Expandable male die bladder for match die shape-forming systems and methods

Patent metadata

Field	Value
Publication number	US-12325668-B2
Application number	US-202217977781-A
Country	US
Kind code	B2
Filing date	Oct 31, 2022
Priority date	Oct 31, 2022
Publication date	Jun 10, 2025
Grant date	Jun 10, 2025

Abstract

A shape forming tool for pre-carbonization compression of a fibrous preform includes a female forming tool comprising a die recess, a support structure moveable with respect to the female forming tool, and at least one bladder coupled to the support structure and configured to be received into the die recess. The support structure is configured to move the bladder(s) with respect to the female forming tool. The bladder(s) is/are configured to be inflated to apply a compressive force to compress and form a fibrous preform between the bladder(s) and the female forming tool.

First claim

What is claimed is:

1. A shape forming tool, comprising:
a female forming tool comprising a die recess;
a support structure moveable with respect to the female forming tool;
a first bladder coupled to the support structure and configured to be received into the die recess;
gripper plates configured to clamp opposing lateral ends of a fibrous preform to the female forming tool; and
at least one actuator associated with the gripper plates and configured to translate the gripper plates laterally;
wherein the support structure is configured to move the first bladder with respect to the female forming tool; and
the first bladder is configured to be inflated to apply a compressive force to compress and form a fibrous preform between the first bladder and the female forming tool.

2. The shape forming tool of claim 1 , wherein, in response to being inflated, the first bladder is configured to extend laterally from a first side of a recess surface of the female forming tool to a second side of the recess surface, opposite from the first side.

3. The shape forming tool of claim 2 , wherein, in response to being inflated, the first bladder is configured to extend vertically from the support structure to a bottom surface of the recess surface of the female forming tool.

4. The shape forming tool of claim 1 , further comprising a center die extending from the support structure toward the female forming tool.

5. The shape forming tool of claim 4 , wherein the first bladder is mounted to a first side of the center die.

6. The shape forming tool of claim 5 , further comprising a second bladder mounted to a second side of the center die.

7. The shape forming tool of claim 6 , wherein the center die is configured to compress the fibrous preform against the female forming tool.

8. The shape forming tool of claim 7 , wherein the control unit is further configured to:
control a position of the center die with respect to the female forming tool; and
control a first state of the first bladder and a second state of the second bladder.

9. The shape forming tool of claim 1 , wherein the control unit is further configured to control the translation of the gripper plates.

10. The shape forming tool of claim 9 , wherein the control unit is further configured to:
receive a compression force of the gripper plates;
receive a tension force of the gripper plates;
receive an inflation pressure of the bladder; and
control at least one of the compressive force of the gripper plates, the tension force of the gripper plates, or the inflation pressure of the bladder based on another of the compressive force, the tension force, or the inflation pressure.

11. The shape forming tool of claim 1 , wherein the female forming tool comprises:
a sidewall portion,
a radii surface,
a top surface, and
an angled surface oriented at an angle of between 5 and 75 degrees with respect to the female top surface and disposed between the radii surface and the tool top surface, wherein the gripper plates are configured to clamp the opposing lateral ends of the fibrous preform against the angled surface.

Assignees

• Rohr Inc
• Goodrich Corp

Inventors

• Waugh Katherine E
• Koroly Christopher C
• Pujar Vijay V
• Linck John S
• Rosenbrock Kyle

Classifications

• C04B2235/604

  Pressing at temperatures other than sintering temperatures · CPC title

• C04B2235/5256

  Two-dimensional, e.g. woven structures · CPC title

• C04B2235/5248

  Carbon, e.g. graphite · CPC title

• B29C70/461

  Rigid movable compressing mould parts acting independently from opening or closing action of the main mould · CPC title

• B29B11/16

  comprising fillers or reinforcement {(non-woven fabrics per se D04H1/00, D04H3/00)} · CPC title