surface of the electrically
conductive carbon foam material defines the tool face.
5. The tool of claim 1, wherein the tool body consists essentially
of carbon foam.
6. The tool of claim 1, wherein the tool face comprises a tool face
material.
7. The tool of claim 1, further comprising a thermostat in
communication with the tool face and the power source, wherein the
thermostat monitors the temperature of the tool face and adjusts
the power of the power source.
8. A tool comprising: a tool body defining a tool face and
comprising a fluid permeable carbon foam material; and a fluid
inlet port connected to one portion of the fluid permeable carbon
foam material.
9. The tool of claim 8, wherein the fluid permeable carbon foam
material provides substantially even heating of the surface of the
tool face when heated fluid is passed through the fluid permeable
carbon foam.
10. The tool of claim 8, wherein a surface of the fluid permeable
carbon foam material defines the tool face.
11. The tool of claim 8, wherein the tool body consists essentially
of carbon foam.
12. The tool of claim 8, wherein the tool face comprises a tool
face material.
13. The tool of claim 8, further comprising a fluid exhaust port
connected to a second portion of the fluid permeable carbon foam
material.
14. The tool of claim 8, further comprising a pump adapted to be in
fluid communication with the fluid inlet port.
15. The tool of claim 8, further comprising: a pump adapted to be
in fluid communication with fluid inlet port; and a heated fluid
supply in fluid communication with the pump.
16. The tool of claim 15, further comprising a thermostat in
communication with the tool face and the heated fluid supply,
wherein the thermostat monitors the temperature of the tool face
and adjusts the temperature of the heated fluid supply.
17. A tool comprising: a tool body defining a tool face, wherein
the tool face is substantially uniformly heated by the tool
body.
18. The tool of claim 17, wherein the tool body comprises
electrically conductive carbon foam material.
19. The tool of claim 18, wherein the electrically conductive
carbon foam material provides substantially uniform heating across
the tool face when current is applied to the electrically
conductive carbon foam material.
20. The tool of claim 17, wherein the tool body comprises fluid
permeable carbon foam material.
21. The tool of claim 20, wherein the fluid permeable carbon foam
material provides a substantially uniform heating of the tool face
when a heated fluid is passed through the fluid permeable carbon
foam material.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional
Patent Application No. 60/549,563, filed Mar. 4, 2004, herein
incorporated by reference in its entirety.
FIELD OF INVENTION
[0002] This invention relates to composite tooling and methods for
using the same, more specifically to a reusable tool body that can
be heated to effect a curing of the composite forming materials
shaped by the tool.
SUMMARY OF THE INVENTION
[0003] The invention may include a tool comprising a tool body
defining a tool face and comprising an electrically conductive
carbon foam material. Electrical connections may be connected to
one portion of the electrically conductive carbon foam material and
a second portion of the electrically conductive carbon foam
material. A power source may be connected to the electrically
conductive carbon foam material through the electrical connections
to produce a current flow resulting in the heating of the
electrically conductive carbon foam material. In some embodiments,
the tool body may be entirely or partially made from the
electrically conductive carbon foam material. In some embodiments,
the electrically conductive carbon foam material may provide
substantially even heating of the surface of the tool face. In
certain embodiments, the tool face may include a tool face
material. In other embodiments, a thermostat may be placed in
communication with the tool face and the power source, where the
thermostat monitors the temperature of the tool face and adjusts
the power of the power source.
[0004] In yet another embodiment, the invention may include a tool
comprising a tool body defining a tool face and comprising a fluid
permeable carbon foam material. A fluid inlet port may be connected
to one portion of the fluid permeable carbon foam material. Heated
fluid is passed through the fluid permeable carbon foam material to
result in heating of the fluid permeable carbon foam material. In
some embodiments, the fluid permeable carbon foam material may
provide substantially even heating of the surface of the tool face
when heated fluid is passed through the fluid permeable carbon
foam. Further, a surface of the fluid permeable carbon foam
material may optionally define the tool face. In certain
embodiments, the tool face may comprise a tool face material. In
yet further embodiments the tool may also include a fluid exhaust
port connected to a second portion of the permeable material.
Further, the invention may include a pump adapted to be in fluid
communication with the fluid inlet port. Still further, the
invention may include a pump adapted to be in fluid communication
with fluid inlet port and a heated fluid supply in fluid
communication with the pump, where the pump moves fluid from the
heated fluid supply to the fluid inlet port. The fluid supply may
be a reservoir and the fluid exhaust port may be connected to the
reservoir to return the fluid from the fluid permeable carbon foam
material. Still further, the tool may include a thermostat in
communication with the tool face and the heated fluid supply, where
the thermostat monitors the temperature of the tool face and
adjusts the temperature of the heated fluid supply.
