US 12,257,788 B2
Preform with variable fiber density, forming and molding tool and method for forming of composite materials
Venkateshwar R Aitharaju, Troy, MI (US); Erik Brandon Golm, Sterling Heights, MI (US); and Xiaosong Huang, Novi, MI (US)
Assigned to GM GLOBAL TECHNOLOGY OPERATIONS LLC, Detroit, MI (US)
Filed by GM GLOBAL TECHNOLOGY OPERATIONS LLC, Detroit, MI (US)
Filed on Oct. 31, 2022, as Appl. No. 17/977,083.
Prior Publication US 2024/0140052 A1, May 2, 2024
Int. Cl. B29C 70/34 (2006.01); B29C 45/00 (2006.01); B29C 45/14 (2006.01); B29C 45/80 (2006.01); B29C 70/06 (2006.01); B29K 105/08 (2006.01); B29L 7/00 (2006.01)
CPC B29C 70/345 (2013.01) [B29C 45/0005 (2013.01); B29C 45/14008 (2013.01); B29C 45/14221 (2013.01); B29C 45/80 (2013.01); B29C 70/06 (2013.01); B29K 2105/0809 (2013.01); B29K 2313/00 (2013.01); B29K 2995/0063 (2013.01); B29L 2007/002 (2013.01)] 7 Claims
OG exemplary drawing
 
1. A tool system for fabricating a composite panel, comprising:
a lower tool defining a cavity;
a preform including a substrate including a peripheral edge, a central portion, and a first step arranged between the peripheral edge and the central portion, the first step defining a radially inwardly facing surface, reinforcing fibers attached to the substrate and defining a first fiber density in first regions of the central portion of the substrate and a second fiber density in second regions of the central portion of the preform,
wherein the first fiber density is lower than the second fiber density, and
wherein the central portion of the substrate has a first thickness,
wherein the peripheral edge portion of the substrate has a second thickness that is greater than the first thickness and forms the first step;
a binder vertically moveable relative to the lower tool during preforming and including a first surface defining a second step with a radially outwardly facing surface configured to bias the radially inwardly facing surface of the first step to center and clamp the preform relative to the lower tool; and
an upper punch vertically moveable relative to the binder and the lower tool to center the preform relative to the cavity during preforming, the upper punch and including a fluid passage configured to deliver resin to impregnate the preform arranged between the upper punch and the lower tool.