GB2403926A

GB2403926A - Process for making a fibre composite part

Info

Publication number: GB2403926A
Application number: GB0315466A
Authority: GB
Inventors: David Roger Sherriff
Original assignee: Individual
Current assignee: Individual
Priority date: 2003-07-02
Filing date: 2003-07-02
Publication date: 2005-01-19
Anticipated expiration: 2023-07-02
Also published as: GB0315466D0; GB2403926B

Abstract

The process comprises a matrix of fibres 15 held inside a chamber 13 by connecting pipes 14, wherein a material is introduced into the chamber and expands compacting the fibres. A resin is then injected via the connecting pipes into the matrix of spaces around the fibres and contained within the expanded material. The resin is then cured and the process is completed by scavenging the expanded material from the cured resin and fibre part and removing the finished part from the expansion chamber. The foam material (18 figure 3) may be expanded polystyrene, expanded under chemical, gaseous and or thermal means and scavenged by pressure-blasting using shot (26 figure 6) or a chemical means and recycled. The fibres may be carbon fibres or any mix of carbon, metal or glass.

Description

FIBRE COMPOSITE PART MAKING USING INTERNAL AND OPEN MOULDS

The present invention relates to an apparatus for and a method of producing a composite of fore and rest.

It is known to produce a composite structure by laying a plurality of fibres onto or into a mouid having a desired * - e md introducer a resin material either dumb laying up process or thereafter in order to ensure the fibres are bonded to each other and produce a component of Me desired Other tt AD hen tD By a mid had pus whim used to define the external shape of the component to be moulded. Additionally, it is also known to employ an injection tecinique in which resin is infected or drawn inn arc and closed mould cavity during the manufacturing process. This Injection process facilitates the mtim of rest material-_n Be Amp matrix and fills He maim thereby to define accurately the final shape of the desired product. K is also known that the fibres can be primprnd win resin prior to being placed in mouid and upon being conineci in the mould the resin is heated to cure solid the fibre and resin combination. These processes can be Faber corlbri in a Ed basso Ah as an isehve.

Whilst the above -processes provide a perfectly adequate method of manufacturing a composite component the pus does not work well when the number of mould pow increase to mould complex thredimensional parts. Problems are met moulding the most basic framework of a cubic it Bet nD anti twelve heath" hues, a Bat basis of many automotive and engineering structures. Using the prior art hand lay-up procedure avid a said enclosing mouid system to make a hoilaw tubular cubic composite home is exceptionally complicated and hence expensive. The process remains complicated even with the ma of prfoms Etch are pry,oarts Bet can Bed to fit Me maws.

In addition these methods of manufacturing composite components ideally require a flexible element which cm compact the fibre. One known solution ailoan for a faxiLh exempt inside a closed mould which expands to compact the fibre around the surfaces of the mould, but as Fleas element is in Me ironer most put of He Asian - , pS# But to control.

The direction otWnWr of his invention is id separate oulthe open cosmetic need for an rollover smooth surface finish provided by a closed mould and instead to focus on Tom the more Worst needs of Bake a Em, htht and low cast Bye.

It is the object of this invention to provide a process for producing a composite structure Rich lends itself to the moulding of bow simple and complicated flsionai strictures without the use of closed moulds.

From diffract Eel D! my it Lyon Hat player ns be expanded in a closed mould to fully contain the mould. The packaging industry uses the known manufacturing technique ended polystyrene to produce low density pay by inflating polystyrene beads. The insulation industry uses a chemical reaction to expand polyurethane to fill cavities. The Fox Be industry #As Ore to expand En or namer against fibre r parts. All these processes make use of gas bubbles that can be inflated within a material to produce an expanded solid Of semi-solid material With ca - ;es cony ravened to in Is context as 'foam'.

in Me Irving, ad-dad ttaF1;at its is7W in an expansion chamber. Foam is expanded to fill the space between the fibres and the expansion Her to Spy He and corm fibres. The expanses presage Al Oh the foam presses down to compact and consolidate the flares on all flare surfaces. The foam *as ad or skin ateinoe doffs. Resin Js IDA fi-s by known techniques with any necessary connecting pipes transporting the resin to the fore it - Tile resin Men at by kr mats al7d press. Rim finished resin and fibre part is done by scavenging the foam oft the finished part by blasting, by my, diSSD or by Ether moms, -I r Tom *e Chamber.

