EP-4737089-A1 - A MOLDING SYSTEM WITH SUCTION HEADS

EP4737089A1EP 4737089 A1EP4737089 A1EP 4737089A1EP-4737089-A1

Abstract

There is provided a molding system for molding a three-dimensional object, comprising: an array of actuation members; suction heads provided on the actuation members of the array of actuation members; a flexible mat support on the suction heads of the array of actuation members, wherein the suction heads are configured to connect to the flexible mat support by vacuum, and wherein the actuation members are individually length adjustable to define a curvature of the flexible mat support to provide a curved base for molding a three-dimensional object.

Inventors

RAUN, Christian

Assignees

Kurvatur A/S

Dates

Publication Date: 20260506
Application Date: 20251031

Claims (16)

A molding system for molding a three-dimensional object from a polymeric or resin-based composite material
, comprising: an array of actuation members; suction heads provided on the actuation members of the array of actuation members; a flexible mat support on the suction heads of the array of actuation members, wherein the suction heads are configured to connect to the flexible mat support by vacuum, and wherein the actuation members are individually length adjustable to define a curvature of the flexible mat support to provide a curved base for molding a three-dimensional object.
The molding system of claim 1, comprising pivotable joints between the suction heads and the actuation members, optionally wherein the pivotable joints comprise a lower joint that is rotatable relative to the actuation member and an upper joint that is connected to the lower joint about a pivot axis.
The mold system of claim 1, comprising pivotable joints between the suction heads and the actuation members, wherein the pivotable joints allow two perpendicular pivoting axes relative to the flexible mat and optionally rolling around a longitudinal axis extending through the respective actuation member.
The molding system of claim 1, wherein the suction heads are in the form of suction cups.
The molding system of claim 4, wherein the suction cups comprise a central cup area and an outer skirt extending about the central cup area, wherein the central cup area is made of a harder material than the outer skirt.
The molding system of claim 1, comprising a vacuum network to connect the suction heads to the flexible mat by vacuum, and, optionally, wherein the vacuum network comprises flexible vacuum hoses and vacuum connectors for connecting the flexible vacuum hoses to the suction heads, and, further optionally, wherein first and second types of the vacuum connectors are provided that extend from the suction heads in different directions to provide for different connection angles for the flexible vacuum hoses.
The molding system of claim 1, wherein the suction heads are configured to be slidable relative to the flexible mat support when connected thereto.
The molding system of claim 1, wherein the flexible mat includes a grid of stiffening rods embedded in a substrate.
The molding system of claim 8, wherein the substrate is made of silicone.
The molding system of claim 1, wherein the suction heads are connected to each other by a grid of rods.
The molding system of claim 1, comprising a heating mat supported on the flexible mat support for heating material to be molded to form the three dimensional object.
The molding system of claim 8, wherein the heating mat comprises a pattern of sinusoidally extending heating elements, optionally wherein a heating area of the mat is arranged in a rectangle.
The molding system of claim 1, wherein there are suction heads of a first type connected to respective actuation members and suctions head of a second type disposed between neighboring actuation members.
The molding system of claim 1, wherein the flexible mat support includes a grid of lumens disposed therein for slidably receiving respective control rods.
A method of molding a three-dimensional object from a polymeric or resin-based composite material comprising: providing the molding system of any preceding claim; supporting molding material on the flexible mat; vacuum connecting the flexible mat to the suction heads; individually adjusting lengths of the actuation members by a control system to define a curvature of the flexible mat; and molding the molding material to assume the curvature defined by the flexible mat.

Description

TECHNICAL FIELD The present disclosure generally relates to molding systems and methods for molding three-dimensional objects. BACKGROUND Molding is commonly used in the manufacturing industry to produce three-dimensional objects. It typically involves some form of surface (mold surface/blank) upon which the object to be molded is formed against. Mold material is typically heated and formed against the mold surface/blank, replicating the shape of the mold surface/blank in the mold material. Traditional molding techniques often involve complex and time-consuming processes, leading to inefficiencies and limitations in design flexibility. In particular, forming the mold surface/blank can involve significant time and use large amounts of material. Therefore, molding is typically only used in the manufacturing of objects where large number of identical objects need to be produced, otherwise the process is cost/time-prohibitive. WO2017153319A1 discloses an apparatus for making a three-dimensionally curved object. The apparatus comprises a membrane having a moulding surface, which is configurable into a predetermined shape by individually adjusting an array of actuators acting on the surface opposite the moulding surface of said membrane. The membrane is a ferromagnetic membrane and the actuators are provided with magnetic joints at the distal ends of said actuators. In some instances, the magnetic interaction of the actuators and the ferromagnetic membrane can cause wrinkles or other deformities in the moulding surface of the membrane. Accordingly, it is desirable to provide molding systems and methods which are particularly suited to improve the molding process by improving efficiency of manufacturing low-volume, custom curved items. Further, the quality of moulding should be ensured and improved. Yet further, it would be desirable ensure uniform heating of the material to be moulded. Other desirable features and characteristics of the present disclosure will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background. SUMMARY In a first aspect, there is provided a molding system for molding a three-dimensional object. The molding system comprises an array of actuation members. Suction heads may be provided on the actuation members of the array of actuation members. A flexible mat support may be provided on the suction heads of the array of actuation members. The suction heads may be configured to connect to the flexible mat support by vacuum. The actuation members may be individually length adjustable to define a curvature of the flexible mat support to provide a curved base for molding a three-dimensional object. Due to the use of a vacuum connection between the suction heads and the flexible mat support, the two elements may slidably move relative to each other, even when connected. Accordingly, the flexible mat support may be arranged in more intricate three-dimensional shapes without causing unforeseen shapes in the flexible mat support. For example, due to the limited slip, wrinkles in the flexible mat support may be reduced. The molding system may comprise pivotable joints between the suction heads and the actuation members. The pivotable joints may comprise a lower joint that is rotatable relative to the actuation member and an upper joint that is connected to the lower joint about a pivot axis. The suction heads may be configured to be slidable relative to the flexible mat support when connected thereto. The suction heads may be in the form of suction cups. The suction cups may comprise a central cup area and an outer skirt extending about the central cup area. The central cup area may optionally be made of a harder material than the outer skirt. The molding system may comprise a vacuum network to connect the suction heads to the flexible mat by vacuum. The vacuum network may comprise flexible vacuum hoses and vacuum connectors for connecting the flexible vacuum hoses to the suction heads. Optionally, first and second types of the vacuum connectors are provided that extend from the suction heads in different directions to provide for different connection angles for the flexible vacuum hoses. The molding system may comprise a heating mat supported on the flexible mat support for heating material to be molded to form the three dimensional object. A heating area of the mat may be arranged in a rectangle. Optionally, terminations of the heating elements are provided on a shorter side of the rectangle. The heating elements may extend along adjacent parallel lines. The lines may be spaced by a length of between 1 mm and 100 mm, preferably 5 mm and 50 mm and preferably 5 mm to 20 mm. Optionally, all heating elements of the heating mat are provided on a single electric circuit. In a second aspect, there is provided a method of molding a three-dimensional object. The method comprises providi