GB2124130A - Vacuum moulding fibre reinforced resin - Google Patents

Vacuum moulding fibre reinforced resin Download PDF

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Publication number
GB2124130A
GB2124130A GB08221467A GB8221467A GB2124130A GB 2124130 A GB2124130 A GB 2124130A GB 08221467 A GB08221467 A GB 08221467A GB 8221467 A GB8221467 A GB 8221467A GB 2124130 A GB2124130 A GB 2124130A
Authority
GB
United Kingdom
Prior art keywords
prepregs
resin
article
laid
vacuum moulding
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB08221467A
Other versions
GB2124130B (en
Inventor
Frank Charles Johnson
Susan Margaret Newsam
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rolls Royce PLC
Original Assignee
Rolls Royce PLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Rolls Royce PLC filed Critical Rolls Royce PLC
Priority to GB08221467A priority Critical patent/GB2124130B/en
Priority to US06/506,422 priority patent/US4562033A/en
Priority to FR8310845A priority patent/FR2530538B1/en
Priority to JP58125987A priority patent/JPS6038247B2/en
Priority to DE3325327A priority patent/DE3325327C2/en
Publication of GB2124130A publication Critical patent/GB2124130A/en
Application granted granted Critical
Publication of GB2124130B publication Critical patent/GB2124130B/en
Expired legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/006—Degassing moulding material or draining off gas during moulding
    • B29C37/0064—Degassing moulding material or draining off gas during moulding of reinforced material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—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
    • B29C70/34—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 and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/342—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 and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/10—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies
    • B29C43/12—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies using bags surrounding the moulding material or using membranes contacting the moulding material