During the foam inflation In the preferred embodiment of the invention the separate foam beads and during expsK,n so as to fig even crevice red convex shies. Jo order to maintain a constant density in the foam material and to prevent void spaces with no foam it is best Ant *e In bubbles it Mobs or in psLips sts Mat Ad end agitated freely in an expansion chamber by vibration, gas turbulence, electrostatic repulsion, or my Oliver men, Bus reset Dim moors, before coheres tar in foam block To avoid void spaces where foam has not reached, pressure venting Is done through the Or As Id She rive aa':an applied Ash *e Fox Arc -to suck the foam onto the fibre surface. The suction applied through the fibre matrix also contributes Free builds of foam - 7 over He fibres *tom make Me surfs Ore abh to and thus a higher vacuum can be maintained in the resin impregnation stage.

Jo Tonal the Jam of *e IS, Ire Imp Corer dimensional parts or complex three-dimensional parts prior to the foam being expanded over them These precede pew for purposes of He en# drips and chime are Chad farmers' and hereby defined as material of three-dimensional form, the surface or open surfaces Ah how the Airy Rear He fiJ So - DO AL He As act ashes -of an open Could. The material of the former can be of any material type which has no adverse reach win any over ire He process Jibe Faber be my opal sum open mould or any material insert or finisher, or one or more surfaces of the expansion chamber.

dimmer d as me An He fame is applied -11 Ever He complete surface of the former.

A process for proteins a caT,ptex nodal Oar 1 of composite fibre uses a lightweight former that precisely matches the internal shape of the desired framework. Fibre is *en over the he of He Elmer Are sDJ *e process" -of He invention as herein before described, of foam expansion, resin wetting out, curing and foam scavenge. Ash tradidon'i}A hymn of He fibres cm used or my rned as spraying, the preferred method is to use a robotic arm under CNC, computer numerical control, At As Pen fibre Am;, small or - 7e or amen=- haps, sri lo He He of The : ; former. Any method can be used to attach the fibres to the former but the preferred method is to use staples or pins *I era fired from a In under con-. The maples fired though the woven fibres into the former material whereby the staples mechanically had down the flare *c farmer Free am pain of *e Layers of Me the dormer.

Furthermore resin pre impregnated fibre staples can be used to staple layers of fibre onto the f. These eim fi - sides become Id fore and resm during rmin curare and can provide additional strength in a direction tending to be perpendicular to the flares in Mean Fox mat. We find Hatred of *e c sptimi ever-e Mare framework as the thickness of the fibre can be controlled by varying the number of layers of -Woo fibrin patches applied he *e tamer. he Edward direct fibres recross for and in particular around the Joints can be controlled by angular orientation of the fibre patches as they D # f DrPnOF. Was Is Ada Wear f e the of Par body em -akwaft structural frames using carbon fibres in applications where the directional strength and thickness aEross0ofafh - d - The former in complex constructions such as frameworics can be made as an assembly of 4 Ah-Ah fir. he Tar At_ building blocks can be individually laid up over their surfaces with fibre and then brought loosely toter nil weir respw asset posWors. The act of Ed-ns of me foam around Rem in the next stage of the production process will push the bionic together creating hidden internal fibre -is on Be Fred ireei part The expansion chamber can act as an autocieve where the ham under increased Measure exam additions 7 forces across me complex surface of me fit. ''or example the foam can be inflated by reducing the pressure from 3 atmospheres to 2 atmospheres presume differed of 2 Is Den 7 me fibre cre Me fire matrix is subjected to a vacuum. This allows her strong pressure forces for drawing the liquid resin enough fibre Mix and for pi unw-W Rom resin In a particular applicaffon of the invention me same foam material used to fill the him Per is Mel Or mall the framer, Is the Owe characteristics when pressure and vacuum forces are applied across He full volume of she art.

