HK1090329B - Thermoplastic molding process and apparatus - Google Patents

Description

Method and apparatus for forming thermoplastic material

Cross reference to related applications

This patent application is a divisional application of a presently filed patent application No. 08/993516, filed on 18/12/1997, filed on 25/2002, and a partial continuation of the pending patent application No. 10/104394.

Technical Field

The present invention relates to a method and apparatus for forming thermoplastic materials, and more particularly to a method and apparatus for forming thermoplastic materials using a patented dynamic extrusion die having an adjustable extrusion orifice to vary the thickness of the extruded material as it passes through the extrusion die.

Background

In the past, it has been generally possible to provide a variety of different molding systems including the molding of thermoplastic resins or thermoplastic composite parts. In vacuum forming, a heated sheet of thermoplastic material (a constant thickness sheet) is placed on a vacuum mold and vacuum suction is applied between the mold and the heated plastic material to draw the plastic material onto the mold. Similarly, in compression molding, a preheated block or sheet of material is pressed between two dies to press the material into a desired part or shape.

Related patent

Previous U.S. patents using materials for thermoforming can be seen in four patents by Winstead, 4420300, 4421712, 4413964 and 3789095, respectively. The Winstead 4421712 and 4420300 patents are directed to an apparatus for continuous thermoforming of sheet material including an extruder, a stretching apparatus, a wheel having a female die thereon, and a plurality of interconnected plug assist members to form a track arrangement with the plug assist members engaging the sheet material about a substantial arc of the wheel surface. The Winstead 4413964 patent discloses an apparatus for continuously extruding and forming shaped products from a roll of thermoplastic material while continuously separating the products from the roll and stacking and handling the products and recycling the edges of the roll for further extrusion. The apparatus uses a plurality of mold cavities in a rotating polygonal structure, and a biaxially oriented web of material is continuously oriented on the outer peripheral surface of the polygonal structure by a driven roller connected to the polygon by a biaxial orientation device. The Winstead 3789095 patent is an integrated process for continuously extruding a low density thermoplastic material and utilizing the extrusion to produce a three-dimensional shaped object.

Howell, U.S. patent 3868209, is a two-sheet thermoplastic former for making a hollow plastic object from a pair of sheets of heat-fusible thermoplastic material which are continuously moved in a common horizontal plane from a heating station to a forming mechanism at a forming station. Held, Jr 3695799 is an apparatus for vacuum forming a hollow object by passing two sheets of thermoplastic material in spaced relation and between two mold halves through a heated zone. The mold halves are brought together as each sheet of material is evacuated to unify the shape of the sheet of material with its respective mold half to facilitate molding of the hollow object. The patent 5551860 to Budzynski et al is a blow molding apparatus for making bottles having continuously rotating rotary dies, one die at a time being aligned with one extrusion die used to load the die. Hujik patent 3915608 is an injection molding machine for multi-layer shoe soles that includes a turntable for rotating a plurality of molds through a plurality of stations to continuously mold the shoe soles. Ludwig patent 3302243 is another device for injection molding of plastic shoes. Lameris et al 3224043 discloses an injection molding machine having at least two molds that can be rotated to align with a plastic injection nozzle. Vismara patent 4698001 is a machine for making shaped plastic motorcycle helmets, using a compression type mold in which a pair of mold halves are switched between positions. Krumm' 4304622 is an apparatus for producing slabs of thermoplastic synthetic resin comprising a pair of extruders each extruding a half slab strand onto a respective roller assembly. The roller assembly has terminal rollers forming a set seam therebetween, and the two half slabs are bonded together at the set seam.

Synthesis and other Processes

Synthetic materials are materials formed from a mixture of two or more components that result in a material having properties and characteristics superior to those of the individual materials. Most composite materials comprise two parts, namely a matrix component and a reinforcement component. The matrix component is a material that joins the composite materials together and they are generally less rigid than the reinforcement component. These materials are press-formed at elevated temperatures. The matrix material encloses the reinforcement materials in place and distributes the load between the reinforcement materials. Because reinforcing materials are generally harder than matrix materials, they are the main load-bearing component within the composite material. The reinforcing material can come in many different forms, from fibers to fabrics, to particles or rods embedded within a matrix forming a composite material.

Synthetic structures have existed in nature for millions of years. Examining the microstructure of wood or the bioceramic of seashells, synthetic materials that occur in nature are found and it is shown that modern synthetic materials have been essentially the evolution of biomimetic structures found in nature. One desirable example of a composite material is concrete. Different forms of concrete enable one to understand how the reinforcement functions. The cement acts as a matrix holding the components together, while the sand, gravel and rebar act as a reinforcement. Concrete made of only sand and cement hardly provides the same strength as concrete made of cement, sand and stone, and conversely, concrete made of cement, sand and stone does not provide the same strength as concrete reinforced with reinforcing bars, sand and stone. The matrix and reinforcing materials of concrete are typically mixed, poured and formed in a forming structure. In the course of making parts from other composite materials, the shape of the composite structure or part is determined by the shape or geometry of the mold, die, or other tool used to form the composite structure.

There are many different types of synthetic materials, including plastic synthetic materials. Each plastic resin has its own unique characteristics that when combined with different reinforcements result in composite materials with different mechanical and physical properties. The number of possible synthetic materials will be surprising if one considers the number of plastic resins present today and multiplies this number by the number of available reinforcements. Plastic composite materials are mainly divided into two categories: thermosetting synthetic materials and thermoplastic synthetic materials.

In the case of thermosetting synthetic materials, after heating and pressure, the thermosetting resin undergoes a chemical change, crosslinking the molecular structure of the material. Once cured, the thermoset part components cannot be reshaped. Because of the tight cross-linked structure formed in the thermoset, thermosets are resistant to high temperatures and have greater dimensional stability than most thermoplastics. The thermoplastic matrix composition is not as constrained as a thermoset material and can be reused and reshaped to create new parts. Common matrix components for thermoplastic composites include polypropylene (PP), Polyethylene (PE), Polyetheretherketone (PEEK) and nylon. Thermoplastics reinforced with high strength high modulus fibers to form thermoplastic composites have a dramatic increase in strength and stiffness as well as toughness and dimensional stability.

Synthetic materials have many applications in a wide range of industries. Typically, composite materials are used to replace products made from metal alloys or multi-element metal structures assembled from fasteners or other connectors. The composite material provides sufficient strength while being lightweight. This is particularly important in industries such as the automotive and aerospace industries where the use of composite materials results in lighter, faster, more fuel efficient and environmentally sound aircraft and automobiles. Synthetic materials may also be designed to replace wood, fiberglass, and other conventional materials. The following is a partial list of industries in which large parts made of thermoplastic synthetic materials can be applied: aviation, automotive, construction, furniture, marine, raw material handling, medicine, military, telecommunications, transportation, and waste management.

In general, thermoplastic composites resist corrosion and provide long fatigue life, among other contributions, which are particularly attractive to many manufacturing industries. Fatigue life refers to the period of time a component lasts to the point where a specified capacity for the component is compromised before exhibiting material wear or significant stress. Typically, composite materials are used in applications where it is desirable to reduce the weight of a particular part while providing strength and other desirable characteristics of the prior art. Many components made of thermosetting synthetic materials are very expensive. These types of components are often referred to as advanced synthetic materials and are most commonly used in the military and aerospace industries.

Product development engineers and production engineers believe that thermoplastic synthetic materials will play an ever increasing role in modern technological development. New thermoplastic resins are steadily developing and more inventive manufacturing methods are also developing that reduce the costs associated with manufacturing parts from synthetic materials. The use of thermoplastic composites has become more feasible for many commercial and industrial applications because of the reduced cost of manufacturing parts from thermoplastic composites.

Currently available thermoplastic synthetic material forming method

The majority of the commercially available manufacturing techniques for thermoplastic synthetic materials are improved by the processing of thermosetting synthetic materials. Because these methods are used for resin systems having very low tack and long cure times, there are inefficiencies and other difficulties with the manufacturing process of thermoplastic materials. Some of the most common methods include compression molding, injection molding, and autoclaving (auto-heat processing), all of which can be used to produce "near precisely formed" parts, i.e., generally conforming to the intended or designed shape after forming. Less common methods for treating thermoplastic composite materials include pultrusion, vacuum forming, diaphragm forming, and hot pressing techniques.

Compression molding

Compression molding is by far the most common method used commercially for manufacturing structural thermoplastic composite components. Typically, compression molding uses a Glass Mat Thermoplastic (GMT) composite comprising a polypropylene or similar matrix mixed with continuous or chopped randomly positioned glass fibers. GMT is manufactured by third party material mixers and sold as standard or custom sized flat blanks to be formed. Using this pre-impregnated synthetic material (or prepreg when using its thermosetting equivalent, more commonly called), the GMT sheet is heated in an oven and then placed in a mould. The two mating mold halves close under great pressure, forcing the resin and fibers to fill the entire mold cavity. Once the part has cooled, it is removed from the mold with the aid of an ejection mechanism.

Typically, mating dies for GMT forming are machined from high strength steel to withstand the high forming pressures that are continuously applied without degradation. These molds are often actively heated and cooled to speed cycle time and improve surface finish. GMT molding is considered to be the most productive method of manufacturing synthetic materials with cycle times in the range from 30 to 90 seconds. Compression molding, however, does require high capital investment to purchase high energy presses (2000- & 3000 tons pressure) and high pressure molds, and is therefore effective only for high throughput. The low volume production of smaller parts can be made using aluminium dies on existing presses to save some costs. Other disadvantages of this method are the low fiber content (20% -30%) due to stickiness problems and its ability to achieve only moderate surface finishes.

Injection molding

Injection molding is the most popular method of manufacturing non-reinforced thermoplastic parts and is becoming more common for short fiber reinforced thermoplastic composites. Using this method, thermoplastic particles are injected into the staple fibers and extruded into a closed two-part hardened steel tool at an injection pressure typically in the range of 15000 to 30000 pounds per square foot (psi). The mold is heated to obtain high fluidity and then immediately cooled to minimize deformation. The mold can be designed using fluid dynamics analysis, the mold producing fibers having specific orientations at different locations, but typically the injection molded part is isotropic. The fibers in the final part are no more than one-eighth inch (1/8) "long, and the maximum fiber volume content is 40%. A slight variation of this process is Resin Transfer Molding (RTM). RTM manufacturing employs padded fibers placed in a mold, which is then fed with fibers under high pressure. The advantage of this method is the ability to manually position the fibers and use longer fiber lengths.

Injection molding is the fastest thermoforming process and is therefore used in a wide variety of applications such as automotive and consumer products. The cycle time is in the range of 20 to 60 seconds. Injection molding also produces highly repeatable near precisely molded parts. The ability to mold around the insert, the bore and the core material is another advantage. Finally, injection molding and RTM generally provide the best surface quality for any process.

Because of the size of the mold required and the capacity of the injection molding machine, the methods discussed above are limited in practice with respect to the size and weight of the parts that can be formed by injection molding. Thus, this method is useful for small to medium size part production. The biggest problem from the aspect of structural reinforcement is the problem regarding the length of the reinforcing fibers that can be used in the injection molding process.

Autoclaving

Autoclaving is another method of producing thermoplastic synthetic materials used industrially. Thermoplastic materials pre-impregnated with unidirectional fibres or fabric are placed on a single-sided tool. Several layers of bag-making material are placed on the prepreg assembly for surface treatment to prevent sticking and can be evacuated once placed in an autoclave. Inside the autoclave, the composite material is heated and pressed to consolidate and crosslink the material layers. Unlike compression molding and injection molding, the tool is an open mold and can be made of aluminum or steel because of the low pressures involved.

Because autoclave is slow and more labor intensive, it is used primarily for very large, small numbers of parts that require very high precision; it is not easy to be used in production line. Significant advantages of this approach include high fiber volume fractions (volume fractions) and control of fiber orientation that can create specific material properties. This method is very useful for producing prototypes because the tooling is relatively inexpensive.

Method for forming thermoplastic synthetic material requiring long fibre

None of the above methods produces a thermoplastic composite material reinforced with long fibers (i.e., greater than one-half inch) that remain largely unbroken during the forming process itself; this is particularly important for producing large and more complex parts. Historically, a three-step process was used to form such components: (1) third party blending of the pre-impregnated synthetic formulation; (2) preheating the prepreg material in an oven; and (3) the molten material enters the mold to form the desired part. This approach has several drawbacks that limit the industrial versatility of creating more complex large parts with sufficient structural reinforcement.

