GB2173144A - Moulding of composite materials - Google Patents

Moulding of composite materials Download PDF

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Publication number
GB2173144A
GB2173144A GB08508580A GB8508580A GB2173144A GB 2173144 A GB2173144 A GB 2173144A GB 08508580 A GB08508580 A GB 08508580A GB 8508580 A GB8508580 A GB 8508580A GB 2173144 A GB2173144 A GB 2173144A
Authority
GB
United Kingdom
Prior art keywords
moulding
composite material
temperature
resin
prepregs
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
GB08508580A
Other versions
GB8508580D0 (en
GB2173144B (en
Inventor
Frank Alan Buxton
David John Barraclough
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 GB8508580A priority Critical patent/GB2173144B/en
Publication of GB8508580D0 publication Critical patent/GB8508580D0/en
Priority to US06/831,490 priority patent/US4683099A/en
Publication of GB2173144A publication Critical patent/GB2173144A/en
Application granted granted Critical
Publication of GB2173144B publication Critical patent/GB2173144B/en
Expired legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/30Shaping 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
    • B29C70/34Shaping 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
    • B29C70/345Shaping 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 matched moulds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/10Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32Component parts, details or accessories; Auxiliary operations
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2827/00Use of polyvinylhalogenides or derivatives thereof as mould material
    • B29K2827/12Use of polyvinylhalogenides or derivatives thereof as mould material containing fluorine
    • B29K2827/18PTFE, i.e. polytetrafluorethene, e.g. ePTFE, i.e. expanded polytetrafluorethene

