Brightened composite sheel and method for making the same

• US 20070222122A1
• Filed: 03/23/2006
• Published: 09/27/2007
• Est. Priority Date: 03/23/2006
• Status: Abandoned Application

• Current Assignee: Cotech, Inc. (Swancor Holding Co., Ltd.)
• Original Assignee: Cotech, Inc. (Swancor Holding Co., Ltd.)
• Inventors: Ong, Ching-Long, Hwang, Diing-Guey, Young, Jun-Hao, Yen, Chia-Tung
• Application Number:
  US11/386,728
• Publication Number:
  US 20070222122A1
• Time in Patent Office: Days
• US Class Current: 264/510
• CPC Class Codes: B29C 70/30 Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
• CPC Class Codes: B29C 70/345 using matched moulds
• CPC Class Codes: B29C 70/545 Perforating, cutting or machining during or after moulding
• CPC Class Codes: B29L 2031/722 Decorative or ornamental articles

Abstract

A method for fabricating a brightened composite shell includes step of (a): providing an uncured composite material on a surface of a metallic mold; step (b): curing the composite material by vacuum molding to form a consolidated composite embryo via the vacuum molding process; and step (c): machining the cured composite embryo so as to fabricate the final brightened shell shape. The present invention employs non-painting method and provides a brightened composite shell having a smooth and stereo surface without blisters and pin-holes being generated thereon.

Claims

1. A method for fabricating a shell, comprising:

step (a);

providing an uncured composite material on a surface of a metallic mold, the composite material comprising lamination of prepreg of matrix resin and fibers, a weight ratio of the matrix reins in the composite material being 30% to 60%;

step (b);

curing the composite material by vacuum molding to form a semi-product; and

step (c);

machining the cured composite semi-product by removing surplus material to become a final product.

2. The method as claimed in claim 1, wherein the composite material is chosen from one of a carbon-fiber composite material, a KEVLER fiber composite material, a glass-fiber composite material, a dyed-fiber composite material and a hybrid-fiber composite material.

3. The method as claimed in claim 1, wherein the composite material includes a matrix resin and fibers, the composite material is used by way of pre-preg and wet lay-up.

4. The method as claimed in claim 3, wherein the matrix resin is chosen from one of a thermosetting resin and a thermoplastic resin.

5. The method as claimed in claim 3, wherein the pre-preg is woven by one of a unidirectional weave, a plain weave, a satin weave, a twill weave and a multi-axial weave.

6. The method as claimed in claim 1, wherein the surface of the metallic surface is treated by a surface treatment.

7. The method as claimed in claim 6, wherein the surface treatment is a surface polish process to form a polished mold.

8. The method as claimed in claim 7, wherein the surface polish is one of the following methods which are mechanical polishing, chemical polishing, chemical-mechanical polishing (CMP).

9. The method as claimed in claim 6, wherein the surface treatment is a surface hardening process.

10. The method as claimed in claim 9, wherein the surface hardening process is one of the following treatments which are a surface chrome coating process, a surface titanium coating process, a surface carburizing process and a surface nitrogenizing process.

11. The method as claimed in claim 1, wherein the vacuum molding is done by a vacuum appliance.

12. The method as claimed in claim 11, wherein the vacuum appliance is one of the following devices which are an autoclave, an oven and a pump.

13. The method as claimed in claim 1, wherein the vacuum molding is to seal the composite material which is heated in a temperature between 0 to 1600 degrees Celsius under pressure.

14. The method as claimed in claim 1, wherein the vacuum molding is to seal the composite material which is applied with a pressure between 0 to 100 atmospheric pressure.

15. The method as claimed in claim 1, wherein the vacuum molding is to seal the composite material by a seal member.

16. A shell with brightened surface is made by an uncured composite material which includes a matrix resin and at least one fiber.