One disadvantage is that sheet forming processes do not produce parts of varying thickness or thermoplastic composite parts that require "deep drawing". The thicker the extruded sheet, the more difficult it is to remelt the sheet uniformly throughout its thickness to avoid problems associated with the structural formation of the final part. For example, the leg of the tray that is extruded perpendicularly from the top surface is a deep drawn portion of the tray that cannot be formed using thicker extruded sheet because the formation of the tray leg requires deep drawing of the material in a "vertical plane" and, as such, will not be uniform in the horizontal plane of the extruded sheet. Other disadvantages associated with the geometric limitations of extruded sheets of uniform thickness are apparent and will be described in greater detail below in conjunction with the present description.

The present invention is directed to a molding system for producing thermoplastic composite parts of thermoplastic resin using either a vacuum mold or a compression mold, the parts being fed directly into the mold from an extrusion die while the thermoplastic sheet still retains heat for heating the resin to a fluid state to form the sheet of material through the extrusion die. The present invention relates to a thermoplastic material forming method and apparatus, and more particularly, to a thermoplastic material forming method and apparatus using a thermoplastic extrusion die having an adjustable extrusion port control plate to vary the thickness of the extruded material that is formed as it passes through the extrusion die.

The present invention is further directed to a continuous thermoplastic forming system that feeds sheets of thermoplastic material directly from an extruder that forms the sheets to a die that can rotate between stations. The thermoplastic material is extruded through an extrusion die that is adjustable to provide a shift from a constant thickness of the plastic sheet to a variable thickness across the lateral surface of the plastic sheet. The variable thickness may be adjusted for any particular forming run, or may be continuously varied as desired. This enables continuous forming or thermoplastic materials with different thicknesses in the transverse direction of the extrusion plate or the whole of the formed part to control the interim thickness of the formed part so that the formed part has thick or thin places throughout the part of the formed part as desired. The present invention is not limited to the size, shape, composition, weight, or strength of the desired part produced by the extrusion process.

Disclosure of Invention

A thermoplastic material forming system includes a thermoplastic extrusion die for extruding a thermoplastic sheet formed by an adjustable die extrusion orifice member, i.e., a dynamic die assembly, for varying the thickness of the extruded material at different portions of the extrusion die. The thermoplastic extrusion die has a cutter for shearing the extruded thermoplastic sheet from the thermoplastic extrusion die. The plurality of thermoplastic dies, either vacuum dies or compression dies, are each mounted on a movable platform, such as a rotary platform, for moving one die at a time to a position to receive a thermoplastic sheet cut from the thermoplastic extrusion die. The profiled part with variable thickness is formed by a heated sheet of thermoplastic material, which is still fed heated from the extrusion die. A plurality of dies are mounted on a platform to feed one die to a loading position for receiving a thermoplastic sheet from the extrusion die and a second die to a release position for removing the formed part from the die. The platform may be a reciprocating or rotating platform and allows each molded part to be cooled while another molded part is receiving a thermoplastic sheet. There is provided a method of forming a thermoplastic material, the method having the step of selecting a thermoplastic extrusion die, the selection of the thermoplastic extrusion die being performed in accordance with means for adjusting the thermoplastic extrusion die to vary the thickness of the extruded material in different portions of the extrusion plate through which it passes. Thermoplastic material is heated to a flowing state and extruded through selected thermoplastic dies that have been adjusted to vary the thickness of the extruded material in different portions of the extrusion plate, cut extruded thermoplastic sheets having variable thicknesses to predetermined dimensions, and introduce the heated thermoplastic material cut sheets into a thermoplastic forming die, and form a predetermined part in the die such that the formed part has a variable thickness formed by the heated sheet of material during material extrusion.

This "extrusion-molding" method also facilitates the formation of thermoplastic composite structures reinforced with long fibers (greater than one-half inch) because the extruder distributes the molten thermoplastic composite material through the dynamic die, directing the material under gravity onto a lower die that is movable relative to the position of the dynamic die. As used herein, the term "lower mold" refers to the lower half of the mating mold into which the thermoplastic material is introduced. Likewise, the term "upper mold" refers to the upper half of a mating mold, and the desired thermoplastic part is formed within the mating mold when the upper and lower molds are joined, i.e., closed. The lower mold may be moved by a roller carriage to fill the mold cavity with a variable amount of thermoplastic composition. For example, if the mold cavity defined by the lower mold and one upper mold is larger at a certain horizontal range, the lower mold may be slowed down to receive more molten thermoplastic composite material in this area. The dynamic die uses flow control elements to vary or adjust the flow of molten extruded thermoplastic composite material to deliver different amounts of material from each flow control element to deposit material selectively across the width of the lower die in a direction perpendicular to the direction of movement of the lower die. The thermoplastic composite may be formed with long fibers (greater than one-half inch) having a weight content of at least ten percent (10%) up to fifty to sixty percent (50% -60%), the fibers having a low breakage rate. After the molten extruded thermoplastic composite material falls under gravity into the lower mold, the roller car is automatically transported into a press which closes the upper mold onto the lower mold to form the composite part.

One embodiment in accordance with the principles of the present invention includes a system and method for forming an article made of thermoplastic material and fibers. The method includes heating a thermoplastic material to form a molten thermoplastic material while mixing with the fibers. The molten thermoplastic material is mixed with the fibers to form a molten composite material having a desired weight and/or volume of fiber content. The molten composite material may then be extruded through the dynamic die to form the desired composite material stream and fall under gravity onto the lower portion of a die for forming the article. The lower die may be discontinuously moved in time and space at varying speeds while receiving the flow of composite material to deposit thereon a predetermined amount of molten composite material that closely corresponds to the desired amount of material in the cavity of the lower die. The upper part of the mould may be pressed against a predetermined amount of molten synthetic material and closed on the lower part of the mould to form the article.

Drawings

Other objects, features and advantages of the present invention will become apparent from the specification and the drawings, in which:

FIG. 1 is a top view of a molding system according to the present invention;

FIG. 2 is a side view of the molding apparatus of FIG. 1;

FIGS. 3A-3E are plan views of the mold of FIGS. 1 and 2 at various steps of the method of the invention;

FIG. 4 is a side view of the extruder of FIGS. 1 and 2;

FIG. 5 is a rear view of the extruder of FIG. 4;

FIG. 6A is an exemplary schematic view of the extrusion-molding system according to FIG. 1 operable to form a structural component;

FIG. 6B is another exemplary block diagram of the extrusion-molding system 600a of FIG. 6A;

FIG. 7 is an exemplary exploded view of the dynamic die of FIG. 6A depositing extruded composite material onto a lower die supported by a roller car;

FIG. 8A is an exemplary flow diagram depicting an extrusion-molding system that may be used to deposit a composite material onto the lower mold of FIG. 6A via two-axis or three-axis control to form an article or structural component;

FIG. 8B is another exemplary flow chart for producing a structural component by a three-axis controlled extrusion method using the extrusion-molding system of FIG. 6A;

FIG. 9 is an exemplary block diagram of the controller of FIG. 6A in connection with a controller in a component of the extrusion-molding system of FIG. 6A;

FIG. 10 is a more detailed exemplary block diagram of the controller of FIG. 6A;

FIG. 11 is an exemplary block diagram of software executed by operating a processor of the controller of FIG. 10;

FIG. 12 is an exemplary schematic view of a flow control element and one lower die divided into a grid for depositing extruded composite material according to the extrusion-molding system of FIG. 6A;

FIG. 13 is a top view of a flow control element designed to deposit a composite material onto the lower mold of FIG. 6A;

FIG. 14 is an exemplary top perspective view of a corner of a pallet produced by the extrusion-molding system of FIG. 6A;

fig. 15A and 15B are exemplary bottom and top perspective views, respectively, of a platform having invisible ribs formed by the extrusion-molding system of fig. 6A.

16A and 16B illustrate exemplary structural members having inserts formed by the extrusion-molding system of FIG. 6A;

FIG. 17 is an exemplary flow chart illustrating the operation of inserting an insert, such as a fastener, support, or other element, into the interior of the structural member shown in FIGS. 16A and 16B using the extrusion-molding system of FIG. 6A.

Detailed Description

For many years, there has been a drawback in the composite manufacturing industry that it has not been possible to provide a method to mass produce large thermoplastic composite structures or parts with the precision and low pressure of autoclave molding at certain compression or injection molding rates and labor efficiencies. The invention aims to provide a method which remedies this drawback and produces such thermoplastic composite parts. The method is suitable for medium to high volume production of parts and can produce large parts and structures with high concentrations of reinforcing fibers at low forming pressures.

Referring to fig. 1 and 2, a thermoforming apparatus 10 for thermoforming thermoplastic resins or thermoplastic composites into parts is shown having an extruder 11, a mold change station 12, and a molding station 13. The extruder has a top mounted hopper 14 for feeding thermoplastic resin or composite material into an auger 15 where a heater heats the thermoplastic material into a fluid material, while the auger feeds the fluid material along the length of the extruder passageway to an extrusion die 16 at the end thereof. The material fed into and discharged through the extruder to the outside of the extrusion die is cut by a cutter 17 installed at the end of the die 16. The material is extruded into a generally flat slab (not shown) and is cut at a predetermined point by the cutter 17 as it exits the extrusion die 16. A support platform 18 will support a moving mold half 19, the moving mold half 19 being directly below the extrusion die 16 to receive the sheet of thermoplastic material. The moving half-mould 19 has wheels 20 which allow the half-mould 19 to be moved from the platform 18 to a rotating platform 21 (indicated by the half-mould 19 '), the rotating platform 21 being mounted on a central rotating shaft 22 to rotate in the direction indicated by the double-headed arrow 21' in fig. 1. The rotary platform 21 has a second half-mould 23 on it, the second half-mould 23 being able to be fed into the moulding station 13 (indicated by the half-mould 23') with the half-mould 19 on the platform 18. The mold halves 23' may be supported on a stationary platform 24 within the compression station directly beneath a common molding stationary mold half 25, the mold half 25 being mounted on a movable platen 26, the molding operation taking place at the movable platen 26. Thus, the mold halves 19 and 23 can be reciprocated back and forth so that one mold can receive the thermoplastic sheet while the other mold molds the part. Each moving half-mould 19 and 23 has a motor 27 for driving the half-mould from the rotating platform 21 onto the platform 18 or onto the stationary platform 24. A linear transducer 28 may be mounted on the platform 18 for controlling the speed of the moving mold halves.

It should be noted at this point that the extruder 11 produces a heated extrusion plate, still having thermal energy on the moving mold halves where it is transferred to the press 13 and formed into a part without having to reheat the sheet of thermoplastic material. It should also be noted that in the context of FIGS. 4 and 5, the thermoplastic sheet may also have a variable thickness across its width to provide reinforcement to the formed thermoplastic shaped part.

Fig. 3A-3E illustrate a thermoplastic molding apparatus 10 having mold halves 19, 19 'and 23, 23' located at various positions in a molding operation according to the present invention. Each figure has an extruder 11 with a hopper 14 which feeds thermoplastic resin or composite material into an auger 15 in which the material is heated prior to being extruded. In fig. 3A, the mold half 23' is empty and the mold half 19 is filled with hot melt directly from the extruder 11. In fig. 3B, the mold transporter moves the mold halves 19 and 23' onto the rotating carousel 21. In fig. 3C, the rotary carousel 21 rotates about a central axis 22 (not shown) between a station for loading the sheet of material onto the mold halves 23 and a station for entering the loaded mold halves 19' into the compression or vacuum molding machine 13. In fig. 3D, the mold half 19' is moved into the die 13, while the empty mold half 23 is moved under the extrusion die 16 for loading the sheet of thermoplastic material. In fig. 3E, the mold half 19' is extrusion cooled and the part is ejected while the mold half 23 is filled with hot melt as it is moved by the transporter under the extrusion die 16 until completely filled.

Referring to fig. 4 and 5, an extrusion die 30 is shown having a die body 31, the die body 31 having a slot 32 for feeding a fluid thermoplastic material through an extrusion slot 33 by an auger 15 in fig. 1 and 2 to produce a thin sheet or slab of thermoplastic extruded material from a port 34. Die 30 has a plurality of extrusion orifice control plates (gated plates) 35, each of which is connected to a threaded shaft 36 driven by a control plate energizing motor 37, motor 37 being either a hydraulic or pneumatic motor, but as shown motor 37 is an electric stepper motor having a control line 38 connected to a remote controller 40, controller 40 being capable of stepping motor 37 to move plate 35 in and out to vary the thickness of the thermoplastic sheet passing through slot portion 41. In fig. 5 can be seen any number of multiple motors 37 driving multiple plates, each plate being mounted next to the next and each plate being controlled individually, whereby the plates 35 in the slots 41 are varied at widely different rates (patters) for producing and discharging material plates from the output 34, the thickness of which can be varied across the width of the extruded plate. It is also clear that the plates 35 can be controlled manually by screwing each plate in and out individually to adjust the thickness of any part of the extrusion die, alternatively by a controller 40, the controller 40 being programmable by a computer to vary the thickness of any part of the extrusion plate under remote control.

