Manufacture of FRP composites

• US 20060216490A1
• Filed: 01/31/2006
• Published: 09/28/2006
• Est. Priority Date: 02/01/2005
• Status: Abandoned Application

• Current Assignee: Honda Motor Co., Ltd. (Honda Motor Company)
• Original Assignee: Honda Motor Co., Ltd. (Honda Motor Company)
• Inventors: Ishii, Masashi, Mitschang, Peter, Weyrauch, Florian
• Application Number:
  US11/345,088
• Publication Number:
  US 20060216490A1
• Time in Patent Office: Days
• US Class Current: 428/292.100
• CPC Class Codes: B29C 70/16 using fibres of substantial or continuous length non-woven fabrics per se D04H3/00
• CPC Class Codes: B29C 70/48 and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM] , e.g. by vacuum
• CPC Class Codes: B29C 70/543 Fixing the position or configuration of fibrous reinforcements before or during moulding for non-woven fabrics D04H3/08
• CPC Class Codes: B29C 70/546 Measures for feeding or distributing the matrix material in the reinforcing structure
• CPC Class Codes: Y10T 428/249924 Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity

Abstract

Techniques are provided for producing low-cost FRP composites which contain heavy tow fibres. Techniques are provided for uniform impregnation and efficient bonding of these heavy tow fibres which eliminates “racetracking,” thus resulting in cost-effective and well performing FRP composites.

Claims

1. A method of manufacturing fibre reinforced plastics (FRP) composites, comprising:

impregnation of heavy tow fibres with a low viscosity resin.

2. The method of claim 1, wherein the fibres comprise one of:

carbon fibres; and

glass fibres.

3. The method of claim 2, wherein the carbon fibres are combined with at least one other type of fibres.

4. The method of claim 3, wherein the at least one other type of fibres comprise glass fibres.

5. The method of claim 1, wherein a tow of the fibres is equal to or greater than 24000 filaments.

6. The method of claim 1, wherein the fibres are woven into fabric sheets with interlacing points.

7. The method of claim 6, wherein the fabric sheets are multi-compacted.

8. The method of claim 6, wherein a volume content of the fibres in the fabric sheets is less than 60%.

9. The method of claim 6, wherein a volume content of the fibres in the fabric sheets is less than 30%.

10. The method of claim 1, wherein the resin, at a time of impregnation, has a viscosity less than 50 mPa*s.

11. The method of claim 10, wherein the resin is a thermoplastic resin.

12. The method of claim 1, wherein the impregnation is carried out by injection of the resin into a fabric sheet comprising the fibres.

13. The method of claim 12, wherein an injection point of the resin is directly in the fabric area.

14. The method of claim 12, wherein the resin is injected with stepwise increments of pressure such that a pressure at a flow front of the resin is balanced before a pressure increment.

15. The method of claim 12, wherein a flow front of the injected resin is against gravity.

16. The method of claim 12, wherein a flow direction of the injected resin is not perpendicular to an orientation of the fibres.

17. The method of claim 12, wherein the fabric is clamped at edges of a mould before the resin injection.

18. The method of claim 17, wherein the edges of the mould have a reduced cavity high.

19. The method of claim 18, wherein a fibre volume fraction at the reduced cavity high is no more than 55%.

20. The method of claim 18, wherein a fibre volume fraction at the reduced cavity high is no more than 50%.

21. A FRP composite product obtained by performing the method of claim 1.

22. The FRP composite product of claim 21, wherein a volume content of the fibres in the composite is less than 60%.

23. The FRP composite product of claim 21, wherein a volume content of the fibres in the composite is less than 30%.

24. An apparatus for the manufacture of FRP by performing the method of claim 1.

25. A method of manufacturing fibre reinforced plastics (FRP) composites, comprising:

impregnation of fibres with resin from an injection side towards a downstream side, wherein a pressure on the injection side is incremented stepwise.

26. The method of claim 25, wherein a time interval in between a first pressure increment and a second pressure increment is such that a pressure at a flow front is balanced across the downstream side before the second pressure increment.

27. The method of claim 25, wherein the fibres comprise one of:

carbon fibres; and

glass fibres.

28. An apparatus for manufacturing FRP composites, comprising:

a reduced cavity high at edges of a mould wherein fibres or fibre fabric is placed;

a clamping mechanism to prevent displacement of the fibres or the fibre fabric; and

a pressure ramp injection system, wherein a resin is injected into the mould under stepwise increments of pressure.

29. The apparatus of claim 28, wherein the resin is injected directly into the fibres or the fibre fabric under the stepwise increments of pressure.