Foam material manufactured specifically for He invention herewithin described is made -up of ii polymer Gaels gas mn -as Peer or Tic Cat have hollow gaseous centres to expand like a bubble or balloon under reduced surrounding pressure.

IJpor aped 7sw Dads Pithy fill US span die fi-and He at chamber. At the end of the process once the resin has cured the pressure surrounding the beads is * Phi *e Is At semi he heseme Pi He m- of the expansion chamber in readiness her re-use.

Fox any slat such es Essex, ass, medal, Amid, poene, kw and natural materials like hemp and cotton, plus any combination mixes of these materials. The Aries cm be ppJ whom The Event Àhii' bscrci is ply Phi Ion fibres.

A preforms for material developed recycling Id is polymer, polystyrene, which is known as expanded polystyrene once expanded. Polystyrene can re mead Me In for Uses He *fir can He I Be necessary vents, injectors and pins for expanding me polystyrene beads within it.

he weapon of ff- me invented *e fi-is c *feted out resin by completely filling the expansion box with resin and unexpanded foam, thus upon high =e Users *e * am Is 11 The resin Bit oF the Eden Or Oh escape pipes leaving the remaining resin in the fibre matrix ready her curing.

One pendular aspect of inv is to reduce me ping of roan prim impregnated fibre by using fibre attached on the surface of a solidified type of resin rather than Eat Me ran. *em is deli ID We Hi e, Ah Dome reinhroarnent to retain its shape, and the fibre is laid and attached onto the surface of the resin she. The fibrin and me reds statue are phceei no the expansion chamber and a semi solid 1-n inflated all around them. The resin is melted under heat so that it infuses with the fibre. An tonal Ion is appi the foam tD Eat semi Ida Ink the re..A vacuum is applied across the resin and fibre matrix to remove any trapped gas. The processed on - nues to as dewed the irwen.

Any types of inserted parts can be used in contact with the flbre prior to foam expansion.

Rae inseteei can be Her mpa, I, Foss ami or smN sediri harrier materials that become bonded with the fibre and resin. The pre made inserts can be made in any Hi It do hat react Rely with me fi - or the rosin For tions inward can be in steel or plastic materials and be used of instance as outer body son parts on to which Eli JavelDp paint fin-3 #5 appeal may ego be ken Jig -I may be of precision manufacture. Inserts can be placed in a precision arrangement using we anus that suppaf Be insets loam points or, *e wags of Be Epson chamber.

awiaDf *e embo*eie*eyteJ-atrium YiDO radiation of a certain wavelength aimed through the expanded ham and on to the resin in the here Marc resin may have a maters mid M with the ebb radiation and convert it to heat her curing. The foam by nature is k\w density and ctfers little Ion for of nion. ennr may be removed before applying the radiation. In another variation electromagnetic radiation absorbing -fibres are woven into the cow fibre matrix and an example heir fibm that can heated by applying microwave radiation through the ham which in turn heat the resin for curing in the fibre matrix.

In a variation of laying-up the fibre on the hrmer certain shapes of hrmer can have Triple misfire homely posh pheed all over the I. {: fibres off a reel eat woven under tension around the hooks and built into a controlled thickness ready for resin I. J lodes in a-per Kim man be Isis *elm Eel He bud -of Be fanner. These islands maybe etched in to the surface to create troughs for the fibre to sit in..

There is preference Cot to use o battier material between ale libre Me expanding-material, or the flare and the former but one may be needed where materials will Rely con This Fame Pier mar ad a atop gas Awe or vacuum leakage during the resin impregnation of the fibres. The barrier material can be applied by o of a rue of Antiques such as ark Props, aprayn, 7 7 a sonar, electroeposition, electro polymerization or as pre mace solid part. Alte'Tabvely the foam may feelfppeesdiingefcr and It can be envisaged that there is a foam material that can set solid after expansion that is id to liquid festal *b to Us, arid herd a vellum cfen applied h foam thus purging unwanted gas from the flare and resin matrix.