A method of forming a thermoplastic material is provided which includes selecting a thermoplastic extrusion die 16 or 30 for extrusion of a thermoplastic slab, the extrusion die having an adjustable die extrusion orifice element for varying the thickness of the extruded material at different portions of the extrusion slab. The method includes adjusting a thermoplastic extrusion die to vary the thickness of the extruded material passing through different portions of the extruded sheet, then heating the thermoplastic material to a fluid, and extruding the fluid thermoplastic material through the selected and adjusted thermoplastic extrusion die into a sheet. The thermoplastic sheet is then cut and introduced onto a heated thermoplastic material, into a thermoplastic forming die 19 or 23 and formed in a forming device 13 to form a part having locally variable thickness.

At this point it should be clear that a thermoplastic material forming method and apparatus have been provided which is capable of thermoforming a part having a variable thickness through an extrusion die which can be continuously controlled to vary the thickness of different parts of the extruded sheet being formed and which is still heated to take advantage of the heat energy from the extrusion process when the forming is complete. It should also be understood, however, that the invention is not to be considered as limited to the forms shown, which are to be regarded as illustrative rather than restrictive. For example, although the extruded material is sometimes described as a generally flat sheet, it may be described as follows: (I) heat is included when transporting to the compression-moulding machine 13 to avoid reheating, (II) a variable thickness across its entire width, (III) a hot melt when entering the mould half 19 from the extruder 11, (IV) the use of a plurality of control plates 35 to vary the thickness across the width of the extruded material and the thickness of different parts of the extruded material, and finally, (V) the extrusion of the molten thermoplastic material through the selected and adjusted extrusion die to obtain a variable thickness across the different parts formed. Thus, extruders generally provide a molten flow of thermoplastic composite material through a dynamic die, dropping by gravity onto one half or lower die in a variable amount in a vertical plane, and traversing the horizontal direction on the die.

The "extrusion-molding" process described above is ideal for making moderate to large thermoplastic composite structures reinforced with glass, carbon, metal or organic fibers, to name a few structures. The extrusion-molding process includes a computer-controlled extrusion system that combines and automates the operation of materials mixed or compounded with matrix material and reinforcing components to dispense a quantity of molten composite material that gravitates into a mating mold lower mold half, the movement of the lower mold half being controlled as the material is received, and a compression molding station for receiving the mold lower mold half to mold the upper mold half against the lower mold half to form the desired structure or part. The lower half of the mating mold moves discontinuously in time and distance at varying speeds to allow the material to settle thicker at a slow speed and thinner at a faster speed. The thermoplastic apparatus 10 described above is one embodiment for implementing an extrusion-molding process. The untreated resin (which may be any form of regrind or pelletized thermoplastic material, or any thermosetting epoxy resin) is the matrix component that is fed into the feeder or hopper of the extruder along with reinforcing fibers having a length in excess of about one-half inch (1/2 "). The composite material may be mixed and/or compounded by the extruder 11 and "intelligently" deposited on the lower die 19 by controlling the output of the extruder 11 and the movement of the lower die 19 relative to the position of the extruder 11 using the control panel 35, as will be described below with respect to the embodiment shown in fig. 6A and 6B. In those embodiments, the bottom of the mating mold is fixed to a roller car that moves discontinuously under the dynamic mold. The bottom of the mating die receives a precise amount of extruded composite material and then moves into a compression molding station.

Thermoplastic matrix materials that may be used to form the composite material in an extrusion-molding process include thermoplastic resins known in the art. The thermoplastic resin that may be used in the concept according to the present invention may include any thermoplastic resin that can be melted and mixed by the extruder 11. Examples of such thermoplastic resins are provided in table 1, it being understood that these examples are not all inclusive and that other thermoplastic resins and materials may be used to create structural components in the use of extrusion-molding systems. The additional thermoplastic resins in table 1 may be used alone or in any combination.

Particular thermoplastic resins have been particularly suited for extrusion-molding processes, including polypropylene, polyethylene, polyetheretherketone, polyester, polystyrene, polycarbonate, polyvinyl chloride, nylon, methacrylic acid (polymethyl), polymethacrylate, acrylic acid, polyurethane, and mixtures thereof.

Fibers used as reinforcing components for thermoplastic synthetic materials generally include those materials that can be used to reinforce thermoplastic resins. Fibrous materials suitable for use in accordance with the principles of the present invention include, but are not limited to, glass, carbon, metal, and natural substances (e.g., flax, cotton), either alone or in combination. Other fibers not listed may also be used as is well known in the art. Although the diameter of the fibers is generally not limited, the diameter of the fibers used to form larger structural components typically ranges between 1 and 20 μm. It should be understood, however, that the diameter of the fibers may be larger depending on a number of factors including the desired strength of the structural member, the desired fiber density, the size of the structural member, and the like. In particular, the effect of improving the mechanical properties of the fibers having a diameter of approximately 1 μm to approximately 9 μm is remarkable.

The number of filament bundles in a fiber is also generally not limited. However, from a handling point of view, a fiber bundle consisting of 10000 to 20000 filament bands or monofilaments is desirable. The roving of reinforcing fibers may be used after being surface treated with a silane or other bonding agent. To improve interfacial adhesion with thermoplastic resins, such as polyester, surface treatment may be accomplished by forming a thermoplastic film of polymer, binder, fiber lubricant, or the like. Such a surface treatment may be carried out before the treated reinforcing fibres are used, or the surface treatment may be carried out just before the reinforcing fibres are fed into the extruder, so that the extrusion process is carried out without interruption, to produce a molten thermoplastic composite material. The proportions of the thermoplastic resin and the fibers are not particularly limited, since it is possible to produce the thermoplastic composite material and the formed article using the components in any proportion according to the end use purpose. However, as in the prior art, the fibers are typically present in an amount of 5% to 50% by weight in order to provide sufficient structural support to the structural component. It has been determined that the fiber content is typically 10% to 70% by weight, preferably 40% by weight, in order to obtain the desired mechanical properties in the larger object product.

The fibers have an average fiber length greater than one-half inch (1/2 "). However, typical structural components produced by extrusion-molding system 600a use fibers having lengths in excess of about 1 inch. It should be noted that when the average fiber length is less than 1 inch, it is difficult to obtain the desired mechanical properties of a large object. The distribution of the fibers in the thermoplastic composite material is substantially uniform so that the fibers and the thermoplastic resin do not separate when melted and compressed. The distribution and payout (distribution) of fibers comprises a process by which fibers are broken up from a single fibril level into a plurality of fibril levels (i.e., bundles of several tens of fibers). In one embodiment, a fiber bundle of about five fibers is dispersed to provide efficacy and structural properties. Also, the "degree of bonding" can be estimated by observing a cross section of the structure with a microscope, and determining the number ratio of the reinforcing fibers in the fiber bundle composed of 10 or more fibers (the total number of reinforcing fibers in the fiber bundle composed of 10 or more fibers/the total number of reinforcing fibers x 100) (percentage) among all 1000 or more observable reinforcing fibers. Typical values generated in accordance with the principles of the present invention do not exceed approximately 60% and are typically below 35%.

FIG. 6A is a representative exemplary diagram of an extrusion-molding system 600a operable to form structural components. The extrusion-molding system 600a is made up of separate elements that are joined together to form a structural component from a composite material. The components include a material receiving device 602, a heater 618, an extruder 604, a dynamic die 606, a roller car 608, a compression press 610, and a controller 612. Other supplemental elements may also be included to form extrusion-molding system 600 a.

The material receiving device 602 may include one or more hoppers or feeders 614 and 615 for receiving materials M1 and M2, respectively, that are to be extruded to form a thermoplastic composite material. It should be understood that additional feeders may be used to receive additional materials or additives to formulate different composite materials. In the present example, the materials M1 and M2 represent the starting materials, i.e. the reinforced thermoplastic material, which is preferably in pellet form. M1 and M2 may be the same or different reinforced thermoplastic materials. The thermoplastic material may be reinforced by fibers, such as glass or carbon fibers, as is known in the art. It should be further understood that non-thermoplastic materials may also be used in accordance with the principles of the present invention.

A heater 618 preheats the thermoplastic materials M1 and M2. Extruder 604 is connected to feeder channel 616 and is operable to mix heated thermoplastic materials M1 and M2 via one auger 620. The extruder 604 further melts the thermoplastic material. Auger 620 may be a spiral or any other shape that allows the composite materials to be mixed and exit through extruder 604. An extruder output channel 622 is connected to the extruder 604 and is used to transport the composite material to a dynamic die 606.

The dynamic die 606 includes a plurality of flow control elements 624a-624n (collectively 624). The flow control element 624 may be a separate extrusion port, valve, or other mechanism operable to control the volume flow rate of the extruded composite material 625 from the dynamic die 606, wherein the volume flow rate of the extruded composite material 625a-625n (collectively 625) is varied in a plane P at or below the flow control element 624. The output range for different volumetric flow rates is between approximately 0 to 3000 pounds per hour. A more preferred volumetric flow rate output range is between approximately 2500 to 3000 pounds per hour. In one embodiment, the flow control element 624 is a control board that is raised and lowered by a separate actuator, such as by an electric motor (i.e., stepper motor), a hydraulic actuator, a pneumatic actuator, or other actuator that is capable of altering the flow of the composite material through the separate or all of the adjustable flow control elements 624. The flow control elements 624 may be configured in close proximity to provide a continuous, independent, close proximity flow control element 624. Alternatively, the flow control elements 624 may be independently configured such that the composite material from immediately adjacent flow control elements 624 remains independent until the composite material is spread onto one of the molds. It should be understood that the flow control element 624 suitably may operate as a cutter. In one embodiment of the invention, the molten composite material may be delivered to a reservoir located between the extruder 604 and the dynamic die 606, and a plunger or other actuating mechanism may be used to deliver the composite material from the reservoir to a lower die.

The roller car 608 may be moved under the dynamic die 606 such that the extruded composite material 625 falls or settles under gravity onto a lower mold 626, which passes a predetermined vertical distance, the "drop distance" (d), under the dynamic die 606. The lower mold 626 has a mold cavity 630 for forming the structural component. The extruded composite material 625 is deposited 628 on the lower mold 626 to fill the volume defined by the mold cavities in the lower mold 626 and the upper mold 632 to form the composite part. In a dual-axis control method, the composite material 625a may be deposited from the dynamic mold 606 onto the lower mold 626 at a substantially constant volumetric flow rate or across a vertical plane (P) based on discrete movements and variable speeds to form a composite material layer 628 having substantially the same thickness or volume along the vertical plane (P) to fill the mold cavities 630 in the lower and upper molds 626 and 632. In one three-axis control method, composite material may be deposited from the dynamic die 606 onto the lower die 626 across the vertical plane (P) at different volumetric flow rates to form composite material layers 628 having different thicknesses or volumes along the vertical plane (P) to fill the mold cavities 630 in the lower and upper dies 626 and 632. It should be understood that a dual axis control method may be used to deposit the composite material into a mold having a cavity 630 with a substantially constant depth in the vertical plane, while a three axis control method may be used to deposit the composite material into a mold having a cavity 630 with a varying depth.

The roller car 608 may further include wheels 634 for movement along a track 636. The track 636 enables the roller car 608 to roll under the dynamic die 606 and into the press 610. The press 610 operates to press the upper mold 632 into the lower mold 626. Although the force of the molding process is less than that of conventional thermoplastic molding methods due to the deposition of the synthetic material layer 628 from the dynamic die 606 directly onto the lower die 626 in accordance with the principles of the present invention, the force applied by the press 610 is still sufficient to damage the wheel 634 if the wheel is not in contact with the rail 636. Thus, the wheels 634 may selectively engage and disengage an upper surface 638 of a base 640 of the press 610. In one embodiment, the roller car 608 is lifted by an inflatable tube (not shown) that is engaged therewith such that the wheels 634 engage the tracks 636 as the tube is inflated so that the roller car 608 may be moved from the lower die 606 to the press 610. When the tube is deflated, the wheels are disengaged so that the body of the roller car 608 rests on the upper surface 638 of a base 640 of the press 610. It should be understood that other operational structural elements may be used to engage or disengage the wheels 634 from the support roller cart 608, but the function of engaging or disengaging the wheels 634 is substantially the same. For example, the upper surface 638 of the base 640 of the press 610 may be raised into contact with the floor 642 of the roller car 608.

