Patent Description:
Continuous compression molding machines may be utilized to form a thermoplastic material into a desired shape. Continuous compression molding machines may utilize a pair of opposed die, a heating assembly, and a cooling assembly. The heating assembly heats the thermoplastic material at an entrance to the die, thereby permitting the thermoplastic material to mold and/or flow to the shape of the die. The die periodically separate, thereby permitting the thermoplastic material to be advanced through the continuous compression molding machine, and move together, thereby pressing the thermoplastic material into shape, which is defined by the die. In conventional continuous compression molding machines, the cooling assembly is utilized to cool the thermoplastic material to a temperature that is below a glass transition temperature of the thermoplastic material prior to separation of the thermoplastic material from the die. While effective in certain circumstances, this process may cause a build-up of stresses within the thermoplastic material, which may cause the thermoplastic material to warp, to twist, and/or to deform subsequent to separation from the die. To account for this deformation, die of conventional continuous compression molding machines may utilize complex shape compensation strategies within which the shape of the thermoplastic material, as defined by the die, differs from the desired shape. Die that include shape compensation strategies are difficult to accurately build and/or only may be effective in certain circumstances, and small changes in one or more process parameters may render the shape compensation ineffective. Thus, there exists a need for improved continuous compression molding machines and methods of continuous compression molding a consolidated thermoplastic matrix composite material.

<CIT>, in accordance with its abstract, states a composite laminate structure which includes a cellular core and a first laminate layer coupled to the cellular core. The first laminate layer includes a first thermoplastic layer and a first fiber-reinforced polymer layer, where a first surface of the first fiber-reinforced polymer layer is thermally consolidated to a second surface of the first thermoplastic layer. A first surface of the first thermoplastic layer is directly in contact with and bound to a first surface of the cellular core by temperature reduction of the first thermoplastic layer below a glass transition temperature of the first thermoplastic layer while the cellular core is pressed against the first thermoplastic layer when the first thermoplastic layer is above the glass transition temperature of the first thermoplastic layer and the cellular core is below a temperature where materials of the cellular core flow or degrade.

Continuous compression molding machines (CCMMs) and methods of continuous compression molding a consolidated thermoplastic matrix composite material are disclosed herein. The CCMMs include a mold, a heat zone heating structure, a consolidation zone heating structure, and a stress relaxation zone heating structure. The CCMMs also include a press structure, a demold structure, and a supply structure. The mold is configured to shape a thermoplastic matrix composite material (TMCM), which includes a thermoplastic material, to a desired shape for a consolidated thermoplastic matrix composite material. The heat zone heating structure is configured to heat a heat zone of the mold to a heat zone temperature that is selected to heat the TMCM to an initial temperature that is above a melt temperature for the thermoplastic material. The consolidation zone heating structure is configured to heat a consolidation zone of the mold to a consolidation zone temperature that is selected to cool the TMCM to a subsequent temperature. The stress relaxation zone heating structure is configured to maintain a stress relaxation zone of the mold at a stress relaxation zone temperature that is selected to maintain the TMCM at a stress relaxation temperature. The press structure is configured to periodically compress the TMCM, within the mold, to form the TMCM to the desired shape. The demold structure is configured to demold the TMCM from the mold while the TMCM is at a demold temperature that is greater than a glass transition temperature of the thermoplastic material. The supply structure is configured to periodically advance the TMCM through the mold.

The methods include providing a thermoplastic matrix composite material (TMCM) that includes a thermoplastic material to a CCMM. During the providing, the methods also include heating the TMCM within a heat zone of the CCMM, cooling and consolidating the TMCM within a consolidation zone of the CCMM, relaxing stress within the TMCM within a stress relaxation zone of the CCMM, demolding the TMCM within a demold zone of the CCMM, and periodically compressing the TMCM. The heating the TMCM includes heating to an initial temperature that is above a melt temperature of the thermoplastic material. The cooling and consolidating the TMCM includes cooling to a subsequent temperature. The relaxing stress within the TMCM includes relaxing stress at a stress relaxation temperature. The demolding the TMCM includes demolding from a mold of the CCMM and at a demold temperature that is greater than a glass transition temperature of the thermoplastic material. The periodically compressing the TMCM includes periodically compressing the TMCM with the mold to form the TMCM to a desired shape for the consolidated thermoplastic matrix composite material.

<FIG> provide illustrative, non-exclusive examples of continuous compression molding machines <NUM> and/or of methods <NUM>, according to the present disclosure. Elements that serve a similar, or at least substantially similar, purpose are labeled with like numbers in each of <FIG>, and these elements may not be discussed in detail herein with reference to each of <FIG>. Similarly, all elements may not be labeled in each of <FIG>, but reference numerals associated therewith may be utilized herein for consistency. Elements, components, and/or features that are discussed herein with reference to one or more of <FIG> may be included in and/or utilized with any of <FIG> without departing from the scope of the present disclosure.

In general, elements that are likely to be included in a given (i.e., a particular) embodiment are illustrated in solid lines, while elements that are optional to a given embodiment are illustrated in dashed lines. However, elements that are shown in solid lines are not essential to all embodiments, and an element shown in solid lines may be omitted from a particular embodiment without departing from the scope of the present disclosure.

<FIG> are schematic illustrations of examples of continuous compression molding machines (CCMMs) <NUM> according to the present disclosure. As illustrated in <FIG>, CCMMs <NUM> include a supply structure <NUM>, a mold <NUM>, a heating structure <NUM>, a press structure <NUM>, and a demold structure <NUM>.

During operation of CCMMs <NUM>, and as discussed in more detail herein with reference to methods <NUM> of <FIG>, supply structure <NUM> is configured to periodically advance a thermoplastic matrix composite material (TMCM) <NUM>, such as in the form of a plurality of unconsolidated layers of TMCM <NUM>, through mold <NUM>. Mold <NUM> is adapted, configured, sized, and/or shaped to shape TMCM <NUM> to a desired shape for a consolidated TMCM <NUM>. TMCM <NUM> includes a thermoplastic material <NUM> and may include a plurality of reinforcing fibers <NUM>.

