WO1996000642A1 - Procede et dispositif de moulage - Google Patents

Procede et dispositif de moulage Download PDF

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Publication number
WO1996000642A1
WO1996000642A1 PCT/GB1995/001497 GB9501497W WO9600642A1 WO 1996000642 A1 WO1996000642 A1 WO 1996000642A1 GB 9501497 W GB9501497 W GB 9501497W WO 9600642 A1 WO9600642 A1 WO 9600642A1
Authority
WO
WIPO (PCT)
Prior art keywords
mould
component
sheet
strip
gas
Prior art date
Application number
PCT/GB1995/001497
Other languages
English (en)
Inventor
Roger Mark Sloman
Original Assignee
Advanced Composites Group Limited
Aerovac Systems (Keighley) Limited
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
Priority claimed from GB9412910A external-priority patent/GB9412910D0/en
Priority claimed from GBGB9500555.9A external-priority patent/GB9500555D0/en
Application filed by Advanced Composites Group Limited, Aerovac Systems (Keighley) Limited filed Critical Advanced Composites Group Limited
Priority to AU27489/95A priority Critical patent/AU2748995A/en
Publication of WO1996000642A1 publication Critical patent/WO1996000642A1/fr

Links

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
    • 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
    • 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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/0038—Moulds or cores; Details thereof or accessories therefor with sealing means or the like
    • 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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B29C33/40—Plastics, e.g. foam or rubber
    • 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
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C43/3607—Moulds for making articles of definite length, i.e. discrete articles with sealing means or the like
    • 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
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • 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
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C43/3642—Bags, bleeder sheets or cauls for isostatic pressing
    • B29C2043/3644—Vacuum bags; Details thereof, e.g. fixing or clamping
    • 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
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/005—Using a particular environment, e.g. sterile fluids other than air
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/757—Moulds, cores, dies

