METHOD AND DEVICE FOR CONSOLIDATION OF A

TEXTILE PREFORM AND OVERMOLDING

The invention relates to a method and a device for consolidating a textile preform and producing an overmolding on the thus consolidated part. The invention is more particularly adapted to the production of a piece of composite material reinforced by long or continuous fibers, in the general shape of a shell, which part comprises an overmolded technical face, comprising in particular ribs, grooves, fixing wells or positioning or assembly elements, without this list being exhaustive or exhaustive.

Such a piece is for example represented by a cover of electronic equipment, such as a television screen, but the invention is also applicable in other fields, such as automotive, aeronautics or luggage. The use of a long-fiber or continuous fiber textile preform makes it possible to reduce the weight of such a piece while increasing its mechanical strength in comparison with the solutions of the prior art using an injected polymer reinforced with short fibers.

For this purpose, according to the prior art, a preconsolidated blank consisting of a continuous fiber laminated thermoplastic composite material is preheated to a temperature sufficient to allow interlaminar sliding of the constituent folds. Said blank is placed on a forming die and thermoformed to the shape of this die, during the closure of the mold. After, or concomitantly with the reconsolidation of said shaped blank, the technical face is overmolded by injection into the same mold, then the part is demolded after cooling.

This manufacturing cycle leads to thermal cycles of heating and cooling of both the blank and the mold. Thus, to achieve thermoforming the blank is brought to a temperature close to or even higher than the melting temperature of its polymer matrix, thus deconsolidating the blank, to allow the interlaminar sliding of the constituent folds, while the forming die, and the mold in general, are preheated to a temperature close to or slightly greater than the consolidation or glass transition temperature of said polymer matrix, the consolidation in the form of the blank then the injection requires cooling of the mold to a suitable temperature the consolidation of the blank but sufficient to allow the injection and filling of all the details of the mold, then the part must be cooled to a temperature suitable for its demolding, before opening the mold. Said mold must then be reheated to resume the cycle. The duration of the heating-cooling cycles, define the time of realization of the part. When they are implemented by indirect heating means of the mold, for example via a fluid circulation or electrical resistors running through the mold, these times are long compared to the production rates referred to for the pieces of the invention. The heating of the blank is, according to the prior art, carried out outside the mold by radiant panels in the infrared, said blank, once deconsolidated and ready to be thermoformed, loses its cohesion and becomes difficult to handle. before opening the mold. Said mold must then be reheated to resume the cycle. The duration of the heating-cooling cycles, define the time of realization of the part. When they are implemented by indirect heating means of the mold, for example via a fluid circulation or electrical resistors running through the mold, these times are long compared to the production rates referred to for the pieces of the invention. The heating of the blank is, according to the prior art, carried out outside the mold by radiant panels in the infrared, said blank, once deconsolidated and ready to be thermoformed, loses its cohesion and becomes difficult to handle. before opening the mold. Said mold must then be reheated to resume the cycle. The duration of the heating-cooling cycles, define the time of realization of the part. When they are implemented by indirect heating means of the mold, for example via a fluid circulation or electrical resistors running through the mold, these times are long compared to the production rates referred to for the pieces of the invention. The heating of the blank is, according to the prior art, carried out outside the mold by radiant panels in the infrared, said blank, once deconsolidated and ready to be thermoformed, loses its cohesion and becomes difficult to handle. The duration of the heating-cooling cycles, define the time of realization of the part. When they are implemented by indirect heating means of the mold, for example via a fluid circulation or electrical resistors running through the mold, these times are long compared to the production rates referred to for the pieces of the invention. The heating of the blank is, according to the prior art, carried out outside the mold by radiant panels in the infrared, said blank, once deconsolidated and ready to be thermoformed, loses its cohesion and becomes difficult to handle. The duration of the heating-cooling cycles, define the time of realization of the part. When they are implemented by indirect heating means of the mold, for example via a fluid circulation or electrical resistors running through the mold, these times are long compared to the production rates referred to for the pieces of the invention. The heating of the blank is, according to the prior art, carried out outside the mold by radiant panels in the infrared, said blank, once deconsolidated and ready to be thermoformed, loses its cohesion and becomes difficult to handle. these times are long in relation to the production rates referred to for the parts in charge of the invention. The heating of the blank is, according to the prior art, carried out outside the mold by radiant panels in the infrared, said blank, once deconsolidated and ready to be thermoformed, loses its cohesion and becomes difficult to handle. these times are long in relation to the production rates referred to for the parts in charge of the invention. The heating of the blank is, according to the prior art, carried out outside the mold by radiant panels in the infrared, said blank, once deconsolidated and ready to be thermoformed, loses its cohesion and becomes difficult to handle.