Description

1 GB 2 124 130 A 1
SPECIFICATION
A method of manufacturing articles from a composite material This invention relates to a method of manufacturing articles from composite materials and in particular composite materials which comprise reinforcing filaments enclosed in a resin matrix.
A common method of manufacturing articles from composite materials is to lay up a number of sheets of uncured resin impregnated filaments called pre pregs on a suitable former and then subject them to heat and pressure in order to coalesce the sheets, mould them to the configuration of the mold and subsequently gel the resin. The resin is then finally cured by further heat treatment in order to fix the resultant configuration of the moulded article.
One way in which this method can be carried out is to utilise an autoclave. An autoclave is capable of subjecting the laid up prepregs to elevated tempera tures and pressures so that they readily coalesce to form the moulded article. It has the attraction of being capable of supplying sufficient pressure to the resin mass that hydraulic pressure within the mass causes a significant reduction in the size of enclosed gas orvapour bubbles or completely forces them into solution depending upon the level of pressure applied (in accordance with Henry's Law). If the pressure is maintained during the gellation of the resin and its subsequent cure, a void-free resin matrix is achieved.
Whilst autoclave moulding is attractive in view of its potential for providing a void-free composite material article, it is nevertheless expensive to carry 100 out in view of the high capital cost of the equipment involved.
A cheaper alternative to autoclave moulding is vacuum bag moulding in which the laid-up prepregs are placed on a former and then enclosed by an impervious membrane. The volume enclosed by the membrane is evacuated and the assembly heated up on a rising temperature schedule. Atmospheric pressure provides the necessary force to coalesce the prepregs to form the moulded article and the rising temperature schedule ensures initially that the uncured resin is sufficiently mobile to permit max imum consolidation to take place and subsequently results in the gelling and curing of the resin.
Whilst vacuum moulding is a lot cheaperto carry out than is autoclave moulding, the resultant moulded article is usually of inferior quality because of the occurance of voids in the resin matrix. Typicallythe minimum voidage level of a vacuum moulded fibre reinforced composite material is in the order of from 4to 6% by volume.
It is an object of the present invention to provide a method of manufacturing articles from fibre reinforced composite materials in which the level of voidage in the result articles is lower than is achieved by conventional vacuum moulding techniques or is completely eliminated.
According to the present invention, a method of vacuum moulding an article from a filament rein- forced composite material comprises the steps of laying up, on a suitable former, a plurality of prepregs each comprising reinforcing filaments and an uncured resin, overlaying at least a major portion of the exposed surface of said laid-up prepregs with at least one sheet of a microporous film material which is permeable to gases and vapours; but impermeable to liquid resin, overlaying at least a major portion of said sheet of microporous film material with a breather material, enclosing said laid-up prepregs, said at least one sheet of microporous film material and said breather material with a gas impermeable membrane, evacuating the volume enclosed by said membrane, heating said prepregs at a temperature which is high enough to cause the resin in said prepregs to outgas and become sufficiently mobile to permit the coalescing and moulding of said prepregs to take place and forsaid resin to subsequently gel but low enough for outgassing to be substantially completed before said gelling commences, for sufficient time for said outgassing, moulding and gelling to occur, and subsequently curing said resin.
The invention will now be described, by way of example, with reference to the accompanying drawing which is a diagrammatic sectioned side view, in partially exploded form, of apparatus for carrying out the method of the present invention.
With reference to the drawing, a low expansion former 10 is located in the surface of a hot plate 11.
Three prepregs 12 are then laid up on the former 10 although it will be appreciated that more or less prepregs could be used depending upon the desired characteristics of the resultant moulded article. Each prepreg 12 consists of a five end satin weave carbon fibre which is impregnated with an uncured epoxy resin. It will be appreciated, however, that the present invention is not specifically restricted to the use of such prepregs and that for instance prepregs consisting of filaments other than carbon fibre, such as glass or Ke,Iar, and uncured resins other than epoxy resins maybe utilised. Moreover the filaments need not be woven but could be unidirectional.
The laid-up prepregs are then covered with a sheet 13 of a microporous film material which is permeable to gases and vapours; but impermeable to liquid resin. The preferred microporous film material is a material known as Celgard Microporous film 4510 (manufactured by Celanese Plastics Company U.S.A.) which is a thin lightweight polypropylene film containing uniform submicron pores. The pores can be considered as discrete, slightly tortuous channels which extend from one surface of the film to the other. The film is highly permeable to gases and vapours but acts as an effective barrier to particles which are greater than 0.04 microns. The particular sheet 13 of microporous film material for use in the method of the present invention is 0.005" (0.125 mm) thick.
The sheet 13 of microporous film material is then overlaid with a sheet of breather material 14. The particular breather material 14 used is a polyester breatherfelt material known as Airweave N10 (obtainable from Aero Consultants Limited). Howev- er other suitable breather materials maybe used, for 2 GB 2 124 130 A 2 instance woven glass cloth or glass scrim.
The assembly of laid-up prepregs 12, the sheet 13 of microporous film material and the sheet of breather material 14 are then enclosed by a gas impermeable membrane 15 which is sealed to the outer edges of the former 10 by means of a suitable sealant material 16. The membrane 15 is a conven tional nylon vacuum bagging film 0.00X' (0.076 mm) thick known as Capran 512H and obtainable from Allied Chemicals International.