Concurrently, press structure <NUM> periodically compresses TMCM <NUM> within mold <NUM>. In some examples, and as illustrated in <FIG>, this periodic compression is via compression of TMCM <NUM> between a first mold surface <NUM>, which is defined by a first mold die <NUM> of mold <NUM>, and a second mold surface <NUM>, which is defined by a second mold die <NUM> of mold <NUM>. In some such examples, and as illustrated in <FIG>, press structure <NUM> also is configured to move first mold surface <NUM> and second mold surface <NUM> away from one another to permit and/or facilitate the periodic advance of TMCM <NUM> through mold <NUM> by supply structure <NUM>. Stated differently, periodic compression of TMCM <NUM> may be performed while first mold die <NUM> and second mold die <NUM> are relatively proximate one another, as illustrated in <FIG>, while periodic advancement of TMCM <NUM> may be performed while first mold die <NUM> and second mold die <NUM> are relatively spaced-apart from one another, as illustrated in <FIG>.

Also concurrently, demold structure <NUM> is configured to demold TMCM <NUM> from mold <NUM>. This includes demolding the TMCM <NUM> while the TMCM is at a demold temperature that is greater than a glass transition temperature of the thermoplastic material. This is illustrated in the temperature profile of <FIG>, where temperature, T, of the TMCM <NUM> is at a demold temperature, Td, that is greater than the gas transition temperature, Tg, of the thermoplastic material upon demolding the TMCM <NUM> within demold zone <NUM>.

Heating structure <NUM> includes a heat zone heating structure <NUM> configured to heat a heat zone <NUM> of mold <NUM>, a consolidation zone heating structure <NUM> configured to heat a consolidation zone <NUM> of mold <NUM>, and a stress relaxation zone heating structure <NUM> configured to heat a stress relaxation zone <NUM> of mold <NUM>. With this in mind, press structure <NUM> also may be referred to herein as being configured to periodically compress TMCM <NUM> within heat zone <NUM>, within consolidation zone <NUM>, and within stress relaxation zone <NUM>, such as to form TMCM <NUM> to the desired shape and/or to define consolidated TMCM <NUM>. Similarly, supply structure <NUM> also may be referred to herein as being configured to periodically advance TMCM <NUM> such that the TMCM extends sequentially through heat zone <NUM>, consolidation zone <NUM>, and stress relaxation zone <NUM> and/or such that the TMCM extends to demold structure <NUM>.

As illustrated in <FIG>, heating structure <NUM> may include, or may be referred to as including corresponding upper and lower heat zone heating structures <NUM>, consolidation zone heating structures <NUM>, and/or stress relaxation zone heating structures <NUM>. In such a configuration, upper heat zone heating structure <NUM>, upper consolidation zone heating structure <NUM>, and upper stress relaxation zone heating structure <NUM> may be configured to heat first mold die <NUM>, while lower heat zone heating structure <NUM>, lower consolidation zone heating structure <NUM>, and lower stress relaxation zone heating structure <NUM> may be configured to heat second mold die <NUM>.

Heat zone heating structure <NUM> is configured to heat a heat zone <NUM> of mold <NUM> to a heat zone temperature, which is selected to heat TMCM <NUM> to an initial temperature that is above a melt temperature for the thermoplastic material. This is illustrated in the temperature profile of <FIG>, where temperature, T, of TMCM <NUM> is increased to initial temperature, Ti, which is greater than the met temperature, Tm, of the thermoplastic material within heat zone <NUM>. In some examples, heat zone heating structure <NUM> also may be referred to herein as being configured to heat TMCM <NUM> to within a plastic phase temperature range for the thermoplastic material. Heat zone heating structure <NUM> may include and/or be any suitable structure that is configured to heat heat zone <NUM> of mold <NUM> to the heat zone temperature. In some examples, heat zone <NUM> is an electrically heated heat zone. In such examples, heat zone heating structure <NUM> includes and/or is an electrical heat zone heating structure.

Consolidation zone heating structure <NUM> is configured to heat a consolidation zone <NUM> of mold <NUM> to a consolidation zone temperature, which is selected to cool TMCM <NUM> to a subsequent temperature. The subsequent temperature may be less than the initial temperature and/or may be within a rubbery temperature range for the thermoplastic material. This is illustrated in the temperature profile of <FIG>, where temperature, T, of TMCM <NUM> is decreased to subsequent temperature, Ts, which is less than initial temperature, Ti, within consolidation zone <NUM>. Consolidation zone heating structure <NUM> may include and/or be any suitable structure that is configured to heat consolidation zone <NUM> of mold <NUM> to the consolidation zone temperature. In some examples, consolidation zone <NUM> is an electrically heated consolidation zone. In such examples, consolidation zone heating structure <NUM> includes and/or is an electrical consolidation zone heating structure. It is within the scope of the present disclosure that consolidation zone <NUM> may maintain TMCM <NUM> at consolidation zone temperatures that are significantly higher when compared to conventional consolidation zones of conventional CCMMs. With this in mind, consolidation zone <NUM> may be free from water cooling.

Stress relaxation zone heating structure <NUM> is configured to maintain a stress relaxation zone <NUM> of mold <NUM> at a stress relaxation zone temperature, which is selected to maintain TMCM <NUM> at a stress relaxation temperature. The stress relaxation temperature may be less than the initial temperature and/or may be within the rubbery temperature range for the thermoplastic material. This is illustrated in the temperature profile of <FIG>, where temperature, T, of TMCM <NUM> is maintained at stress relaxation temperature, Tr, within stress relaxation zone <NUM>. Stress relaxation zone heating structure <NUM> may include and/or be any suitable structure that is configured to heat stress relaxation zone <NUM> of mold <NUM> to the stress relaxation zone temperature. In some examples, stress relaxation zone <NUM> is an electrically heated stress relaxation zone. In such examples, stress relaxation zone heating structure <NUM> includes and/or is an electrical stress relaxation zone heating structure. It is within the scope of the present disclosure that stress relaxation zone <NUM> may maintain TMCM <NUM> at stress relaxation zone temperatures that are significantly higher when compared to conventional stress relaxation zones of conventional CCMMs. With this in mind, stress relaxation zone <NUM> may be free from water cooling.

As illustrated in dashed lines in <FIG>, CCMM <NUM> also may include a quench structure <NUM>. Quench structure <NUM>, when present, is adapted, configured, designed, and/or constructed to receive TMCM <NUM> from demold structure <NUM> and/or to quench TMCM <NUM> to a quench temperature that is less than the stress relaxation temperature. Quench structure <NUM> may include and/or may be defined by any suitable structure and/or structures that may permit and/or facilitate cooling of TMCM <NUM> to any suitable quench temperature. In a specific example, quench structure <NUM> includes support structure <NUM>, which is discussed in more detail herein and is configured to operatively support TMCM <NUM> during the cooling. In some such examples, the TMCM may be cooled via natural convection. In some examples, quench structure <NUM> may include any suitable fan, blower, cooling assembly, and/or air conditioning unit. Examples of the quench temperature include an ambient temperature of an ambient environment that surrounds the TMCM and/or to temperatures that are within a threshold temperature differential of the ambient temperature. Examples of the threshold temperature differential include temperature differentials of <NUM> degrees Celsius (°C), <NUM>, <NUM>, <NUM>, or <NUM>.