Description

1 GB 2 173 144 A 1
SPECIFICATION
Moulding of composite materials This invention relates to the moulding of composite materials and in particular to the moulding of composite materials comprising reinforcing filaments enclosed in a resin matrix.
It is known to manufacture components by moulding composite materials using what is commonly known as the rubber expansion method. In one version of that method, layers of filaments which have been pre-impregnated with a resin binder are laid-up in a suitably shaped former and covered by an appropriately shaped silicone rubber 80 member. The rubber member is covered in turn by a suitable rigid member so that as the whole assembly is heated, the silicon rubber expands to exert pressure upon the prepregs so that they conform to the shape of the former, consolidate and the resin, if it is a thermosetting resin, cures.
The silicone rubber expansion method of moulding is effective in the moulding of composite materials having a resin matrix material which flows and cures at temperatures around 200'C. However, if the resin matrix material flows and cures at higher temperatures, for instance temperatures of about 2500C and upwards in the case of polyimides, the silicone rubber thermally degrades to such an extent that it is not re-usable.
It is an object of the present invention to provide a method of moulding composite materials in which the problems associated with expansion moulding utilizing silicone rubber at higher tem- peratures are substantially avoided.
According to the present invention. a method of moulding composite materials which composite materials comprise reinforcing filaments enclosed in a resin matrix comprises the subsequent steps of interposing a plurality of prepregs comprising resin impregnated filaments between a shaped, partially contained body, the major portion of which body is polytetrafluoroethylene, and means corresponding in shape with said shaped body which means is adapted to resist any force exerted thereon by said prepregs, and increasing the temperature of the resultant assembly to a level at which both said matrix resin and polytetrafluoroethylene are mobile, said shaped polytetrafluoroe- EO thylene body being so contained that the thermal expansion thereof upon said temperature increase is constrained to be generally in the direction of said prepregs so that said prepregs are compressed thereby against said resistance means and thereby consolidated and moulded to a shape cor- 120 responding generally with that defined by the original shape of said shaped body and said resistance means.
The invention will now be described, by way of example, with reference to the accompanying drawings in which:- Figure 1 is a cross-sectional view of apparatus for use in the method of the present invention.
Figure 2 is a cross-sectional view of an alterna- tive form of apparatus for use in the method of the 130 present invention.
With reference to Figure 1, a cylindrical body 10 formed from polytetrafluoroethylene is sprayed with a conventional polytetrafluoroethylene-based release agent, although other suitable release materials could be used if desired, before being surrounded by a plurality of prepregs 11 which comprises uncured polyimide resin impregnated carbon filaments. The prepregs 11 may be conve- niently wound around the body 10 if so desired. When the prepregs 11 have been laid-up upon the body 10, they are enclosed by a two-part steel die 13, the inner surface 14 of which has been sprayed with the same release agent. The die 13 inner surface 14 is of circular cross-section, engages the outer surface of the laid-up prepregs 11 and is coaxial with the longitudinal axis of the cylindrical body 10. Each part of the die 13 is flanged at its edges to receive u-shaped cross-section members 15 which serve to clamp the die parts 13 together. Blanking pieces (not shown) are finally fixed to the ends of the assembly so that the polytetrafluoroethylene body 10 is totally contained.
The assembly is then placed in a suitable oven and its temperature is slowly increased from room temperature to 205'C. As the temperature of the assembly rises, the polytetrafluoroethylene body 10 expands at a higher rate than that of the steel die 13 so that the radial gap between them, which is occupied by the laid-up prepregs 11, decreases, thereby resulting in the compression of the prepregs 11.
The temperature of the assembly is held at 205'C for two hours. This is done to ensure that any sol- vents within the prepregs 11 are released, the polytetrafluoroethylene body 10 fully soaks to 205'C and that there is consolidation of the prepregs 11. The temperature of the assembly is then slowly increased to between 290'C and 330'C and is held at that temperature for one hour. By the time that the polytetrafluorethylene body 10 has reached between 290'C and 3300C it has of course thermally expanded further so that the pressure which it exerts upon the prepregs 11 is correspondingly greater and consolidation of the prepregs 11 is completed. In addition it has softened to such an extent that it behaves as a fluid, thereby providing a substantially even pressure distribution over the prepreg 11 surface which it contacts. The holding of the assembly temperature for one hour additionally results in the curing of the polyimide resin in the prepregs 11. It will be understood however that the method of the present invention is not specifically restricted to thermosetting resins and that thermoplastic resins could be utilised if so desired and of course if they will withstand the high processing temperatures of the present invention (up to 330'C). It will not of course by necessary with thermoplastic resins to allow time during the process to permit curing to take place.
