Method for forming fiber-reinforced composite member

• US 6,391,246 B2
• Filed: 11/13/1997
• Issued: 05/21/2002
• Est. Priority Date: 11/15/1996
• Status: Expired due to Fees

• Current Assignee: Honda Patents and Technologies North America, LLC (Honda Motor Company)
• Original Assignee: Honda Giken Kogyo Kabushiki Kaisha (Honda Motor Company)
• Inventors: Shiraishi, Koji, Nasu, Makoto
• Primary Examiner(s): Silbaugh, Ian H.
• Assistant Examiner(s): Staicovici, Stefan
• Application Number:
  US08/968,616
• Publication Number:
  US 20010040317A1
• Time in Patent Office: 1,650 Days
• Field of Search: 264/510, 264/511, 264/257, 264/313, 264/258, 264/102, 156/60, 156/70, 156/247, 156/289
• US Class Current: 264/510
• CPC Class Codes: B29C 43/12 using bags surrounding the moulding material or using membranes contacting the moulding material
• CPC Class Codes: B29C 43/18 incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles B29C43/206 takes precedence
• CPC Class Codes: B29C 70/342 using isostatic pressure
• CPC Class Codes: B29C 70/46 using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
• CPC Class Codes: B29D 99/0014 provided with ridges or ribs, e.g. joined ribs
• CPC Class Codes: B29K 2105/0809 Fabrics

Abstract

A novel fiber-reinforced composite member having at least one projection is formed by (a) disposing a preform made of a fiber-reinforced composite material on a forming plate; (b) placing a shape-retention means composed of a plurality of soft unit members adjacent to each projection of the preform; (c) completely covering the preform and the shape-retention means with a bagging film having a sealant attached to the periphery; (d) adhering the sealant to the forming plate such that the preform and the shape-retention means are completely sealed by the bagging film; (e) evacuating the inside of the bagging film; and (f) heating the preform under pressure to form a fiber-reinforced composite member.

Claims

1. A method for forming a fiber-reinforced composite member, comprising the steps of

(a) placing a shape-retention means adjacent to at least one projection of a preform made of a fiber-reinforced composite material;

(b) completely sealing said preform and said shape-retention means with a bagging film; and

(c) forming said preform into a fiber-reinforced composite member by heating under pressure;

said shape-retention means comprising a plurality of soft unit members having simple cross-sectional shapes selected from the group consisting of a triangular prism, a rectangular parallelepiped, and a flat plate, wherein said unit members are reuseable;

wherein said plurality of soft unit members substantially covers the surface of said pre-form to provide a gradually changing contour to prevent said at least one projection from being subjected to deforming during pressing.

2. The method for forming a fiber-reinforced composite member according to claim 1, wherein said preform and said shape-retention means sealed in said bagging film are subjected to said step of heating while evacuating an inside of said sealed bagging film.

4. The method for forming a fiber-reinforced composite member according to claim 1, wherein said soft unit members have simple cross-sectional shapes such as a triangle or a rectangle.

6. The method for forming a fiber-reinforced composite member according to claim 1, wherein the fiber-reinforced composite material is formed by laminating a plurality of prepregs comprising reinforcing fibers impregnated with thermosetting or thermoplastic resins.

7. The method for forming a fiber-reinforced composite member according to claim 6, wherein the reinforcing fibers are selected from the group consisting of carbon fibers, glass fibers, and aramide fibers.

8. The method for forming a fiber-reinforced composite member according to claim 6, wherein the thermosetting resins comprise epoxy resins.

9. The method for forming a fiber-reinforced composite member according to claim 6, wherein the thermoplastic resins comprise nylons.

10. The method for forming a fiber-reinforced composite member according to claim 1, wherein the bagging film comprises nylon or polyimide.

11. The method for forming a fiber-reinforced composite member according to claim 1, wherein the bagging film has a thickness of about 50-75 μ

m.

12. The method for forming a fiber-reinforced composite member according to claim 6, wherein the heating is performed at about 180-250°

C.

13. The method for forming a fiber-reinforced composite member according to claim 6, wherein the bagging film has a heat resistance of 180°

C. or higher when the prepregs contain a thermosetting resin and 250°

C. or higher when the prepregs contain a thermoplastic resin.

3. A method for forming a fiber-reinforced composite member having at least one projection, comprising the steps of

(a) disposing a preform having projections and made of a fiber-reinforced composite material on a forming plate;

(b) placing a shape-retention means adjacent to each projection of said preform;

(c) completely covering said preform and said shape-retention means with a bagging film having a sealant attached to a periphery thereof;

(d) adhering said sealant to said forming plate such that said preform and said shape-retention means are completely sealed by said bagging film;

(e) evacuating an inside of said bagging film; and

(f) heating said preform under pressure to form said fiber-reinforced composite member;

wherein said shape-retention means comprises a plurality of soft unit members having simple cross-sectional shapes selected from the group consisting of a triangular prism, a rectangular parallelepiped, and a flat plate, wherein said unit members are reuseable;

wherein said plurality of soft unit members substantially covers the surface of said pre-form to provide a gradually changing contour to prevent said at least one projection from being subjected to deforming during pressing.

5. The method for forming a fiber-reinforced composite member according to claim 3, wherein said soft unit members have simple cross-sectional shapes such as a triangle or a rectangle.

14. The method for forming a fiber-reinforced composite member according to claim 3, wherein the fiber-reinforced composite material is formed by laminating a plurality of prepregs comprising reinforcing fibers impregnated with thermosetting or thermoplastic resins.

15. The method for forming a fiber-reinforced composite member according to claim 14, wherein the reinforcing fibers are selected from the group consisting of carbon fibers, glass fibers, and aramide fibers.

16. The method for forming a fiber-reinforced composite member according to claim 14, wherein the thermosetting resins comprise epoxy resins.

17. The method for forming a fiber-reinforced composite member according to claim 14, wherein the thermoplastic resins comprise nylons.

18. The method for forming a fiber-reinforced composite member according to claim 3, wherein the bagging film comprises nylon or polyimide.

19. The method for forming a fiber-reinforced composite member according to claim 3, wherein the bagging film has a thickness of about 50-75 μ

m.

20. The method for forming a fiber-reinforced composite member according to claim 14, wherein the heating is performed at about 180-250°

C.

21. The method for forming a fiber-reinforced composite member according to claim 14, wherein the bagging film has a heat resistance of 180°

C. or higher when the prepregs contain a thermosetting resin and 250°

C. or higher when the prepregs contain a thermoplastic resin.

22. A method for forming a fiber-reinforced composite member, comprising the steps of

(a) placing a shape-retention means comprising a plurality of soft, reuseable unit members having simple cross-sectional shapes adjacent to at least one projection of a preform made of a fiber-reinforced composite material;

(b) completely sealing said preform and said shape-retention means with a bagging film; and

(c) forming said preform into a fiber reinforced composite member by heating under pressure;

wherein said plurality of soft unit members substantially covers the surface of said pre-form to provide a gradually changing contour to prevent said at least one projection from being subjected to deforming during pressing.