As also illustrated in dashed lines in <FIG>, CCMM <NUM> may include support structure <NUM>. Support structure <NUM>, when present, is adapted, configured, designed, sized, and/or constructed to receive TMCM <NUM> from demold structure <NUM> and/or to support TMCM <NUM>, such as while the TMCM cools from the demold temperature and/or to the quench temperature. Examples of support structure <NUM> include any suitable mechanical support, surface, tabletop, benchtop, conveyor, and/or inner mold line support that physically and/or operatively supports TMCM <NUM>, in the form of consolidated TMCM <NUM>, against gravity. In a specific example, a lower surface of consolidated TMCM <NUM> has and/or defines a lower surface shape, which corresponds to the desired shape for the lower surface of the consolidated TMCM. In some such examples, an upper surface of support structure <NUM> may correspond to the lower surface shape of consolidated TMCM <NUM>. Stated differently, the upper surface of support structure <NUM> may include and/or be a tooled surface that is shaped to correspond to the shape of the lower surface of consolidated TMCM <NUM>. Such a configuration may decrease a potential for deformation of consolidated TMCM <NUM> upon cooling of the consolidated TMCM from the demold temperature and/or to the quench temperature.

As also illustrated in dashed lines in <FIG>, CCMM <NUM> may include a controller <NUM>. Controller <NUM>, when present, is adapted, configured, and/or programmed to control the operation of at least one other component of CCMM <NUM>. As examples, and as indicated by the dashed arrows in <FIG>, controller <NUM> may be programmed to control the operation of supply structure <NUM>, heating structure <NUM>, press structure <NUM>, demold structure <NUM>, and/or quench structure <NUM>. In a specific example, controller <NUM> is programmed to control the operation of CCMM <NUM> according to methods <NUM> of <FIG>, which are discussed in more detail herein. This may include control of any suitable structure of CCMM <NUM> disclosed herein with reference to methods <NUM> and/or directing CCMM <NUM> to perform any suitable function disclosed herein with reference to methods <NUM>.

Controller <NUM> may include and/or be any suitable structure, device, and/or devices that may be adapted, configured, designed, constructed, and/or programmed to perform the functions discussed herein. As examples, controller <NUM> may include one or more of an electronic controller, a dedicated controller, a special-purpose controller, a personal computer, a special-purpose computer, a display device, a logic device, a memory device, and/or a memory device having computer-readable storage media.

The computer-readable storage media, when present, also may be referred to herein as non-transitory computer readable storage media. The (optionally, non-transitory) computer readable storage media may include, define, house, and/or store computer-executable instructions, programs, and/or code; and these computer-executable instructions may direct CCMM <NUM> and/or controller <NUM> thereof to perform any suitable portion, or subset, of methods <NUM>. Examples of such (optionally, non-transitory) computer-readable storage media include CD-ROMs, disks, hard drives, flash memory, etc. As used herein, storage, or memory, devices and/or media having computer-executable instructions, as well as computer-implemented methods and other methods according to the present disclosure, are considered to be within the scope of subject matter deemed patentable.

As discussed, mold <NUM> includes a plurality of zones, including heat zone <NUM>, consolidation zone <NUM>, and stress relaxation zone <NUM>. As also discussed, these zones each may be heated to corresponding and/or different temperatures, with these temperatures being selected to provide a certain and/or specific function during forming of unconsolidated layers of TMCM <NUM> to consolidated TMCM <NUM>. Because of these differing temperatures, the various zones of mold <NUM> may experience differing levels, or amounts, of thermal expansion. In some examples of CCMMs <NUM>, it may be desirable to ensure that consolidation zone <NUM> provides a greater pressure to TMCM <NUM> when compared to stress relaxation zone <NUM>. In some such examples, and to facilitate the cooling of TMCM <NUM> within consolidation zone <NUM> that is illustrated in <FIG>, the consolidation zone temperature is less than the stress relaxation zone temperature. In some such examples, stress relaxation zone <NUM> defines a stress relaxation zone thickness that is less than a consolidation zone thickness of consolidation zone <NUM>. Such a configuration may decrease a potential for thermal expansion effects to cause stress relaxation zone <NUM> to apply a greater pressure to TMCM <NUM> when compared to consolidation zone <NUM>.

Mold <NUM> may include, or may be referred to herein as including, a plurality of mold die regions <NUM>. In some such examples, heat zone <NUM>, consolidation zone <NUM>, and stress relaxation zone <NUM> each may be defined by at least one corresponding mold die region of the plurality of mold die regions <NUM>. Examples of the plurality of mold die regions <NUM> include at least <NUM> mold die regions, at least <NUM> mold die regions, at least <NUM> mold die regions, at least <NUM> mold die regions, at most <NUM> mold die regions, at most <NUM> mold die regions, at most <NUM> mold die regions, at most <NUM> mold die regions, at most <NUM> mold die regions, and/or at most <NUM> mold die regions.

In a specific example, heat zone <NUM> includes a pair of mold die regions <NUM>, each of which is maintained at a single fixed, or at least substantially fixed, heat zone temperature. In another specific example, consolidation zone <NUM> includes a pair of mold die regions <NUM> that are maintained at different consolidation zone temperatures. As yet another specific example, stress relaxation zone <NUM> includes a pair of mold die regions that are maintained at a single fixed, or at least substantially fixed, stress relaxation zone temperature.

Mold die regions <NUM>, when present, may have and/or define any suitable region length. Examples of the region length include region lengths of at least <NUM> meters (m), at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, and/or at most <NUM>.