[0005] In yet another embodiment, the invention may include a tool
comprising a tool body defining a tool face, where the tool face is
substantially uniformly heated by the tool body. The tool body may
comprise an electrically conductive carbon foam material. The
electrically conductive carbon foam material may provide
substantially uniform heating across the tool face when current is
applied to the electrically conductive carbon foam material.
Further, tool body may comprise a fluid permeable carbon foam
material. The fluid permeable carbon foam material may provide a
substantially uniform heating of the tool face when a heated fluid
is passed through the fluid permeable carbon foam material.
BRIEF DESCRIPTION OF THE FIGURES
[0006] FIG. 1 is an illustration of a self-heated tool in
accordance with an embodiment of the invention.
[0007] FIG. 2 is an illustration of a self-heated tool in
accordance with another embodiment of the invention.
DESCRIPTION OF THE INVENTION
[0008] Generally, composite materials are prepared by imbedding a
reinforcing material within a matrix material. Composite materials
having high degrees of utility typically exhibit mechanical, or
other, properties superior to those of the individual materials
from which the composite was formed. A common example of a
composite material is fiberglass. Fiberglass is produced by
infusing glass fibers, which are the reinforcing material, with a
resin, which constitutes the matrix material. Reinforcing materials
known in the art have included, but are not limited to, for
example, fiberglass, carbon fibers, quartz fibers, ceramic fibers,
Kevlar.RTM. fibers, Aramid.RTM. fibers, and particulates of glass,
ceramic, carbides, carbon, chopped fibers, and the like. Matrix
materials known in the art have included, but are not limited to,
thermoplastic and thermosetting resins, including phenolics and
epoxies, and the like. Such matrix materials will be collectively
referred to as resins.
[0009] Composite materials have been found to have a high degree of
utility when used as parts of structures, components,
sub-assemblies, and the like, herein after collectively referred to
as parts, of assemblages such as, for example, aircraft, missiles,
vehicles, medical equipment, and sporting goods. The utility of
such composites is typically related to their high
strength-to-weight ratio and their fatigue and corrosion
resistance. In most instances, these beneficial properties exceed
those of the metals or other materials supplanted by the use of the
composites.
[0010] Composites materials are typically formed to required
dimensions by the use of mold-like devices commonly referred to as
tools. These tools encompass one or more surfaces, referred to as
tool-faces, upon which the composite is formed, shaped, molded, or
otherwise produced into parts of predetermined sizes and shapes.
Such parts can include structures, sub-assemblies, and the like.
The tool face is a surface, typically formed such that the shape of
its surface produces the predetermined size and shape of the
desired composite part.
[0011] In addition to the tool face, a tool is also includes a tool
body and may include a support structure. The tool body defines,
includes, or otherwise comprises, the tool face. That is, the tool
face, upon which the composite is formed, may be a surface of the
tool body. The support structure is connected to the tool body and
may serve a number of purposes, including but not limited to, such
purposes as support, orientation, and transportation of the tool
body and tool face along with protection of the tool body and face
from damage.
[0012] In forming the composite part, mixed matrix material and
reinforcing material are placed upon the tool face by any of a
number of procedures know to those skilled in the art, and brought
into essentially intimate contact with the tool face. The
dimensions of the tool face are such that this contact effectively
molds a surface of the resin and reinforcing material mixture into
the desired shape and dimensions. The reinforcing material
containing matrix material, for example carbon fibers in a resin,
is subsequently cured, typically by the application of heat, to
yield a solid composite part having the shape and dimensions
imparted by the tool face.
[0013] The application of heat is typically required to cure the
composite forming materials to result in a composite part and is a
result of the chemical nature of many matrix materials. For
example, many resins, such as thermosetting resins, require the
application of heat to effect the chemical reactions that converts
the fluid or semi-fluid resin to a solid polymeric material. Other
matrix materials, such as epoxies, may convert from a fluid or
semi-fluid material to a solid polymeric material over an extended
period of time without the application of heat. However, such
materials will generally solidify in a much shorter time period,
and may have higher glass transition temperatures, if heated.