The induction heating technique as described, in particular, in document EP 1 894 442, makes it possible to rapidly heat and cool a mold intended for thermoforming or injection, and to obtain a fine control of both the temperature and the temperature. uniformity of this temperature on the molding surfaces of the mold by limiting the volume of the actually heated mold. This technical solution, if it allows to control the temperature of a mold including injection or thermoforming does not allow to preheat the blank.

EP 2 861 399 discloses another technical solution for heating the surfaces of a mold, using a radiating element carried at high temperature, placed vis-à-vis said molding surfaces. This technical solution alone does not allow control of the temperature in the molding cavity once the radiating element spaced from the surfaces and the closed mold.

The invention aims at solving the drawbacks of the prior art for the high-speed production of a thermoformed composite part comprising an overmoulding, and for this purpose concerns a device for thermoforming a composite part and overmolding by injection molding. a shape on one side of said composite part, in a mold comprising a forming die and a paired punch defining between them a closed cavity, said forming die being mounted on a transfer comprising:

at. a loading station unloading a blank on the matrix of

forming;

b. a mold injection and closure station between the punch and the forming die for thermoforming;

wherein the forming die comprises an inductor array for heating its molding surface and a cooling network of said flow-forming molding surface, and the loading-unloading station comprises a device for placing a radiating element facing the molding surface of the forming die.

Thus, the device which is the subject of the invention makes it possible to preheat the blank directly on the forming die before closing the mold to perform the injection. The blank being preheated once placed on the forming die, it is easy to handle during its loading, in particular by a robot.

The invention is advantageously implemented according to the embodiments and variants described below, which are to be considered individually or in any technically operative combination.

Advantageously, the radiating element is a screen heated by induction. Thus the screen, for example a graphite screen, is quickly heated to high temperature and allows rapid heating of the blank and the forming die.

Advantageously, the device according to the invention comprises a high frequency generator, the array of inductors of the forming die and the one providing the heating of the radiating element being supplied with high frequency current by this single and same generator, reducing thus the installed electrical power and the cost of the installation.

According to a particular embodiment, the device of the invention comprises a switch for alternately supplying the array of inductors of the forming die and that ensuring the heating of the radiating element by the single high frequency generator. The switch allows to easily and automatically change the transfer station supplied with high frequency current by the single generator.

According to a particularly advantageous embodiment, the device according to the invention comprises two forming dies each paired with the punch and each comprising an array of inductors and a cooling circuit for heating and cooling their molding surfaces, mounted on the transfer so that one of the dies is at the loading-unloading station when the other is at the thermoforming and injection station.

Advantageously, the induction heating circuit of the radiating element or the circuit comprising the array of inductors of the forming die comprises a capacitance box or an adjustment coil. These means make it possible to adapt the impedance of each circuit and to ensure the starting of the high frequency generator and its optimal operation, whatever the circuit supplied, although these have different electrical characteristics.

