WO2014202953A1 - Methods for composite material processing - Google Patents
Methods for composite material processing Download PDFInfo
- Publication number
- WO2014202953A1 WO2014202953A1 PCT/GB2014/051803 GB2014051803W WO2014202953A1 WO 2014202953 A1 WO2014202953 A1 WO 2014202953A1 GB 2014051803 W GB2014051803 W GB 2014051803W WO 2014202953 A1 WO2014202953 A1 WO 2014202953A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- mould
- preform
- carbon fibre
- impregnated carbon
- fibre material
- Prior art date
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Classifications
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- 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
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
- B29C70/345—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using matched moulds
-
- 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
- B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B11/00—Making preforms
- B29B11/14—Making preforms characterised by structure or composition
- B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
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- 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
- B29C31/00—Handling, e.g. feeding of the material to be shaped, storage of plastics material before moulding; Automation, i.e. automated handling lines in plastics processing plants, e.g. using manipulators or robots
- B29C31/04—Feeding of the material to be moulded, e.g. into a mould cavity
- B29C31/08—Feeding of the material to be moulded, e.g. into a mould cavity of preforms to be moulded, e.g. tablets, fibre reinforced preforms, extruded ribbons, tubes or profiles; Manipulating means specially adapted for feeding preforms, e.g. supports conveyors
Definitions
- the present invention relates to composite material processing, in particular to a compression moulding process suitable for moulding carbon fibre based composite material systems and a preparatory pre-moulding process.
- a pre-moulding process adapted for use with pre-impregnated carbon fibre materials to be used in the production of carbon fibre based composite components, the pre-moulding process comprising at least the steps of:
- a method for the production of carbon fibre based composite components comprising a compression moulding stage and a pre-moulding stage, the pre-moulding stage comprising at least the steps of:
- the compression moulding stage comprising at least the steps of: (i) inserting the frozen preform into a mould cavity;
- the term 'frozen' describes the pre-impregnated carbon fibre material or preform being substantially rigid, the matrix material (e.g. resin such as an epoxy) having been refrigerated or cooled so that it is no longer freely malleable or flexible.
- the matrix material e.g. resin such as an epoxy
- the pre-impregnated carbon fibre material is stored in step (a) at temperature at or below its freezing temperature. In this way, the pre-impregnated carbon fibre material is maintained in a substantially rigid, or semi-rigid, state.
- preforming of the pre-impregnated carbon fibre material of step (b) takes place at ambient temperature whereby the pre-impregnated carbon fibre material is in a malleable state.
- preforming of the pre-impregnated carbon fibre material reduces part anomalies and aids in the prediction of material flow during moulding, and in the prediction of subsequent material properties.
- debulking of the preform on the preforming tool of step (c) is carried out under vacuum.
- debulking of the preform reduces the number and/or size of voids within the preform and increases ply consolidation so that a high quality part may subsequently be formed.
- the preformed part(s) are kept in cold storage prior to compression moulding.
- the preformed shape is reinforced and the likelihood of deformation during transfer between further processing stages is reduced. This also enables easier placement of the part within the compression moulding tool during a subsequent moulding stage.
- the preformed parts are susceptible to stacking so that a stockpile of preforms ready for moulding can be maintained in advance.
- the mould is closed on stops which prevent the moulded part from being compressed below a desired or optimal part thickness.
- vacuum may be applied to the preform under compression, which helps to reduce the porosity of the moulded part.
- Figure 1 is a flowchart showing the general steps of a pre-moulding process in accordance with the invention
- Figure 2 is a flowchart showing the steps of a compression moulding process in accordance with the invention.
- FIG. 1 there is shown schematically the steps (a) - (d) of a pre- moulding process in accordance with one aspect of the invention, the pre-moulding process adapted for use with pre-impregnated carbon fibre materials that are to be used in the production of carbon fibre based composite components by subsequent moulding.
- step (a) pre-impregnated carbon fibre material, or 'prepregs', are received and stored.
