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
  • B29C70/42—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
  • B29C70/48—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 and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
• • 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
  • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
  • B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
  • B29C63/04—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material by folding, winding, bending 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
  • B29C70/06—Fibrous reinforcements only
  • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
  • B29C70/088—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of non-plastics material or non-specified material, e.g. supports
• • 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
  • B29C70/302—Details of the edges of fibre composites, e.g. edge finishing or means to avoid delamination
• • 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
  • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
  • B29C70/70—Completely encapsulating inserts
• • 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
  • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
  • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
  • B29C70/865—Incorporated in coherent impregnated reinforcing layers, e.g. by winding completely encapsulated
• • 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
  • B29C70/88—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
  • B29C70/887—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced locally reinforced, e.g. by fillers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/38—Layered products comprising a layer of synthetic resin comprising epoxy resins
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
  • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
  • B32B3/04—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
  • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
  • B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B38/00—Ancillary operations in connection with laminating processes
  • B32B38/08—Impregnating
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
  • B32B5/024—Woven fabric
• • 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
  • B29L2031/771—Seats
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B38/00—Ancillary operations in connection with laminating processes
  • B32B2038/0052—Other operations not otherwise provided for
  • B32B2038/0076—Curing, vulcanising, cross-linking
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
  • B32B2260/02—Composition of the impregnated, bonded or embedded layer
  • B32B2260/021—Fibrous or filamentary layer
  • B32B2260/023—Two or more layers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
  • B32B2260/04—Impregnation, embedding, or binder material
  • B32B2260/046—Synthetic resin
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/10—Inorganic fibres
  • B32B2262/101—Glass fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/10—Inorganic fibres
  • B32B2262/106—Carbon fibres, e.g. graphite fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2479/00—Furniture
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2605/00—Vehicles
  • B32B2605/003—Interior finishings
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2605/00—Vehicles
  • B32B2605/08—Cars

Definitions

• the present invention relates to a method of manufacturing reinforced lightweight composites and to reinforced lightweight composites manufactured according to said method. More particularly, the present invention relates to a Resin Transfer Moulding (or, “RTM”) method of manufacturing reinforced lightweight composite components which are reinforced at the edge, and to reinforced lightweight composite components manufactured accordingly, such as essentially two-dimensional or shell-like reinforced lightweight composite components, such as composite shells for passenger seats, or the like.
• RTM Resin Transfer Moulding
• Resin T ransfer Moulding refers to a closed-mould method of manufacturing composites wherein, initially, fibres are disposed on a lower mould, then an upper mould is closed onto the lower mould and, finally, a resin mixture is injected through the mould into a mould cavity defined between the lower and upper moulds, which cavity contains said fibres ready for impregnation.
• the fibres may be in the form of a woven cloth, but other fibre packs or fibre lay-ups are equally possible.
• RTM is therefore a method that may be used to manufacture composite components quickly and efficiently, thereby reducing costs.
• RTM mechanical stiffness at the edge.
• These concerns have limited the suitability of RTM for the manufacturing of composite structural components, i.e. components designed to transmit significant loads despite their light weight.
• l Manufacturers have successfully resolved the above problem by using ‘open-trench’ cross- sectional designs around the edges of such components. These designs do offer at least a degree of localised three-dimensionality, at the periphery, which increases stiffness.
• the unavoidable edge recesses may not always be acceptable from a technical, aesthetical and/or regulatory point of view, depending on the category of the components, and their ultimate applications and related norms and/or standards.
• US 2013/0127092 A1 discloses moulded multilayer plastics components with continuously reinforced fibre plies, and a process for producing these components.
• Each component has a sandwich structure that comprises an internal reinforcement, that may be made of a foam material, embedded between two or more outer plies of fibre composite plastic.
• the component Around the periphery, the component has a coherent edge made of fibre reinforced plastic formed through peripheral overdimensioning of at least one of the fibre plies with respect to the internal structure.