Greater rates of matrix material solidification can result in more
rapid and increased part production. This benefit may then result
in greater tool utilization with corresponding reductions in part
production costs. Greater tool utilization can also be achieved by
partially curing the composite forming materials in the tool,
followed by complete curing of the resulting partially cured
composite outside of the tool.
[0014] Heating of the composite forming materials has previously
been accomplished by placing the tool with an autoclave, oven, or
similar heating device. Such oven-like devices can be very large,
and correspondingly expensive, as some tools may be of considerable
size. Also, large oven-like heating devices may be required as
multiple tools, all requiring the use of an oven-like heating
device, may be in use simultaneously. It may also be possible that
simultaneous use of multiple tools may require that the composite
formed on each tool be heated at a different temperature. Such a
situation would then require the use of multiple ovens. Therefore,
due to the scale involved, oven-like heating devices can be
expensive and thus contribute to increased composite part cost.
Additionally, the use of such oven-like heating devices typically
requires the transport of the tool with the composite forming
materials in place. Such transport may not be desirable as it may
possibly have a detrimental effect on the quality of the resultant
composite part.
[0015] Other tools have been previously designed that can heat cure
tool-formed composite forming materials without the use of
oven-like devices. These tools have been designed where heating
devices, such as heating tapes, steam tracing, heating elements,
and the like, have been incorporated into or on the tool body to
result in a heating of the tool. In operation, the heating devices
would be activated once the composite forming material had been
adequately positioned and shaped on the tool face. The activation
of the heating devices would then heat the tool body, tool face,
and the shaped composite forming materials on the tool face. Such
heating would then cure, or accelerate the curing of, the composite
forming materials without the use of an autoclave, oven, or similar
heating device. The incorporation of such heating devices into the
tools can add complexity to the tool body and increase tool cost.
Additionally, the heat applied by these methods is typically
localized to the general area of the heating devices. Therefore it
can be difficult to uniformly heat a tool face by use of these
methods. Therefore, as a result of the previously described
limitations, improved methods for the heating of composite forming
materials on a tool face are desired.
[0016] The tools of the present invention have a tool face that can
be heated by the application of an electrical current or heating
fluid to the tool body. These self-heating tools differ from
previous tools as the heating of the tool faces of the tools of the
present invention do not require the addition of specific heating
devices, such an oven, heating tape, resistance heaters, steam
tracing, and the like. The capability of the self-heating tools of
the present invention to be heated is derived from the materials of
construction of the tools rather than from the addition of some
additional heating device. In particular, the present invention
uses electrically conductive or fluid permeable carbon foam
material in the construction of the tool. The heating of the tools
of the present invention can result in the partial or total curing
of a composite part formed thereon.
[0017] The tools of the present invention may be comprised, at
least in part, from carbon foam materials that are electrically
conductive or permeable to the passage of fluids. These carbon foam
materials can be both electrically conductive and permeable to the
passage of fluids. The carbon foam materials are an intrinsic part
of the construction of these tool bodies and are not add-on
devices. By intrinsic part it is meant that the body of a tool of
the present invention would not be substantive without the
inclusion of such electrically conductive or permeable carbon foam
materials.
[0018] Carbon foam is typically a strong, electrically conductive,
open-cell, durable, stable, easily machined, resin-bondable, and
relatively unreactive lightweight material. Carbon foams can also
exhibit very low coefficients of thermal expansion (CTE) which can
be essentially equivalent to that of carbon fiber composites. Such
CTE equivalency makes the carbon foam especially useful for
incorporation into tool bodies for the production of carbon fiber
composites. The CTE of carbon foam can be modified by control of
the maximum temperature to which the carbon foam is exposed during
preparation. Likewise, the electrical conductivity of carbon foam
can be modified by control of the maximum temperature to which the
carbon foam is exposed during preparation. Also, it is believed
that the electrical conductivity of carbon foam can be modified by
adding various materials, such as non-electrically conductive
particulates, such as glass or sand, to the carbon foam forming
materials prior to foam formation to reduce the electrical
conductivity of the resultant foam. Alternatively, the electrical
conductivity of carbon foam may be modified by adding various
materials, such as electrically conductive particulates, such as
metal particles, to the carbon foam forming materials prior to foam
formation to increase the electrical conductivity of the resultant
foam.