- An Example of such a prepreg material is CYCOM® 934 epoxy prepreg. It will be appreciated that the method is not limited to use with such material, however, it has been noted that such material is particularly susceptible to the disclosed pre-moulding and compression moulding processes described herein. Generally, such materials have a time-limited shelf-life and may be initially received in either a refrigerated state or at ambient temperature. However, in step (a] the prepreg(s] are refrigerated during storage, preferably at a temperature below -12 ° C whereby they are maintained in a substantially rigid, or semi-rigid, state.
- prepregs are then transferred to a preforming tool for step (b), in which they are preformed to have a near net shape of the final product.
- the pregregs will have warmed to ambient temperature such that they are malleable and susceptible to forming over the preforming tool. In this way, they are able to take up the general tree-dimensional shape of the product or part being manufactured.
- preforming of the prepregs reduces part anomalies and aids the prediction of material flow during moulding and the prediction of subsequent material properties.
- a prepreg is then debulked in step (c). Debulking of the preform on the preforming tool is carried out under vacuum.
- debulking of the preform reduces the presence or likelihood of voids and increases ply consolidation so that a high quality part is subsequently produced.
- the preformed prepregs are stored at a reduced temperature in step (d) prior to subsequent moulding. In this way, preform is frozen. In this way, the preformed shape is reinforced and the likelihood of deformation during transfer to moulding stages is mitigated. This also enables easier placement of the part within the compression moulding tool during the subsequent moulding stage.
- the preformed parts are susceptible to stacking so that a stockpile of preforms ready for moulding can be maintained in advance. It will be apprenticed that such cold storage can be for extended periods of time, for example to build up stock ready for a moulding run.
- Compression moulds generally comprise two mould halves, one half being static, and the other half being movable such that the mould can be opened and closed.
- One or both mould halves may be heated.
- both mould halves are heated.
- the mould is associated with a press suitable to open and close the mould, and to apply pressure to a preform inserted therein.
- step (i) a frozen preform (not shown) is inserted into an open, heated mould cavity.
- the preform is generally placed in contact with the static mould half.
- step (ii) the movable mould half is moved towards a closed position proximate the static mould half.
- the mould is not closed at this stage, but rather the movable mould half is stopped at a distance spaced apart from the adjacent surface of the preform. This is referred to as the dwell position, and is maintained for a desired period of time in accordance with step (iii).
- step (iii) the preform is heated by the mould and facilitates material flow and improved conformance with the mould shape.
- the dwell distance and time parameters are selected based upon the desired material viscosity to be achieved. This step also serves to prevent dry areas on the preform and the subsequently formed part.
- step (iv) the mould is closed on stops at a desired pressure and maintained at the desired moulding temperature. By closing the mould on stops, a desired part thickness can be attained.
- vacuum may be applied to the preform under compression, which helps to reduce the porosity of the moulded part.
- step (v) there follows a cure cycle in which the mould is maintained in a closed position against the stops for a desired period. After curing, the mould is opened in step (vi)m whereby the part is removed and left to cool at ambient temperature.
Abstract
A method for the production of carbon fibre based composite components comprising a compression moulding stage and a pre-moulding stage, the pre-moulding stage comprising at least the steps of: (a) receiving and/or storing pre-impregnated carbon fibre material, the pre-impregnated carbon fibre material being preferably received/stored in a refrigerated or frozen state; (b) preforming the pre-impregnated carbon fibre material on a preforming tool to provide a preform having a near net shape of the final product; (c) debulking the preform on the preforming tool; and (d) storing the debulked preform at a reduced temperature so that it is frozen prior to the moulding stage.
Description
METHODS FOR COMPOSITE MATERIAL PROCESSING
Summary
The present invention relates to composite material processing, in particular to a compression moulding process suitable for moulding carbon fibre based composite material systems and a preparatory pre-moulding process.
Background
Current structural applications utilising composite technology require the properties of high performing materials such as carbon fibre, with maximum properties being ascertained by incorporating the fibres into woven or unidirectional forms. However, carbon fibre material systems are expensive in both material and processing costs, the processes typically being manual processes or processes requiring considerably long cycle times with limits on the product quality that can be achieved. It is therefore an object of the present invention to provide an improved and economical processing method for the production of carbon fibre based composite parts.