As illustrated in <FIG>, and in some examples, mold <NUM> defines an elongate mold channel <NUM>. Elongate mold channel <NUM>, when present, extends between an entrance region <NUM> of mold <NUM>, which is configured to receive TMCM <NUM> as unconsolidated layers of TMCM <NUM>, and an exit region <NUM> of mold <NUM>, which is configured to discharge TMCM <NUM> as consolidated TMCM <NUM>. Elongate mold channel <NUM> defines, or is shaped to define, a desired shape for consolidated TMCM <NUM>. In some examples, and as discussed herein, mold <NUM> includes first mold die <NUM>, which defines first mold surface <NUM>, and second mold die <NUM>, which defines second mold surface <NUM>. In some such examples, first mold surface <NUM> extends parallel, or at least substantially parallel, to a first mold surface plane along an entirety of a length of elongate mold channel <NUM>. Similarly, and in some such examples, second mold surface <NUM> extends parallel, or at least substantially parallel, to a second mold surface plane along an entirety of a length of elongate mold channel <NUM>. In some such examples, a distance between first mold surface <NUM> and second mold surface <NUM> decreases, or decreases monotonically, along the length of elongate mold channel <NUM> and between entrance region <NUM> and exit region <NUM> (or between heat zone <NUM> and stress relaxation zone <NUM>). Stated differently, and in some examples, mold <NUM> is free of shape composition for consolidated TMCM <NUM>. This is in contrast to conventional CCMMs, which demold corresponding TMCMs at conventional demold temperatures that are significantly lower than the demold temperatures utilized in CCMMs <NUM>, that require correspondingly utilized molds to include shape compensation in order to form the corresponding TMCMs into the corresponding desired shape.

In some examples, entrance region <NUM> and/or exit region <NUM> include corresponding curved, chamfered, and/or tapered relief regions. These relief regions, when present, are configured to facilitate entrance of TMCM <NUM> into mold <NUM> at entrance region <NUM> and/or to facilitate demolding of TMCM <NUM> from mold <NUM> at exit region <NUM>. In such examples, the above-discussed first mold surface <NUM> and/or second mold surface <NUM> are defined by regions of mold <NUM> that are outside, or that extend between, these relief regions.

TMCM <NUM> may include and/or may be defined by any suitable material and/or materials. As discussed, TMCM <NUM> includes thermoplastic material <NUM>. Examples of thermoplastic material <NUM> include an amorphous thermoplastic material, a semicrystalline thermoplastic material, a polyphenylene sulfide (PPS) thermoplastic material, a polyether ether ketone (PEEK) thermoplastic material, a polyetherketoneketone (PEKK) thermoplastic material, and a polyaryletherketone (PAEK) thermoplastic material. As also discussed, TMCM <NUM> may include a plurality of reinforcing fibers <NUM>. Examples of reinforcing fibers <NUM> include a carbon fiber, a fiberglass fiber, and an aramid fiber.

Supply structure <NUM> may include any suitable component and/or components that may be adapted, configured, designed, and/or constructed to provide TMCM <NUM> and/or to periodically advance TMCM <NUM> through mold <NUM>. Examples of supply structure <NUM> include a source of TMCM <NUM>, a supply of TMCM <NUM>, a roller, a conveyor, a feeder, a motor, and/or an electric motor.

Press structure <NUM> may include any suitable component and/or components that may be adapted, configured, designed, and/or constructed to periodically compress TMCM <NUM> within mold <NUM>. Examples of press structure <NUM> include a hydraulic press, a hydraulically actuated press, an electric press, an electrically actuated press, and/or an electric over hydraulic press.

Demold structure <NUM> may include any suitable component and/or components that may be adapted, configured, designed, and/or constructed to demold, or to separate, TMCM <NUM> from mold <NUM> while the TMCM is at the demold temperature. Examples of demold structure <NUM> include a region of mold <NUM> that tapers and/or expands away from TMCM <NUM>, a mechanism that physically separates the TMCM from the mold, and/or a structure that supports the TMCM subsequent to the TMCM exiting the mold, such as support structure <NUM>.

<FIG> is a flowchart depicting examples of methods <NUM> of continuous compression molding a consolidated thermoplastic matrix composite material, according to the present disclosure. Methods <NUM> may be performed utilizing a continuous compression molding machine, such as CCMMs <NUM> of <FIG>. With this in mind, any of the structures, functions, and/or features, which are disclosed herein with reference to CCMMs <NUM> of <FIG> may be included in and/or utilized with methods <NUM> of <FIG> without departing from the scope of the present disclosure. Similarly, any of the structures, functions, and/or features, which are disclosed herein with reference to methods <NUM> of <FIG>, may be included in and/or utilized with CCMMs <NUM> of <FIG> without departing from the scope of the present disclosure.

As illustrated in <FIG>, methods <NUM> include providing a thermoplastic matrix composite material (TMCM) at <NUM>, heating the TMCM at <NUM>, and cooling and consolidating the TMCM at <NUM>. Methods <NUM> also include relaxing stress within the TMCM at <NUM>, demolding the TMCM at <NUM>, and periodically compressing the TMCM at <NUM>. Methods <NUM> further may include quenching the TMCM at <NUM> and/or supporting the TMCM at <NUM>.

Providing the thermoplastic matrix composite material (TMCM) at <NUM> includes providing any suitable TMCM, which includes a thermoplastic material, to a continuous compression molding machine. Examples of the TMCM are disclosed herein with reference to TMCM <NUM> of <FIG>. Examples of the continuous compression molding machine are disclosed herein with reference to CCMM <NUM> of <FIG>. The providing at <NUM> may be performed utilizing any suitable structure, such as supply structure <NUM> of <FIG>.

In some examples, the providing at <NUM> includes providing the TMCM at a linear feed rate, or at an average linear feed rate. The linear feed rate may be selected and/or established based upon material properties of the TMCM and/or a desired production rate of consolidated TMCM <NUM> from the CCMM. Examples of the linear feed rate include linear feed rates of at least <NUM> meters per hour (m/h), at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, at most <NUM>/h, at most <NUM>/h, at most <NUM>/h, at most <NUM>/h, at most <NUM>/h, at most <NUM>/h, at most <NUM>/h, at most <NUM>/h, and/or at most <NUM>/h.

Heating the TMCM at <NUM> includes heating the TMCM during the providing at <NUM>. This includes heating the TMCM within a heat zone of the CCMM, to an initial temperature, and/or to within an initial temperature range. The initial temperature and/or the initial temperature range is above a melt temperature of the thermoplastic material. Examples of the heat zone are disclosed herein with reference to heat zone <NUM> of <FIG>.

The initial temperature may be selected and/or established based upon material properties for the TMCM, desired material properties for the consolidated TMCM, and/or the desired production rate of the consolidated TMCM from the CCMM. Examples of the initial temperature include initial temperatures of at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, and/or at most <NUM>.

Cooling and consolidating the TMCM at <NUM> includes cooling and consolidating the TMCM during the providing at <NUM>. This includes cooling and consolidating the TMCM within a consolidation zone of the CCMM, to a subsequent temperature, and/or to within a subsequent temperature range. In some examples, the subsequent temperature and/or the subsequent temperature range is less than the initial temperature and/or is within a rubbery temperature range of the thermoplastic material. Examples of the consolidation zone are disclosed herein with reference to consolidation zone <NUM> of <FIG>.