The controller 612 is selectively integrated with various elements forming the extrusion-molding system 600. Control 612 is a processor-based device that operates to coordinate the formation of structural components. In part, the operation of the controller 612 controls the deposition of the composite material on the lower mold 626 by controlling the temperature of the composite material, the volumetric flow rate of the extruded composite material 625, and the position and speed of movement of the lower mold 626 through the roller car 608 to receive the extruded composite material 625. The controller 612 may further operate to control the heater 618 to heat the thermoplastic material. The controller 612 may control the speed of the auger 620 to maintain a substantially constant flow of the composite material through the extruder 604 and into the dynamic die 606. Alternatively, the controller 612 may vary the speed of the auger 620 to vary the volumetric flow rate of the composite material from the extruder 604. The controller may further control a heater (not shown) and a dynamic die 606 in the extruder 604. Based on the formed structural component, a predetermined set of parameters may be established for the dynamic die 606 to apply the extruded composite material 625 to the lower die 626. The parameters may be defined such that the flow control elements 624 may be selectively set such that the movement of the roller car 608 is synchronously set by the volumetric flow rate of the composite material defining the mold cavity 630 of the resulting structural component.

The roller car 608 may further include a heater (not shown) that is controlled by the controller 612 and operable to maintain the extruded composite material in a heated or molten state. By varying the desired speed of the roller car, the controller may control the roller car 608 during the time that the extruded composite material 625 is applied to the lower mold 626. Upon completion of the application of the extruded composite material 625 onto the lower mold 626, the controller 612 drives the roller car 608 into the press 610. The controller then signals a mechanism (not shown) to disengage the wheels 634 from the rails 636 so that the press 610 can force the upper mold 632 against the lower mold 626 without damaging the wheels 634.

FIG. 6B is another exemplary block diagram of the extrusion-molding system 600a of FIG. 6A. The extrusion-molding system 600b is configured to support two presses 610a and 610b that are operable to receive a roller car 608 that supports a lower mold 626 to form a structural component. It should be understood that the two roller cars 608 may be supported by rails or rails 636 to enable the formation of multiple structural elements by a single extruder 604 and dynamic die 606. In one embodiment, wheels 634 and tracks 636 may be used to move the roller car 608, it being understood that other movement mechanisms may be used to control the movement of the roller car. For example, a conveyor, suspension system, or track drive system may be used to control the movement of the roller car 608.

The controller 612 is configured to support a plurality of structural components such that the extrusion-molding system 600b may form different structural components simultaneously through different presses 610a and 610 b. Because the controller 612 is capable of storing parameters that enable the formation of multiple structural components, the controller 612 can simply alter the control of the dynamic die 606 and the roller cars 608a and 608b by utilizing the parameters in a common software program, thereby using a single extruder 604 and dynamic die 606 to form two different structural components. It should be appreciated that additional presses 610 and roller cars 608 may be used to produce more structural components substantially simultaneously through a single extruder 604 and dynamic die 606.

Fig. 7 is an exemplary exploded view of the dynamic die 606 depositing the extruded composite material 625 onto the lower die 626 supported by the roller car 608. As shown, the dynamic die 606 includes flow control elements 624a-624 i. It should be appreciated that the number of flow control elements 624 may be increased or decreased depending on the resolution or detail of the structural features being formed. As shown, the flow control element 624 is disposed at a different height so as to provide a different height than the flow control elementMore or less volumetric flow rate of the extruded composite material 625 associated with each flow control element. For example, the flow control element 624a is fully closed to prevent passage of the composite material through the cross-section of the dynamic die 606. Since the flow control element 624a is closed, the volumetric flow rate f_aIs zero. The flow control element 624b is open to form a valve having a height h₁Thereby providing a volumetric flow rate f of the extruded synthetic material 625b_b. Likewise, the flow control element 624c is open with a larger opening for extruding the composite material 625c at a higher volumetric flow rate f_cAnd output to the lower mold 626.

As indicated by the variation in the shading of the extruded composite material 625 associated with each flow control element 624, the flow control elements 624 may be dynamically adjusted by the lower and upper dies 626 and 632 based on the structural component being formed. Thus, on the basis of the formed (e.g. deep drawn in a certain area) structural component, the flow control element 624 may be adjusted to vary the volumetric flow rate of the extruded composite material 625 over a limited area of the lower and upper dies. In other words, the thickness of the composite material layer 628 may vary based on the mold cavity 630 defined by the lower and upper molds. For example, the layer area 628a of the composite material is thinner than the layer area 628b of the composite material, the layer area 628b of the composite material is thicker enough to fill the mold cavity 630a, and the draft angle of the mold cavity 630a is deeper than the draft angle of the rest of the mold cavity 630 in the lower mold 626. In other words, the extruded composite material layer 628 dynamically changes based on the depth of the mold cavity 630 defined by the lower and upper molds. In the two-axis and three-axis control methods that can be implemented on the extrusion-molding system 600a, the thickness of the extruded composite material layer 628 can be varied based on the volumetric flow rate of the extruded composite material 625 and the travel speed of the roller car 608.

The amount of extruded composite material deposited on two or three shafts is controlled according to the structural component to be produced, thereby achieving deposition of the extruded composite material onto the lower mold. For two-axis control, the movement of the roller car may be controlled along the axis of movement to deposit the extruded composite material in different amounts along the deposition axis. For three-axis control, the output of the extruder may use one dynamic die comprising a flow control element, thereby providing different volumetric flow rates to deposit onto the lower die simultaneously along an axis perpendicular to the axis of movement. It should be understood that other embodiments may be used for shaftless control to deposit extruded composite material onto specific areas of the lower die.

By providing control over the roller car and the composite material applied to the lower mold, any pattern can be formed on the lower mold, from a thick continuous layer to a thin circular or elliptical profile; any two-dimensional shape that can be described by discrete mathematics can be formed by the material. Furthermore, because there is control over the volume of synthetic material deposited onto a given area, three-dimensional patterns may also be created to enable the creation of structural elements having, for example, deep draft and/or hidden ribs. Once the structural component is cooled, an ejector may be used to release the solidified material from the mold. The principle of the invention may be to have two or more distinct components produced simultaneously, thereby maximizing productivity by using a practical continuous flow of synthetic material.

Value-added benefits of extrusion-molding processes

With the extrusion-molding system, large long fiber-reinforced plastic parts can be produced in parallel and at a low production cost. Extrusion systems that can provide a production line for reinforced plastic components are characterized by providing (I) material flexibility, (II) a precipitation process, (III) low pressure, and (IV) machine efficiency. Material flexibility properties save material costs and processing costs in parallel blending and further provide flexibility characteristics of the material. The precipitation process adds value in the material precipitation process, which can create more complex shapes (e.g., large draft angles and ribs), allow better material flow, and allow easier accommodation of large inserts in the mold. Low pressure refers to reduced forming pressure, which reduces wear in the die and machine, and leaves little pressure on the structural components. Machine efficiency ensures that two or more disparate dies can be used at a time to improve the efficiency of the extrusion system, thereby reducing the number of machines required to run a production operation. In addition, the material delivery system according to the principles of the present invention may be integrated with many existing machines.

Material flexibility

Extrusion-molding systems allow a specific synthetic material mixture to be synthesized from several different types of resins and fibers. Extrusion systems can produce parts with several of the resins described above. By conventional compression molding, pre-manufactured thermoplastic sheets are purchased from thermoplastic sheet manufacturers, which are generally known blanks incorporating fibers and desired additives. However, these blanks are expensive because they have passed through several intermediaries and are usually sold only in the form of a predetermined mixture. By using an extrusion-molding process in accordance with the principles of the present invention, it is possible to reduce these costs by using raw materials to create structural components through a parallel mixing process without having to purchase pre-manufactured sheets. Labor and machine costs are also significantly reduced because the extrusion-molding system does not require an oven to preheat the material, nor does it require an operator to move the heated sheet into the mold. Because the operator controls the desired mixing rate, almost unlimited flexibility is added to the process, including the ability to change characteristics, for example, in molding, or to make gradual changes in color. Moreover, unlike sheet forming, extrusion-forming systems do not require the material to have melt strength, as long as flexibility is added to the system. In one embodiment, the extrusion-molding system may utilize thermoset plastics to create the structural component. The extrusion-molding system may also use a variety of fiber materials, including carbon, glass, and other fibers as described above, to provide reinforcement by achieving fiber volume fractions in excess of 50% and fiber lengths of 85% or greater, remaining 1/4 inches or more from raw material to finished part.

Precipitation process

An extrusion system according to the principles of the present invention allows for variable precipitation of synthetic materials; in areas of the mold where more material is used, such as for deep draft or hidden ribs, to minimize the forces used during the forming and compression process. As is known in the art, variable precipitation of synthetic material can result in more precision, more mold fill, and less "short-shots" than using typical compression molding processes. Variable deposits also enable large structures to be molded on both sides of the structural component and allow inserts or cores to be moved into the interior of the structural component. Finally, because the material has a relatively low viscosity when deposited in a molten state on the mold (as opposed to being pre-mixed into a sheet and then pressed into the mold), the fibers can easily enter the ribs and cover large dimensional areas without being trapped or undesirably guided.

Low pressure

The thermoplastic composite material which is precipitated during the extrusion-moulding process flows better than the heated pre-mixed sheet, thus making it easier for the thermoplastic composite material to flow into the mould. The flowability of the composite material deposited on the mold results in a significant reduction in the required molding pressure compared to other molding processes. The pressure for this process is typically in the range of 100 psi, while compression molding uses 1000 psi. This low pressure translates into low wear, thereby reducing maintenance on the die and press. Because of the low pressure, steel tooling costing $ 200,000 is no longer needed, and aluminum molds that can be cycled 300,000 times for $ 40,000 can be used. Low cost tooling also means more flexibility for further design changes. Because the thermoplastic resin is repositioned and formed on the face of the mold at low pressure, little pressure remains inside the material, thus resulting in better dimensional tolerances and less thermal deformation.

Efficiency of the machine

Since the extrusion-molding method can be simultaneously operated using two or more molds, the first mold set can be cooled and removed while the second mold is filled and compressed, so that the average cycle time per part is reduced, thereby improving productivity. Moreover, the extrusion-molding system utilizes minimal redundant components. In one embodiment, the extrusion system uses a separate press for each die, but other equipment can be unified and shared in the die set and can be easily changed with software to accommodate the other dies. The extrusion and delivery system 600a may be further integrated with current manufacturing equipment, and existing compression dies and presses may also be integrated.

FIG. 8A is an exemplary flow chart depicting an extrusion-molding process that may be used to deposit a composite material onto the lower mold 626 to form an article or structural component using two-axis or three-axis control. The extrusion-molding process begins at step 802. At step 804, the thermoplastic material is heated to form a molten thermoplastic material and mixed with the fibers at step 806 to form a composite material. At step 808, the molten composite material is delivered by gravity through the dynamic mold onto a lower mold 626. For the two-axis extrusion precipitation method, a fixed output from the die may be utilized. In the two-axis method, the movement of the roller car is maintained at a constant speed. In a three-axis extrusion control method, one dynamic die 606 may be utilized with varying roller car or die speeds. For both two-axis and three-axis extrusion control methods, the lower mold 626 may be moved in space and time while receiving the composite material at step 810 to equalize the amount of composite material needed in the mold cavity 630 defined by the lower mold 626 and the upper mold 632. At step 812, the upper mold 632 is pressed onto the lower mold 626 to press the composite material into the lower and upper molds. The process ends at step 814.

FIG. 8B is an exemplary flow diagram for producing a structural component by a three-axis controlled extrusion-molding process using the extrusion-molding system of FIG. 6A. The structural component generation process begins at step 816. At step 818, thermoplastic material is received. The thermoplastic material is heated at step 822. In one embodiment, the thermoplastic material is heated to a molten or molten state. At step 820, a fiber having a predetermined fiber length is received. At step 822, the fibers are mixed with a thermoplastic material to form a composite material. The fibers may be long strands of fibers formed of glass or other reinforcing (stilbening) material for forming large structural components. For example, fibers having lengths of one-half inch (1/2 ") to 4 inches (4") or more may be used to form the structural member.

At step 826, the composite material is extruded. The structure of the auger 620 or other mechanism used to extrude the composite material substantially avoids damage to the fibers during extrusion, such that the initial fiber length is substantially maintained (e.g., 85% or greater). For example, where a screw-type auger 620 is used, the pitch of the screw should be selected to be greater than the length of the fiber, thereby substantially avoiding damage to the fiber.

At step 828, the extruded composite material 625 may be dynamically output across a plane at different volumetric flow rates to enable control of the deposition of the extruded composite material onto the lower mold 626. At step 830, the lower mold 626 may be positionally synchronized to receive the extruded composite material across a plane P at different volumetric flow rates. In one embodiment, the position synchronization of the mold 626 is accomplished in accordance with a flow control element 624 disposed at a height d above the roller car 608, which may be switched at a substantially constant or adjustable speed. For example, to deposit a constant or flat layer 628 of extruded synthetic material, roller car 608 is moved at a substantially constant speed. However, to increase or decrease the volume of the extruded composite layer 628, the roller car 608 may be moved at a slower or faster speed, respectively. At step 832, the extruded composite material 625 forming the extruded composite material layer 628 is pressed into a mold 626 to form a thermoplastic structural member. The structural component formation process ends at step 834.