Summary of the Invention
In one aspect of the invention there is provided a pre-moulding process adapted for use with pre-impregnated carbon fibre materials to be used in the production of carbon fibre based composite components, the pre-moulding process comprising at least the steps of:
(a) receiving and/or storing pre-impregnated carbon fibre material, the pre- impregnated carbon fibre material being preferably received/stored in a refrigerated or frozen state;
preforming the pre-impregnated carbon fibre material on a preforming tool to provide a preform having a near net shape of the final product; debulking the preform on the preforming tool; and
storing the debulked preform at a reduced temperature so that it is frozen prior to a subsequent moulding stage.
In a further aspect of the invention, there is provided a method of compression moulding of carbon fibre based composite components, the method comprising at least the steps of:
(i) inserting a frozen preform into a mould cavity;
(if) moving the mould towards a closed position whereby at least one half of the mould cavity is maintained at a dwell position that is spaced apart from a surface of the preform;
(iii) maintaining the dwell position for a period of time;
(iv) closing the mould at a desired pressure and temperature to form a moulded component;
(v) curing the moulded component for a period of time; and
(vi) opening the mould to retrieve the moulded component. In a further aspect of the invention, there is provided a method for the production of carbon fibre based composite components comprising a compression moulding stage and a pre-moulding stage, the pre-moulding stage comprising at least the steps of:
(a) receiving and/or storing pre-impregnated carbon fibre material, the pre- impregnated carbon fibre material being preferably received/stored in a refrigerated or frozen state;
(b) preforming the pre-impregnated carbon fibre material on a preforming tool to provide a preform having a near net shape of the final product;
(c) debulking the preform on the preforming tool; and
(d) storing the debulked preform at a reduced temperature so that it is frozen prior to the moulding stage;
and the compression moulding stage comprising at least the steps of:
(i) inserting the frozen preform into a mould cavity;
(if) moving the mould towards a closed position whereby at least one half of the mould cavity is maintained at a dwell position that is spaced apart from a surface of the preform;
(iii) maintaining the dwell position for a period of time;
(iv) closing the mould at a desired pressure and temperature to form a moulded component;
(v) curing the moulded component for a period of time; and
(vi) opening the mould to retrieve the moulded component.
It will be appreciated that the term 'frozen' describes the pre-impregnated carbon fibre material or preform being substantially rigid, the matrix material (e.g. resin such as an epoxy) having been refrigerated or cooled so that it is no longer freely malleable or flexible.
Preferably, the pre-impregnated carbon fibre material is stored in step (a) at temperature at or below its freezing temperature. In this way, the pre-impregnated carbon fibre material is maintained in a substantially rigid, or semi-rigid, state. Preferably, preforming of the pre-impregnated carbon fibre material of step (b) takes place at ambient temperature whereby the pre-impregnated carbon fibre material is in a malleable state. Advantageously, preforming of the pre-impregnated carbon fibre material reduces part anomalies and aids in the prediction of material flow during moulding, and in the prediction of subsequent material properties.
Preferably, debulking of the preform on the preforming tool of step (c) is carried out under vacuum. Advantageously, debulking of the preform reduces the number and/or size of voids within the preform and increases ply consolidation so that a high quality part may subsequently be formed.
Advantageously, in the storage step (d), the preformed part(s) are kept in cold storage prior to compression moulding. In this way, the preformed shape is
reinforced and the likelihood of deformation during transfer between further processing stages is reduced. This also enables easier placement of the part within the compression moulding tool during a subsequent moulding stage. Advantageously also, the preformed parts are susceptible to stacking so that a stockpile of preforms ready for moulding can be maintained in advance.
Preferably, during closing of the mould in step (iv), the mould is closed on stops which prevent the moulded part from being compressed below a desired or optimal part thickness.
Optionally, in an intermediate step ((iv(a)), vacuum may be applied to the preform under compression, which helps to reduce the porosity of the moulded part.
Embodiments of the present invention will now be described by way of example only, and with reference to the accompanying Figures in which:
Figure 1 is a flowchart showing the general steps of a pre-moulding process in accordance with the invention; and Figure 2 is a flowchart showing the steps of a compression moulding process in accordance with the invention.