Definitions

  • the present invention concerns an improved moulding method directed towards the moulding of components from fibre reinforced synthetic resinous material on moulds made from fibre reinforced synthetic resinous materials and to said moulds-
  • the impervious membrane is often attached to the peripheral regions of the mould by use of a sealant strip applied near the edge of the mould.
  • the mould must fulfil at least three criteria. Firstly, it must stay in shape during repeated moulding processes. Secondly, it must provide a satisfactory moulding surface. Thirdly, it must not leak, that is it must not be porous such that the vacuum between the mould and the membrane is destroyed or degraded during curing .
  • thermoplastic film within the structure of the mould with a view to minimising the extent of micro cracking.
  • a further solution has been to bond a sheet of a suitable rubber to the face of the mould remote from the face on which the component is supported. This rubber seldom extends around the edges of the tool to those areas at which the sealing strip is attached as it is generally not possible to place the sealant strip on the rubber itself as the characteristics of the two materials are incompatible. Furthermore, any rubber at the edges of the mould can easily be damaged.
  • the present invention is intended to provide a method of and apparatus for obviating or mitigating the problem presented by existing moulds and moulding methods .
  • a method for moulding a fibre reinforced synthetic resinous component comprising supporting the component on a fibre reinforced synthetic resinous mould, covering the component with a membrane sealed to the mould at its edges, evacuating gas from beneath the membrane and curing the component at an elevated temperature in an enclosure surrounding the mould and component, the method being characterised in that during the curing operation any material which could result in the oxidation material forming portions of mould in the vicinity of the surface supporting the component is kept out of contact with the exposed surfaces of the mould.
  • oxygen is removed from the atmosphere within the enclosure by evacuating the enclosure prior to its being pressurised by an inert non-oxidising gas such as nitrogen.
  • an inert non-oxidising gas such as nitrogen can be introduced into the air-filled enclosure to dispel the air therefrom. This operation may be repeated several times.
  • the oxygen content of the air within the enclosure may be chemically or physically absorbed either prior to or during pressurisation of the enclosure with an inert gas such as nitrogen prior to elevating the temperature to levels at which oxidation could take place.
  • apparatus for moulding a fibre reinforced synthetic resinous component comprising a fibre reinforced synthetic resinous material mould, a membrane adapted to cover synthetic resinous material to be moulded after it has been laid on the mould, sealing means for sealing the membrane to the mould, means for evacuating gas from beneath the membrane, means for elevating the temperature of the mould and its surrounds characterised in that the apparatus includes also means for preventing regions of the mould in the vicinity of the mould surface supporting the component being contacted by any material which could result in oxidation of the material forming the mould.
  • the apparatus includes an impervious sheet of a synthetic rubber-like material incorporated within or on the surface of the mould opposite to the surface supporting the material to be moulded and means for covering the said first surface of the mould at peripheral regions between the sealant strip and the edge of the impervious sheet, said covering means being impervious and capable of withstanding the elevated temperatures to which the mould is subjected during a curing cycle.
  • the said covering means comprises a further sheet of synthetic rubber-like material or an extension of said impervious sheet.
  • it may comprise a sheet of self-adhesive, heat resistant, material of, for example, polyester or polyimide fixed to the said peripheral regions.
  • the said peripheral regions are covered by a further sheet of synthetic rubber-like material
  • a second strip made from a material having substantially the same co-efficient of expansion as the material of the mould, being resistant to degradation resulting in porosity as a result of repeated thermal cycling and being capable of receiving in a gas-tight manner the said sealing strip .
  • apparatus as characterised in that it includes an impervious sheet of a synthetic rubber-like material incorporated within the mould below and in the vicinity of the surface supporting the material to be moulded, said further sheet extending over the surface of the mould at peripheral regions thereof mounting a second strip made from material having substantially the same co-efficient of expansion as the material of the mould being resistant to degradation resulting in porosity as a result of repeated thermal cycling and being capable of receiving in a gas-tight manner the said sealing strip.
  • the second strip is metallic and continous .
  • the reinforcement in the mould is carbon fibre and the second strip is Invar (Registered Trade Mark).
  • the reinforcement within the mould is glass fibre and the second strip is steel.
  • the said impervious sheet may be formed from a type of silicone rubber, the characteristics of which are such that it bonds with and cures with the material forming the mould.
  • the material forming the mould is a sheet of fibrous material pre-impregnated with resin and hardner (a prepreg) which itself is formed by a moulding operation .
  • an additional layer or layers of fibre reinforced resinous material are provided on the further impervious sheet covering the peripheral regions.
  • the sheet is provided on the rear of the mould it is bonded thereto during the manufacturing operation. Alternatively it may be adhered thereto by a suitable adhesive.
  • the self-adhesive sheet is formed from a medium weight polyester tape with a fully cured non-transforming pressure sensitive silicone adhesive applied to one side.
  • the present invention stems from the recognition that micro-cracking results from oxidation of the synthetic resinous material of the mould at elevated temperatures, particularly when the mould is subject to repeated moulding operations. By eliminating oxygen contact with exposed surfaces of the mould during the moulding operation micro-cracking by oxidation is eliminated thereby obviating or mitigating the problem of gas intrusion into the space between the mould and the membrane surrounding the component being moulded.
  • Fig. 1 shows apparatus for curing a synthetic resinous material, fibre reinforced component
  • Fig. 2 shows diagrammatically and in cross-section an edge portion of a first embodiment of a fibre reinforced resinous mould
  • F ⁇ igs. 3 and 4 show views similar to Fig. 2 of a second and third embodiment of a fibre reinforced resinous mould.
  • a component 10 is formed from a synthetic resinous material reinforced, for example, by glass, carbon or other fibrous material R supported during the moulding operation on a pre-formed fibre reinforced synthetic resinous material mould 12 whose shape matches the shape of the component being moulded.
