GB2254820A - Tooling for composite component manufacture - Google Patents

Tooling for composite component manufacture Download PDF

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Publication number
GB2254820A
GB2254820A GB9108089A GB9108089A GB2254820A GB 2254820 A GB2254820 A GB 2254820A GB 9108089 A GB9108089 A GB 9108089A GB 9108089 A GB9108089 A GB 9108089A GB 2254820 A GB2254820 A GB 2254820A
Authority
GB
United Kingdom
Prior art keywords
mould tool
tool
mould
foam
adhesive
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
GB9108089A
Other versions
GB9108089D0 (en
GB2254820B (en
Inventor
Derrick James Booth
Robert Stevens
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.)
BAE Systems PLC
Original Assignee
British Aerospace 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 British Aerospace PLC filed Critical British Aerospace PLC
Priority to GB9108089A priority Critical patent/GB2254820B/en
Publication of GB9108089D0 publication Critical patent/GB9108089D0/en
Publication of GB2254820A publication Critical patent/GB2254820A/en
Application granted granted Critical
Publication of GB2254820B publication Critical patent/GB2254820B/en
Anticipated expiration legal-status Critical
Expired - Fee Related 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
    • B29C33/00Moulds or cores; Details thereof or accessories therefor
    • B29C33/38Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B29C33/3842Manufacturing moulds, e.g. shaping the mould surface by machining
    • 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
    • B29C33/00Moulds or cores; Details thereof or accessories therefor
    • B29C33/38Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B29C33/40Plastics, e.g. foam or rubber
    • 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
    • B29C33/00Moulds or cores; Details thereof or accessories therefor
    • B29C33/56Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents

Abstract

A body of a mould tool which is machined from a laminar assembly of adhered structural foam slabs (2) on an aluminium base (3), has good mechanical stability under conditions of varying pressure and temperature and is particularly suitable for use in the autaclave curing of articles moulded on the tool from composites. The moulding surface of the tool is provided either by a coating of filled epoxy, or of a polyester blanket wetted with adhesive, which may be machined, sanded and then painted or gell coated and polished, to produce a smooth moulding surface. <IMAGE>