Fig. 9 is an exemplary block diagram 900 of the controller 612 in communication with a controller operating within the elements of the extrusion system 600a of fig. 6A. The controller 612 communicates with various controllers, bi-directionally using digital and/or analog channels, as is well known in the art. The controller operating within the element may be a processor based on control open loop or closed loop control software as is well known in the art, and operates as a slave computer to the controller 612. Alternatively, the controller may be a non-controller based processor, such as analog or digital circuitry, operating as a slave to the controller 612.

Feeder 614 may include a speed and temperature controller 902, controller 902 operable to control the speed or rate and temperature of feeder 614 to mix synthetic material M1 with fibrous material M2. The feeder speed and temperature controller 902 may be formed of a single or multiple controllers to control the motor and heater. The controller 612 may be operable to specify or command the speed and temperature of the feeder 614, and the speed and temperature controller 902 of the feeder 614 may be operable to execute commands received by the controller 612. For example, the controller 612 may increase the rate at which the materials M1 and M2 are fed into the extruder 606 based on the amount of composite material extruded through the dynamic die 606.

The controller 612 is further in communication with a heater controller 904. Based on feedback data received from the heater controller 904, the controller 612 may communicate control data to the heater controller 904. For example, if the temperature of the heater controller 904 decreases during a feed operation, the controller 612 may issue a command to the heater controller 904 via the control data 1018 to increase the temperature of the heater 618. Alternatively, the heater controller 904 may use a feedback adjustment loop, well known in the art, to adjust the temperature to the temperature commanded by the controller 612 and simply report the temperature to the controller 612 to monitor the effect.

The controller 612 is further in communication with an extruder speed and temperature controller 906, the controller 906 being capable of controlling the speed of the auger 620 and the temperature of the extruder 604. The extruder speed and temperature controller 906 may be operable to control a plurality of heaters within the zone of the extruder 604 and communicate the temperature of each heater to the controller 612. It should be understood that the extruder speed and temperature controller 906 may be formed by a plurality of controllers.

The controller 612 is further in communication with a dynamic die controller 908, the controller 908 controlling a flow control element 624 of the dynamic die 606. The dynamic mode controller 908 may be operable to selectively or individually control each flow control element 624. Alternatively, each flow control element 624 may be separately controlled by a separate controller. Thus, the controller 612 may be operable to issue instructions to the dynamic mode controller 908 to set the position of each flow control element 624 in an open-loop manner. For example, a stepper motor may be used in an open loop manner. The actual position of each flow control element 624 may be communicated back to the controller 612 via feedback data 1022 for the controller 612 for use in controlling the position of the flow control element 624.

The controller 612 is further in communication with a roller car controller 910, and the controller 910 is in communication with the roller car 608 and is operable to control the position of the roller car 608 and the temperature of the lower mold 626. The controller 612 may provide control signals 1018 to the trolley controller 910, the controller 910 operating as a servo system to drive the trolley 608 to a position commanded by the controller 612, the controller 910 setting the position of the lower mold 626 accordingly as extruded composite material is deposited onto the lower mold 626. Although the extruded synthetic material layer 628 deposited on the lower mold 626 is melted at the time of deposition, the extruded synthetic material layer 628 deposited first is easily cooled at the time of deposition of the following extruded synthetic material 625. Accordingly, controller 612 may communicate control data 1018 to cart controller 910 to maintain the temperature of extruded composite layer 628 or at a substantially constant temperature based on the settling time of extruded composite 625 and/or other factors, such as the melt state temperature requirements of thermoplastic material M1. The feedback data 1022 may provide the current temperature and position status and speed of the roller car 608, as well as the temperature of the lower mold 626, so that the controller 612 may perform management and monitoring functions.

The controller 612 is further in communication with a heating/cooling controller 912, the controller 912 operable to control the temperature of heaters and/or coolers for the extrusion-molding system 600 a. Heating/cooling controller 912 may receive control data 1018 from controller 612, and controller 612 instructs heating/cooling controller 912 to operate at a particular or variable temperature based on factors such as thermoplastic material M1, ambient temperature, characteristics of the resulting structural member, production rate, etc. The heating/cooling controller 912 may control a system-level heater and cooler or an element-level heater and cooler. The feedback data 1022 may provide the current temperature and status of the heater and cooler so that the controller 612 may perform management and monitoring functions.

The controller 612 is further in communication with a press controller 914, the controller 914 being operable to control the press operation and the temperature of the upper die 632. The press controller 914 may be a standard controller supplied by the manufacturer of the press 610 along with the press 610. Similarly, the press controller 914 may include a temperature controller to control the temperature of the upper die 932. Alternatively, the temperature controller may not be integrated with the press controller 914 provided by the manufacturer of the press 910. The feedback data 1022 may provide the current position and force of the press and the temperature of the upper die 632 so that the controller 612 may perform management and monitoring functions.

The controller 612 is further in communication with a demolding tool controller 916, the controller 916 being operable to control demolding operations on the formed structural element. In response to the controller 612 receiving notification from the press controller 914 that the press 610 has completed the pressing operation, the controller 612 may issue a control signal 1018 to the demolding tool controller 916 to begin demolding the formed structural element. Thus, feedback data 1022 may be used to indicate the current operation of the demolding tool. If the feedback data 1022 indicates that it is difficult for the demolding tool to demold the molded structural element, the operator of the extrusion-molding system 600a is notified that there is a problem with the demolding tool, the lower or upper mold 626 or 632, the press 610, the heater or cooler of the lower or upper mold 626 or 632, or other element or function of the extrusion-molding system 600 a.

It should be understood that while the controller 612 may be configured as an overall controller for each of the elements of the extrusion-molding system 600a, the controller 612 may be configured to manage the elements in the form of a plurality of distributed controllers. In other words, the controllers of the elements may operate as more intelligent controllers that use the generated parameters of the structural components to calculate operational and control parameters, and a few as servos under the direction of the controller 612 to perform functions. It should further be appreciated that the controller 612 may be programmed to accommodate different mechanical configurations of the extrusion-molding system 600 a. For example, if the extrusion-molding system 600a is configured to translate or move the output of the extruder 606 relative to a stationary lower mold 626, wherein the lower mold 626 may or may not be coupled to the roller cart 608, the controller 612 may be programmed to control the movement of the output of the extruder 606 instead of the roller cart 608.

Fig. 10 is an exemplary block diagram of the controller 612 of fig. 6A. The controller 612 includes a processor 1002 coupled to a memory 1004 and user interface 1006. The user interface 1006 may be a touch screen, an electronic display and keyboard, a pen interface, or any other user interface known in the art. The processor 1002 is further coupled to an input/output device and a storage device that stores information in databases or files 1012a-1012n (collectively 1012). The database 1012 may be used to store control parameters for controlling the extrusion-molding system 600a, such as data associated with the lower and upper molds 626 and 632. Additionally, the database 1012 may store data fed back by the extrusion-molding system 600a during operation of the extrusion-molding system 600 a.

The processor 1002 is operable to execute software 1014 that controls the various elements of the extrusion-molding system 600a and manages the database 1012. In controlling the extrusion-molding system 600a, software 1014 is coupled to the extrusion-molding system 600a via the I/O device 1008 and the control bus 1016. Control data 1018 is coupled to the extrusion-molding system 600a via data packets and/or analog control signals via a control bus 1016. It should be appreciated that the control bus 1016 may be formed by a plurality of control buses, whereby each control bus is connected to a different element of the extrusion-molding system 600 a. It should be further appreciated that the control bus 1016 may operate using a serial or parallel protocol.

One feedback bus 1020, which may be a single or multiple bus structure, may operate to feed back data 1022 from the extrusion-molding system 600a during operation. Feedback data 1022 may be sensed data such as temperature, position, velocity, altitude, pressure, or any sensor information measured from extrusion-molding system 600 a. Accordingly, the I/O device 1008 may be operable to receive feedback data 1022 from the extrusion-molding system 600a and communicate the feedback data 1022 to the processor 1002 for use by the software 1014. The software 1014 may store the feedback data in the database 1012. And utilizes feedback data 1022 to control the elements of extrusion-molding system 600 a. For example, for heater temperatures that are fed back to the controller 612 by the heater controller 904, if the temperature of the heater 618 becomes too low, the controller 612 may issue a command to the heater 618 to increase its temperature via the control data 1018. The controller 612 or element (e.g., heater) may include an automatic control system, as is well known in the art, for effecting control and regulation of the element.

In operation, the controller 612 may store control parameters for producing one or more structural components by the extrusion-molding system 600 a. For example, data relating to parameters of the molds 626 and 632, such as dimensions of the mold cavity 630, may be stored in the database 1012. By storing multiple sets of parameters for different structural components, the extrusion-molding system 600a may be used to form multiple structural components substantially simultaneously. The processor 1002 may execute software 1014 having different sets of parallel parameters to form multiple structural components substantially simultaneously. That is, while one structural member is being pressed, the extruded composite material 625 may also be applied to the lower mold 626 through the dynamic mold 606 to form another structural member.

Fig. 11 is an exemplary block diagram of software 1014 executed by processor 1002. A system manager 1100 may operate to manage various aspects of the controller 612. The system manager 1100 is coupled to an operator interface 1102, system drivers 1104, and a database manager 1106.

The operator interface 1102 is used to provide an interface for an operator of the extrusion-molding system 600a to manually control the extrusion-molding system 600a or to program and/or contour the structural components to be produced. The operator interface 1102 is coupled to a program selector 1108, which, when preprogrammed, allows the operator to select a program to produce the structural component. For example, a program programmed to create a pallet may be selected by an operator via the operator interface 1102 to control the extrusion-molding system 600a to create a pallet as determined by a pallet designer based on the lower and upper molds 626, 632. In one embodiment, the program selector 1108 simply selects a general program to produce a particular structural component by the extrusion-molding system 600a using a particular set of parameters for controlling the corresponding component. Program selector 1108 may be coupled to a parameter selector/editor 1110, which parameter selector/editor 1110 allows an operator to select a particular set of parameters to form a particular structural component and/or edit parameters to change the process of forming the structural component. A parameter selector/editor 1110 may be coupled to database manager 1106 to select a particular set of parameters from a plurality of different parameter data files for controller 612 to drive extrusion-molding system 600a to form different structural components. For example, database manager 1106 may use a set of parameters for creating a pallet, I-beam, leveling plate, etc. It should be appreciated that each of the elements of the extrusion-molding system 600a may be controlled by a common driver, and that the parameters selected to create the structural component may change the operating state of each of the respective elements of the extrusion-molding system 600 a.

The system driver 1104 may be used in conjunction with elements of the extrusion-molding system 600a, as is well known in the art. For example, a single system drive 1104 may be used to control the feeder 614, heater 618, extruder 604, dynamic die 606, roller car 608, and press 610. The system driver 1104 may be customized by an operator of the extrusion-molding system 600a or a generic driver provided by a manufacturer of a particular component, such as the press 610. In operation of the extrusion-molding system 600a to produce a structural component, the system driver 1104 may drive the elements of the extrusion-molding system 600a using the parameters selected to produce the structural component.

Among the elements controlling the extrusion-molding system 600a, a database 1012 and a status alert feedback manager 1114 are used to provide feedback control for each element of the extrusion-molding system 600 a. For example, the heater 618 may feed back the actual temperature via a temperature sensor (not shown). Based on the measured temperature of the heater 618, a system driver 1104 for controlling the heater 618 may increase or decrease the temperature of the heater 618 based on the actual temperature measurement. Accordingly, other sensors may be used to feedback the temperature, pressure, velocity, weight, position, etc. of each component and/or composite material within the extrusion-molding system 600 a. If a fatal failure of the component occurs, the alert can be fed back to the controller 612 and detected by the status alert feedback manager 1114. If an alert is deemed to be a major failure, the system driver 1104 may shut down one or more components of the extrusion-molding system 600a to prevent hardware damage or personal injury to the operator. In response to such an alert, system manager 1100 may trigger operator interface 1102 to display the failure and provide notification of correct operation or incorrect operation.

FIG. 12 is an exemplary schematic view of the flow control elements 624a-624f and the lower mold 626, with the lower mold 626 being segmented into a grid 1202. The grid spacing is defined by the flow control element 624 along the y-axis (denoted as spacing 1-5) and by spacing a-e along the x-axis. It should be appreciated that higher resolution of the grid may be achieved by using more flow control elements 624 along the y-axis and defining smaller spacing along the x-axis. Depending on the particular structural component being formed, a higher or lower resolution may be required, and the parameters established by the operator to define the higher or lower resolution may be stored in the controller 612 by the database manager 1106 for use in generating the structural component.