  • the component 10 Prior to the moulding operation the component 10 is covered by a gas impervious membrane 14 which is attached to the mould 12 by a peripheral sealing strip 16 so that the space 18 between the membrane 14 and the mould 12 occupied by the component 10 can be evacuated by vacuum apparatus V.
  • the mould, component and membrane are placed in an oven or autoclave 13 provided with controlled heating means illustrated diagrammatically at 15. Prior to the application of heat to the autoclave its interior is treated to remove oxygen therefrom.
  • an inert gas is introduced to the closed autoclave through an inlet valve 17 while the air which has until that time occupied the autoclave is purged from the autoclave through valve 19.
  • the valves 17 and 19 are closed off so that the curing cycle can commence by the application of heat from the element 15.
  • an inert gas such as nitrogen, is introduced through the inlet valve 17 while air is discharged from the outlet valve 19 as described in the preceding paragraph.
  • the air can be removed by way of valve 19 and after removal replaced by an inert gas fed into the oven by way of the valve 17.
  • the oxygen content of the air within the autoclave may be chemically or physically absorbed either prior to or during pressurisation of the enclosure with an inert gas such as nitrogen. This operation is carried out prior to elevating the temperature of the autoclave to a level at which oxidation could take place.
  • the mould 12 has a sheet of impervious high temperature silicone rubber 20 fixed on its rear face, by the self adhesive properties of the sheet or by a suitable adhesive A.
  • the impervious sheet 20 reduces the porosity of the mould my eliminating any leaks through the structure of the mould by w,ay of micro cracks which are formed during repeated thermal cycling of the mould due mainly to oxidation of the resinous material of the mould.
  • the problem can be obviated or mitigated in theory by extending the sheet 20 beyond the edge 22 of the mould so that the sheet extension 20' extends over the top surface of the mould 12 around its periphery.
  • Invar Registered Trade Mark
  • the Invar strip 24 is located at the periphery of the mould in a position where it can receive on its upper surface the sealing strip 16. It is moulded into the high temperature silicone rubber impervious sheet extension 20' so that with a component 10 to be moulded on the mould 12 and covered by an impervious membrane 14 sealed to the edge regions of the mould by the sealing strip 16, a gas-tight joint can be achieved which, due to the material of the strip 24 can operate satisfactorily with a much increased life span. To protect the sheet 20 and its extensions 20' from damage the edge of the mould can be covered in a further layer 26 of synthetic resinous material.
  • steel is a suitable material for the strip 24.
  • the cross-section of the strip 24 can be of any suitable shape other than rectangular provided it provides a suitable sealing surface to accept the sealing strip. It is preferable that the strip 24 is continous around the periphery of the mould but it can be provided from a plurality of section which, preferably, are joined in end-to-end or overlapping relationship by a gas-tight joint.
  • the strip 24 can in other modifications be formed from carbon fibre and epoxy resin, glass fibre and epoxy resin or any suitable fibre and resin system which is impervious, compatible with the sealing strip and has a co-efficient of expansion compatible with the mould.
  • the peripheral regions of the mould form a downwardly directed flange 28, this enables the mould to be removeable supported on a suitably shaped former F at least some of the peripheral portions of which are adapted to abut the flange 28 and hold the mould lateral against movement relative to the support.
  • This is an advantageous support arrangement as it permits easy removal and replacement of the mould from the support surface without the need for any mechanical connections which, if used, must accommodate the ranges of temperature changes to which the mould is subjected in the oven and consequently are relatively complicated and expensive .
  • FIG. 3 A modified embodiment is illustrated in Fig. 3.
  • the sheet of impervious high temperature silicone rubber 20" is moulded into the structure of mould 12 during its manufacture.
  • the further impervious sheet projects out of the mould and extends along the top surface thereof around the periphery of the mould and the strip 24, adapted to receive the sealing strip 16, is in turn supported on the said extension 23 of the impervious sheet 20".
  • the modification illustrated in Fig. 3 is similar to that illustrated in Fig. 2.
  • the impervious sheet 25 can be incorporated in the mould 12 and extend from edge-to-edge of the mould. It has been discovered in practice that certain mould users, particularly where the number of times that the mould is re-used is likely to be low, wish to reduce the cost of the mould as far as possible and the embodiment shown in Fig.4 of the drawings illustrates a reduced cost mould which, whereas it is intended for relatively low levels of useage can, if necessary, be converted to a mould for high levels of useage.
  • the mould is formed in a manner exactly similar to that described with reference to Fig. 2 and is provided on its surface remote from the surface in which the item 10 to be moulded and the moulding consumables 11 are supported with a sheet 20 which is similar to the sheet 20 described with reference to Fig. 2 but terminates at the end of the flange 28.
  • This leaves exposes to the action of any oxidising gases within the oven the top surface of the mould around its periphery (including the outer surface of the flange 28) and the edge 30 of the mould.
  • the sealing strip 16 can once again be applied to a receptive surface, that is the uncovered upper surface of the mould 12.
  • a tape known as blue Flashtape 2 (supplied by Aerovac Systems (Keighley) Limited) is employed and it protects the otherwise exposed surfaces of the mould from micro-cracking due to oxidation, thereby further reducing the problem caused by the introduction of gas into the moulding compartment 18.
  • Tape of this type is formed from a medium weight polyester tape with a fully cured non-transferring pressure sensitive silicone adhesive applied to one side .
  • Flashtape can be readily achieved by hand and any breaks in the tape due, for example, to abrasion during use, can be readily repaired by sticking a further piece of tape over the abraded area.
  • the strip 24 can be eliminated and the time required to manufacture the mould reduced.
  • the mould user decides that the life span of his mould (as illustrated in Fig. 4) should be extended then it is a simple matter to remove the Flashtape 32 and replace it with a silicone rubber sheet extension 26 and a sealing strip 24 so that, effectively, the arrangement illustrated in Fig. 2 embodiemnt is achieved.
  • the sheet extension 26 overlaps the backing sheet 20 at the bottom end of the flange in the same manner that the Flashtape 32 extends over the outer peripheral edges of the backing sheet 20 in the Fig. 3 embodiment.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Manufacturing & Machinery (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