Flashed pats made as Ed in the Odium of the Samson ':an te:re- employed and built-up like a thrdimensional jigsaw p8SlQ to CQ an ever more complex former which have hidden webs and Internal potions for applications like high strength sandwich sh2 and mashed dda harms for impact Ads. DUId - 4 those successive generations of parts are built up like successive skins of a 'Russian Doll'.

The trade name material 'Cortex is made up of carbon fibre woven Into a tube with an gMffi*e. i':anen assembly of parts to make up a complete former.

In a further exnsron of the embodiment the invention two or Arc processed and finished fibre loadedames can be joined together by wrapping fibre around the joint areas like a bandage and enclosing just this joint area alone in an expandingbox and continuing through the as descried at He mairr smelt of ore Err to crow solid Girl. This technique can be used to repair a crash impacted area. Furlher more the same technique can be used to attach additional parts on to a finished part aspect of Me invention is mat me find finished pad hes me main shahs fibres an the outside surface of the part which is Ideal for inspect on and quality control.

DESCRIPTION OF THE DRAWINGS

The present invenffon At now be more parUcdnly destain by way of exernple only with reference to the accompanying drawings in which: Figures 1, 2, 3, 4, 5, 6 and 7 show (in that orders successive stages of the process in Adam win tine monad anot Stratus of e pi Revlon; Figure 8 shows a vehicle substructure which might be produced in accordance with the method and apparatus of the peasant Invention, Figure g iNustrabs production of a flat enter sheet nil,d wibr the present invention; Figure 10 illustrates inserted parts being made integrally with a composite component made in accordance with the invention; Figure 14 iffuss a basic composite cwronent made in aaxanoa USA fife invention; Figure 12 illustrates a method of fixing fibre onto a former; Figure 13 arid 14 iNuste a windier process far saying sdre onto a farm - ; and Figures 15, 16, 17, 18 and 19 show (in that order) successive stages of a repair of a damaged part made by means of inventlan.

Referring to me drw;gs an Qr of ff - it is showr' as process sucosssively in Figures 1, 2, 3, 4, 5, 6 and 7. Starting with Figure 1, the '!orrnef 10 as heminare described is drawn for the sake or example as a cube shaped Irk. The dimmer 10 goes through a prom of being eV W7 Abre. for We sake of He example two woven fibre parts 12 are shown out of the many required for the lay-up. The preferred aRachmant Fox pads to the former is by Kaplan (not *I) with Ha s - - embedding into the former and pinning down the fibres.

The next step in the process shown in Figure 2, is attaching the connecting pipes 14 to herHy cove 15 to radio ash my, atone top and bottom comers 16. The connecting pipe 14 on the under side is shown going through the base of the expansion chamber 13.

The price ares in fin 3, erg* Ink Is -14 spenddhe loaded-frame 15 in the expansion chamber from the base 13. The covering part of the expansion chamber 17 sits down on the base of the expansion chamber 13 and together they are Sealed.

For Me sake of *e he She expansion *fir part 17 is Ion as being my of transparent material so that the contents included the fibrloaded-frame 15 can be seen. The tbam is represented by polyrrr beads 18 which are sag irdo fife seated expansiarr chamber 13, 17 via the hole 19 in the direction shown by an arrow20. On completion of the filling the hole 19 is sealed.

the process lL7es In 7 4, 7 - t" chamber 13, 17 and passing through steam or another hot gas represented in form and direction by arrows 23. This in turn agitates the beads 21 infix a sfafe d chaade flying in all direcdans art fibre-toact-Frame 15, white at the Salting aims the "ads 24 are - ó lading 7JF the heat imparted by the steam. Only a few of the many expanding beads 21 are shown. The expansion at the agitated beads continues until the whale space vain me expansion Harrier 43, 17 is art bat 7 it 7 sit 24 Figure 5. In reality He steam ports Z may be many in number and have opening and closing mecilanisns.