After one hour at between 290'C,.and 330'C, the temperature of the assembly is gradually reduced until its temperature has reached 600C. The clamps 15 are then removed and the polytetrafluoroethylene body 10, which by this time has thermally 2 GB 2 173 144 A 2 contracted to a diameter less than the internal di ameter of the consolidated and cured prepregs 11, is removed to leave a tube comprising reinforcing carbon filaments enclosed in a matrix of a cured polyimide resin.
In a variation upon the method of the present in vention, a polytetrafluoroethylene body 16 shown in Figure 2 which is of generally square cross-sec tional shape, is placed upon a sheet 17 comprising carbon fibres in a cured polyimide resin matrix al- 75 though an uncured resin matrix may be utilized if so desired. The polytetrafluoroethylene body 16 is then coated with a release agent before being cov ered by a plurality of prepregs 18 comprising un cured polyimide impregnated carbon filaments.
The prepregs 18 are laid up on the polytetrafluo roethylene body 16 in such a manner that the end portions 19 of the prepregs 18 are in intimate con tact with the surface of the sheet 17 upon which the polytetrafluoroethylene body 16 is placed. The 85 prepregs 18 are in turn overlaid by layers 20 of po rous release material and resin bleed material of the type conventionally used in vacuum moulding.
Finally containment means (not shown) are at tached to the ends of the polytetrafluoroethylene 90 body 16 and the whole assembly of the polytetra fluoroethylene body 16, prepregs 18, and the re lease and bleed material layers 20 is covered by a sheet of impervious material 21. Clamping mem bers 22 are located at the extents of the imper vious material 21 to urge the sheet 21 into sealing engagement with the sheet 17 of cured polyimide resin impregnated carbon filaments. An aperture 22 is provided in the sheet of impervious material 21 which is in operation connected via an appro- 100 priate pipe (not shown) to an air pump to facilitate the evacuation of the volume enclosed by the sheet of impervious material 21.
The assembly depicted in Figure 2 is then placed in an autoclave (not shown) which of course has 105 facilities for the passage therefrom of the vacuum pipe connected to the aperture 22 in the sheet of impervious material 21. The volume enclosed by sheet of impervious material is then evacuated and the temperature within the autoclave slowly in creases from room temperature to 205'. As in the previous embodiment, the temperature is held at 20WC for two hours in order to permit the removal of solvents, temperature soaking and partial con solidation of the prepregs 20. The temperature is then slowly raised from 205' to between 29WC, and 33WC. However, when the temperature reaches 25WC, the pressure within the autoclave is increased from ambient to 200 pounds per square inch. The temperature is then held at between 120 29WC and 33WC for one hour in order to achieve complete consolidation, cure the polyimide resin in the prepregs 18 and the bonding of the prepregs 18 to the sheet 17. The temperature is then al lowed to slowly fail to around WC whereupon the autoclave pressure and the vacuum applied to the volume enclosed by the sheet of impervious mate rial 21 are released.
The clamping members 22 are then removed to gether with the sheet of impervious material 21 130 and the release and bleed layers 20. Finally, the polytetrafluoroethylene body 16, which by this time has contracted to have a cross-sectional area which is less than that defined by the cured pre- pregs 18, is removed. The resultant structure comprises a sheet 17 of cured polyimide resin reinforced with carbon filaments which is stiffened by a square cross-sectioned member bonded thereto and also consisting of a cured polyimide resin matrix reinforced by carbon filaments.
In both of the above examples in accordance with the present invention, the body used to thermally expand and exert pressure on the laid-up prepregs is formed from pure polytetrafluoroethy- lene. It may be desirable in certain circumstances however to provide the polytetrafluoroethylene with a suitable filler material which is chemically inert with respect to polytetrafluorethylene such as fibreglass or bronze powder in order to tailer its expansion characteristics to the particular applications in which it is used as well as prevent creep and deformation thereof under load. Such modification may be readily determined by empirical means in each individual application of the present invention.
It will be seen therefore that polytetrafluoroethylene body provides advantages in thermal tolerance over the conventionally used silicone rubbers in the moulding of composite materials. It also has the additional advantage of being capable of being thermally formed into highly complicated shapes. This being so, it can be used in the process of vacuum bag moulding, as described above, or without the use of an autoclave to apply additional moulding pressure, to produce composite material parts of complex configuration without resorting to the use of complex dies in the moulding process.
Although the present invention has been described with reference to the moulding of prepregs which are impregnated with a polyimide resin, it will be appreciated that other thermosetting resins could be used, subject of course to their curing temperatures being conducive with the thermal characteristics of the polytetrafluoroethylene body used. Moreover it will be appreciated that the present invention is also applicable to the moulding of composite materials comprising reinforcing filaments enclosed in a matrix of thermoplastic resin. In such circumstances the moulding cycle would have to be suitably modified in order to take into account the fact that it would only be for the consolldation of the prepregs, not their curing.