The subsequent temperature may be selected and/or established based upon material properties for the TMCM, desired material properties for the consolidated TMCM, and/or the desired production rate of the consolidated TMCM from the CCMM. Examples of the subsequent temperature include subsequent temperatures at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, and/or at most <NUM>.

Relaxing stress within the TMCM at <NUM> includes relaxing stress within the TMCM during the providing at <NUM>. This includes relaxing stress within a stress relaxation zone of the CCMM, to a stress relaxation temperature, and/or to within a stress relaxation temperature range. In some examples, the stress relaxation temperature and/or the stress relaxation temperature range is less than the initial temperature and/or within the rubbery temperature range of the thermoplastic material. Examples of the stress relaxation zone are disclosed herein with reference to stress relaxation zone <NUM> of <FIG>.

In some examples, the stress relaxation temperature is a stress-free temperature for the thermoplastic material. The stress-free temperature may be selected such that a relaxation time constant for the thermoplastic material is less than a process time for the TMCM within the CCMM. In some such examples, the relaxation time constant for the thermoplastic material is less than <NUM>%, less than <NUM>%, less than <NUM>%, less than <NUM>%, less than <NUM>%, less than <NUM>%, less than <NUM>%, or less than <NUM>% of the process time for the TMCM within the CCMM. The process time for the TMCM may be a time period that begins when a given region of the TMCM enters the heat zone and ends when the given region of the TMCM exits the stress relaxation zone. Stated differently, the stress-free temperature may be selected such that stresses within the thermoplastic material are completely relaxed, or at least substantially completely relaxed, when the consolidated TMCM exits the stress relaxation zone.

The stress relaxation temperature additionally or alternatively may be selected and/or established based upon material properties for the TMCM, desired material properties for the consolidated TMCM, and/or the desired production rate of the consolidated TMCM from the CCMM. Examples of the stress relaxation temperature include stress relaxation temperatures of at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, and/or at most <NUM>.

As discussed, the stress relaxation temperature is less than the initial temperature. It is within the scope of the present disclosure that the stress relaxation temperature may differ from the initial temperature by any suitable magnitude. As examples, a difference between the initial temperature and the stress relaxation temperature may be at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, and/or at most <NUM>.

In general, methods <NUM> are performed during a finite timeframe within which kinetic effects cause the temperature of the TMCM to differ from the temperature of the various zones of the CCMM that are heating and/or cooling the TMCM. With this in mind, and in some examples, the heat zone has a heat zone temperature, the consolidation zone has a consolidation zone temperature, and the stress relaxation zone has a stress relaxation zone temperature. In such examples, the heat zone temperature is at least the initial temperature and is selected to heat the TMCM to the initial temperature, the consolidation zone temperature is at most the subsequent temperature and is selected to cool the TMCM to the subsequent temperature, the stress relaxation zone temperature, which is at most the consolidation zone temperature and is selected to maintain the TMCM at the stress relaxation temperature. In some such examples, the consolidation zone temperature is less than the stress relaxation zone temperature. Stated differently, and in such examples, the consolidation zone temperature is at least a threshold consolidation zone temperature differential less than the stress relaxation zone temperature. Examples of the threshold consolidation zone temperature differential include temperature differentials of at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, and/or at most <NUM>.

Demolding the TMCM at <NUM> includes demolding the TMCM during the providing at <NUM>. The demolding at <NUM> also includes demolding the TMCM from a mold <NUM> of the CCMM, within a demold zone <NUM> of the CCMM, at a demold temperature, and/or within a demold temperature range. The demold temperature and/or the demold temperature range is greater than a glass transition temperature of the thermoplastic material. In some examples, the demolding at <NUM> include demolding with, via, and/or utilizing a demold structure, examples of which are disclosed herein with reference to demold structure <NUM> of <FIG>.

As illustrated in <FIG>, methods <NUM> may be performed as part of a continuous process within which the TMCM extends within and/or through the heat zone, the consolidation zone, the stress relaxation zone, and the demold zone of the CCMM. With this in mind, the heating at <NUM> also may be referred to herein as heating a region of the TMCM, or a region of a continuous length of the TMCM, that extends within the heat zone of the CCMM; and the cooling and consolidating at <NUM> also may be referred to herein as cooling and consolidating a region of the TMCM, or a region of the continuous length of the TMCM, that extends within the consolidation zone of the CCMM. Similarly, the relaxing at <NUM> also may be referred to herein as relaxing stress within a region of the TMCM, or a region of the continuous length of the TMCM, that extends within the stress relaxation zone of the CCMM; and the demolding at <NUM> also may be referred to herein as demolding a region of the TMCM, or a region of the continuous length of the TMCM, that extends within the demold zone of the CCMM.

Stated differently, the providing at <NUM> may include periodically advancing a continuous length of the TMCM sequentially through the heat zone, the consolidation zone, the stress relaxation zone, and the demold zone. This may include periodically advancing a predetermined length of the TMCM into the heat zone. Examples of the predetermined length of the TMCM include lengths of at least <NUM> millimeters (mm), at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, and/or at most <NUM>.

Periodically compressing the TMCM at <NUM> includes periodically compressing the TMCM during the providing at <NUM>. The periodically compressing at <NUM> also includes periodically compressing the TMCM within the mold of the CCMM and/or to form the TMCM to a desired shape for the consolidated TMCM. In some examples, the periodically compressing at <NUM> includes periodically compressing via a press structure, examples of which are disclosed herein with reference to press structure <NUM> of <FIG>.

As discussed in more detail herein, the mold may include a first mold die, which defines a first mold surface, and a second mold die, which defines a second mold surface. Examples of the first mold die, the first mold surface, the second mold die, and the second mold surface are disclosed herein with reference to first mold die <NUM>, first mold surface <NUM>, second mold die <NUM>, and second mold surface <NUM>, respectively, of <FIG>. In such examples, the first mold surface faces toward the second mold surface, such as to define an elongate mold channel, examples of which are disclosed herein with reference to elongate mold channel <NUM> of <FIG>. In some such examples, methods <NUM> include moving the first mold surface away from the second mold surface, such as to the configuration that is illustrated in <FIG>, to permit and/or facilitate the periodically advancing of the continuous length of the TMCM through the mold. Also in some such examples, methods <NUM> include moving the first mold surface toward and/or into contact with the second mold surface, such as to the configuration that is illustrated in <FIG>, to permit and/or facilitate compression of the TMCM by the mold during the periodically compressing at <NUM>.