Tables 2-10 are exemplary data tables used to control the elements of the extrusion-molding system 600 a. In particular, the table is used for control data 1018, the control data 1018 being used to control the components and feedback data 1022 from the components received by the controller 612. Table 2 is a control of the feeder 614, the feeder 614 being used to feed the thermoplastic composite material M1, the fibrous material M2, and any other material (such as pigments) to form the structural component. As shown, control data 1018 includes the rate at which each feeder 614 delivers material to extrusion-molding system 600a, and feedback data 1022 includes the height of material currently in each feeder 614. During operation of extrusion-molding system 600a, the rate of material delivered from feeder 614 is controlled and the height of material in feeder 614 is measured, and an operator may be alerted that a minimum amount of material height has been reached corresponding to feeder 614 so that the operator can add additional material to feeder 614.

Table 3 is an exemplary table for temperature control of the heaters in the extruder 604. If the extruder 604 is defined to have several temperature zones 1-n, the temperature of each zone can be set by extruder temperature control, where extruder temperature control is defined to heat or cool, turn on or off, and/or to a particular temperature (not shown). The feedback data 1022 may include the actual temperature of each zone of the extruder 604. Accordingly, a temperature sensor is integrated with each zone of the extruder, and the temperature measured by the sensor is fed back to the controller 612 for feedback control via a feedback bus 1020.

Table 4 is an exemplary table of speed control for a motor (not shown) driving auger 620 operating within extruder 604. Control data 1018 includes speed control settings to drive the motor. The actual speed and load of the motor is fed back to the system driver 1104 via feedback data 1022, and the system driver 1104 controls the speed of the auger 620 in the extruder 604 via control data 1018.

Table 5 defines the temperature control for the heater within the dynamic die 606. The control data 1018 may be defined by regions 1-n within the dynamic model 606. Similar to the temperature control of the extruder 604, the heater 618 may include heating and cooling controls and/or on and off settings to control and/or regulate the temperature of different zones within the dynamic die 606. Accordingly, the feedback data 1022 may include the actual temperature of each region within the dynamic die 606 to control same.

Table 6 is an exemplary table for control of the flow control element 624 of the dynamic die 606. As shown, the control data includes the flow control elements 1-n and the position of each flow control element 624 in the range of 1-m. It should be appreciated that the flow control element 624 may have an almost infinite number of positions. However, for practical purposes, the position of the flow control element is typically set to have certain predetermined positions, such as every quarter inch ranging from 0 to 6 inches. A stepper motor or other type of motor may be used in controlling the position of the flow control element 624. Accordingly, the feedback data 1022 for the flow control element 624 includes the current position of the flow control element 624 such that any positional deviation between the control data 1018 conveyed by the controller 612 to the dynamic model 606 can be corrected by a feedback loop via the feedback data 1022 as is well known in the art.

Table 7 is an exemplary table for temperature control of the lower mold 626. It should be understood that a similar table may be used to control the temperature of the upper die 632. As shown, the lower mold 626 may be divided into zones 1-n, where heaters and/or coolers may be applied to each zone to heat and cool the lower mold 626 under the direction of the control data 1018. Accordingly, the feedback data 1022 may provide the actual temperature of the lower mold 626 so that feedback control may be implemented by the controller 612 to regulate the temperature of the lower mold 626. For example, as the extruded composite material 625 is applied to the lower mold 626, the temperature of the lower mold 626 may be adjusted across the area to adjust the temperature of the extruded composite material layer 628 based on the time the composite material is deposited onto the lower mold 626 and other factors, and until the structural component is removed from the molds 626 and 632.

Table 8 is an exemplary table providing control parameters for controlling the roller car 608. As shown, the control data 1018 includes position, speed, and lift control of the roller car 608. It should be appreciated that additional control data 1018 may be included to control the movement of the roller car 608. For example, acceleration, rotation or angular position, or other dynamic control data may be used to move or synchronize the roller car 608 to properly align with the lower mold 626 to enable application of the extruded composite material 625, which extruded composite material 625 will settle or gravitate onto the lower mold 626. The feedback data 1022 for the roller car 608 may include the actual position and current speed of the roller car 608. The lift control data may be used to engage or disengage the wheels 634 of the roller car 608 during the deposition of the extruded composite material 625 onto the lower mold 626 and during the pressing of the extruded composite material layer 628 into the molds 626 and 632, respectively, by the press 610. The actual position of the lift may be fed back in order to ensure that the press 610 is not actuated until the wheels 634 are disengaged by the lift mechanism (e.g., air tubes).

Table 9 is an exemplary table of the control of the press 610. Control data 1018 may include lock control data and cycle squash time. The feedback data 1022 may include the position of the roller car 608 in the press 610 as well as the position of the platens. Other control and feedback parameters may be included to control the press. For example, temperature control of the upper die 632, force of the press 610, and the like may also be included.

Table 10 is an exemplary table for control of a drawing tool (not shown) used to draw a formed structural component from the molds 626 and 632 after pressing (and optionally after cooling) in forming the structural component. Control data 1018 may include a start draft cycle and feedback data 1022 may include a single draft tool position. It should be understood that multiple drawing tools or multiple elements of a drawing tool may be used, and other sensed feedback data may be sensed and fed back to the controller 612.

Table 13 is a top view of the flow control elements 624a-624i arranged to deposit a composite material onto the lower mold 626 of FIG. 6A. As shown, the flow control element 624 is positioned along the y-axis, which provides three-axis control for depositing the extruded composite material 625 onto the lower mold 626. Accordingly, x-axis control of the precipitated extruded composite material 625 may be controlled by controlling movement of the roller car 608 at different speeds under the flow control element 624, y-axis control of the precipitated extruded composite material 625 may be controlled by adjustment of the flow control element 624, and z-axis control of the precipitated extruded composite material 625 may be achieved by controlling precipitation of the extruded composite material 625 along the x-axis and y-axis.

Control for depositing the extruded composite material 625 along the x, y, z axes can be achieved using a variety of techniques, including: (1) controlling the volumetric flow rate of the composite material from the extruder 604 by the rate of rotation of the auger 620; (2) controlling the rate of movement of the roller car 608 on the single axis; (3) controlling the output of the extruder 604 with a single flow control element 624 or multiple flow control elements 624 operating in unison; (4) individually controlling the plurality of flow control elements 624; and (5) controlling the movement of the roller car 608 on the plurality of axes. Each of these techniques assumes that the other variables remain constant. For example, technique (1) assumes that the output port of the extruder 604 is fixed and the roller car 608 is running at a constant velocity below the output port. Technique (2) assumes that the volumetric flow rate of the composite material from the extruder 604 is constant and the output of the extruder 604 is fixed. However, it should be understood that these techniques may be combined to provide additional control over the placement of the extruded composite material 625 on the lower mold 626, as discussed with respect to FIG. 6A, where techniques (1), (2), and (4) are combined. Technique (5) includes providing control not only of the x-axis and y-axis of the lower mold 626, but also of the z-axis and rotation about any axis. By providing such control of the lower mold 626 using technique (5), a variety of structural components may be formed that would otherwise not be possible. In summary, all computer control of the different elements of the inventive method plays a key role in the coordination of the extrusion process and the production of the desired parts and all the operability of the process.

Finally, without controlling the movement of the lower mold 626, the extruded composite material 625 may be deposited onto a stationary or moving lower mold 626 using the moving output opening from the extruder 604. For example, output openings that run along rails or other mechanical structures may be controlled to deposit the composite material at specific locations on the lower mold 626. One such mechanism is similar to a laser jet printer.

Referring again to fig. 13, the relationship of the flow control element 624 to the lower mold 626 as the lower mold 626 passes through the dynamic mold 606 is shown, as well as the number in inches corresponding to the right side of the position of the roller car 608 as the roller car 608 passes through the dynamic mold 606. Since the lower mold 626 is smaller than the roller car 608, the lower mold 626 begins ten inches into the roller car 608. Tables 11-12 are exemplary tables providing speed and door control parameters for the flow control element 624. The parameters may be used to produce a pallet using the extrusion-molding system 600 a.

Tables 11 and 12 provide positional synchronization between the flow control element 624 and the movement of the roller car 608. By coordinating the movement between these two elements (i.e., the dynamic die 606 and the roller car 608), the extruded composite material 625 may be deposited along the lower mold 626 at a location determined by the volume of the mold cavities 630 of the lower and upper molds 626 and 632. In other words, the extruded composite material 625 is deposited onto the lower mold 626 to form an extruded composite material layer 628 having a thickness sufficient to fill the mold cavities 630 of the lower and upper molds 626, 632, thereby providing the ability to form deep draft and hidden ribs in certain areas of the structural component.

FIG. 14 is an exemplary top perspective view of a corner of one of the trays 1400 produced by the extrusion-molding system 600a of FIG. 6A. As shown, the draft angle or depth d of the base 1402 of the tray 1400₁Depth d of the pedestal 1404 of the tray 1400₂Shallow. Controlling extruded composite materials by utilizing principles of the present invention625 are deposited onto the lower mold 626, a large structural member having a structure like the pedestal 1404 may be formed using a harder material M2 (e.g., long strand fibers) and having a deeper draft d in certain regions of the structural member₂。

Fig. 15A and 15B are exemplary top and bottom perspective views, respectively, of a platform 1500 having hidden ribs 1502a-1502e (collectively 1502). As shown, the hidden ribs 1502 may vary in height, but have a defined volume in one or more regions. Thus, more extruded synthetic material 625 is deposited onto areas with hidden ribs 1502 and less extruded synthetic material 625 is deposited onto areas without hidden ribs 1502. Because platform 1500 is a single molded composite structure formed using extrusion-molding system 600a, platform 1500 has fewer points of weakness in the structure than platforms formed from multiple portions.

Embedding technique

In forming large components, in addition to using synthetic materials in which fibers are mixed to provide strength to form the structural components, some structural components further improve the structure by other elements, such as connectors, fasteners, and/or reinforcements that are embedded or inserted into certain areas. For example, structural members that provide internal connections may use metal members that extend from composite materials to provide a strong and reliable interconnection. One such structure is a floor covering 1600 for a rink, as shown in figure 16A. The floor covering 1600 includes a thermoplastic material 1602 and a fastener 1604 made of metal, the thermoplastic material 1602 may be formed of a thermoplastic material M1 and a fiber M2.

In forming bottom plate overlay 1600, fasteners 1604 are disposed or otherwise configured within lower die 608 such that extruded composite material layer 628 forms a bonding layer 1606 with one fastener 1604 to maintain it in place. To further secure the fastener 1604 to the floor covering 1600, holes (not shown) may be included in the fastener 1604 to allow the extruded composite material layer 628 to fill the holes. During the molding operation, an actuator may be configured within the lower mold 626 to maintain the position of the fastener 1604 during the extrusion-molding process and to be released by the controller 612 while the extruded composite material layer 628 is still in a molten state. It should be appreciated that the fastener 1604 may alternatively be configured within the upper die 632.

Fig. 16B is an exemplary portion of a correction plate 1610 that is often used by a caregiver. The correction plate 1610 is formed of a composite material 1612 and includes an insert 1614 sealed within the composite material 1612. The inserts 1614 may be carbon fiber tubes such that the correction plate 1610 may be reinforced, reduced in weight, and transparent to x-rays. In sealing the insert, the lower mold 626 may have actuators or simple pins that hold the insert in place while the extruded composite material layer 628 forms the bonding layer 1616 therewith. Also, when the extruded composite layer 628 is in a molten state, the actuators and/or pins may be released such that the extruded composite layer 628 fills any voids left by the actuators or pins. It should be appreciated that insert 1614 may be virtually any material based on the particular application or structural component being formed.

FIG. 17 is an exemplary flow diagram 1700 that illustrates the operation of inserting or embedding an insert, such as a fastener, support, or other element, into a structural member using the extrusion-molding system 600a of FIG. 6A. The embedding process begins at step 1702. At step 1704, an insert is constructed in the lower mold 626 or the upper mold 632. At step 1706, molten extruded composite material 625 is deposited onto the lower mold 626. At step 1708, an extruded composite material is formed around at least a portion of the insert to secure the insert within the formed structural component. In one embodiment, the insert is enclosed or fully embedded in the extruded composite material 625 (see, e.g., fig. 16B). Alternatively, only a portion of the insert is embedded within the extruded composite material 625 such that a portion extends from the structural member.