After the expansion phase the process continues in Figure 5, with the opening of the correcting pipes 14 and to Know *'e resin to flow in the direction of I Angus 25 under i

-

pressure, vacuum and gravitational forces. The resin flows down the connecting pipe and through info the micra cavities armed the fibrin the fibre itself being cordained by the former and the foam. The fibre loadedme is hidden from view but is contained inside the foam block 24. Over a certain period of time the resin flows right through to the lower connecting pipe 14 and out -indiQded lay Me terror 25. Through maitairrg *e process, at a cam point me Fitch is deed to be fully wetted out and all cavity spaces around the fibre filled with resin. The resin is ton cured into a said vouch may require the application of heat depending on the resin type. Aver the resin is cured tl,. expansion dr 17 can be red. shy process of r arid predictive analysis using flow analysis the number and IDeation of the connecting pipes may be adjusted to optimise tte resin flow around the fibre and to remove void spaces where the resin fed * Penelope. ME nnbm of fig npm may bc needed Ah ear have double function of also suspending the flbreJoadedrame inside the expansion chamber.

With the expansion chamber removed in order JO rmea the finished part hidden inside the foam block there is a process shown in Figure 6, of scanvering off the foam block 24 by using pressure blasting with shot 26. After the finished part has been striped of the covering of mom As bass of the anon charmer -13 is Ed ngfird part mulched- to the connecting pipes 14. The mrnoved foam material is then rounded.

Finally in Figure 7, the connecting pipes 14 are detached from the finished part 28.

in Few 8, a cloned fin c ear body*ntir Anal 29 is Wurd as being attached to a load bearing car frame 30, the frame 30 losing produced by the process embodying the invention. By nature of the fibre being moulded around a former me car frame has weaved an interior moutd, *e seer surface finish Defames are not of moor quality as they are not moulded against a mould surface and subsequent faxing of aerodynamic and cosmetic Paris sum as the wing pare 2g is Al: wed.

Although the process is suited to making complex shapes, one of simplest cases of an embodiment of the invention is shown in Figure 9, whereby a former is not required as the fibre 34 is laid out on the base of the expermon chamber 33. The top of sior do 32, shown to be made in a transparent material, is placed on top of the expansion chamber base 33 and sealed. Rho space 31 inside me expansion chamber 32, 33 is where We foam is Inserted and expanded. The Anew pipes, steam vents and foam may hole are not shown. As arrangement is suitable for the making of sheet materials and can be a laboratory test bed for testing and experimentation to perfect the material types and some of the process techniques b.

Precise location and alignment of inserts is shown in Figure 10. An embodiment of the invention has urcudar inserts -37 Red in He fibrin Em- me 38, mcKn by at - ens of brackets 35. The brackets 36 are in turn mounted on the expansion chamber base 35 and covered by the expansion chamber top 39. The process of making the parts can continue as described by Me invention whereby We foam expands and surrounds bow the mountings 36 For Ace nserts 37 and e fibre lwdefme 38 within e exparsron charrer 35, 39 In variations the mounting of the inserts can be done with any structure such as mounting arms and brackets, and in turn these mountings can be attached to any part of Vile expansion chamber.

F 11 iffustra a Sac Edit of c' ireorr wee fibrin 40, mat tom primpregnated with resin are suspended by means of connecting pipes 14 and clamps 41 in a transparent (for illustrafJon purposes) expansion Camber to, 17. Foam (not sho kin) is expanded en -'a'Le' card fit easer grout *e fi - s. The res or is aired by applying heat or by timely chemical reaction. The finished fibrin and cured resin part is revealed both by scavenging We exparded polymer Elm the finished part and try removal from the deer.

Figure 1Z shows a reel of woven fibre 42 being unwwnd and cut into patches 43. Staples 46 are fired *om a staple gun 45 into the patches to fix them to the Amber 44. -Staples 47 have bedded down into the tom er and trapped and mmpacted the fibre patches.