• the method comprises (a) providing a fibre preform on a first mould surface, wherein said fibre preform comprises a first portion for reinforcing the composite component (i.e. a first reinforcement portion) comprising a reinforcement filler disposed at an edge region of the fibre preform, and a second, non-reinforced portion that conforms to the first mould surface.
• a first portion for reinforcing the composite component i.e. a first reinforcement portion
• a reinforcement filler disposed at an edge region of the fibre preform
• second, non-reinforced portion that conforms to the first mould surface.
• preform we intend any arrangement of fibres with and filler that have been adequately prepared as described herein on the first mould surface in readiness for impregnation using RTM.
• the method may thus further comprise, in some implementations, disposing one or more layers of fibres on the first mould surface of a first mould part.
• said fibres may take any suitable description.
• said fibres may be an essentially two- dimensional cloth (such as a woven or non-woven cloth), or a three-dimensional stack or layup comprising multiple such layers.
• Other fibre packs would however be equally possible.
• three fibre layers each in the form of a fibre mat may be disposed one on another to form a three-layer lay-up.
• the first mould part may be, for example, a lower mould half, which may be particularly practical for the advantageous use of gravity for disposing the fibres.
• a lower mould half which may be particularly practical for the advantageous use of gravity for disposing the fibres.
• other possibilities are contemplated.
• the method may also comprise disposing the filler on said fibre layer, mat or lay-up, the filler being adapted to provide localized edge reinforcement to the ultimate composite component.
• the filler does not necessarily need to provide reinforcement in light of its own mechanical properties. This would be the case, for example, if the filler was made of metal or other strong material with mechanical properties.
• the filler only needs to provide an element around which fibres can be wrapped, so as to confer to the composite component a localised level of three-dimensionality yet avoiding a recessed or open-trenched design.
• the filler - which will be of any suitable construction and shape, for example an expandable foam, or any other suitable structure or material - must not be disposed across substantially the whole layer or layers of fibres, that is across the whole area of the mould surface of the first mould part, as instead would have been the case, for example, for a wholly reinforced, layered composite structure.
• the filler is intended to reinforce only a region of the finished component, which region will be reinforced only in correspondence of the filler, i.e. where the filler is present, at or close to the edge of the finished component.
• the resulting fibre preform (that is the fibre arrangement disposed on the mould in readiness for impregnation by RTM) will generally mainly extend across two dimensions (except in correspondence of the filler, which provides a localised three- dimensional shape to the composite component).
• the reinforcing filler may accordingly be provided in the form of a lump or lumps of material, or in the shape of, just as an example, one or more one-dimensional structures, such as a rope, a line or the like. Other forms or configurations, however, will be possible.
• the method may also comprise forming a fibre loop around said reinforcing filler.
• a fibre loop around said reinforcing filler.
• a portion of a fibre mat, or fibre layer or multi-layer fibre lay-up may be wrapped around the filler.
• new fibres could be used.
• the loop of fibres around the filler will be preferably continuous, that is the filler will be completely embedded into fibres. However, the filler could otherwise be only partially wrapped with fibres. Likewise, it is not necessary that the whole length of said edge of the composite component be so reinforced.
• the method also comprises (b) disposing a second mould surface relative to the first mould surface, such that a mould cavity is defined between the first and second mould surfaces, wherein the second mould surface comprises first, and second mould surface areas adapted to conform, respectively, to the first and second portions of the fibre preform, wherein the second mould surface area also conforms to the first mould surface.
• the method may comprise disposing a second mould part relative to said first mould part, such that the mould cavity is defined between said first mould surface of the first mould part and a second mould surface of said second mould part, said mould cavity containing said fibre loop and filler, and at least a remaining portion of said fibres.
• the method also comprises (c) transferring a mixture into said mould cavity, said mixture comprising a resin and a curing agent, and allowing said mixture to impregnate said first and second portions of the fibre preform.
• resins such as epoxy resins
• curing agents are possible, as known in the arts of RTM. It will be important to achieve a viscosity of the mixture that allows the mixture to properly impregnate the fibres, but this aspect too is known from the RTM arts.