[0019] Carbon foams are materials of very high carbon content that
have appreciable void volume. In appearance, excepting color,
carbon foams can resemble readily available commercial plastic
foams. As with plastic foams, the void volume of carbon foams is
located within numerous empty cells. The boundaries of these cells
are defined by the carbon structure. These cells typically
approximate spheres or ovoids of regular, but not necessarily
uniform, size, shape, distribution, and orientation. The void
volumes in these cells typically connect directly to neighboring
void volumes. Such an arrangement is referred to as an open-cell
foam. The carbon in these foams forms a structure that is
continuous in three dimensions across the material. Typically, the
cells in carbon foams are of a size that is readily visible to the
unaided human eye. Also, the void volume of carbon foams is such
that it typically occupies much greater than one-half of the carbon
foam volume. The regular size, shape, distribution, and orientation
of the cells within carbon foam readily distinguishes this material
from other materials such as metallurgical cokes. Carbon foams have
been prepared from a variety of feedstocks using a variety of
processes. For example, feedstocks for carbon foam production have
included, but are not limited to, pitches, coals, and coal
derivatives. Likewise, processes for the production of carbon foams
from each of these feedstocks have been identified. Most of these
processes include exposure of the carbon foam to an elevated
temperature, sometimes a great as about 3000.degree. C., after
preparation of the foam.
[0020] Carbon foam can be incorporated in the tools of the present
invention such that a surface of the carbon defines a tool face.
The carbon foam defining the tool face can be filled with a
cell-filling material such as a resin or pitch to result in a
sealed or otherwise impermeable surface. Other outer surfaces of
the carbon foam can also be sealed in a similar manner. The other
outer surfaces of the carbon foam can also be sealed by laminating
an impervious material to the carbon surface. Alternatively, a
surface of the carbon foam can support another material, a
tool-face material, which then defines the tool face.
[0021] With reference now to FIG. 1, there is shown a self-heating
tool in accordance with an embodiment of the invention and
designated generally by the reference numeral 10. The self-heating
tool 10 includes a tool body 12 having a tool face 14. The tool
body 12 comprises an electrically conductive carbon foam material
16. Preferably, the electrical resistance of the electrically
conductive carbon foam material 16 is such that excessive
electrical power is not required for heating. The self heating tool
10 is constructed such that passage of an electrical current
through the electrically conductive carbon foam material 16 heats
the tool face 14 of the tool body 12. An electrical power source 18
is connected to the electrically conductive carbon foam material 16
through electrical connections 18a and 18b. Multiple electrical
connections may be used. These connections can include any
connector that provides for the transfer of electrical current from
the power source to the electrically conductive carbon foam
material. Such connectors may include, but are not limited to,
wires, cables, combinations of wire and cables, commonly known
terminal connectors, bus bars, and other similar connectors. Such
connections may be located advantageously to produce the desired
electrical current flow through the electrically conductive carbon
foam material. As electrical current passes through the
electrically conductive carbon foam material 16, heat is generated
and transferred to the tool face 14. The heating of the tool face
14 then results in a heat transfer to, and a heating of, the
composite forming materials on the tool face.
[0022] Preferably, the electrically conductive carbon foam material
is distributed in the tool body such that it uniformly heats the
entire tool face 12. In certain embodiments the electrically
conductive carbon foam material should be distributed and arranged
such that heat being transferred to the tool face results in
substantially even curing or heating of the composite forming
materials on the tool face. The configuration of the electrically
conductive carbon foam material can vary widely depending upon such
factors as the size, shape, and thickness of the resulting
composite part. Thicker areas of the composite part may require the
application of greater heat in that area of the tool face as
compared to other areas of the tool face in order for all areas of
the part to effectively cure at the same temperature and rate. In
some embodiments, the wattage density across the tool face is
relatively equal. Further, in some instances a relatively uniform
wattage density may be obtained by providing a relatively uniform
current density across the tool face. Additionally, a relatively
uniform wattage density across the tool face may be obtained by
applying electrical currents of differing magnitudes to volumes of
carbon foam having differing resistances.
[0023] One or more thermostats 20 may be used to monitor and
control the temperature of the tool face 12 by monitoring the
temperature of the tool face 12 and adjusting the electrical power
applied to the electrically conductive carbon foam material 16. The
electrically conductive carbon foam material 16 may define the tool
face 14. That is, a surface of the electrically conductive carbon
foam material 16 of the tool body 12 may comprise the tool face 14.
Alternatively, the electrically conductive carbon foam material 16
may support another material which defines the tool face 14.