Figure 13 demonstrates the weaving of raw strand fibre 50 using posts 49 as pulling points to build a complex fibre Lattice aver a flat former Be. Take preppie into Tree dimensions in Figure 14 an egg shape 52 is covered with posts 51 and a head 54 issues fibre thread 50 guided by CNC, computer numerical combs, which weaves a continuous fibre thread Ear sew tendon amends posts Ad. {)nthe ry=indings shown of Mat would be built up with thousands of windings to cream a fibre weave ready for processing as described by the invention herevAthin described. Simple convex shapes may not need any posts lo Provide ab mefflod is more:anpkD Elms infirm Concave surfaces where hooks might be substituted in place of posts.

Figures 15, 16, 17, 18 and 1g respectively show a repair of a part made by the process Red byeinrenn. The sad TTt "sine asen>'n Figure 15. The impact area is shown cut out in Figure 16 ninth a former 62 Inserted between the divided part 63. Following an to Figure 17 fin B4 is applied aver ff. farmer with overtops and the original parts 63. An expansion chamber 65 as illustrated in Figure 18 is then clamped war We parts 63 containing We repair area. Pressure seals 66 seal the expansion chamber and the process continues as described by the invention Utah foam exparmion inside fife expansion chamber, resin infection, curing, followed by removal of the expansion chamber and at avenging on the foam. Figure 19 shouts the revealed repaired pan owl repair area 68 ovelappir the Rigid parts 63.

Claims

1. The process starts with a matrix of fibres being held inside a chamber, and continues with compaction of the fibres by a material expanding within the chamber. This is followed by resin injection via connecting pipes into the matrix of spaces around the fibres contained within the expanded material, and further followed by resin curing. The process is completed by scavenging the expanded material from the cured resin and fibre part and removing the finished part from the expansion Chamber.

2. The process as claimed in claim 1, dharacterised in that the expanding material is a foam material expanded under chemical, gaseous and/or thermal means.

3. The process as claimed in claim 1, dharacterised in that the expanding material is a made up of individual bubbles of material that are inflated.

4. The process as claimed in claim 1, dharacterised in that the expanding material and expanding method is the known material and process named 'expanded polystyrene'.

5. The process as claimed in claim 1, characterized in that the fibres are carbon fibres or any mix of fibres like kevlar, glass, metal, for instance, with carbon fibres.

6. The process as claimed in claim 1, dharacterised in that the fibres are placed on and subse- quently compacted against the surface of a former or the surface of the chamber to impart a certain shape. These surfaces may be complex and may form frameworks.

7. The process as claimed in all proceeding claims, dharacterised in that the suction is applied through the fibres to pull down the expanding material onto the interface between the expanding material and the fibres.

8. The process as cdaimed in all proceeding claims, dharacterised in that there is a barrier in- serted between the expanding material and the fibres.

9. The process as claimed in claim 6, characterized in that the fibres are laid on to the surfaces by hand or machine means using staples or pins to hold down the fibres to the former in readi- ness for compaction.

10. The process as claimed in claim 9, dharacterised in that the staples and pins are fibre parts pre-impregnated with resin.

11. The process as claimed in claim 6, characterised in that the fibres are woven over the surface by hand or machine means and can be wound around multiple protrusions or hooks on concave surfaces.

12. The process as claimed in claim 2, characterised in that the expansion of the foam forms a skin over the surface of the fibres.

13. The process as claimed in claim 1, characterised in that the former is a framework.

14. The process as claimed in claim 1, characterised in that the former is made of any material.

15. The process as claimed in claim 1, characterised in that the former is the same material as the expanding material in its expanded state.

16. The process as claimed in claim 1, characterised in that the expanding chamber has a high, low or vacuum gas pressure applied internally thus acting like an autoclave.

17. The process as claimed in claim 16, characterised in that the expanding material passes gas pressure variations but is impervious to the liquid resin.

18. The process as claimed in claim 1, Characterised in that the fibres are held in the expansion chamber by the connecting pipes or any other connecting material.