• the finished edge-reinforced composite component will thus present a reinforced region as well as a non-reinforced region in connection with the remaining portion of the fibres. This is in the interest of manufacturing a component which is light in weight, yet sufficiently strong at the edge, to provide structural performance to said component.
• Figure 1 represents a fibre lay-up on a lower mould half in accordance with the prior art
• Figure 2 shows an upper mould half closed on the lower mould half of Figure 1 , also according to the prior art
• Figure 3 represents a fibre lay-up on a lower mould half in accordance with the present disclosure
• Figure 4 shows a reinforcing filler deposed on the fibres of Figure 3;
• Figure 5 shows the creation of a loop of fibres around the filler of Figure 4.
• Figure 6 shows an upper mould half closed on the lower mould half of Figures 3, 4 and 5;
• Figure 7 represents the injection of a resin mixture into a cavity of the closed mould of Figure 6, and the resin mixture’s subsequent heating;
• Figure 8 shows a method of applying a surface finish to a reinforced lightweight composite component manufactured according to the method shown in Figures 3-7;
• Figure 9 shows a demoulded edge-reinforced lightweight composite component manufactured as described herein;
• Figure 10 is a comparison between cross sections of similar components manufactured using a standard autoclave method (Figure 10A), a standard RTM method (Figure 10B) and the presently disclosed RTM method (Figure 10C); and,
• Figure 11 shows a sport car seat comprising composite components manufactured as described herein:
• Figure 11 A is a partial, front perspective view of a portion of the seat;
• Figure 11 B is a top plan view of the seat of Figure 11 A;
• Figure 11C is a cross section representation of the seat of Figures 11A and 11 B according to plane A-A of Figure 11 B;
• Figure 11 D is a cross section representation of the seat of Figures 11 A, 11 B and 11 C along plane B-B of Figure 11B (all the stated radius dimensions are in mm, and the drawings are not to scale).
• Figures 1 and 2 represent a conventional RTM method for manufacturing a lightweight, edge- reinforced composite component.
• a fibre preform 11 in this case consisting of a fibre cloth 16 of substantially uniform thickness, is accommodated on a first mould surface 31 provided on a first mould half 34, as shown in Figure 1.
• the finished product 2 this is visible in Figure 10.
• the first mould half 34 has been provided with a recessed design. Accordingly, an edge portion 17 of the fibre cloth 16 can be accommodated on a recess 37 formed by the first mould surface 31.
• an upper mould half 35 is then disposed on the first mould half 34 to form a mould cavity 33 around the fibre cloth 16 forming the fibre preform 11 - as shown.
• the mould cavity 33 is provided so as to receive a resin mixture 40 (shown in Figure 7) through a transfer channel 36 which, in this case, is formed on the upper mould half 35 (but could be located elsewhere, for example on the lower mould half 34, or this channel 36 could alternatively have been defined or provided between the two different mould parts 34, 35).
• the cavity 33 is bound by the first mould surface 31 introduced above in connection with Figure 1, and by a second mould surface 32 provided on a lower face of the upper mould half 35.
• the second mould surface 32 is generally shaped to conform to the first mould surface 31 (including its recess 37) and, accordingly, the fibre preform 11 , as disposed on the first mould surface 31.
• the first and second mould halves 34, 35 are secured together (for example by using a set of clamps, but other manners are equally possible), but these details are of no importance to the present disclosure and will therefore not be described further.
• the resin mixture 40 can be transferred to the cavity 33 through the transfer channel 36.
• the final product 2 is shown in Figure 10B. This is a reinforced lightweight composite component 2 which exhibits an open trench OT on at least one of its edges.
• the open-trenched portion OT of the edge of the composite component 2 has a generally three-dimensional extension or envelope (as opposed to the remainder of the component 2, which instead is essentially two- dimensional), which, as such, can better resist forces, especially bending moments acting out- of-plane.