With reference to Figure 1, there is shown schematically the steps (a) - (d) of a pre- moulding process in accordance with one aspect of the invention, the pre-moulding process adapted for use with pre-impregnated carbon fibre materials that are to be used in the production of carbon fibre based composite components by subsequent moulding.
In step (a], pre-impregnated carbon fibre material, or 'prepregs', are received and stored. An Example of such a prepreg material is CYCOM® 934 epoxy prepreg. It will be appreciated that the method is not limited to use with such material, however, it has been noted that such material is particularly susceptible to the disclosed pre-moulding and compression moulding processes described herein. Generally, such materials have a
time-limited shelf-life and may be initially received in either a refrigerated state or at ambient temperature. However, in step (a] the prepreg(s] are refrigerated during storage, preferably at a temperature below -12 ° C whereby they are maintained in a substantially rigid, or semi-rigid, state.
From their refrigerated storage, prepregs are then transferred to a preforming tool for step (b), in which they are preformed to have a near net shape of the final product. At this stage the pregregs will have warmed to ambient temperature such that they are malleable and susceptible to forming over the preforming tool. In this way, they are able to take up the general tree-dimensional shape of the product or part being manufactured. Advantageously, preforming of the prepregs reduces part anomalies and aids the prediction of material flow during moulding and the prediction of subsequent material properties. While on the preforming tool, a prepreg is then debulked in step (c). Debulking of the preform on the preforming tool is carried out under vacuum. Advantageously, debulking of the preform reduces the presence or likelihood of voids and increases ply consolidation so that a high quality part is subsequently produced. After debulking, the preformed prepregs are stored at a reduced temperature in step (d) prior to subsequent moulding. In this way, preform is frozen. In this way, the preformed shape is reinforced and the likelihood of deformation during transfer to moulding stages is mitigated. This also enables easier placement of the part within the compression moulding tool during the subsequent moulding stage. Advantageously also, the preformed parts are susceptible to stacking so that a stockpile of preforms ready for moulding can be maintained in advance. It will be apprenticed that such cold storage can be for extended periods of time, for example to build up stock ready for a moulding run. Referring to Figure 2, there is shown schematically the steps (i) - (vi) of a compression moulding process in accordance with one aspect of the invention.
Compression moulds (not shown) generally comprise two mould halves, one half being static, and the other half being movable such that the mould can be opened and closed. One or both mould halves may be heated. Preferably, both mould halves are heated. The mould is associated with a press suitable to open and close the mould, and to apply pressure to a preform inserted therein.
In step (i), a frozen preform (not shown) is inserted into an open, heated mould cavity. The preform is generally placed in contact with the static mould half. In step (ii), the movable mould half is moved towards a closed position proximate the static mould half. The mould is not closed at this stage, but rather the movable mould half is stopped at a distance spaced apart from the adjacent surface of the preform. This is referred to as the dwell position, and is maintained for a desired period of time in accordance with step (iii). In step (iii), the preform is heated by the mould and facilitates material flow and improved conformance with the mould shape. The dwell distance and time parameters are selected based upon the desired material viscosity to be achieved. This step also serves to prevent dry areas on the preform and the subsequently formed part.
In step (iv), the mould is closed on stops at a desired pressure and maintained at the desired moulding temperature. By closing the mould on stops, a desired part thickness can be attained.
In an optional intermediate step ((iv(a)), vacuum may be applied to the preform under compression, which helps to reduce the porosity of the moulded part.
In step (v), there follows a cure cycle in which the mould is maintained in a closed position against the stops for a desired period.
After curing, the mould is opened in step (vi)m whereby the part is removed and left to cool at ambient temperature.
After moulding, removal and cooling, formed parts and components can then be transferred for secondary processing and inspection as shown in Figure 1.
It will be appreciated that the composite moulding processes in accordance with the aspects of the invention described above provide significant advantages over other composite processing methods. For example, unlike the case with resin transfer moulding (RTM) or autoclaving, in the process defined by steps (i) - (vi), there is no need for ramping up the temperature of, or cooling down, the moulding tools. This enables a significant reduction in part production cycle time thereby reducing production costs and enabling an increase in throughput. Carbon fibre composite products and parts formed from the compression moulding process benefit from other advantages:
• Highly repeatable products with "class A" surfaces; unlike carbon fibre moulded in autoclave, both surfaces of a part display this level of quality.