Quenching the TMCM at <NUM>, when performed, includes quenching the TMCM to a quench temperature and is performed subsequent to the demolding at <NUM>. The quench temperature is less than the stress relaxation temperature. In some examples, the quench temperature is a threshold quench temperature differential less than the stress relaxation temperature. Examples of the threshold quench temperature differential include temperature differentials of at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM> , at most <NUM> , at most <NUM>, at most <NUM>, at most <NUM> , at most <NUM>, at most <NUM> , at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, and/or at most <NUM>.

The quenching at <NUM> may be performed in any suitable manner and/or utilizing any suitable structure, such as quench structure <NUM> of <FIG>. In a specific example, the quenching at <NUM> includes quenching to an ambient temperature of an ambient environment that surrounds the TMCM and/or to temperatures that are within a threshold temperature differential of the ambient temperature. In some such examples, the quenching at <NUM> includes quenching via natural convection.

Supporting the TMCM at <NUM>, when performed, includes supporting the TMCM subsequent to the demolding at <NUM> and/or with a support structure. Examples of the support structure are disclosed herein with reference to support structure <NUM> of <FIG>. In some examples, the supporting at <NUM> includes supporting a lower surface, or only a lower surface, of the TMCM. In some examples, the supporting at <NUM> includes maintaining contact between the TMCM and the support structure via, or only via, a gravitational force that acts on the TMCM. In some examples, the support structure is a stationary, or at least substantially stationary, support structure. In some examples, the TMCM is free from compression, by the support structure, during the supporting at <NUM>.

It is within the scope of the present disclosure that CCMMs <NUM> may form and/or methods <NUM> may be performed utilizing a variety of different TMCMs, including the TMCMs <NUM> that are disclosed herein. In some examples, the TMCMs are categorized as including either semicrystalline thermoplastic material or amorphous thermoplastic material.

In a specific example, the TMCMs include thermoplastic materials in the form of the semicrystalline thermoplastic material. In some such examples, the subsequent temperature is below the melt temperature of the semicrystalline thermoplastic material and above the glass transition temperature of the semicrystalline thermoplastic material. Also in some such examples, the stress relaxation temperature is below the melt temperature of the semicrystalline thermoplastic material and above the glass transition temperature of the semicrystalline thermoplastic material.

In some examples, the stress relaxation temperature is selected to provide at least a threshold relative crystallinity for the semicrystalline thermoplastic material within the consolidated TMCM <NUM>. Stated differently, the stress relaxation temperature is selected such that the semicrystalline thermoplastic material within the consolidated TMCM exhibits at least the threshold relative crystallinity, when compared to a maximum possible crystallinity based upon a chemical composition of the semicrystalline thermoplastic material. Examples of the threshold relative crystallinity include thresholds of at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, or at least <NUM>% of the maximum possible crystallinity.

In some examples, the stress relaxation temperature and/or the demold temperature are within a threshold temperature differential of a peak isothermal crystallization temperature of the semicrystalline thermoplastic material. Examples of the threshold temperature differential include differentials of <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>. Such a configuration may increase the relative crystallinity of the consolidated TMCM <NUM> when compared to continuous compression molding processes that do not maintain the semicrystalline thermoplastic material near the peak isothermal crystallization temperature.

In some example, the stress relaxation temperature is greater than the peak isothemal crystallization temperature of the semicrystalline thermoplastic material. As examples, the stress relaxation temperature is at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, and/or at most <NUM> greater than the peak isothermal crystallization temperature of the semicrystalline thermoplastic material. In such examples, the stress relaxation temperature may be selected based upon a desired crystallization rate for the semicrystalline thermoplastic material, with higher temperature differentials providing a relatively higher crystallization rate and lower temperatures providing a relatively lower crystallization rate.

In another specific example, the TMCMs include thermoplastic materials in the form of the amorphous thermoplastic material. In some such examples, the subsequent temperature is greater than the glass transition temperature of the amorphous thermoplastic material. Additionally or alternatively, and in such examples, the stress relaxation temperature is greater than the glass transition temperature of the amorphous thermoplastic material.

Illustrative, non-exclusive examples showing technical information useful for understanding the presently claimed invention, as defined by the appended claims, are described in the following paragraphs.

According to a first example, there is provided a method of continuous compression molding a consolidated thermoplastic matrix composite material, the method comprising: providing a thermoplastic matrix composite material (TMCM), which includes a thermoplastic material, to a continuous compression molding machine (CCMM); and during the providing: (i) heating the TMCM, within a heat zone of the CCMM, to an initial temperature that is above a melt temperature of the thermoplastic material; (ii) cooling and consolidating the TMCM, within a consolidation zone of the CCMM, to a subsequent temperature, optionally that is less than the initial temperature and within a rubbery temperature range of the thermoplastic material; (iii) relaxing stress within the TMCM, within a stress relaxation zone of the CCMM, at a stress relaxation temperature, optionally that is less than the initial temperature and within the rubbery temperature range of the thermoplastic material; (iv) demolding the TMCM from a mold of the CCMM, within a demold zone of the CCMM and at a demold temperature that is greater than a glass transition temperature of the thermoplastic material; and (v) periodically compressing the TMCM, with the mold of the CCMM, to form the TMCM to a desired shape for the consolidated thermoplastic matrix composite material.

Optionally, the thermoplastic material includes, or is, a semicrystalline thermoplastic material. Optionally, the subsequent temperature is below the melt temperature of the semicrystalline thermoplastic material and above the glass transition temperature of the semicrystalline thermoplastic material. Optionally, the stress relaxation temperature is below the melt temperature of the semicrystalline thermoplastic material and above the glass transition temperature of the semicrystalline thermoplastic material. Optionally, at least one of the stress relaxation temperature and the demold temperature is within a threshold temperature differential of a peak isothermal crystallization temperature of the semicrystalline thermoplastic material, wherein optionally the threshold temperature differential is <NUM> degree Celsius (°C), <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>. Optionally, the stress relaxation temperature is at least one of at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, or at most <NUM> greater than a/the peak isothermal crystallization temperature of the semicrystalline thermoplastic material.

Alternatively, the thermoplastic material optionally includes, or is, an amorphous thermoplastic material. Optionally, the initial temperature is greater than a glass transition temperature of the amorphous thermoplastic material. Optionally, the subsequent temperature is greater than a/the glass transition temperature of the amorphous thermoplastic material. Optionally, the stress relaxation temperature is greater than a/the glass transition temperature of the amorphous thermoplastic material.