The invention also relates to a method for producing a shaped composite part comprising an overmolding, implementing a device according to the invention and comprising the steps of:

i. placing on one of the cold forming dies at the loading / unloading station, a composite blank;

ii. preheating said matrix and the blank in contact therewith by means of the radiating element to a temperature T1 adapted to thermoforming said blank;

iii. transfer the matrix to the thermoforming and injection station, iv. closing the mold on said matrix while maintaining the temperature T1 so as to thermoform the blank;

v. cooling the matrix to a temperature T2 adapted to the consolidation of the blank and to the injection;

vi. inject the overmolded part;

vii. cooling the molding cavity to the demolding temperature; viii. open the mold;

ix. transfer the matrix to the loading / unloading station;

x. unmold the piece and resume in step i)

wherein steps i) and x) are performed on the first matrix at the same time that steps iv) to vi) are performed on the second matrix and that step ii) is performed on the first matrix together with the steps vii and viii) on the second matrix.

Thus the tasks are performed in parallel and the rate of production is increased. When one of the matrices arrives at the loading-unloading station it is said to be cold, that is to say that its temperature is at most the demolding temperature. It is then easy to manipulate the blank, itself at a temperature close to ambient temperature, and to place it on said matrix, whether by a manual operation or by means of a robot.

Advantageously, step ii) comprises heating the blank and the forming die by means of the radiating element.

According to an embodiment implementing a device according to the invention comprising a switch, said switch directs the high frequency power supply to the heating means of the radiating element during step ii) and to the network of inductors the second forming die during steps iv) to vi).

The invention is explained below according to its preferred embodiments, in no way limiting, and with reference to FIGS. 1 to 5, in which:

- Figure 1 shows in a perspective view an embodiment of the device object of the invention;

- Figure 2 is a partial perspective view of an embodiment of the switch without its covers;

FIG. 3 represents, in a partial perspective view, an exemplary embodiment of the controlled connection, without its covers, for the electrical connection of the inductor array of the forming die to the high frequency generator at the injection station of the device. object of the invention;

- Figure 4 illustrates in a schematic sectional view, an embodiment of the device of the invention comprising two forming dies;

and FIG. 5 is a timing diagram of an exemplary implementation of the device that is the subject of the invention according to an exemplary embodiment of the method that is the subject of the invention.

1, according to an exemplary embodiment of the device according to the invention in an embodiment having only one forming die, said device comprises a circular transfer (100) rotatable over at least a quarter turn (90 °). ). A die (1 10) is mounted on said transfer (100) and is in this figure at the injection station, opposite a punch (120) paired with said die and whose vertical movement is controlled by a jack (121). Vertical movement of said punch (120) allows to close and open the mold constituted by the punch (120) and the matrix (1 10) whose molding surfaces define a closed cavity comprising the part when the mold is closed. When the circular transfer tray is turned a quarter of a turn, said die (1 10) is located at the loading / unloading station, under a preheating device (130) comprising a radiating screen and means for allowing the heating of this radiating screen. As a non-limiting example, the radiating screen consists of a graphite panel. The device is connected by a power line (150) to a high frequency current generator (190). By way of example, said generator produces a current at a frequency of between 10 kHz and 200 kHz for a power of between ten and a few hundreds of kW, depending on the intended application. A switch (160) is provided for supplying the forming die (110) with high frequency current from this single generator (190) when it is in the position of injection or the preheating device (130) at the loading / unloading station. According to this exemplary embodiment, the injection station further comprises a controlled connection (170) cooperating with means associated with the forming die (1 10) so as to electrically supply an array of inductors of said matrix.

2, according to an exemplary embodiment, the switch (160) comprises a high frequency electric current inlet (150) connected on one side to the high frequency generator and on the other side to a jumper (260) consisting of two conductive blocks, for example copper. According to this embodiment, the jumper (260) is able to move in a translation movement controlled by an electric stepper motor (265), between two pairs (261, 263) of receiving contacts, one (263) ) said pairs being connected to the induction heating circuit of a radiating panel and the other (261) to the induction circuit comprising an array of inductors in the forming die. Said receiving contacts (261, 263) each consist of two conductive blocks, for example copper.

of inductors of the forming die. Each of the electrical induction circuits of the radiating panel and of the forming die comprises, if necessary, a capacitance box and an adjustment coil (not shown), as described in document EP 2 742 773 / US-2014. -0183178, so as to allow the start of the high frequency generator and its optimal operation when it supplies one or the other of the induction circuits.