[0024] The tool body 12 may be composed of an electrically
conductive carbon foam material 16 in the form of a sheet, plate,
block, or layer deposited on a support material 17. The carbon foam
may consist of pieces of carbon foam that are bonded together with
conductive or nonconductive resins or high temperature adhesives
such that the desired electrically conductive pathways are present.
Preferably, the electrical resistance of the material is such that
excessive electrical power is not required for heating. This
conductive material may be shaped or formed to define a tool face
14. Alternatively, this material may support a relatively thin
layer of another material, a tool face material, which defines the
tool face 14. In either configuration, the electrically conductive
carbon foam material 16 comprises or underlies the entire tool
face. Preferably, this electrically conductive carbon foam material
16 will produce uniform heating of the entire tool face 14.
[0025] For non-planer tool faces, such uniform heating may be
provided by varying the conductive material thickness across the
tool face such that the electrical current density is uniform
across the tool face. Thermostats 20 may be used to monitor and
control the heating of the electrically conductive carbon foam
material 16.
[0026] In use, a mixture of composite forming materials is
positioned, as desired, on the tool face 14. Electrical connections
18a and 18b are made to the electrically conductive carbon foam
material 16, from an electrical power source 18, such that an
electrical current flows though the electrically conductive carbon
foam material and across the tool face. Heat generated in this
electrically conductive carbon foam material 16 transfers across
any tool face material and to the composite forming materials. This
transferred heat increases the temperature of the composite forming
materials such that a cured composite is formed. During this
process, temperature may be monitored and controlled by the
thermostat 20 such that over-heating of the composite and/or
composite forming materials does not occur.
[0027] Turning now to FIG. 2, there is shown another embodiment of
a self-heating tool and designated generally by the reference
numeral 100. The self-heating tool 100 includes a tool body 120
having a tool face 140. The tool body 120 comprises a fluid
permeable carbon foam material 160. Preferably, the fluid permeable
carbon foam material 160 has a porosity such that heated fluids or
gases may pass through the fluid permeable carbon foam material and
the fluid permeable carbon foam material transfers heat from the
heated fluids or gases to the tool face 140 which in turn transfers
heat to the composite part. Preferably, the porosity of the fluid
permeable carbon foam material 160 is such that excessive pressures
are not required to obtain adequate and/or desired volumes of fluid
flow. Holes may be formed in the fluid permeable carbon foam
material 160 such that fluid flow pressure drop across the fluid
permeable carbon foam material is decreased. Preferably, the fluid
permeable carbon foam material 160 is positioned in the tool body
120 such that the entire tool face 140 is uniformly heated. The
fluid permeable carbon foam material 160 of the present invention
may define the tool face 140. That is, a surface of the fluid
permeable carbon foam material 160 of the tool body 120 may
comprise the tool face 140. Alternatively, the fluid permeable
carbon foam material 160 may support another material which defines
the tool face 140.
[0028] The self heating tool 100 is constructed such that passage
of a heated fluid or gas through the fluid permeable carbon foam
material 160 heats the tool face 140 of the tool body 120. A pump
180 may supply hot or heated fluid or gases from a heated fluid
supply 200 to the tool body 120 through a fluid inlet port 220
connected to one portion of the fluid permeable carbon foam
material 160. The heated fluid supply 200 may include heaters 210
for heating the fluid. A fluid exhaust port 240 is connect to a
second portion of the fluid permeable carbon foam material 160 and
allows for the fluid or gas to exit the permeable material 160. In
certain embodiments, the fluid inlet port 220 and fluid exhaust
port 240 are connected to the fluid permeable carbon foam material
160 such that the hot or heated fluid or gases pass through the
fluid permeable carbon foam material 160 of the tool body 120 to
result in heating of the tool face 140. Multiple fluid inlet ports
and outlet ports may be used. In some embodiments the fluid exhaust
port 240 returns the fluid to the heated fluid supply 200 for
reheating. Edges and surfaces of the fluid permeable carbon foam
material 160 are preferably sealed such that the fluid is not
admitted or discharged except through the ports 220 and 240. Such
sealing may be accomplished by coating the surfaces with materials
that eliminate the surface porosity of the fluid permeable carbon
foam material. Such materials can include, but are not limited to,
cured resins and the like. One or more thermostats 260 may be used
to monitor and control the temperature of the tool face 140 by
communicating with heaters 210 to adjust the temperature of the
fluid. Heated fluids may include, but are not limited to, gases
and/or liquids such as steam and heated gases, including air and/or
process exhausts, and liquids, including water and/or oil.