Optionally, the initial temperature is at least one of: (i) at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, or at least <NUM>; and (ii) at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, or at most <NUM>.

Optionally, the subsequent temperature is at least one of: (i) at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, or at least <NUM>; and (ii) at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, or at most <NUM>.

Optionally, the stress relaxation temperature is a stress-free temperature for the thermoplastic material at which a relaxation time constant for the thermoplastic material is less than a process time for the TMCM within the CCMM, wherein optionally the relaxation time constant is less than <NUM>%, less than <NUM>%, less than <NUM>%, less than <NUM>%, less than <NUM>%, less than <NUM>%, less than <NUM>%, or less than <NUM>% of the process time for the TMCM within the CCMM.

Optionally, the stress relaxation temperature is at least one of: (i) at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, or at least <NUM>; and (ii) at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, or at most <NUM>.

Optionally, a difference between the initial temperature and the stress relaxation temperature is at least one of: (i) at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>; and (ii) at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, or at most <NUM>.

Optionally: (i) the heat zone has a heat zone temperature, which is at least the initial temperature and is selected to heat the TMCM to the initial temperature; (ii) the consolidation zone has a consolidation zone temperature, which is at most the subsequent temperature and is selected to cool the TMCM to the subsequent temperature; and (iii) the stress relaxation zone has a stress relaxation zone temperature, which is at most the consolidation zone temperature and is selected to maintain the TMCM at the stress relaxation temperature, optionally wherein the consolidation zone temperature is less than the stress relaxation zone temperature. Optionally, the consolidation zone temperature is at least a threshold consolidation zone temperature differential less than the stress relaxation zone temperature, optionally wherein the threshold consolidation zone temperature differential is at least one of: (i) at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, or at least <NUM>; and (ii) at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, or at most <NUM>.

Optionally, the providing includes periodically advancing a continuous length of the TMCM sequentially through the heat zone, the consolidation zone, the stress relaxation zone, and the demold zone, optionally wherein the mold includes a first mold die, which defines a first mold surface, and a second mold die, which defines a second mold surface that faces toward the first mold surface, and optionally wherein the method includes: (i) moving the first mold surface away from the second mold surface to permit the periodically advancing; and (ii) moving the first mold surface toward the second mold surface during the periodically compressing. Optionally, the mold defines an elongate mold channel that defines the desired shape for the consolidated thermoplastic matrix composite material, optionally wherein the first mold surface extends parallel, or at least substantially parallel, to a first mold surface plane along an entirety of a length of the elongate mold channel. Optionally, the second mold surface extends parallel, or at least substantially parallel, to a second mold surface plane along an/the entirety of a/the length of the elongate mold channel, optionally wherein a distance between the first mold surface and the second mold surface decreases along the length of the elongate mold channel and from the heat zone to the stress relaxation zone. Optionally, the periodically advancing includes periodically advancing a predetermined length of the TMCM into the heat zone, optionally wherein the predetermined length of the TMCM is at least one of: (i) at least <NUM> millimeters (mm), at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, or at least <NUM>; and (ii) at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, or at most <NUM>.

Optionally, the mold is free of shape compensation for the consolidated TMCM.

Optionally, the providing the TMCM includes providing the TMCM at a linear feed rate, optionally wherein the linear feed rate is at least one of: (i)at least <NUM> meters per hour (m/h), at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, at least <NUM>/h, or at least <NUM>/h; and (ii) at most <NUM>/h, at most <NUM>/h, at most <NUM>/h, at most <NUM>/h, at most <NUM>/h, at most <NUM>/h, at most <NUM>/h, at most <NUM>/h, or at most <NUM>/h.

Optionally, a/the continuous length of the TMCM extends through the heat zone, the consolidation zone, and the stress relaxation zone.

Optionally, the thermoplastic material includes at least one of: (i) an/the amorphous thermoplastic material; (ii) a/the semicrystalline thermoplastic material; (iii) a polyphenylene sulfide (PPS) thermoplastic material; (iv) a polyether ether ketone (PEEK) thermoplastic material; (v) a polyetherketoneketone (PEKK) thermoplastic material; and (vi) a polyaryletherketone (PAEK) thermoplastic material.

Optionally, the TMCM further includes a reinforcing fiber, optionally wherein the reinforcing fiber includes at least one of: (i) a carbon fiber; (ii) a fiberglass fiber; and (iii) an aramid fiber.

Optionally, the mold includes a plurality of mold die regions, and further wherein the heat zone, the consolidation zone, and the stress relaxation zone each are defined by at least one corresponding mold die region of the plurality of mold die sections. Optionally, the plurality of mold die region includes at least one of: (i) at least <NUM> mold die regions, at least <NUM> mold die regions, at least <NUM> mold die regions, or at least <NUM> mold die regions; and (ii) at most <NUM> mold die regions, at most <NUM> mold die regions, at most <NUM> mold die regions, at most <NUM> mold die regions, at most <NUM> mold die regions, or at most <NUM> mold die regions. Optionally, the at least one mold die region that defines the heat zone includes at least <NUM> mold die region that are maintained at a single fixed, or at least substantially fixed, heat zone temperature. Optionally, the at least one mold die region that defines the consolidation zone includes at least <NUM> mold die region that are maintained at different consolidation zone temperatures. Optionally, the at least one mold die region that defines the stress relaxation zone includes at least <NUM> mold die region that are maintained at a single fixed, or at least substantially fixed, stress relaxation zone temperature. Optionally, each mold die region of the plurality of mold die region defines a corresponding region length, optionally wherein the corresponding region length is at least one of: (i) at least <NUM> meters (m), at least <NUM>, at least <NUM>, at least <NUM>, or at least <NUM>; and (ii) at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, or at most <NUM>.

Optionally, at least one of: (i) the heat zone is an electrically heated heat zone; (ii) the consolidation zone is an electrically heated consolidation zone; and (iii) the stress relaxation zone is an electrically heated stress relaxation zone.

Optionally, at least one of: (i) the consolidation zone is free from water cooling; and (ii) the stress relaxation zone is free from water cooling.

Optionally, subsequent to the demolding, the method further includes quenching the TMCM to a quench temperature that is less than the stress relaxation temperature, optionally wherein the quench temperature is a threshold quench temperature differential less than the stress relaxation temperature, and further optionally wherein the threshold quench temperature differential is at least one of: (i) at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, or at least <NUM>; and (ii) at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM> , at most <NUM> , at most <NUM> , at most <NUM> , at most <NUM> , at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, or at most <NUM>.

