WO2015159050A2 - Fabrication de composite renforcé de fibres - Google Patents

Fabrication de composite renforcé de fibres Download PDF

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Publication number
WO2015159050A2
WO2015159050A2 PCT/GB2015/051093 GB2015051093W WO2015159050A2 WO 2015159050 A2 WO2015159050 A2 WO 2015159050A2 GB 2015051093 W GB2015051093 W GB 2015051093W WO 2015159050 A2 WO2015159050 A2 WO 2015159050A2
Authority
WO
WIPO (PCT)
Prior art keywords
matrix
die
mould
composite
length
Prior art date
Application number
PCT/GB2015/051093
Other languages
English (en)
Other versions
WO2015159050A3 (fr
Inventor
Kevin Lindsey
Original Assignee
Far-Uk Ltd
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 Far-Uk Ltd filed Critical Far-Uk Ltd
Priority to GB1617824.6A priority Critical patent/GB2539849A/en
Publication of WO2015159050A2 publication Critical patent/WO2015159050A2/fr
Publication of WO2015159050A3 publication Critical patent/WO2015159050A3/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
    • 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
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
    • B29C44/32—Incorporating or moulding on preformed parts, e.g. linings, inserts or reinforcements
    • B29C44/332—Incorporating or moulding on preformed parts, e.g. linings, inserts or reinforcements the preformed parts being three-dimensional structures
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/36—Feeding the material to be shaped
    • B29C44/38—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length
    • B29C44/385—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length using manifolds or channels directing the flow in the mould
    • B29C44/386—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length using manifolds or channels directing the flow in the mould using a movable, elongate nozzle, e.g. to reach deep into the mould