When the membrane 15 has been sealed to the mould 10, the volume which it encloses is evacuated by a vacuum pump (not shown). A short time may be allowed to elapse in order to ensure consolidation of the prepregs 12. The temperature of the hot plate 11 is then increased from room temperature up to and then maintained at a temperature at which the resin in the prepreg outgases and becomes sufficiently mobile for the prepregs to coalesce and conform to the shape of the former 10 before gelling of the resin.
The actual temperature and the time for which that temperature is maintained are chosen so that the outgassing of the resin and the moulding of the prepregs are substantially completed before the resin begins to gel. This encures that porosity in the gelled, coalesced prepregs resulting from entrained gases and vapour is at a very low level or is completely eliminated. The temperature of the hot plate is then increased to a temperature at which complete curing of the resin takes place. When the temperature has been maintained for sufficient time for substantially complete curing of the resin to take place, the temperature of the hot plate is reduced, the vacuum removed and the assembly dismantled to facilitate the removal of the resultant moulded article.
Although a hot plate and separate former assem bly have been described above, other methods of heating the laid-up prepregs 12 could be employed.
For instance the former 10 could incorporate its own heating elements. Alternatively the whole assembly of former 10, the prepregs 12, the sheet 13 of microporous film material, the breather material 14 and the membrance 15 could be placed in a suitable oven.
The sheet 13 of microporous film material and the breather material 14 ensure that the whole of the exposed surface of the prepregs 12 is exposed to the vacuum. The breather material 14 provides access to the vacuum but the sheet 13 of microporous film material, in addition to providing access to the vacuum, ensures that none of the liquid resin from the prepregs passes through it.
Thus the method of the present invention ensures that no liquid resin is drawn into the breather material prior to gelling taking place. This being so, the prepregs have access to the vacuum throughout the moulding operation. Consequently the outgas sing of the resin in the prepregs 12 is extremely effective, thereby ensuring thatthe levels of porosity in the final moulded article are very low or elimin ated altogether.
It may be desirable in certain cases to provide a release material on either or both of the surfaces of the laid-up prepregs. Such material may be neces- 130 sary, if for instance, a particular surface finish is required on the moulded article.
The method of the present invention is illustrated by the following examples:- Example 1
Three prepreg layers each measuring 13 inches by 11 inches and comprising 5 end satin weave carbon fibre fabric (T3003K obtainable from Toray Industries) impregnated) impregnated with BSL-914 epoxy resin (43 -t: 2. 5% w/w resin) were laid-up on the former 10 (BSI- 914 epoxy resin is obtainable from CIBA - Geigy Plastics and Additives Co B.S.D. Cambridge). The exposed surface of the laid-up prepregs was then covered with a release fabric called Bleeder lease B which is a nylon peel ply coated with a non-transferring release agent and obtainable from Aero Consultants Limited. This was followed by the sheet 13 of Celgard microporous film 4510, the breather material 14 of Airweave N1 0 polyester breather felt material and finally the membrane 15 of Capran 512H nylon vacuum bagging film.
The laid-up prepregs were preconsolidated under a vacuum of 16:i-. 16 mbars for 30 minutes at room temperature. The temperature of the hot plate was then increased from room temperature to 130 -t: 3'C at the rate of 1 to YC per minute. The temperature was maintained at 130 - XC for 90 minutes in order to allow the prepregs to outgas, coalesce, conform to the configuration of the mould 10 and finally gel. The temperature was then increased at the rate of 1 - XC per minute to 175 -i: 5'C and maintained at that temperature for 60 minutes to complete the cure of the resin. The temperature was then reduced to below 600C before the vacuum was removed and the assembly dismantled to remove the moulded article. The article was then heated at 190 -j: 50C for 4 hours in order to effect a posture of the resin.
Upon examination of the moulded article, it was found that although its lower surface finish was not entirely satisfactory, the level of porosity within the article was less than 1 %. Each ply of the moulded article was 0.0105 -!: 0.001 inches (0.226:L 0.025 mm) thick.
Example 2
1 n order to redu ce the sma I I deg ree of porosity present in the article manufactured in the previous example and to improve the surface finish of its lower surface, the method described in Example I was repeated with two modifications. Firstly, in order to reduce the porosity in the final article, the prepregs were individually laid-up on the former with each successive prepreg being consolidated for 15 minutes under a minimum vacuum of 16 _t 16 mbars. Secondly, a sheet of release fabric called Tygaf lor which is a non-porous PTFE coated fibreglass obtainable from Fothergill and Harvey Limited was interposed between the laid up prepregs 12 and the mould 10.
The resultant article was found to be free of porosity and had an excellent surface finish.
The method of the present invention provides that the moulding operation may be carried out with zero c 3 GB 2 124 130 A 3 resin bleed i.e. with no resin loss during the moulding operation. This being so, the amount of resin in the prepregs 12 may be fixed at the level desired in the final moulded article. It must be born in mind, however, that if the reinforcing filaments in the prepregs 12 are woven, they will exhibit a certain degree of resilience. This being so the atmospheric pressure exerted on the prepregs during the moulding operation may be sufficieritto completely com- press the woven filaments. If the amount of resin present in the prepregs is only sufficient to provide a continuous matrix if complete compression of the woven filaments is achieved then incomplete compression will leave voids within the resultant moulded article. In such circumstances it is necessary to provide a small increase in the resin content in the prepregs in order to ensure that such voids are not present whilst at the same time avoiding any bleeding of the resin out of the moulded article.
If a certain degree of resin bleed is desired a layer of a suitable porous material may be interposed between the layer of release fabric (if used) and the sheet 13 of microporous film material.