• Greater pressures aid in higher material consolidation and reduction in failure, inducing anomalies.
• Reduced cycle times due to lack of ramp up and cool down times in moulding.
• Reduced cycle times due to pressure and heat producing comparable product properties at lower cycle times than expected.
• Improved manufacturing throughput The disclosed process enables the production of lower cost products utilising high performance carbon fibre material systems. This facilitates further product developments and creations of product ranges which could otherwise not be produced by current production means or at current costs.
It will be appreciated that the various aspects of the present invention can be practiced alone or in combination with one or more of the other aspects, as will be appreciated by those skilled in the relevant arts. The various aspects of the
invention can optionally be provided in combination with one or more of the optional features of the other aspects of the invention. Also, optional features described in relation to one embodiment can typically be combined alone or together with other features in different embodiments of the invention.
Claims
1. A method for the production of carbon fibre based composite components comprising a compression moulding stage and a pre-moulding stage, the pre- moulding stage comprising at least the steps of:
(a) receiving and/or storing pre-impregnated carbon fibre material, the pre- impregnated carbon fibre material being preferably received/stored in a refrigerated or frozen state;
(b) preforming the pre-impregnated carbon fibre material on a preforming tool to provide a preform having a near net shape of the final product;
(c) debulking the preform on the preforming tool; and
(d) storing the debulked preform at a reduced temperature so that it is frozen prior to the moulding stage.
2. A method as claimed in claim 1, wherein the compression moulding stage comprises at least the steps of:
(i) inserting the frozen preform into a mould cavity;
(if) moving the mould towards a closed position whereby at least one half of the mould cavity is maintained at a dwell position that is spaced apart from a surface of the preform;
(iii) maintaining the dwell position for a period of time;
(iv) closing the mould at a desired pressure and temperature to form a moulded component;
(v) curing the moulded component for a period of time; and
(vi) opening the mould to retrieve the moulded component.
3. A method as claimed in claim 1 or in claim 2, wherein the pre-impregnated carbon fibre material is stored in step (a) at temperature at or below its freezing temperature.
4. A method as claimed in any preceding claim, wherein preforming of the pre- impregnated carbon fibre material of step (b) takes place at ambient temperature whereby the pre-impregnated carbon fibre material is in a malleable state.
5. A method as claimed in any preceding claim, wherein debulking of the preform on the preforming tool of step (c) is carried out under vacuum.
6. A method as claimed in any of claims 2 to 5, wherein during closing of the mould in step (iv), the mould is closed on stops to prevent a moulded part from being compressed below a desired or optimal part thickness.
7. A method as claimed in any of claims 2 to 6, optionally comprising an intermediate step ((iv(a)), wherein vacuum is applied to the preform under compression.
8. A composite component produced by the method as claimed in any of claims 1 to 7.
9. A mould arranged to implement the method as claimed in claim 6 or claim 7.
10. A method of compression moulding carbon fibre based composite components, the method comprising at least the steps of:
(i) inserting a frozen pre-impregnated carbon fibre preform into a mould cavity;
(ii) moving the mould towards a closed position whereby at least one half of the mould cavity is maintained at a dwell position that is spaced apart from a surface of the preform;
(iii) maintaining the dwell position for a period of time;
(iv) closing the mould at a desired pressure and temperature to form a moulded component;
(v) curing the moulded component for a period of time; and
(vi) opening the mould to retrieve the moulded component.
11. A method as claimed in claim 10, wherein during closing of the mould in step (iv), the mould is closed on stops to prevent a moulded part from being compressed below a desired or optimal part thickness.
12. A method as claimed in any of claims 10 or claim 11, optionally comprising an intermediate step ((iv(a)), wherein vacuum is applied to the preform under compression.
Applications Claiming Priority (2)
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GB1310930.1A GB2515316B (en) | 2013-06-19 | 2013-06-19 | Methods for composite material processing |
GB1310930.1 | 2013-06-19 |
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GB201310930D0 (en) | 2013-07-31 |
GB2515316B (en) | 2018-02-07 |
GB2515316A (en) | 2014-12-24 |
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