Definitions

  • the present invention relates to the manufacture of fibre-reinforced composites, in particular to their manufacture in a continuous - rather than batch - process.
  • US5707571 discloses a process for making a fiber-reinforced thermoplastic, said process comprising the steps of: mixing a thermoplastic, a foaming agent, and a plurality of discrete expanded reinforcing fibers coated with a coupling agent which enhances bonding between said thermoplastic and the fibers and bonding between the fibers, each fiber exhibiting a length within the range from about 0.5 mm to about 25 mm in an extruder under conditions including: (a) sufficient heat and friction within said extruder to melt said thermoplastic and activate said coupling agent; and (b) a pressure sufficiently high to prevent premature expansion of said foaming agent, to form a molten, reinforced, unfoamed plastic; extruding said molten, reinforced, unfoamed plastic to atmospheric or lower pressure to form an extrudate wherein said fibers have an inherent orientation in said molten plastic induced by the directional shear forces of extrusion as said molten plastic exits the extruder; and allowing said foaming agent to expand at
  • a method of making a composite comprising a reinforcement in a solid matrix comprising the steps of:
  • the pressure in the die may move the composite within the die to increase the alignment of the fibres in the composite.
  • the method may comprise the step of moving the die and first location relative to one another in an arc or other complex shape non-linear path.
  • the method may comprise the step of providing two dies and simultaneously ejecting composite therefrom.
  • the dies may be configured such that the respective composites join together.
  • the die may have an inlet for introduction of matrix or the components of the matrix and an outlet for ejection of composite, the outlet having a greater cross-sectional area than that of the inlet.
  • the die may define a passageway interconnecting the inlet and outlet and increasing in cross-sectional area along its length.
  • the passageway may taper outwardly between the inlet to the outlet.
  • the passageway may be of uniform cross-section over a length adjacent the inlet.
  • the passageway may be of uniform cross-section over a length adjacent the outlet.
  • the length adjacent the outlet may contain a mandrel configured to form a bore in the resulting composite.
  • the mould cavity may be elongate, the lance being withdrawn along the length of the cavity.
  • the reinforcement may be a three-dimensional structure, in particular a braid.
  • the lance may be configured to extend inside the structure, in particular the braid, for injection of the matrix or the components of the matrix.
  • the bag may be placed inside the structure.
  • the structure is a braid
  • the bag may be placed inside the braid.
  • the reinforcement may be a fibre, in particular carbon or glass fibre.
  • the reinforcement may comprise fibres having lengths of less than or equal to 3mm and/or greater than 3mm.
  • the fibre may have a length greater than or equal to the length of the composite to be manufactured.
  • the fibre may be mixed with the matrix prior to introduction into the mould.
  • the fibre may be introduced into the mould separately from the matrix.
  • the step of expanding the matrix in the mould may comprise heating the matrix.
  • the step of heating the matrix may comprise curing the matrix.
  • the step of heating the matrix may comprise heating the mould.
  • the matrix may be a thermosetting material, in particular a polymer resin.
  • the matrix may be thermoplastic material, in particular a thermoplastic polymer.
  • the matrix may comprise a foaming agent. The foaming agent may be configured to expand when heated.
  • Figure 1 illustrates a method according to a first embodiment of the invention
  • Figure 2 illustrates a method according to a second embodiment of the invention
  • Figure 3 illustrates a method according to a third embodiment of the invention
  • Figures 4A and B are sectional views illustrating a method according to a fourth embodiment of the invention.
  • Figure 5 is a sectional view illustrating a method according to a fifth embodiment of the invention.
  • Figure 6 is a sectional view illustrating a method according to a sixth embodiment of the invention.
  • Figure 1 illustrates a method according to a first embodiment of the invention and is a sectional view of a mould 10 in the form of a die 10 having three contiguous surfaces 12, 14,16 that respectively define a mould cavity having a constant cross-section mixture inlet region 12' connected to a passageway comprising a tapered expanding throat section 14' connected to a (larger) constant cross-section region 16' having an outlet 18.
  • Reinforcing fibres 28 are mixed into a matrix of resin and foaming agent with fast-acting catalyst to form a mixture that is injected into the mould as indicated by arrow 20.
  • Fibres 28 comprise a mix of 'short' fibres of length less than or equal to 3mm and 'long' fibres of length greater than 3mm.
  • the fibres are typically carbon or glass, although other types of fibre may be used.
  • the resin is typically a thermosetting polymer resin, although thermoplastic resin may also be used.
  • a physical blowing agent may be used such as carbon dioxide or nitrogen gas.
  • the side wall surfaces 16 of the die form the external shape of the resultant composite 30 that leaves the outlet, the forward motion F of the material generating some corresponding alignment (in the direction F of material flow) of the fibres 28 in the composite.
  • the matrix solidifies (for thermoset materials, this is by a chemical - curing - reaction) to form a solid composite beam comprising reinforcement in a solid resin matrix 26.
  • FIG. 2 is a similar cross-sectional view to that of figure 1 and illustrating a method according to a second embodiment of the invention.
  • Resin and foaming agent are again mixed with fast-acting catalyst (with/without reinforcing fibres), which mixture is again injected (as indicated by arrow 20) into a die 10 having three regions 12, 14, 16 that respectively define a smaller volume mixture inlet 12', a tapered throat section 14' and a larger volume section 16' leading to an outlet 18.
  • a floating centre element or mandrel 40 Inside the die 10, particularly inside volume 16', is a floating centre element or mandrel 40 that allows hollow sections to be produced as is known per se.
  • FIG. 3 illustrates a method according to a third embodiment of the invention and shows a sectional view of a three-dimensional tubular reinforcing braid (indicated by dashed lines 50) provided inside a die 10.
  • resin and foaming agent are mixed with fast acting catalyst to form a mixture which is then injected inside the braid as indicated by arrow 20 by an injection lance 54 having an outlet 52.
  • the mixture foams and expands it increases the pressure in the die, forcing the braid to open up and compress against the surface of the die.
  • the foaming mixture can push through braid to form the external surface of the final composite product having a solid, cured resin matrix.
  • the process can use pre-made discrete lengths of braid or directly follow on the end of a continuous braiding machine to form a continuous process, resulting in reinforcement fibres that are as long as or longer than the manufactured composite article itself.
  • Figures 4A and B are sectional views illustrating a method according to a fourth embodiment of the invention.
  • long reinforcing fibres are mixed into resin and foaming agent with fast acting catalyst.
  • the mixture is then injected by injector 65 into an open mould tool in the form of a trough 10.
  • the mould is then sealed by a lid 60 placed on top, as shown in figure 4B.
  • the foaming mixture expands and increases the pressure in the mould, compressing against the mould trough and lid and consolidating to form a discrete length of solid beam comprising fibres in cured solid resin matrix.
  • the trough and lid may be disposable or may become part of the final beam.
  • the trough 10 may be configured to continuously traverse under the stationary lid section 60, thereby producing a continuous beam, the lid being of length sufficient to provide time for the mixture to foam against the tool and cure.
  • a continuous composite beam or the like can form curved and three-dimensional structures.
  • a first, solidified end of the beam is initially generated and anchored at a first stationary location. Beam generation then continues, the die being moved in space away from the anchor point (by a robot or similar) at a speed corresponding to the rate at which solid composite is ejected from the die, the direction in which the die is moved relative to the anchor point determining the overall shape of the solid composite.
  • anchor point can equally be moved in space away from the stationary die or both anchor point and die can move in space.
  • curved beams can be produced by moving the die on the end of the robotic arm in an arc relative to the anchor point. This means that complex shapes can be built up without the need for a mould.
  • the die outlet can be shaped to give the resulting composite a desired profile.
  • a door ring for an automobile can be shaped with the profile required for the door seals.
  • the methods of the present invention are particularly suited to the manufacture of automotive structures in general.
  • FIG. 5 is a sectional view illustrating a method according to a fifth embodiment of the invention.
  • An injection lance 70 having an outlet 75 is inserted into the open end 80 of a tool or mould 10 such that the outlet 75 lies adjacent the closed end 85 of the tool.
  • a mixture of resin, catalyst and foaming agent is pumped as indicated at 20 through lance 70 and outlet 75 and into the tool 10. As the mixture exits the lance it foams and compresses against the walls. Fibre reinforcement of the beam is achieved by the introduction of fibres into the resin mixture or by lining the tool with braid as indicated by dashed lines 90.
  • a solid beam comprising fibres in cured solid resin matrix is formed as the lance 70 is gradually withdrawn along the length of the tool through its open end as indicated by arrow W.
  • FIG. 6 is a sectional view illustrating a method according to a sixth embodiment of the invention.
  • a plastic bag 100 is filled with a mixture 20 of resin, catalyst and foaming agent.
  • the bag 100 is placed inside a three-dimensional reinforcement sock or tubular braid (indicated by dashed lines 110) of mingled thermoplastic fibres and continuous carbon or glass fibres of the kind sold under the brand name Twintex (RTM).
  • RTM Twintex
  • the cured mixture forms a matrix around the sock reinforcement.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Moulding By Coating Moulds (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)