If supports are used to construct the insert in the lower mold 626 or the upper mold 632, the supports are removed at step 1710. The support, which may be a controlled actuator, a simple mechanical pin, or other mechanism capable of supporting the insert during deposition of the extruded composite material 625 onto the lower mold 626, is removed before the extruded composite material layer 628 is hardened in step 1712. The extruded synthetic material layer 628 may be hardened by natural or forced cooling during pressing, vacuum or other operations to form the structural component. By removing the support before the extruded synthetic material layer 628 hardens, the gap created by the support is filled, thus leaving no traces or weak points of the support in the structural component. At step 1714, the structural component in which the insert is at least partially embedded is removed from the molds 626 and 632. The embedding process ends at step 1716.

In another embodiment of the invention, an insert is closed by the claimed method. In a process similar to the process described in fig. 17, an insert, such as a fastener, support, or other element, may be enclosed by the extruded thermoplastic material using the claimed extrusion-molding system. In another embodiment of the present invention, multiple layers of materials having different thicknesses may be deposited one on top of the other using the claimed extrusion-molding system. In particular, a first layer of thermoplastic material is extruded into the lower mold, and a second layer of the same or different thermoplastic material is disposed on top of the first layer. In certain embodiments of the present invention, an insert may be disposed on top of the first extruded layer, either before or without laminating the first layer to the second layer. This "laminated" form may facilitate the formation of structures having multiple layers of the same or different thermoplastic composite materials as well as different layers of embedding material. The preceding description is of the preferred embodiment to implement the invention and the scope of the invention should not be limited by this description. The scope of the invention is actually defined by the following claims.

TABLE 1 thermoplastic resins

Polyethylene	Polysulfone
		Polypropylene	Poly-phenoxy group
Polyvinyl chloride	Polybutylene terephthalate
		Polyvinylidene chloride	Polyethylene terephthalate
Polystyrene	Polycyclohexane-terephthalic acid diethylene glycol ester
		Styrene-butadiene-acrylonitrile copolymer	Polybutylene naphthalate (polybutylene naphthalate)
Nylon 11	Other polyesters for the Soft component
		Nylon 12	Thermotropic liquid crystal polymer
Nylon 6	Polyphenylene sulfide
		Nylon 66	Polyether ketone ether
Other aliphatic nylons	Polyether sulfone
		Aliphatic nylon copolymers further copolymerized with terephthalic acid or other aromatic dicarboxylic acids or aromatic diamines	Polyether imide
Other aromatic polyamides	Polyamide-imide
		Multiple copolyamides	Polyamide

Polycarbonate resin	Polyurethane
		Polyacetal (PA)	Polyether amides
Polymethyl methacrylate	Polyester amides

TABLE 2 Material feeder

Control data	Feedback data
		Rate of feeding material 1	Height of material 1
Rate of feeding material 2	Height of material 2
		Rate of feeding material 3	Height of material 3
---	---
		N rate of feeding material	Height of n of material

TABLE 3 extruder temperature control

Control data			Feedback data
				Region(s)	Extruder temperature control	On/off
1	Heating/cooling	On/off	Actual temperature
				2	Heating/cooling	On/off	Actual temperature
3	Heating/cooling	On/off	Actual temperature
				---	---	---	---
7	Heating/cooling	On/off	Actual temperature

TABLE 4 extruder Motor control

Control data	Feedback data
		Speed control signal	Actual speed of the motor
	Actual load of motor

TABLE 5 dynamic die temperature control

Control data			Feedback data
				Region(s)	Dynamic die temperature control	On/off
1	Heating/cooling	On/off	Actual temperature
				2	Heating/cooling	On/off	Actual temperature
3	Heating/cooling	On/off	Actual temperature

---	---	---	---
				N	Heating/cooling	On/off	Actual temperature

TABLE 6 dynamic mode flow control element control

Control data		Feedback data
			Flow control element	Position of
1	Position 1-m	Current position
			2	Position 1-m	Current position
3	Position 1-m	Current position
			---	---	---
N	Position 1-m	Current position

TABLE 7 heating/cooling die control

Control data			Feedback data
				Region(s)	Mold temperature control	On/off
1	Heating/cooling	On/off	Actual mold temperature
				2	Heating/cooling	On/off	Actual mold temperature
3	Heating/cooling	On/off	Actual mold temperature
				4	Heating/cooling	On/off	Actual mold temperature
---	---	---	---
				N	Heating/cooling	On/off	Actual mold temperature

TABLE 8 roller car control

Control data	Feedback data
		Position control data	Actual position of roller car
Speed control data	Current speed of roller car
		Lifting control data	Actual position of lift

Meter 9 Press control

Control data	Feedback data
		Locking control data	Position of roller car in press
Period compression time	Position of the platen

Watch 10 pattern tool control

Control data	Feedback data
		Beginning of the pattern drawing cycle	Position of the pattern drawing tool

TABLE 11 Rolling-wheel vehicle speed control parameters

Region(s)	Control (%)	Rate (feet/minute)	Starting position (inch)	End position (inches)
					1	0.50	6.67	0.0	10.0
2	2.00	1.67	10.0	15.0
					3	1.00	3.33	15.0	27.0
4	2.00	1.67	27.0	33.0
					5	1.00	3.33	33.0	45.0
6	2.00	1.67	45.0	50.0

TABLE 12 flow control element parameters

Extrusion port	Region(s)	Height (inch)	Starting position (inch)	End position (inches)
					1	1	0.00	0.0	50.0
2	1	0.00	0.0	10.0
					2	2	1.0	10.0	15.0
2	3	0.50	15.0	27.0
					2	4	1.00	27.0	33.0
2	5	0.50	33.0	45.0
					2	6	1.00	45.0	50.0
3	1	0.00	0.0	10.0
					3	2	0.50	10.0	15.0
3	3	0.00	15.0	27.0
					3	4	0.50	27.0	33.0
3	5	0.00	33.0	45.0
					3	6	0.00	45.0	50.0
4	1	0.00	0.0	10.0
					4	2	0.50	10.0	15.0

4	3	0.00	15.0	27.0
					4	4	0.50	27.0	33.0
4	5	0.00	33.0	45.0
					4	6	0.00	45.0	50.0
5	1	0.00	0.0	10.0
					5	2	1.00	10.0	15.0
5	3	0.50	15.0	27.0
					5	4	1.00	27.0	33.0
5	5	0.50	33.0	45.0
					5	6	1.00	45.0	50.0
6	1	0.00	0.0	10.0
					6	2	0.50	10.0	15.0
6	3	0.00	15.0	27.0
					6	4	0.50	27.0	33.0
6	5	0.00	33.0	45.0
					6	6	0.00	45.0	50.0
7	1	0.00	0.0	10.0
					7	2	0.50	10.0	15.0
7	3	0.00	15.0	27.0
					7	4	0.50	27.0	33.0
7	5	0.00	33.0	45.0
					7	6	0.00	45.0	50.0
8	1	0.00	0.0	10.0
					8	2	1.00	10.0	15.0
8	3	0.50	15.0	27.0
					8	4	1.00	27.0	33.0
8	5	0.50	33.0	45.0
					8	6	1.00	45.0	50.0
9	1	0.00	0.0	50.0

Claims (120)

1. A method of forming an article from a thermoplastic material and fibers, the method comprising:

heating a thermoplastic material to form a molten thermoplastic material for mixing with the fibers;

mixing the molten thermoplastic material with the fibers to form a molten composite material having a fiber weight content;

extruding said molten composite material to form a composite material stream, said composite material stream falling by gravity to a lower portion of a mold for forming said article;

moving the lower portion of the mold in space and time while receiving the stream of composite material to deposit thereon a predetermined amount of molten composite material in conformity with the mold cavities of the lower and upper portions of the mold; and

pressing the upper portion of the mold against the predetermined amount of molten composite material and closing on the lower portion of the mold to form the article.

2. The method of claim 1, further comprising controlling a flow of composite material to vary an amount of molten composite material delivered to the lower portion of the mold.

3. The method of claim 1, wherein the mixing comprises mixing the molten composite material with fibers having a length of between at least one-half inch and four inches.

4. The method of claim 1, wherein the mixing forms a molten composite material having a fiber weight content of at least 10%.

5. The method of claim 1, wherein the moving of the lower portion of the mold forms a predetermined amount of molten composite material of varying thickness over the mold.

6. The method of claim 1, wherein said moving of said lower portion of said mold is along a single axis.

7. The method of claim 1, wherein the extruding produces a molten composite material having a minimum of 85% unbroken fibers.

8. The method of claim 1, wherein the gravitational action causes the synthetic material to flow onto the lower portion of the mold at substantially the same volumetric flow rate.

9. The method of claim 1, wherein the gravitational force causes the composite material to flow onto the lower portion of the mold at different volumetric flow rates.

10. The method of claim 1, further comprising controlling the extruding to vary a volumetric flow rate of the molten composite material falling by gravity onto the lower portion of the mold.

11. The method of claim 1, wherein the molten composite material is deposited directly onto the lower portion of the lower mold under the force of gravity.

12. The method of claim 1, wherein the step of moving the lower portion of the mold in space and time comprises moving the lower portion of the mold in time along a direction selected from the group consisting of an x-axis direction, a y-axis direction, a z-axis direction, or a rotational direction, or a combination thereof.

13. The method of claim 1, wherein the molten composite material is extruded onto an insert inside the lower portion of the lower die.

14. The method of claim 13, wherein the insert is partially embedded within the thermoplastic material.

15. The method of claim 13, wherein the insert is completely embedded within the thermoplastic material.

16. The method of claim 13, wherein the insert is encapsulated by the thermoplastic composite material.

17. The method of claim 1, wherein a first layer of thermoplastic synthetic material is extruded into the lower portion of the die.

18. The method according to claim 17, wherein a second layer of thermoplastic synthetic material is laminated on top of the first layer.

19. The method of claim 17, wherein an insert is disposed on the first layer.

20. The method of claim 19, wherein the insert is partially embedded within the first layer.

21. The method of claim 19, wherein the insert is completely embedded within the first layer.

22. The method of claim 19, wherein a second layer of thermoplastic material is laminated on top of the insert.

23. An apparatus for forming an article from thermoplastic material and fibers, the apparatus comprising:

a heater capable of preheating the thermoplastic material to form a molten thermoplastic material;

an extruder connected to said heater and operable to melt said molten thermoplastic material and mix it with said fibers to form a composite stream that falls under gravity to a lower portion of a die for forming said article;

a movable structure associated with said lower portion of said mold and operable to move in space and time upon receipt of said composite stream to deposit thereon a predetermined amount of molten composite material in conformity with the mold cavities of the lower and upper portions of said mold; and

a press coupled to said upper portion of said mold and capable of receiving said movable structure having said lower portion of said mold, said press operable to press said upper portion of said mold against said predetermined amount of molten composite material on said lower portion of said mold to form said article.

24. The apparatus of claim 23, further comprising a dynamic die having at least one flow control element and operable to control the flow of composite material such that the amount of molten composite material delivered to the lower die of the mold is variable.

25. The apparatus of claim 23, wherein the extruder comprises an auger having a thread with a pitch sufficiently large to mix the molten composite material with fibers ranging in length from 1 inch to 4 inches.

26. The apparatus of claim 23, wherein the mixed molten composite material has a fiber weight content of at least 10%.

27. The apparatus of claim 23, further comprising a controller coupled to the movable structure and operable to move the movable structure to position the lower portion of the mold to form a predetermined amount of molten composite material of varying thickness on the mold.

28. The apparatus of claim 23, wherein the movable structure comprises wheels operable to move the movable structure.

29. The apparatus of claim 23, wherein the extruder comprises an auger operable to produce molten composite material having a minimum of 85% unbroken fibers.

30. The apparatus according to claim 23, further comprising a die coupled to said extruder and operable to gravitate a flow of composite material onto said lower portion of said die, said flow of composite material having a volumetric flow rate that is substantially equal in a planar transverse direction.

31. The apparatus according to claim 23, further comprising a dynamic die coupled to said extruder and operable to gravitate a flow of composite material onto said lower portion of said die, said flow of composite material having a volumetric flow rate that varies laterally in a plane.

32. The apparatus of claim 23, further comprising a controller coupled to the extruder and operable to vary the volumetric flow rate of the molten composite material from the extruder and cause the molten composite material to fall under gravity onto the lower portion of the mold.

33. The apparatus of claim 32, wherein the controller moves the movable structure directly below the extruder to cause the extruded composite material to fall under gravity onto the lower portion of the mold.

