LIQUID MATRIX SHEAR PRESSURE IMPREGNATOR APPLICATIONS

• US 20190322060A1
• Filed: 04/23/2019
• Published: 10/24/2019
• Est. Priority Date: 04/23/2018
• Status: Active Grant

• Current Assignee: Jerry R. Fram
• Original Assignee: Jerry R. Fram
• Inventors: FRAM, JERRY R.
• Granted Patent: US 11,400,663 B2
• Time in Patent Office: Days
• CPC Class Codes: B29B 15/125 by dipping
• CPC Class Codes: B29C 48/0022 combined with cutting
• CPC Class Codes: B29C 48/08 flexible, e.g. films
• CPC Class Codes: B29C 48/16 Articles comprising two or more components, e.g. co-extruded layers
• CPC Class Codes: B29C 48/2886 of fibrous, filamentary or filling materials, e.g. thin fibrous reinforcements or fillers
• CPC Class Codes: B29C 70/28 Shaping operations therefor
• 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 70/504 using rollers or pressure bands for corrugating B29C53/22
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12

Abstract

Systems and methods are described where a volume receiving a liquid matrix and fibers at an inlet where opposing sides of the volume converge to form a gap and a moving surface in contact with the liquid matrix and the fibers and moving with respect to the liquid matrix and the fibers through the gap such that shear force is transferred to the liquid matrix and the fibers pushing the liquid matrix and the fibers forward through the gap, creating currents in the liquid matrix and increasing pressure. The increased pressure within the volume forms a barrier to entrained gases within the liquid matrix such that the entrained gases are inhibited from passing through the gap along with the liquid matrix and the fibers.

Claims

1. A composite processing apparatus, comprising:

a volume receiving a liquid matrix and fibers at an inlet where opposing sides of the volume converge to form a gap for the liquid matrix and the fibers to pass and at least one cylindrical surface forms one of the opposing sides of the volume and the gap; and

a moving surface in contact with the liquid matrix and the fibers and moving with respect to the liquid matrix and the fibers through the gap such that shear force is transferred to the liquid matrix and the fibers pushing the liquid matrix and the fibers forward through the gap, creating currents in the liquid matrix and increasing pressure in the liquid matrix within the volume in a forward direction toward the gap;

wherein the increased pressure within the volume forms a barrier to entrained gases within the liquid matrix such that the entrained gases are inhibited from passing through the gap along with the liquid matrix and the fibers.

2. The apparatus of claim 1, wherein the liquid matrix comprises a viscous liquid matrix, where the viscous liquid matrix is at least an order of magnitude more viscous than water.

3. The apparatus of claim 1, wherein the volume is formed between the at least one cylindrical surface and a second cylindrical surface.

4. The apparatus of claim 3, wherein the second cylindrical surface is on a stationary roller and the moving surface comprises a film moving along the at least one cylindrical surface through the gap.

5. The apparatus of claim 4, wherein the fibers comprise a mat entering the inlet with the liquid matrix and passing through the gap with the liquid matrix and the film.

6. The apparatus of claim 1, wherein the moving surface is a surface of a driven roller.

7. The apparatus of claim 6, wherein the surface of the driven roller is also the at least one cylindrical surface.

8. The apparatus of claim 7, wherein the driven roller is one of a pair of rollers disposed parallel to one another forming the gap therebetween.

9. The apparatus of claim 8, wherein a second volume for the liquid matrix after the gap is enclosed by the pair of rollers, a scraper, side dams and a carrier roller and an outlet for the liquid matrix from the second volume is formed between one of the pair of rollers and the carrier roller.

10. The apparatus of claim 9, wherein a film enters the gap on one of the pair of rollers and passes through the outlet around the carrier roller.

11. The apparatus of claim 9, wherein the pair of rollers are both driven.

12. The apparatus of claim 10, wherein a second film enters the second volume through a film gap between the carrier roll and the scraper and sandwiches the liquid matrix and fibers with the film at the outlet.

13. The apparatus of claim 1, further comprising dams on each side of the volume keeping the liquid matrix moving from the inlet through the gap without escaping from each side.

14. The apparatus of claim 13, wherein each of the dams on each side of the volume bound an end of a roller and a cylindrical surface of a second roller.

15. The apparatus of claim 13, wherein each of the dams has a film gap between itself and the cylindrical surface of a second roller to allow film to pass by each dam but stop the liquid matrix.

16. The apparatus of claim 1, wherein the fibers comprise chopped fibers.

17. The apparatus of claim 1, wherein the fibers comprise a continuous web selected from the group consisting of a chopped strand mat, a woven roving, and continuous parallel fibers.

18. The apparatus of claim 1, wherein the apparatus is disposed in a tank filled with the liquid matrix.

19. The apparatus of claim 18, wherein the moving surface comprises a surface of a driven roller and the at least one cylindrical surface is the surface of the driven roller immersed in the liquid matrix in the tank and disposed adjacent a second surface forming the gap therebetween and dams on each side of driven roller and the second surface bound the liquid matrix between the rollers into the gap and the fibers are continuous passed through the gap with the liquid matrix.

20. The apparatus of claim 19, wherein the second surface comprises a second driven roller.

21. The apparatus of claim 18, wherein the fibers are continuous and are pulled external to the tank to contact and thereby drive a pair of idler rollers such that the moving surface comprises at least one surface of the pair of idler rollers and the at least one cylindrical surface is the at least one surface of the pair of idler rollers, the pair of idler rollers being immersed in the liquid matrix in the tank and disposed parallel to one another forming the gap therebetween and having dams on each side of the pair of idler rollers to bound the liquid matrix between the idler rollers into the gap, and the gap is changed by adjusting a position of at least one of the pair of idler rollers relative to the other.