Abstract

L'invention concerne un procédé de fabrication d'un composite comprenant un renforcement dans une matrice solide comprenant les étapes comprenant la fourniture d'un moule (10), l'introduction du renforcement (28) et de la matrice ou des éléments constitutifs de la matrice dans le moule; l'expansion de la matrice dans le moule de manière à augmenter la pression dans le moule, la pression dans le moule déplaçant le composite à l'intérieur du moule pour éjecter le composite du moule (10); l'éjection d'une première longueur de composite (30); l'ancrage de ladite première longueur au niveau d'un premier emplacement; puis l'éjection d'une seconde longueur de composite de manière continue sans interruption perceptible et d'un seul tenant avec ladite première longueur tout en déplaçant simultanément le moule et le premier emplacement l'un par rapport à l'autre.
PCT/GB2015/051093 2014-04-17 2015-04-10 Fabrication de composite renforcé de fibres WO2015159050A2 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB1617824.6A GB2539849A (en) 2014-04-17 2015-04-10 Manufacture of fibre-reinforced composite

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GBGB1406983.5A GB201406983D0 (en) 2014-04-17 2014-04-17 Manufacture of fibre-reinforced composite
GB1406983.5 2014-04-17

Publications (2)

Publication Number Publication Date
WO2015159050A2 true WO2015159050A2 (fr) 2015-10-22
WO2015159050A3 WO2015159050A3 (fr) 2015-12-10

Family

ID=50928951

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB2015/051093 WO2015159050A2 (fr) 2014-04-17 2015-04-10 Fabrication de composite renforcé de fibres

Country Status (2)

Country Link
GB (2) GB201406983D0 (fr)
WO (1) WO2015159050A2 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116945444A (zh) * 2023-07-18 2023-10-27 肥城三合工程材料有限公司 玄武岩纤维增强pvc复合材料的制备工艺

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3617594A (en) * 1969-06-06 1971-11-02 Specialty Converters Manufacture of foam-filled sheet products
US5707571A (en) * 1991-03-28 1998-01-13 Reedy; Michael Edward Process for producing fiber reinforced foam having a random orientations of fibers
DE102008013467A1 (de) * 2007-03-23 2008-11-13 Thomas Gmbh + Co. Technik + Innovation Kg Verfahren und Vorrichtung zur Herstellung eines Kunststoffprofils

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116945444A (zh) * 2023-07-18 2023-10-27 肥城三合工程材料有限公司 玄武岩纤维增强pvc复合材料的制备工艺
CN116945444B (zh) * 2023-07-18 2024-05-31 肥城三合工程材料有限公司 玄武岩纤维增强pvc复合材料的制备工艺

Also Published As

Publication number Publication date
GB2539849A (en) 2016-12-28
WO2015159050A3 (fr) 2015-12-10
GB201617824D0 (en) 2016-12-07
GB201406983D0 (en) 2014-06-04

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