Claims (8)

1. A method of vacuum moulding an article from a filament reinforced composite material comprising the steps of laying up, on a suitable former, a plurality of prepregs, each comprising reinforcing filaments and an uncured resin, overlaying at least a major portion of the exposed surface of said laid-up prepregs with at least one sheet of a microporous film material which is permeable to gasses and vapours but impermeable to liquid resin, overlaying at least a major portion of said sheet of microporous film material with a breather material, enclosing said laid up prepregs, said at least one sheet of microporous film material and said breather material with a gas impermeable membrane, evacuating the volume enclosed by said membrane, heating said prepregs at a temperature which is high enough to cause the resin in said prepregs to outgas and become sufficiently mobile to permit the coalescing and moulding of said prepregs to take place and for said resin to subsequently gel but low enough for outgassing to be substantially completed before said gelling commences, for sufficient time for said outgassing, moulding and gelling to occur, and subsequently curing said resin.
2. A method of vacuum moulding an article as claimed in claim 1 wherein a release material is interposed between the surface of said laid-up prepregs and said sheet of microporous film mate- rial.
3. A method of vacuum moulding an article as claimed in claim 1 or claim 2 wherein a release material is interposed between the surface of said laid-up prepregs and said former.
4. A method of vacuum moulding an article as claimed in any one preceding claim wherein said heating of said prepregs is commenced only after sufficient time has elapsed after said evacuation step to permit said laid up prepregs to consolidate.
5. A method of vacuum moulding an article as claimed in any one of claims 1 to 4 wherein said volume enclosed by said membrane is evacuated after each successive prepreg is laid-up on said former for suff icient time for said laid-up prepregs to consolidate.
6. A method of vacuum moulding an article as claimed in any one preceding claim wherein said filaments are of carbon.
7. A method of vacuum moulding an article as claimed in any one preceding claim wherein said uncured resin is an epoxy resin.
8. A method of vacuum moulding an article substantially as hereinbefore described with reference to the accompanying examples.
Printed for Her Majesty's Stationery Office, by Croydon Printing Company Limited, Croydon, Surrey, 1984. Published by The Patent Office, 25 Southampton Buildings, London, WC2A 1 AY, from which copies may be obtained.
GB08221467A 1982-07-24 1982-07-24 Vacuum moulding fibre reinforced resin Expired GB2124130B (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
GB08221467A GB2124130B (en) 1982-07-24 1982-07-24 Vacuum moulding fibre reinforced resin
US06/506,422 US4562033A (en) 1982-07-24 1983-06-21 Method of manufacturing articles from a composite material
FR8310845A FR2530538B1 (en) 1982-07-24 1983-06-30 PROCESS FOR MANUFACTURING ARTICLES OF COMPOSITE MATERIALS
JP58125987A JPS6038247B2 (en) 1982-07-24 1983-07-11 Vacuum molding method
DE3325327A DE3325327C2 (en) 1982-07-24 1983-07-13 Vacuum forming process for articles made of fiber-reinforced composite material

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB08221467A GB2124130B (en) 1982-07-24 1982-07-24 Vacuum moulding fibre reinforced resin

Publications (2)

Publication Number Publication Date
GB2124130A true GB2124130A (en) 1984-02-15
GB2124130B GB2124130B (en) 1985-11-27

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US (1) US4562033A (en)
JP (1) JPS6038247B2 (en)
DE (1) DE3325327C2 (en)
FR (1) FR2530538B1 (en)
GB (1) GB2124130B (en)

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JPS5922722A (en) 1984-02-06
JPS6038247B2 (en) 1985-08-30
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FR2530538A1 (en) 1984-01-27
DE3325327C2 (en) 1986-06-12
US4562033A (en) 1985-12-31
FR2530538B1 (en) 1986-04-18
GB2124130B (en) 1985-11-27

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