Claims (15)

1. A method of moulding composite materials which composite materials comprise reinforcing filaments enclosed in a resin matrix comprising the subsequent steps of interposing a plurality of pre- pregs comprising resin impregnated filaments between a shaped, partially contained body, the major portion of which body is polytetrafluoroethylane and means corresponding in shape with said shaped body which means is adapted to resist any force exerted thereon by said prepregs, and in- 3 GB 2 173 144 A 3 creasing the temperature of the resultant assembly to a level at which both said matrix resin and poly tetrafluoroethylene are mobile, said shaped polyte trofluoroethylene body being so contained that the thermal expansion thereof upon said temperature 70 increase is constrained to be generally in the direc tion of the prepregs so that said prepregs are com pressed thereby against said resistance means and thereby consolidated and moulded to a shape cor responding generally with that defined by the orig75 inal shape of said shaped body and said resistance means.
2. A method of moulding a composite material as claimed in claim 1 wherein said resin is a ther mosetting resin and the maximum temperature which is reached during said method is sufficiently high and is maintained for a sufficiently long pe riod for said resin to cure.
3. A method of moulding a composite material as claimed in claim 1 or claim 2 wherein at least some of said prepregs are placed in intimate con tact with a previously moulded composite material comprising reinforcing filaments enclosed in a resin matrix in such a manner that said prepregs are bonded by the resin therein to said previously moulded composite material during the course of said moulding process.
4. A method of moulding a composite material as claimed in any one preceding claim wherein said means corresponding in shape with said shaped body comprises a shaped body which is in the form of a die.
5. A method of moulding a composite material as claimed in claim 1 or claim 2 wherein said means corresponding in shape with said shaped body comprises a vacuum bag moulding assembly which assumes the shape of said shaped body upon the evacuation thereof.
6. A method of moulding a composite material as claimed in claim 5 wherein additional pressure is exerted upon said vacuum bag moulding assem bly after the evacuation thereof to augment the re sistance of said vacuum bag moulding assembly to the pressure exerted thereon resulting from the thermal expansion of said shaped polytetrafluoroe thylene body.
7. A method of moulding a composite material as claimed in claim 6 wherein said additional pres sure is exerted by an autoclave.
8. A method of moulding a composite material as claimed in any one preceding claim wherein said polytetrafluoroethylene is intimately mixed with a filler material which filler material is chemically inert with respect to polytetrafluoroethylene.
9. A method of moulding a composite material as claimed in claim 8 wherein said filler material is glass-fibre or bronze powder.
10. A method of moulding a composite material as claimed in any one preceding claim wherein said filaments are of carbon.
11. A method of moulding a composite material as claimed in claim 2 wherein said thermosetting resin is a polyimide.
12. A method of moulding a composite material as claimed in claim 11 wherein the temperature of said assembly is slowly raised to a temperature of 205T, said temperature of 205T being maintained for two hours whereupon the temperature is slowly increased to between 2900C and 330T and held at that temperature for one hour whereupon the temperature is slowly reduced to 60T.
13. A method of moulding a composite material as claimed in claim 6 wherein the pressure exerted by said autoclave is 200 pounds per square inch.
14. A method of moulding a composite material substantially as hereinbefore described with reference to the accompanying drawings.
15. A composite material moulded by the method of any one previous claim.
Printed in the UK for HMSO, D8818935, 8186, 7102. Published by The Patent Office, 25 Southampton Buildings, London, WC2A lAY, from which copies may be obtained.
GB8508580A 1985-04-02 1985-04-02 Moulding of composite materials Expired GB2173144B (en)

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GB8508580A GB2173144B (en) 1985-04-02 1985-04-02 Moulding of composite materials
US06/831,490 US4683099A (en) 1985-04-02 1986-02-20 Moulding of composite materials

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GB2173144B GB2173144B (en) 1989-08-09

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EP0377651A1 (en) * 1987-08-26 1990-07-18 Lockheed Corporation Elastomeric ball pressurizing method for adhesive bonding of assemblies
EP0408161A2 (en) * 1989-07-12 1991-01-16 Mecron Medizinische Produkte Gmbh Method of manufacturing a hollow body
EP0415207A2 (en) * 1989-08-29 1991-03-06 The Yokohama Rubber Co., Ltd. Process for producing hollow article of fiber-reinforced thermoplastic resin
EP0419401A2 (en) * 1989-09-21 1991-03-27 United Technologies Corporation Methods of making composites using single sided resin impregnated fabric piles
DE4100510A1 (en) * 1991-01-10 1992-07-16 Heribert Dipl Ing Kampmann Press tool for mfg. hollow profiles from polyester-prepregs - comprises metal female part and male part comprising extruded rubber crude profile, is light and can withstand high pressures
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US6962637B2 (en) * 1994-11-08 2005-11-08 Canon Kabushiki Kaisha Method of manufacturing tubular film
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Cited By (21)