Procédé et dispositif de moulage d'un élément (10) résineux synthétique renforcé par des fibres, ce procédé consistant à placer l'élément à mouler sur un moule (12) formé à partir d'un matériau résineux synthétique renforcé, et à couvrir cet élément d'une membrane (14) imperméable scellée au moule (12) sur les bords de l'élément à l'aide d'une bande (16) de scellement, des moyens (17, 19; 20, 20', 20', 23, 24; 20, 32) étant conçus pour permettre aux surfaces non couvertes du moule (12) d'être gardées libres de tout matériau pouvant créer une oxydation du matériau du moule.
PCT/GB1995/001497 1994-06-28 1995-06-26 Procede et dispositif de moulage WO1996000642A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU27489/95A AU2748995A (en) 1994-06-28 1995-06-26 Moulding method and apparatus

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
GB9412910.3 1994-06-28
GB9412910A GB9412910D0 (en) 1994-06-28 1994-06-28 Improvements in or relating to moulds
GB9424907A GB2290742A (en) 1994-06-28 1994-12-09 Sealing mould assemblies
GB9424907.5 1994-12-09
GB9500555.9 1995-01-12
GBGB9500555.9A GB9500555D0 (en) 1995-01-12 1995-01-12 Improved moulding method

Publications (1)

Publication Number Publication Date
WO1996000642A1 true WO1996000642A1 (fr) 1996-01-11

Family

ID=27267257

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB1995/001497 WO1996000642A1 (fr) 1994-06-28 1995-06-26 Procede et dispositif de moulage

Country Status (2)

Country Link
AU (1) AU2748995A (fr)
WO (1) WO1996000642A1 (fr)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4671837A (en) * 1985-08-15 1987-06-09 Stewart Robert B Process for forming composite molds to be used in the manufacture of composite parts
EP0383667A1 (fr) * 1989-02-14 1990-08-22 L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude Procédé d'élaboration d'une atmosphère pour la fabrication d'éléments composites à haute performance
JPH03275321A (ja) * 1990-03-27 1991-12-06 Japan Steel Works Ltd:The オートクレーブ型真空プレス装置のための不活性ガス供給システム
EP0487868A2 (fr) * 1990-11-30 1992-06-03 Cytec Technology Corp. Outillage composite

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4671837A (en) * 1985-08-15 1987-06-09 Stewart Robert B Process for forming composite molds to be used in the manufacture of composite parts
EP0383667A1 (fr) * 1989-02-14 1990-08-22 L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude Procédé d'élaboration d'une atmosphère pour la fabrication d'éléments composites à haute performance
JPH03275321A (ja) * 1990-03-27 1991-12-06 Japan Steel Works Ltd:The オートクレーブ型真空プレス装置のための不活性ガス供給システム
EP0487868A2 (fr) * 1990-11-30 1992-06-03 Cytec Technology Corp. Outillage composite

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
DATABASE WPI Week 9204, Derwent World Patents Index; AN 92-028716 *

Also Published As

Publication number Publication date
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