Figure 3, according to an exemplary embodiment, the controlled connection comprises a portion (371) fixed relative to the transfer injection station and a portion (372) connected to the forming die. The fixed part (371) comprises a pair of female contacts (31 1) insulated on their outer surface, able to make a connection with a pair of male contacts (312) on the part (372) connected to the forming die. According to this embodiment, the connection is made by the displacement of said female contact (31 1), this movement being performed by a pneumatic cylinder (375) double effect. Means (320) for circulating compressed air make it possible to cool the contacts (31 1).

Figure 4, according to one embodiment, the device of the invention comprises two forming dies (41 1, 412) placed on the transfer plate (100). Said transfer plate (100) makes it possible to move the first (411) and the second matrix (412) alternately between the loading / unloading station and the injection station by producing a turn portion, 90 ° or 180 °. Thus the device according to the invention, according to this embodiment makes it possible to produce two parts by operations performed in parallel on these two parts according to a pendular cycle. Each forming die (41 1, 412) comprises an array of inductors (413) extending into cavities in said die and cooling conduits (414) for fluid flow. This embodiment of the forming dies and its variants are described in particular in document EP 1 894442. The punch (120) positioned at the injection station, is paired with the dies, defining with each of them a closed cavity when it is brought into contact with one of the forming dies, a closed cavity comprised between the molding surfaces of the die and the punch. The molding surface of the punch comprises shapes (422) corresponding to the reliefs created on the piece made by overmolding. For this purpose, said punch comprises injection means (421) it is brought into contact with one of the forming dies, a closed cavity between the molding surfaces of the die and the punch. The molding surface of the punch comprises shapes (422) corresponding to the reliefs created on the piece made by overmolding. For this purpose, said punch comprises injection means (421) it is brought into contact with one of the forming dies, a closed cavity between the molding surfaces of the die and the punch. The molding surface of the punch comprises shapes (422) corresponding to the reliefs created on the piece made by overmolding. For this purpose, said punch comprises injection means (421)

plastic in the closed cavity between the molding surfaces of the punch and the forming die. According to one embodiment, the punch also comprises cooling ducts (423) for the circulation of a fluid. The loading / unloading station comprises a radiant element heating device (130). This heating device comprises, for example, a panel

(431) placed in a turn (432) which turn is connected to the high frequency generator (190) via the switch (160). When said coil

(432) is supplied with high frequency current, the graphite panel (431) is heated by induction and quickly heated to a high temperature, for example 1000 ° C. The high emissivity coefficient of the graphite makes it possible to transfer by radiation a great deal of energy used for its heating. The induction heating allows a rapid heating of the radiating panel which avoids maintaining said panel permanently at high temperature, thus limiting its degradation by oxidation. The thermal radiation (435) generated by the radiating element heating device (130) makes it possible to carry the laminated composite blank (450) used for the production of the part, up to a temperature T1 adapted to its thermoforming, while said blank (450) is placed on the die (412) at the loading / unloading station, but also to preheat the molding surface of said die (412) while the blank is placed on said die. Said blank (450) is deposited cold on the cold matrix (412) by an operator or a robot according to alternative embodiments.

According to exemplary embodiments, the blank is a fibrous ply stratification in a fully consolidated or partially consolidated thermoplastic matrix, in this case the thermoforming operation corresponds to a stamping, or the blank consists of a non-ply layering. consolidated, and in this case the thermoforming operation is close to a consolidation in shape, the prepreg plies of a thermoplastic polymer being relatively rigid, even if the lamination is not consolidated.

