Process for the manufacture of polymer and composite products

• US 6,495,091 B1
• Filed: 11/18/1997
• Issued: 12/17/2002
• Est. Priority Date: 05/18/1995
• Status: Expired due to Term

• Current Assignee: Ecole polytechnique fãdãrale de lausanne epfl (Schweizerische Eidgenossenschaft)
• Original Assignee: Ecole polytechnique fãdãrale de lausanne epfl (Schweizerische Eidgenossenschaft)
• Inventors: Bourban, Pierre-Etienne, Manson, Jan-Anders, Bonjour, François
• Primary Examiner(s): Staicovici, Stefan
• Application Number:
  US08/973,075
• Time in Patent Office: 1,855 Days
• Field of Search: 264/257, 264/572, 264/258, 264/266-267, 264/136, 264/137, 264/271.1, 264/328.13, 264/250, 264/254, 264/255, 264/234, 264/297.2, 264/279.1, 264/297.3, 264/297.6, 264/297.7, 264/322-325, 106/245
• US Class Current: 264/572
• CPC Class Codes: B29B 15/125 by dipping
• CPC Class Codes: B29C 2791/001 Shaping in several steps
• CPC Class Codes: B29C 70/38 Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns application heads for tyres B29D30/28
• CPC Class Codes: B29C 70/465 and impregnating by melting a solid material, e.g. sheets, powders of fibres
• CPC Class Codes: B29C 70/54 Component parts, details or accessories; Auxiliary operations , e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
• CPC Class Codes: B29C 70/545 Perforating, cutting or machining during or after moulding

Abstract

The invention is concerned with an integrated process for the manufacture of polymer and/or composite products, comprising the integration of processing operations to achieve a plurality of material conversion steps, such as impregnation, consolidation and bonding, within one single controlled fabrication cycle. The process includes an in-situ final preparation of at least one composite preform at the location of the moulding operation and an integrated moulding operation comprising a step of providing an additional matrix-functioning material into the mould to at least partially enclose the composite preform, the operation of providing the additional matrix-functioning material providing the pressure for an in-situ final consolidation of the composite product.

Claims

1. Process for an integrated manufacture of a composite product comprising an in-situ final forming of at least one composite preform at a location of the moulding operation in an integrated moulding operation, wherein said composite preform comprises a reinforcing material and a first matrix material, said process comprising a first step of impregnating said reinforcing material by said first matrix material, a second step of pre-consolidating said reinforcing material impregnated by said first matrix material, said process comprising a third step of in-situ final placement of said reinforcing material impregnated by said first matrix material into said location, thereby forming said pre-consolidated composite preform, wherein said in-situ placement is performed through heated means that maintain said reinforcing material impregnated by said first matrix material at an elevated temperature, and wherein said integrated moulding operation comprises a step of material integration by further providing a second thermoplastic matrix material in a melted state at said location to at least partially enclose and bond to said pre-consolidated composite preform, said second melted matrix material being used as a pressure media providing heat and a consolidation pressure within said location for both an in-situ final consolidation of said composite preform and for moulding and final consolidation of the composite product and wherein said first step, said second step, said in-situ placement and said moulding operation are performed within one uninterrupted fabrication cycle.

2. Process according to claim 1, wherein said integrated moulding operation comprises at least one step selected from the group consisting of a polymer injection step, a gas injection step, a liquid injection step, an interlayer extrusion step, and combinations thereof.

3. Process according to claim 1, where in said uninterrupted cycle comprises forming said at least one preform through orientation of fibres, impregnation and preconsolidation of a fibre-based preform, and in-situ placement of said preform in a predetermined oriented direction within said location of said integrated moulding operation.

4. Process according to claim 3, wherein said uninterrupted cycle comprises the steps of impregnating and preconsolidating a fibre-based composite to form an impregnated tow preform and placing said impregnated tow preform in a predetermined orientation into said location through a guided temperature and position-controlled nozzle.

5. Process according to claim 1, wherein said integrated moulding operation comprises an inner-gas injection step for manufacturing hollow structured composite parts, and wherein said injected inner-gas is used for consolidation and for release of process induced stresses developed from the integration of different material forms.

6. Process according to claim 2, wherein said integrated moulding operation comprises an inner-gas injection step for manufacturing hollow structured composite parts, and wherein said injected inner-gas is used for consolidation and for release of process induced stresses developed from the integration of different material forms.

7. Process according to claim 1, comprising introduction of an extruded slit-die film into a consolidation mould in order to provide at least one of the following capabilities:

compatibility of different integrated materials, gradient interface between integrated materials and material forms, release of interfacial stresses, surface coating onto the final part and through-thickness resin impregnation.

8. Process according to claim 2, comprising introduction of an extruded slit-die film into a consolidation mould in order to provide at least one of the following capabilities:

compatibility of different integrated materials, gradient interface between integrated materials and material forms, release of interfacial stresses, surface coating onto the final part and through-thickness resin impregnation.

9. Process according to claim 1, comprising the steps of impregnating and preconsolidating a fibre-based composite to form an impregnated tow preform and placing said impregnated tow preform in a predetermined orientation into said location through a guided temperature and position-controlled nozzle.

10. Process according to claim 1, wherein said uninterrupted cycle comprises the steps of impregnating and preconsolidating a fibre-based composition to form an impregnated sheet preform.

11. Process according to claim 3, wherein said uninterrupted cycle comprises the steps of impregnating and preconsolidating a fibre-based composite to form an impregnated sheet preform.