19. The process as claimed in claim 1, characterised in that the fibres are pre-impregnated with resin.

20. The process as claimed in claim 1, characterised in that the fibres hold their shape by their own construction.

21. The process as claimed in claim 1, characterised in that the fibres hold a required shape by having other materials embedded within the fibres.

22. The process as claimed in claim 1, characterised in that the resin is cured by heat created by electromagnetic induction applied on the fibres or certain materials in the fibre mix such as metal fibres.

23. The process as claimed in claim 1, dharacterised in that the former has inserts of other materials embedded or attached to the former before the expanding process commences.

24. The process as claimed in claim 23, dharacterised in that the inserts can be connected to the expansion Chamber using precision material connections.

25. The process as claimed in claim 1, dharacterised in that the expanded material is scavenged by pressure blasting or by chemical means.

26. The process as claimed in claim 1, characterized in that the expanded material is scavenged inside the expansion chamber.

27. The process as claimed in claim 1, dharacterised in that the expanded material is scavenged and re-cycled.

28. The process as claimed in all proceeding claims, characterized in that the expanding chamber is full of resin with the fibres fully wetted out and then the expanding material pushes the surplus resin out through the connecting pipes.

29. The process as claimed in all proceeding claims, dharacterised in that the finished apart at the À end of the process can be used as the former in the next processing operation.

30. The process as claimed in all proceeding claims, characterized in that two parts can be joined together by laying up fibres across the two parts and initiating the process described within a sealed chamber containing the joint area. This may be called a repair in certain circumstances.

31. The process as claimed in all proceeding claims, characterized in that the expansion stage of the process might be aided by vibration, internal induced turbulence, electromagnetic fluxes or electrostatic effects. It

Amendments to the claims have been filed as follow

1. The process characterized in that a matrix of fores are laid out on the chamber's internal base.

The chamber imparts the desired shape onto the fibres. The prowess continues with compaction of the fibres by a material expanding within the chamber. This is followed by resin injection via connecting pipes into the matrix of spaces around the fares and further followed by resin curing.

me process is completed by Scavenging the expanded material from the cured resin and fibre part and removing the finished part from the chamber.

2. The process characterized in that a woven matt of fibres is suspended inside a chamber. me process continues with compaction of the fibres by a material expanding within the chamber. This is followed by resin injection via connecting pipes into the matrix of spaces around the fibres contained within the expanded material, and further followed by resin curing. The process is completed by scavenging the expanded material from the cured resin and fibre part and removing the finished part from the chamber.

3. The process characterized in that a matrix of fibres are laid-up on the former, the former imparting the desired shape on the finished part. The matrix of fibres laid on the former are held inside a chamber. The process continues with compaction of the fibres onto the former by a material expanding within the chamber. This is followed by resin injection via connecting pipes into the matrix of spaces around the fibres contained within the expanded material, and further followed by resin curing. The process is completed by scavenging the expanded material from the cured resin and fibre part and removing the finished part from the chamber.

4. The process which has any combinations of the processes in claims 1, 2 and 3.

5. The process as claimed in claims 1, 2, 3 and 4, characterized in that the expanding material is a foam material expanded under chemical, gaseous andlor thermal means.

6. The process as claimed in claims 1, 2, 3 and 4, characterized in that the expanding material is a made up of individual bubbles of material that are inflated.

7. The process as claimed in claims 1, 2, 3 and 4, characterized in that the expanding material and expanding method is the known material and prowess named 'expanded polystyrene. . : , : 8. The process as claimed in claims 1, 2, 3 and 4, dharacterised in that the fibres are carbon fibres or any mix of fibres like kevlar, glass, metal, for instance, with carbon fibres.

9. The process as claimed in all proceeding claims, dharacterised in that the suction is applied 1L through the fibres to pull doom the expanding material onto the interface between the expanding material and the fibres.

10. The process as claimed in all proceeding claims, charactefised in that there is a barrier Inserted between the expanding material and the fores.