Optionally, subsequent to the demolding, the method further includes supporting the TMCM with a support structure. Optionally, the supporting includes supporting a lower surface, or only a lower surface, of the TMCM. Optionally, the supporting includes maintaining contact between the TMCM and the support structure via, or only via, a gravitational force acting on the TMCM. Optionally, the support structure is a stationary support structure. Optionally, the TMCM is free from compression by the support structure during, or during an entirety of, the supporting.

According to a second example, there is provided a continuous compression molding machine (CCMM), comprising: a mold configured to shape a thermoplastic matrix composite material (TMCM), which includes a thermoplastic material, to a desired shape for a consolidated thermoplastic matrix composite material; a heat zone heating structure configured to heat a heat zone of the mold to a heat zone temperature selected to heat the TMCM to an initial temperature that is above a melt temperature for the thermoplastic material; a consolidation zone heating structure configured to heat a consolidation zone of the mold to a consolidation zone temperature selected to cool the TMCM to a subsequent temperature, optionally that is less than the initial temperature and within a rubbery temperature range for the thermoplastic material; a stress relaxation zone heating structure configured to maintain a stress relaxation zone of the mold at a stress relaxation zone temperature selected to maintain the TMCM at a stress relaxation temperature, optionally that is less than the initial temperature and within the rubbery temperature range for the thermoplastic material; a press structure configured to periodically compress the TMCM within the mold, and optionally also within the heat zone, the consolidation zone, and the stress relaxation zone, to form the TMCM to the desired shape; a demold structure configured to demold the TMCM from the mold while the TMCM is at a demold temperature that is greater than a glass transition temperature of the thermoplastic material; and a supply structure configured to periodically advance the TMCM through the mold, optionally such that the TMCM extends sequentially through the heat zone, the consolidation zone, and the stress relaxation zone and to the demold structure.

Optionally, the CCMM further includes a quench structure configured to receive the TMCM from the demold structure and to quench the TMCM to a quench temperature that is less than the stress relaxation temperature.

Optionally, the CCMM further includes a support structure configured to receive the TMCM from the demold structure and to support the TMCM.

Optionally, the consolidation zone of the mold defines a consolidation zone thickness, wherein the stress relaxation zone of the mold defines a stress relaxation zone thickness, and further wherein the stress relaxation zone thickness is less than the consolidation zone thickness.

Optionally, the CCMM further includes a controller programmed to control operation of the CCMM according to the method of the first example (the method optionally including any of its optional features).

Optionally, the CCMM further includes any suitable structure described in the method of the first example (the method optionally including any of its optional features).

Optionally, the CCMM further is configured to perform any suitable function described in any of the methods of the first example (the method optionally including any of its optional features).

As used herein, the terms "selective" and "selectively," when modifying an action, movement, configuration, or other activity of one or more components or characteristics of an apparatus, mean that the specific action, movement, configuration, or other activity is a direct or indirect result of user manipulation of an aspect of, or one or more components of, the apparatus.

As used herein, the phrase "at least one," in reference to a list of one or more entities should be understood to mean at least one entity selected from any one or more of the entity in the list of entities, but not necessarily including at least one of each and every entity specifically listed within the list of entities and not excluding any combinations of entities in the list of entities. This definition also allows that entities may optionally be present other than the entities specifically identified within the list of entities to which the phrase "at least one" refers, whether related or unrelated to those entities specifically identified. Thus, as a non-limiting example, "at least one of A and B" (or, equivalently, "at least one of A or B," or, equivalently "at least one of A and/or B") may refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including entities other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including entities other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other entities). In other words, the phrases "at least one," "one or more," and "and/or" are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions "at least one of A, B, and C," "at least one of A, B, or C," "one or more of A, B, and C," "one or more of A, B, or C" and "A, B, and/or C" may mean A alone, B alone, C alone, A and B together, A and C together, B and C together, A, B, and C together, and optionally any of the above in combination with at least one other entity.

The various disclosed elements of apparatuses and steps of methods disclosed herein are not required to all apparatuses and methods according to the present disclosure, and the present disclosure includes all novel and non-obvious combinations and subcombinations of the various elements and steps disclosed herein. Moreover, one or more of the various elements and steps disclosed herein may define independent inventive subject matter that is separate and apart from the whole of a disclosed apparatus or method. Accordingly, such inventive subject matter is not required to be associated with the specific apparatuses and methods that are expressly disclosed herein, and such inventive subject matter may find utility in apparatuses and/or methods that are not expressly disclosed herein.

As used herein, the phrase, "for example," the phrase, "as an example," and/or simply the term "example," when used with reference to one or more components, features, details, structures, embodiments, and/or methods according to the present disclosure, are intended to convey that the described component, feature, detail, structure, embodiment, and/or method is an illustrative, non-exclusive example of components, features, details, structures, embodiments, and/or methods according to the present disclosure. Thus, the described component, feature, detail, structure, embodiment, and/or method is not intended to be limiting, required, or exclusive/exhaustive; and other components, features, details, structures, embodiments, and/or methods, including structurally and/or functionally similar and/or equivalent components, features, details, structures, embodiments, and/or methods, are also within the scope of the present disclosure.

Claim 1:
A method (<NUM>) of continuous compression molding a consolidated thermoplastic matrix composite material (<NUM>), the method (<NUM>) comprising:
providing (<NUM>) a thermoplastic matrix composite material 'TMCM' (<NUM>), which includes a thermoplastic material (<NUM>), to a continuous compression molding machine 'CCMM' (<NUM>); and
during the providing (<NUM>):
(i) heating (<NUM>) the TMCM (<NUM>), within a heat zone (<NUM>) of the CCMM (<NUM>), to an initial temperature that is above a melt temperature of the thermoplastic material (<NUM>);
(ii) cooling and consolidating (<NUM>) the TMCM (<NUM>), within a consolidation zone (<NUM>) of the CCMM (<NUM>), to a subsequent temperature;
(iii) relaxing stress (<NUM>) within the TMCM (<NUM>), within a stress relaxation zone (<NUM>) of the CCMM (<NUM>), at a stress relaxation temperature;
(iv) demolding (<NUM>) the TMCM (<NUM>) from a mold (<NUM>) of the CCMM (<NUM>) within a demold zone (<NUM>) of the CCMM (<NUM>) and at a demold temperature that is greater than a glass transition temperature of the thermoplastic material (<NUM>); and
(v) periodically compressing (<NUM>) the TMCM (<NUM>), with the mold (<NUM>) of the CCMM (<NUM>), to form the TMCM (<NUM>) to a desired shape for the consolidated thermoplastic matrix composite material (<NUM>).