[0029] The tool body 120 may be composed of a fluid permeable
carbon foam material 160 in the form of a plate or block. The
carbon foam may consist of pieces of carbon foam that are bonded
together with resins or high temperature adhesives such that the
desired fluid transport pathways are present. A surface of this
fluid permeable carbon foam material 160 may be shaped or formed to
define a tool face 140. Alternatively, this material may support a
relatively thin layer of another material, a tool face material,
which defines the tool face. In either configuration, the permeable
material 160 comprises or underlies the entire tool face 140.
Opposite sides or edges of the fluid permeable carbon foam material
may be equipped with fluid inlet and exhaust ports.
[0030] Preferably, the flow of heated fluid through the fluid
permeable carbon foam material will produce uniform heating of the
entire tool face. For non-planer tool faces, such uniform heating
may be provided by varying the flow pressure drop in the permeable
material across specific areas of the tool face such that heated
fluid flow is uniform across the tool face. The fluid flow pressure
drop in the permeable material will vary with the permeable
material thickness. Thermostats may be used to monitor and control
the heating/temperature of the tool face and/or fluid.
[0031] In use, a mixture of composite forming materials is
positioned, as desired, on the tool face 140. The tool face 140 may
include a surface of a relatively thin carbon fiber composite, in
this example a tool face material, supported by a permeable
material 160 made from a carbon foam block. Connections are made to
the fluid inlet 220 and exhaust ports 240 positioned on the carbon
foam block such that a heated fluid flows though the carbon foam
block and thus across the carbon foam block volume underlying the
tool face. The heated fluid is supplied from a source of heated
fluid such as, but not limited to, a reservoir, process stream, or
the like. The heated fluid may be forced through the carbon foam
block by use of a pump, gravity, or the like. Holes may have been
previously formed in the carbon foam block to lower the fluid flow
pressure drop. The heat contained in the heated fluid transfers
across the tool face material and to the composite forming
materials. This transferred heat increases the temperature of the
composite forming materials such that a cured composite is formed.
During this process, the temperature of the heated fluid is
monitored and controlled such that over-heating of the composite
and/or composite forming materials does not occur.
[0032] Tooling may be used to fabricate composite parts of various
types, shapes, sizes and materials with a high dimensional
accuracy. The design of the tooling typically is dependent on the
desired shape of the composite part to be formed, the materials
used to form the composite part, the amount of strength and
rigidity which the tooling must have to support the materials
necessary for forming the composite part, and/or the method used to
provide the materials for forming the composite part.
[0033] In practice, materials comprising the composite are placed
upon the tool face by any of a number of procedures known to those
skilled in the art. Typically the composites utilize a resin(s) as
the matrix material and fiber as the reinforcing material. But, a
resin(s) and a particulate(s) can also be used, respectively, as
the matrix and reinforcing material. Sometimes fiber placement is
closely controlled such that the resulting composite part exhibits
a preferred fiber spacing and/or orientation. The fiber and resin
may be mixed or otherwise combined prior to placement on the tool
face. Alternatively, the fiber may be placed on the tool face and
the resin subsequently infused into the fiber by any of a number of
procedures. In some instances, prior to the placement of materials
which comprise the composite, the tool face may be covered with a
thin sheet of material, sometimes referred to as a parting sheet or
release film, which forms closely to the tool face. Such sheets can
be considered to be a temporary coating on the tool face. The
surface of this sheet that is not in contact with the tool face,
that is, the outside surface of the sheet, then effectively becomes
the tool face. Such sheets may be used to protect the tool face
and/or to provide for easier removal, or release, of the formed
composite part. Alternatively, the materials comprising the
composite may be prevented from bonding to the tool face by coating
the tool face with a release agent. Release agents can include
various polymers, including PVA, and waxes, among other materials.
Release films are composed of any of a number of polymeric
materials that do not bond with any of the materials comprising the
composite. Many types of release materials, compounds, and agents
are known in the associated arts and may be used with the present
invention.
[0034] The dimensions of the tool face are such that a surface of
the materials comprising the composite, typically a fiber
containing resin, is effectively molded into the desired shape and
dimensions. The resin(s) included in the materials comprising the
composite is subsequently cured, typically by the application of
heat, to yield a solid composite part having a surface of the shape
and dimensions imparted by the tool face.
[0035] The above description is not to be considered limiting in
any way and is only illustrative of certain embodiments of the
invention. The present invention may be varied in may ways without
departing from the scope of the invention and is only limited by
the following claims.
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