Description

TOOLING FOR COMPOSITE COMPONENT MANUFACTURE This invention relates to tooling for the manufacture of articles from composite materials such as, for example, carbon fibre composites.
A conventional method of manufacturing articles from composite material involves laying up layers of composite material, such as carbon cloth impregnated with resin, in a metal mould tool to a desired thickness. The article is then cured under pressure in an autoclave and the finished article removed from the mould. One problem with this method, however, results from the difference in coefficient of thermal expansion (CTE) between the metal mould tool and the composite material. This difference results in a relative movement between the mould tool and the composite article being formed during the heating and cooling cycle which spoils the surface of the article.
Other materials have also been proposed for use as mould tools, e.g. wood and micarta. However, these materials are difficult to machine to a high quality finish. A further disadvantage is their lack of mechanical stability under conditions of varying and/or high temperatures.
The present invention aims to provide a mould tool which suffers from none of the aforementioned disadvantages.
A mould tool according to the invention and suitable for use in the manufacture of articles from composite materials is made from structural foam.
Structural foam of the type known as Rohacell (Trade Name) has been found to exhibit the desired mechanical stability in use and to be capable of withstanding 100 psi pressure.
The foam has the further advantage of being easy to machine. Female or male moulds can readily be machined from this material.
A smooth surface finish can be achieved by coating the machined foam with an epoxy-based filler, sanding down, then painting. This method is preferred for ambient temperature cures.
Alternatively, a smooth surface finish can be achieved by overlaying the surface of the foam with a "wetted out" polyester blanket, which is cured, machined if necessary and then painted with a gelcoat. This method is preferred if the mould tool is to be used for high-temperature curing operations.
Some embodiments of the invention will now be described, by way of example only, with reference to the drawings, of which: Fig. 1 is a side view of a mould tool in accordance with the invention at an intermediate stage of its fabrication; and Fig. 2 is a view of the final, finished mould of Fig.
1.
Structural foam is presently commercially available in slabs of several mm thickness and moulds can be made by building up the desired shape from several slabs.
Fig. 1 shows a mould tool 1 built up from several slabs 2 of structural foam. The base of the mould 2a is bonded to an aluminium block 3. An adhesive suitable for bonding foam slabs together is BSL 319 (Trade Name) film adhesive. Care should be taken to ensure that adhesive does not intrude into any area which is to be machined. An adhesive FM 96 (Trade Name) has been found to be suitable for bonding the foam to aluminium.
To build the mould tool of Fig. 1 firstly the base 2a is bonded to the aluminium block 3 and the FM 96 adhesive allowed to cure on a Platten press at 1750 for one hour.
The remaining foam blocks 2 are then built up to the required height using the BSL 319 adhesive. The assembly is then bagged up, evacuated and placed in an autoclave for 1 hour at 1750C.
The curing process has been found to enhance the foam's mechanical stability.
The cured assembly is then machined to the desired size. Ball-ended cutters can be used for this task.
Open cells left in the foam by the machining process are filled with an epoxy-based filler. The surface is sanded down and then painted. The paint can be further cut back to give a good surface finish.
The mould produced by the above method will withstand vacuum and autoclave pressure. It can be used as a master mould on which could be cured, for example, a composite mould or composite components cured at ambient temperature or at up to 600C using currently available epoxy fillers and paints.
The finished mould is shown in Fig. 2. In this example the mould is to be used for making a nose-cone from composite materials.
In an alternative method of fabricating a mould tool in accordance with the invention, the mould is fabricated from slabs of Rohacell foam on an aluminium base as previously described but a different surface finish technique is employed.
After curing the BSL 319 adhesive, the mould tool is machined to a few mm under size. Next, a polyester blanket wetted-out with adhesive is laid over the surface of the mould. A suitable adhesive is TMR 2500 (Trade Name) obtainable from Airtech. The assembly is then cured in a vacuum inside an autoclave.
After curing, the surface of the polyester is machined and sanded down if necessary to give a reasonably smooth surface finish. Next is applied a gelcoat (such as gelcoat TMR 2000) which is cured and polished to give the final smooth finish to the surface of the mould tool.
The mould tool produced by this second, alternative method will withstand vacuum and autoclave pressure and, using a high temperature-resistant gelcoat, temperatures up to 2O00C.
It has been found that the polyester blanket can be machined easily and that a good surface finish can be obtained.
This alternative mould tool can also be used in the manufacture of composite moulds or components.

Claims (7)

1. A mould tool for use in the manufacture of articles from composite materials which is made from structural foam.
2. A mould tool according to claim 1 in which the surface of the tool is treated with epoxy-based filler.
3. A mould tool according to claim 1 in which the surface of the tool is composed of a polyester blanket wetted-out with adhesive.
4. A method of manufacturing a mould tool for use in the manufacture of articles from composite materials comprising the steps of: machining structural foam to a desired shape; coating a surface of the foam with epoxy-based filler; sanding down the filler and painting.
5. A method of manufacturing a mould tool for use in the manufacture of articles from composite materials comprising the steps of machining structural foam to a desired shape; laying over a surface of the foam a polyester blanket wetted-out with adhesive; curing; machining the polyester blanket to produce a smooth surface; and painting.
6. A mould tool substantially as hereinbefore described with reference to the drawings.
7. A method of manufacturing a mould tool substantially as hereinbefore described with reference to the drawings.
GB9108089A 1991-04-16 1991-04-16 Tooling for composite component manufacture Expired - Fee Related GB2254820B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB9108089A GB2254820B (en) 1991-04-16 1991-04-16 Tooling for composite component manufacture

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB9108089A GB2254820B (en) 1991-04-16 1991-04-16 Tooling for composite component manufacture

Publications (3)

Publication Number Publication Date
GB9108089D0 GB9108089D0 (en) 1991-06-05
GB2254820A true GB2254820A (en) 1992-10-21
GB2254820B GB2254820B (en) 1995-04-19

Family

ID=10693371

Family Applications (1)

Application Number Title Priority Date Filing Date
GB9108089A Expired - Fee Related GB2254820B (en) 1991-04-16 1991-04-16 Tooling for composite component manufacture

Country Status (1)