11. The process as claimed in claim 3, characterized in that the fibres are laid on to the surfaces by hand or machine means using staples or pins to hold down the fibres to the romper in readi- ness for compaction.

12. The process as claimed in claim 11, characterized in that the staples and pins are fibre parts preAmpregnated with resin.

13. The process as claimed in claims 1, 2, 3 and 4, characterized in that the fibres are woven under slight tension over the surface by hand or machine means and can be wound around multiple protrusions or hooks on Concave surfaces.

14. The process as cdaimed in claim 5, dharacterised in that the expansion of the foam forms a skin over the surface of the flares.

15. The process as claimed in claims 1, 2, 3 and 4, dharacterised in that the fommer is a frame- 16. The process as claimed in claims 1, 2, 3 and 4, dharacterised in that the former b made of any material.

17. The process as claimed in claims 1, 2, 3 and 4, dharactefised in that the fommer is the same materfial as the expanding material in its expanded state.

18. The process as cdaimed in claims 1, 2, 3 and 4, charactefised in that the expanding chamber has a high, low or vacuum gas pressure applied internally thus acting like an autoclave.

19. The process as cdaimed in Maims 1, 2, 3 and 4, charactefised in that the expanding material passes gas pressure variations but is impervious to the liquid resin.

20. The process as claimed in claims 1, 2, 3 and 4, characterized in that the fibres are held in the expansion chamber by the connecting pipes. 1;

21. The process as claimed in cdaim 2, 3 and 4, dharacterised in that the fibres are pre- impregnated With resin.

22. The process as claimed in claims 1, 2, 3 and 4, dharacterised in that the fibres hold their shape by their own construction.

23. The process as claimed in claims 1, 2, 3 and 4, dharacterised in that the fibres hold a required shape by having other materials embedded within the fibres.

24. The process as claimed in cairns -1, 2' 3 and 4 dharacterised in that the resin is-cured by - - heat created by electromagnetic hductlon applied on the fibres or certain materials in the fibre mix such as metal fibres.

25. The process as claimed in claims 1, 2, 3 and 4, dharacterised in that the fomner has inserts of other materials embedded or attached to the former before the expanding process commences.

26. The process as claimed in claim 25, dharacterised in that the inserts can be connected to the expansion chamber using precision material connections.

27. The process as claimed in claims 1, 2, 3 and 4, dharacterised in that the expanded material is scavenged by pressure blasting or by chemical means.

28. The process as claimed in claims 1, 2, 3 and 4, dharacterised in that the expanded material is scavenged inside the expansion chamber.

29. The process as claimed in claims 1, 2, 3 and 4, characterized in that the expanded material is scavenged and recycled.

30. The process as claimed in all proceeding claims, dharacterised in that the expanding chamber is full of resin with the fibres fully wetted out and then the expanding material pushes the surplus resin out through the connecting pipes.

31. The process as claimed in all proceeding claims, characterized in that the finished part at the end of the process can be used as the former in the next processing operation.

32. The process as claimed in all proceeding claims, dharacterised in that two parts can bepined together by laying up fibres across the two parts and initiating the process described within a sealed chamber containing the joint area. This may be called a repair in certain circumstances.

S3. The process as claimed in all proceeding claims, characterized in that the expansion stage of the process might be aided by Vibration, internal induced turbulenos, e ectomagnetic fluxes or electrostatic effects.

34. The process as calmed in claims 1, 2, 3 and 4, characterized in that the fibres are suspended in the chamber by means of a clamp.

I- .

35.- The -process as claimed in claim 12 characterized in that the staples are fired from a staple -- . - . - . - gun.

36. The process as claimed in claim 35, characterized in that the staple gun is under CNC, computer numerical control.

37. The process as claimed in all proceeding claims, characterized in that the fibre can be built-up in thickness in woven patch form or with continuous fibres to increase the strength of the final part

38. The process as claimed in claim 13, characterized in that the head issues nbre thread under CNC, computer numerical control. 1;