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Publication number Priority date Publication date Assignee Title
EP0377651A1 (en) * 1987-08-26 1990-07-18 Lockheed Corporation Elastomeric ball pressurizing method for adhesive bonding of assemblies
EP0377651A4 (en) * 1987-08-26 1991-09-25 Lockheed Corporation Elastomeric ball pressurizing method for adhesive bonding of assemblies
EP0318415A3 (en) * 1987-09-08 1990-06-13 United Technologies Corporation Method for making a flexible fluoroelastomer reinforced with a polyaramide fibre, and its use as tooling material
EP0318415A2 (en) * 1987-09-08 1989-05-31 United Technologies Corporation Method for making a flexible fluoroelastomer reinforced with a polyaramide fibre, and its use as tooling material
EP0408161A2 (en) * 1989-07-12 1991-01-16 Mecron Medizinische Produkte Gmbh Method of manufacturing a hollow body
EP0408161A3 (en) * 1989-07-12 1991-09-11 Mecron Medizinische Produkte Gmbh Method of manufacturing a hollow body
EP0415207A2 (en) * 1989-08-29 1991-03-06 The Yokohama Rubber Co., Ltd. Process for producing hollow article of fiber-reinforced thermoplastic resin
EP0415207A3 (en) * 1989-08-29 1992-01-29 The Yokohama Rubber Co., Ltd. Process for producing hollow article of fiber-reinforced thermoplastic resin
US5409767A (en) * 1989-09-21 1995-04-25 United Technologies Corporation Methods of making composites using single sided resin impregnated fabric plies
EP0419401A2 (en) * 1989-09-21 1991-03-27 United Technologies Corporation Methods of making composites using single sided resin impregnated fabric piles
EP0419401A3 (en) * 1989-09-21 1991-09-18 United Technologies Corporation Methods of making composites using single sided resin impregnated fabric piles
DE4100510A1 (en) * 1991-01-10 1992-07-16 Heribert Dipl Ing Kampmann Press tool for mfg. hollow profiles from polyester-prepregs - comprises metal female part and male part comprising extruded rubber crude profile, is light and can withstand high pressures
US6962637B2 (en) * 1994-11-08 2005-11-08 Canon Kabushiki Kaisha Method of manufacturing tubular film
EP0862978A1 (en) * 1997-03-06 1998-09-09 Hispano-Suiza Aerostructures Method of manufacturing hollow articles from a composite material
WO1998039151A1 (en) * 1997-03-06 1998-09-11 Hispano Suiza Aerostructures Method for making hollow parts of composite material
FR2760398A1 (en) * 1997-03-06 1998-09-11 Snecma METHOD FOR PRODUCING PRECISION HOLLOW PIECES OF COMPOSITE MATERIAL
FR2760399A1 (en) * 1997-03-06 1998-09-11 Hispano Suiza Sa PROCESS FOR THE MANUFACTURE OF HOLLOW PARTS OF COMPOSITE MATERIAL
EP0865892A1 (en) * 1997-03-06 1998-09-23 Societe Nationale D'etude Et De Construction De Moteurs D'aviation "Snecma" Process for manufacturing precision hollow articles made of composite material
US6290889B1 (en) 1997-03-06 2001-09-18 Societe Nationale d'Etude et de Construction de Moteurs d'Aviation “SNECMA” Process for producing precision hollow articles made of composite material
CN109878002A (en) * 2017-12-06 2019-06-14 航天特种材料及工艺技术研究所 A kind of flexible-mould assisted positioning mold
CN109878002B (en) * 2017-12-06 2020-12-25 航天特种材料及工艺技术研究所 Soft mould auxiliary positioning mould

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GB8508580D0 (en) 1985-05-09
GB2173144B (en) 1989-08-09
US4683099A (en) 1987-07-28

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