CPC A42C 2/005 (2013.01) [B29C 70/446 (2013.01); B29C 2791/002 (2013.01); B29C 2791/006 (2013.01); B29L 2031/4821 (2013.01)] | 27 Claims |
1. A helmet forming system for creating a deep drawn helmet preform, the system comprising:
a forming draw ring and a non-forming draw ring, each including a metal rigid body bounded by a contact surface and a non-contact surface opposed to the contact surface, wherein a stack of prepreg material (“prepreg stack”) is supported between a forming aperture of the forming draw ring and a non-forming aperture of the non-forming draw ring;
a controller that directs the system to advance the forming draw ring and the non-forming draw ring towards one another to form a clamped assembly of the forming draw ring, the prepreg stack and the non-forming draw ring, wherein a flange portion of the prepreg stack is clamped between the contact surfaces of the forming draw ring and a non-forming draw ring;
wherein the controller directs advancement of the prepreg stack relative to a punch to form the deep drawn helmet preform, during which the system applies a clamping force to the clamped assembly, and during which the punch enters and passes through the non-forming aperture and then draws the prepreg stack through the forming aperture and above the non-contact surface of the forming draw ring until a desired drawing depth of the prepreg stack is achieved; and
a temperature control system under control of the controller that is connected to the punch, the forming draw ring and the non-forming draw ring and provides heating and cooling, wherein the temperature control system is configured to independently control the temperature of the punch, the forming draw ring and the non-forming draw ring.
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