34. An apparatus for forming an article from thermoplastic material and fibers, the system comprising:

means for heating a thermoplastic material to form a molten thermoplastic material for mixing with the fibers;

means for mixing the molten thermoplastic material with the fibers to form a molten composite material having a fiber weight content;

means for extruding said molten composite material to form a composite material stream, said composite material stream falling by gravity to a lower portion of a mold for forming said article;

means for moving said lower portion of said mold in space and time while receiving said stream of composite material to deposit thereon a predetermined amount of molten composite material in conformity with the mold cavities of the lower and upper portions of said mold; and

means for pressing the upper portion of the mold against the predetermined amount of molten composite material and closing on the lower portion of the mold to form the article.

35. The apparatus of claim 34, further comprising means for controlling the flow of composite material to vary the amount of molten composite material delivered to the lower portion of the mold.

36. The apparatus of claim 34, further comprising means for controlling the apparatus to extrude a stream of composite material and to vary the volumetric flow rate of the stream of composite material falling by gravity onto the lower portion of the die.

37. An article formed from an extruded composite material, wherein the article is prepared according to the method of claim 1, the composite material comprises a thermoplastic material and has a fiber weight content of at least 10%, the fibers being at least one-half inch in length.

38. The article according to claim 37, further comprising a hidden rib.

39. The article according to claim 37, wherein the article is a single composite material having structural components of different depths.

39. The article according to claim 39, wherein the structural components all have a depth greater than about 1 inch.

40. The article of claim 37, wherein the weight content of fibers for the synthetic material is at least 30%.

41. The article of claim 37, wherein the fiber length is at least 3 inches.

42. An article formed from an extruded composite material, wherein the article is prepared according to the method of claim 1, the composite material comprising a thermoplastic material mixed with fibers, the article having hidden ribs.

43. The article of claim 43, wherein the fibers are at least 3 inches in length.

44. The article of claim 43, wherein the fiber is present in an amount of at least 10%.

45. The article of claim 43, wherein the fiber content is at least 40%.

46. An article formed from an extruded composite material, wherein the article is prepared according to the method of claim 1, the composite material comprising a thermoplastic material mixed with fibers, the article having structural components comprising different draft depths.

47. The article of claim 47, wherein the fibers are at least 3 inches in length.

48. The article of claim 47, wherein the fiber is present in an amount of at least 10%.

49. The article of claim 43, wherein the fiber content is at least 40%.

50. An article formed from an extruded composite material, wherein the article is prepared according to the method of claim 1, the composite material comprising a thermoplastic material mixed with fibers, at least a portion of one component of the article being enclosed in the extruded composite material.

51. The article according to claim 51, wherein the entire member is enclosed in the extruded synthetic material.

52. The article of claim 51, wherein the fibers are at least 3 inches in length.

53. The article of claim 51, wherein the fibers are present in an amount of at least 10%.

54. The article of claim 51, wherein the fiber content is at least 40%.

55. The article of claim 51, wherein the member is a fastener.

56. The article according to claim 51, wherein the member is a stiffener.

57. The article of claim 51, wherein the member is a connector.

58. The article according to claim 51, wherein the thermoplastic material comprises one or more layers of thermoplastic synthetic material.

59. The article according to claim 59, wherein the one or more layers of thermoplastic material have the same composition.

60. The article according to claim 59, wherein the one or more layers of thermoplastic material have different compositions.

61. A method for forming a thermoplastic structural element, the method comprising:

receiving a thermoplastic material;

heating the thermoplastic material;

receiving a fiber having a predetermined fiber length;

mixing the fibers with the heated thermoplastic material to form a composite material;

extruding the synthetic material;

dynamically outputting the extruded composite material at different volumetric flow rates across a plane;

synchronously positioning a die in space and time to receive the extruded composite material at different volumetric flow rates across the plane; and

pressing the extruded composite material into the mold to form the thermoplastic structural element.

62. The method of claim 62, further comprising forming the thermoplastic material from a thermoplastic resin.

63. The method of claim 62, wherein the heating comprises melting the thermoplastic material.

64. The method of claim 62, further comprising selecting the fibers to be at least 1 inch in length.

65. The method of claim 62, wherein the different volumetric flow rates have an output range between 0 and 3000 pounds per hour.

66. The method of claim 66, wherein the flow rate ranges between 2500 to 3000 pounds per hour.

67. The method of claim 62, wherein the synchronously positioning comprises moving the mold according to the volume rate.

68. The method of claim 62, further comprising predetermining different volumetric flow rates across the plane based on a cavity volume of the mold.

69. The method of claim 62, wherein forming the thermoplastic structural element comprises forming a tray.

70. The method of claim 62, further comprising constructing a member enclosed by the composite material in the mold.

71. The method of claim 62, wherein the dynamic output of the extruded composite material is achieved by controlling a discrete flow control element.

72. The method of claim 62, wherein the mixing produces a synthetic material having a fiber weight content of 10%.

73. The method of claim 62, wherein the mixing produces a synthetic material having a fiber weight content of 40%.

74. An apparatus for forming a thermoplastic structural element, the apparatus comprising:

means for receiving a thermoplastic material;

means for heating the thermoplastic material;

means for receiving a fiber having a predetermined fiber length;

means for mixing the heated thermoplastic material with the fibers to form a composite material;

means for extruding the synthetic material;

means for dynamically outputting the extruded composite material at different volumetric flow rates across a plane;

means for synchronously positioning a die in space and time to receive the extruded composite material at different volumetric flow rates across the plane; and

means for pressing the extruded composite material into the die to form the thermoplastic structural element.

75. The apparatus of claim 75, further comprising means for forming the thermoplastic material from a thermoplastic resin.

76. The apparatus of claim 75, wherein the means for heating comprises means for melting the thermoplastic material.

77. The apparatus according to claim 75, wherein said means for synchronously positioning comprises means for moving said mold according to said volume rate.

78. The apparatus of claim 75, further comprising means for predetermining different volumetric flow rates across the plane based on a cavity volume of the mold.

79. The apparatus according to claim 75, further comprising means for constructing a non-thermoplastic structure enclosed by the composite material in the mold.

80. The apparatus of claim 75, wherein the means for mixing produces a synthetic material having a fiber weight content of 10%.

81. The apparatus of claim 75, wherein the means for mixing produces a synthetic material having a fiber weight content of 40%.

82. An apparatus for forming a thermoplastic structural element, the apparatus comprising:

a material receiving device operable to receive the thermoplastic material and the reinforcing material;

a heating device operable to heat the thermoplastic material;

an extruder coupled to said material receiving means and operable to extrude said composite material;

a dynamic die having a plurality of selectively alterable flow control elements operable to control the output of said composite material;

a movable device operable to support a mold and dynamically positionable in space and time beneath said dynamic mold;

a controller in electrical communication with the dynamic die and the movable device, the controller operable to dynamically vary the flow control element to output the extruded composite material at different volumetric flow rates across a plane and to synchronously position the movable device as the flow control element is varied to apply the extruded composite material to the die; and

a press operable to receive the movable device and press the extruded composite material into the mold.

83. The apparatus according to claim 83, wherein the material receiving device includes at least one feeder.

84. The apparatus of claim 83, wherein the heating device is further operable to heat the thermoplastic material to a molten thermoplastic state.

85. The apparatus of claim 83, wherein the extruder comprises a dynamic device operable to substantially avoid damage to the reinforcing material.

86. The device of claim 86 wherein the reinforcing material is formed from fibers having a predetermined maximum length of 1 inch.

87. The device of claim 86 wherein the reinforcing material is formed from fibers having a predetermined maximum length of 3 inches.

88. The device of claim 83 wherein the dynamic member is a screw having a thread pitch greater than a maximum length of the reinforcing material.

89. The device of claim 83 wherein the movable means has a rotation means associated therewith.

90. The device of claim 90 wherein the movable means comprises at least one dynamic positioning means operable to engage and disengage the rotating means.

91. The apparatus of claim 91, wherein the controller is operable to disengage the rotating device when the movable device is in the press to press the extruded composite material into the mold.

92. The device of claim 83, wherein the synthetic material comprises 10% by weight of the reinforcing material.

93. A method for forming a structural component from a thermoplastic material and fibers, the method comprising:

disposing an insert in a lower portion of a mold;

depositing molten extruded composite material into a lower portion of the die;

forming an extruded composite material around at least a portion of the insert;

removing a support for disposing the insert in a lower portion of the mold, if any;

compressing the extruded composite material to form the structural component; and

removing the structural component with the insert from the lower portion of the mold, the insert being at least partially embedded,

wherein the molten extruded synthetic material is prepared by the following method:

heating a thermoplastic material to form a molten thermoplastic material for mixing with the fibers;

mixing the molten thermoplastic material with the fibers to form a molten composite material having a fiber weight content; and

extruding the molten composite material to form a composite material stream,

and the lower part of the mould is moved in space and time while the molten extruded synthetic material is deposited on the lower part of the mould.

94. The method of claim 94, wherein the positioning of the insert is effected in a lower portion of the mold.

95. The method of claim 94, wherein said depositing of molten extruded composite material is effected dynamically across a plane.

96. The method of claim 94, wherein the forming of the extruded composite material includes enclosing an entire insert within the extruded composite material.

97. The method of claim 94, further comprising pressing the extruded composite material into the mold.

98. An apparatus for forming a structural component from thermoplastic material and fibers, the apparatus comprising:

means for positioning an insert in a mold;

means for depositing molten extruded composite material onto the die in space and time;

means for forming an extruded composite material around at least a portion of the insert;

means for removing a support that places the insert in the mold;

means for compressing the extruded composite material to form the structural component; and

means for removing the structural component with an insert from the mold, the insert being at least partially embedded.

99. The apparatus of claim 99, wherein the means for positioning the insert is coupled to a lower portion of the mold.

100. The apparatus of claim 99 wherein the means for precipitating the molten extruded composite material comprises means for dynamically flowing the extruded composite material across a plane.

101. The apparatus of claim 99, wherein the means for forming the extruded composite material comprises means for enclosing an entire insert within the extruded composite material.

102. The apparatus according to claim 99, further comprising means for pressing the extruded composite material into the die.

103. A method of forming a solid article from a viscous material and a fiber, the method comprising:

mixing the viscous material with the fibers to form a composite material;

extruding said molten composite material onto a portion of a mold for forming said article;

moving at least a portion of the mold relative to the synthetic material in a space and time to deposit a quantity of synthetic material thereon that conforms to a cavity of the mold; and

maintaining the quantity of synthetic material in a condition that enables it to harden within the mold to form the article.

104. The method of claim 104, further comprising controlling the flow of composite material throughout the process to vary the amount of composite material delivered to the portion of the mold.

105. The method of claim 104, wherein the fibers mixed with the viscous material are between one-half and four inches in length.

106. The method of claim 104, wherein the fibers have an average fiber length of at least one inch.

107. The method of claim 104, wherein the synthetic material has a fiber weight content of at least 10%.

108. The method of claim 104, wherein the synthetic material has a fiber weight content of at least 40%.

109. The method of claim 104, wherein the moving of the portion of the mold forms a predetermined amount of composite material of varying thickness across the mold.

110. The method of claim 104, wherein said moving of said portion of said mold is along a single axis.

111. The method of claim 104, wherein the extruding produces a composite material having a minimum of 85% unbroken fibers.

112. The method of claim 104, further comprising controlling said extruding to vary a volumetric flow rate and a relative position of an extrusion die and said portion of said die.

113. The method of claim 104, wherein the composite material is extruded onto an insert inside the portion of the die.

114. The method of claim 104, wherein the insert is at least partially embedded within the thermoplastic material.

115. The method of claim 104, wherein the extruding comprises extruding at least a first layer and at least a second layer onto the portion of the die.

116. The method of claim 104, wherein the tacky material comprises a thermoplastic resin.

117. The method of claim 104, wherein the adhesive material comprises a thermosetting resin.

118. The method of claim 104, wherein the maintaining step comprises creating a chemical reaction within the mold cavity.

119. The method of claim 104, wherein the adhesive material comprises at least one polymer selected from the group consisting of: polyethylene, polysulfone, polypropylene, polyphenoxy, polyvinyl chloride, polybutylene terephthalate, polyvinylidene chloride, polyethylene terephthalate, polystyrene, polycyclohexane-diethylene terephthalate, styrene-butadiene-acrylonitrile, polybutylene naphthalate copolymer, nylon 6, nylon 66, nylon 11, nylon 12, polyphenylene sulfide, polyether ketone ether, polyether sulfone, aliphatic nylon copolymer further copolymerized with terephthalic acid or other aromatic dicarboxylic acid or aromatic diamine, polyamideimide, copolyamide, polyamide, polycarbonate, polyurethane, polyacetal, polyether amide, polymethyl methacrylate, polyesteramide.

120. The method of claim 104, wherein the extruding comprises: dynamically outputting the composite material at different volumetric flow rates across a plane;

synchronously positioning a mold portion to receive the composite material corresponding to different volumetric flow rates across the plane.