Densification of formed composite parts

Abstract

Methods and apparatuses for combining raw fibrous and binding materials in single mixing step (Step S 3 ), followed by consolidation (Step S 5 ) to greatly shorten overall cycle time to finished fiber-reinforced composite part. Chopped fibrous materials and binder materials are deposited sequentially onto belt conveyor (Step S 2 ) so that materials are successively layered on top of one another in predetermined ratio and subsequently mixed (Step S 3 ) to achieve uniform dispersion throughout. Mixed materials are deposited into rotating mold (Step S 4 ), which further ensures uniform dispersion of fibrous and binder materials. Impregnation of fibrous materials with the binder material occurs in situ as uniformly mixed materials are heated and subsequently compacted in mold (Step S 5 ) to obtain desired shape of fiber-reinforced composite part. Rotation device including: turntable for rotating mold; and actuator for supporting turntable and providing reciprocating motion to mold.

1 . A rotation device adapted for use in forming fiber-reinforced composite parts, said rotation device comprising:
 a turntable for rotating a mold thereon; and   an actuator for supporting said turntable, and for providing reciprocating motion to said mold,
 wherein said turntable and actuator simultaneously rotate and reciprocate said mold during a deposition of materials therein to provide improved densification of the final formed composite part. 
   
   
   
       2 . The rotation device of  claim 1 , wherein said actuator is a linear actuator. 
   
   
       3 . The rotation device of  claim 2 , further comprising air cylinders for reciprocating said mold in a +X and −X direction. 
   
   
       4 . A method of improving densification of a formed composite part employing a rotation device adapted for use in forming fiber-reinforced composite parts, said method comprising the steps of:
 rotating a mold on a turntable; and   providing reciprocating motion to said mold with an actuator for supporting said turntable,   whereby said turntable and actuator simultaneously rotate and reciprocate said mold during a deposition of materials therein to provide improved densification of the final formed composite part.   
   
   
       5 . The method of  claim 4 , wherein said materials are mixed fibrous and binder materials and wherein said simultaneous rotation and reciprocation provide substantially uniform dispersion of said fibrous and binder materials. 
   
   
       6 . The method of  claim 4 , wherein said actuator is a linear actuator and wherein said rotation device further comprises air cylinders for reciprocating said mold in a +X and −X direction. 
   
   
       7 . The method of  claim 4 , further comprising the step of:
 adjusting said linear actuator to move said mold up to four inches to a side of a centerline of a cyclone dust collector.