Country Link
GB (1) GB2254820B (en)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0662380A2 (en) * 1993-12-28 1995-07-12 Honda Giken Kogyo Kabushiki Kaisha Mould for fibre-reinforced plastics
GB2423496A (en) * 2003-01-23 2006-08-30 Advanced Composites Group Ltd A foam body for a master model
WO2012010827A1 (en) * 2010-07-22 2012-01-26 Advanced Composites Group Limited Mould tools
US9744694B2 (en) 2015-04-02 2017-08-29 The Boeing Company Low-cost tooling and method for manufacturing the same
US10060042B2 (en) 2016-04-04 2018-08-28 The Boeing Company Tooling having a durable metallic surface over an additively formed polymer base and method of forming such tooling
CN109732816A (en) * 2019-02-22 2019-05-10 长沙博兴汽车科技有限公司 It is a kind of using foam as the composite material manufacture craft of mould substrate

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB828518A (en) * 1958-05-02 1960-02-17 Geographical Projects Ltd Improvements in or relating to the production of relief models of surfaces
GB980754A (en) * 1962-03-20 1965-01-20 Ici Ltd Moulding polyurethane foam
GB1287513A (en) * 1969-01-29 1972-08-31 Basf Ag Manufacture of polyamide moulded articles by the activated anionic polymerisation of lactams
GB1328958A (en) * 1970-04-15 1973-09-05 Bayer Ag Process for the production of heavy duty foam resin products
GB1436808A (en) * 1973-05-04 1976-05-26 Sweco Inc Vibratory mill structures and method of forming same
GB1441334A (en) * 1972-10-20 1976-06-30 Steinsvik K R Method for prodocing prefabricated concrete articles
GB2105251A (en) * 1981-07-16 1983-03-23 New Press Tools Limited A mould for use in the moulding of plastics materials
WO1985002143A1 (en) * 1983-11-11 1985-05-23 DUPRÉ-RISÉN, Andrée, Marie Form for the production of boat hulls, or other containers, and parts connected to the same

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB828518A (en) * 1958-05-02 1960-02-17 Geographical Projects Ltd Improvements in or relating to the production of relief models of surfaces
GB980754A (en) * 1962-03-20 1965-01-20 Ici Ltd Moulding polyurethane foam
GB1287513A (en) * 1969-01-29 1972-08-31 Basf Ag Manufacture of polyamide moulded articles by the activated anionic polymerisation of lactams
GB1328958A (en) * 1970-04-15 1973-09-05 Bayer Ag Process for the production of heavy duty foam resin products
GB1441334A (en) * 1972-10-20 1976-06-30 Steinsvik K R Method for prodocing prefabricated concrete articles
GB1436808A (en) * 1973-05-04 1976-05-26 Sweco Inc Vibratory mill structures and method of forming same
GB2105251A (en) * 1981-07-16 1983-03-23 New Press Tools Limited A mould for use in the moulding of plastics materials
WO1985002143A1 (en) * 1983-11-11 1985-05-23 DUPRÉ-RISÉN, Andrée, Marie Form for the production of boat hulls, or other containers, and parts connected to the same

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0662380A2 (en) * 1993-12-28 1995-07-12 Honda Giken Kogyo Kabushiki Kaisha Mould for fibre-reinforced plastics
EP0662380A3 (en) * 1993-12-28 1996-01-10 Honda Motor Co Ltd Mould for fibre-reinforced plastics.
GB2423496A (en) * 2003-01-23 2006-08-30 Advanced Composites Group Ltd A foam body for a master model
WO2012010827A1 (en) * 2010-07-22 2012-01-26 Advanced Composites Group Limited Mould tools
CN103097097A (en) * 2010-07-22 2013-05-08 尤米柯结构材料(德比)有限公司 Mould tools
CN103097097B (en) * 2010-07-22 2016-10-05 尤米柯结构材料(德比)有限公司 Mold tool
US10800070B2 (en) 2010-07-22 2020-10-13 Cytec Industrial Materials (Derby) Limited Mould tools
US9744694B2 (en) 2015-04-02 2017-08-29 The Boeing Company Low-cost tooling and method for manufacturing the same
US10060042B2 (en) 2016-04-04 2018-08-28 The Boeing Company Tooling having a durable metallic surface over an additively formed polymer base and method of forming such tooling
CN109732816A (en) * 2019-02-22 2019-05-10 长沙博兴汽车科技有限公司 It is a kind of using foam as the composite material manufacture craft of mould substrate

Also Published As

Publication number Publication date
GB2254820B (en) 1995-04-19
GB9108089D0 (en) 1991-06-05

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PCNP Patent ceased through non-payment of renewal fee

Effective date: 19970416