The heating temperature T1 adapted to the thermoforming of the blank is a sufficiently high temperature to observe a softening of the polymer constituting the matrix of the composite constituting the blank, and, depending on the nature of the reinforcements, sufficient to allow interlaminar slippage of the fibrous folds. Depending on the nature of the blank and the polymer constituting the matrix, this temperature is between the glass transition temperature and the polymer melting temperature. The temperature is determined in particular by tests according to the nature of the blank.

Advantageously, the molding surface of the matrix comprises a coating, for example a black chromium, or based on silicon carbide (SiC), making it possible to improve its absorption of infrared radiation and its heating by radiation. A pyrometer (not shown) makes it possible to measure the temperature of the blank or the molding surface of the matrix during their radiant heating. According to a variant, the surface of the matrix is ​​preheated to a temperature adapted by the radiating panel (431) before depositing the blank. The switch (160) makes it possible to direct the power current generated by the high frequency generator (190) via the controlled connection (170) to the inductor array (413) of the forming die (41 1). finding at the injection station.

FIG. 5, according to an exemplary implementation of the method that is the subject of the invention, a part of the manufacturing steps (510-512) are implemented on the loading / unloading station and the other part of the manufacturing steps ( 520-524) is implemented on the thermoforming / injection station. Thus, the steps are performed in parallel so as to increase the rate of production. Starting from the loading / unloading station, according to a demolding step (510), the previously thermoformed and overmolded part is removed from the forming die and the die is cleaned. During a step (51 1) of loading, a composite blank is placed on the matrix. During a preheating step (512), the blank and the forming die are brought to the radiation thermoforming temperature. During this step (512) the radiant heater is supplied with high frequency current. By rotation (513) of the transfer tray, the preheated die and blank are fed to the thermoforming and injection station. At the same time the thermoformed piece and overmolded in the other matrix is ​​brought to the loading / unloading station. During a step (520) of closing the mold the blank is thermoformed. The array of inductors of the forming die is connected to the high frequency generator at the end of the transfer step. During a step (521) of maintaining the preheated matrix and blank are fed to the thermoforming and injection station. At the same time the thermoformed piece and overmolded in the other matrix is ​​brought to the loading / unloading station. During a step (520) of closing the mold the blank is thermoformed. The array of inductors of the forming die is connected to the high frequency generator at the end of the transfer step. During a step (521) of maintaining the preheated matrix and blank are fed to the thermoforming and injection station. At the same time the thermoformed piece and overmolded in the other matrix is ​​brought to the loading / unloading station. During a step (520) of closing the mold the blank is thermoformed. The array of inductors of the forming die is connected to the high frequency generator at the end of the transfer step. During a step (521) of maintaining

temperature said matrix is ​​maintained at a temperature at least equal to the thermoforming temperature to ensure uniform impregnation of the folds of the plane thus formed. This step is aimed at the subsequent consolidation of the stratification, which is the development of the molecular chains of the polymer through the interfaces between the folds of the stratification, and the reduction of the porosities to an acceptable level with the intended application.

During this temperature maintenance step the radiating means are no longer powered by the generator. During a cooling step (522), the thermoformed blank at the thermoforming / injection station is cooled to a temperature below the glass transition temperature of its polymer matrix but sufficient to allow overmolding. During an injection step (523), overmolding is performed. During this step, the inductor network of the forming die is no longer supplied, which makes it possible to supply the heating means with radiation. During a cooling step (524), the mold consisting of the forming die and the punch is cooled by fluid circulation, and the mold is opened before the transfer plate performs (513) a new rotation, bringing the finished part, on its forming die to the loading / unloading station where it is removed from the mold. Thus the manufacturing operations are performed in parallel on both parts although only one high frequency generator is used.

The use of induction heating, both for the matrices and for the radiating means allows rapid heating / cooling cycles over large temperature ranges, between the mold release temperature and the thermoforming temperature, and thus to have at the two stations of the transfer a tool, a blank and a piece; at temperatures adapted to the operations carried out on these stations, without delay.

The device and method of the invention are suitable for a wide variety of thermoplastic composites, both as regards the nature of the fibers, the nature of the composite matrix and the nature of the injected polymer for overmolding. The blank preheating, temperature maintenance, injection and demolding temperatures are determined according to the materials used, from existing data or from tests. The achievement of these temperatures during the various steps and the organization of the corresponding means, in particular in terms of the number of inductors in the dies, installed induction power and fluid flow in the cooling channels are for example obtained by numerical simulation of the heating and cooling cycles.

The above description and the exemplary embodiments show that the invention achieves the aim of knowing that it makes it possible to perform, in parallel, the tasks of manufacturing two thermoformed and overmoulded parts, almost doubling the production rate, while using a single high frequency current generator, thus limiting the installed electrical power.

CLAIMS

Device for thermoforming a composite part and overmolding by injecting a shape on one side of said composite part, in a mold comprising a forming die (1 10, 41 1, 412) and a punch (120) paired defining between them a closed cavity, said forming die being mounted on a transfer (100) comprising:

at. a loading station unloading a blank (150, 450) on the forming die (1 10, 41 1, 412);

b. a mold injection and closure station between the punch (120) and the forming die (110, 41 1, 412) for thermoforming;

characterized in that the forming die comprises an array of inductors (413) for heating its molding surface and a cooling network (414) of said molding surface by fluid circulation, and that the loading-unloading station comprises a device for placing a radiating element (431) facing the molding surface of the forming die.

An apparatus according to claim 1, wherein the radiating element (431) is an inductively heated screen.

Device according to claim 2, comprising a high frequency generator (190), the inductor network (413) of the forming die and the (432) heating of the radiating element (431) being supplied with high current. frequency by this one and the same generator.

Device according to claim 3, comprising a switch (160) for alternately supplying the inductor network (413) of the forming die and that (432) for heating the radiating element (431) by the high generator frequency (190) unique.

Device according to Claim 3, in which the heating induction circuit of the radiating element (431) or the circuit comprising the inductor network (413) of the forming die comprises a capacitance box or a coil of 'adjustment.

Device according to claim 1, comprising two forming dies (41 1, 412) each paired with the punch (120) and each comprising an array of inductors (413) and a cooling circuit (414) for heating and cooling of their molding surfaces, mounted on the transfer (100) so that one of the matrices (412) is at the unloading loading station when the other (41 1) is at the thermoforming station - injection.

A method for producing a shaped composite part comprising an overmoulding, using a device according to claim 6, comprising the steps of:

i. placing (51 1) on one of the forming dies (41 1) at the loading / unloading station, a composite blank (450);

ii. preheating (512) said die (41 1) and the blank (450) in contact therewith to a temperature T1 adapted for thermoforming said blank;

iii. transferring (513) the matrix to the thermoforming - injection station;

iv. closing (520) the mold on said die by maintaining the temperature T1 so as to thermoform the blank; v. cooling (522) the matrix at a temperature T2 adapted to the consolidation of the blank and to the injection;

vi. injecting (523) the overmolded portion;

vii. cooling (524) the molding cavity to the demolding temperature;

viii. open the mold;

ix. to transfer (51 3) the mast to the loading / unloading station;

x. unmold (51 1) the piece and resume in step i)

characterized in that steps i) and x) are performed on the first matrix at the same time that steps iv) to vi) are performed on the second matrix and that step ii) is performed on the first matrix at the same time that steps vii and viii) on the second matrix.

8. The method of claim 7, implementing a device according to claim 3, wherein step ii) comprises heating the blank and the forming die by means of the radiating element (431).

9. The method of claim 7, implementing a device according to claim 4, wherein the switch (160) directs the high frequency power supply to the heating means (431) of the radiating panel during step ii ) and to the inductor array (413) of the second forming die during steps iv) to vi).