• FIGs 3 to 5 there are shown preparations for carrying out an improved RTM method which disposes of the issues related to the open-trench OT described above.
• a fibre mat 16 similar to that described in connection with Figures 1 and 2.
• Other similar features shown in Figure 3 are the first mould half 34, and the first mould surface 31 and its recess 37, so these features will not be described further. It is noted, however, that the recess 37 in the first mould half 34 of Figure 3 is different than the recess 37 in the first mould half 34 of Figures 1 and 2.
• the fibre mat 16 has, with respect to the fibre mat 16 of Figures 1 and 2, some additional length at the edge region 17, and that in this edge region 17 the thickness of the fibre mat 16 narrows slightly compared to the thickness of the remainder of the fibre mat 16. It is equally possible that said thickness be unchanged, or it could increase.
• the additional length at the edge region 17 is so that the fibre mat 16 may receive, after the fibre mat 16 has been disposed on the first mould surface 31, a reinforcement filler 13, which in the described implementation is in the form of a length of a material, in this case a foam (but other materials can in principle be used, such as a rope or the like) - as shown in Figure 4.
• the filler 13 has in this case a circular cross section 14, but other cross-sectional shapes would however be possible. Likewise, the filler 13 does not need to be a length of material, but lumps or discrete portions of filler 13 may similarly be used. The filler 13 does not provide reinforcement through the whole structure, so as not to defeat the advantages of conventional RTM (that is, to maintain lightness). Most of the composite component manufactured as described herein is according to conventional RTM, except for the reinforced edge.
• Figure 4 shows the filler 13 in association with the fibre mat 16, and the recess 37 defined by the first mould surface 31. Multiple fibre mats could however likewise be used, depending on the required structural performance of the component.
• the recess 37 of the first mould surface 31 is sized and shaped to receive the filler 13. Accordingly, depending on the size and shape of the filler 13, and its cross section 14, the recess 37 may take different shapes. It is not necessary for this shape to be constant along the edge region 17 of the fibre mat, since variations are possible and indeed contemplated, depending on the applications. Disposition of the filler 13 on the fibre mat 16 defines first and second fibre preform portions 12, 22. The first fibre preform portion 12 is located at the edge region 17 of the fibre mat 16, and the second fibre preform portion 22 instead comprises, in this case, all the rest of the fibre mat 16. However, it will be understood that there is no requirement for this second fibre preform portion 22 to extend to comprehend the total of the remainder portion of the fibre mat 16.
• the additional length of fibre mat 16 is folded backwardly from the position shown in Figure 4 to - in this occurrence - completely wrap, surround and therefore cover the filler 13, as shown.
• the filler 13 may only at least partially be wrapped or surrounded by fibres.
• new fibres could be added for at least partially wrapping or surrounding the filler 13. The order of these operation can be reversed, in that first it would be possible to dispose fibres for wrapping around the filler, once the filler has been disposed on the lower mould half, and then additional fibres could be laid on the lower mould half.
• a loop 18 is defined by the fibre mat 16 by folding the fibre mat 16 at the edge region 17 over the filler 13.
• a distal end 19 of the fibre mat 16 is folded backwards over the filler 13 until it abuts the fibre mat 16 at an abutment 20.
• the filler 13 is completely enclosed and embedded into fibres - but partial embedment is a possibility at other places along the edge region 17 of the fibre mat, or the filler may be completely enclosed so as not to be longer visible, depending on the application.
• the loop 18 comprises a gap G to allow expansion of the filler 13 with heat H, as will be described further below. Expansion of the filler 13 with temperature may be advantageous, because the expanded filler 15 (see, for example, Figure 8) can then provide adequate support to the incoming resin mixture 40 around the whole internal surface of the fibre loop 18, such that there are no gaps in the finished product, and thus no weakness points. It is of course possible to use fillers that have controlled expansion rates at the relevant moulding temperatures.
• Figure 5 shows the preform 11 ready for impregnation, according to the method described herein.
• Figure 6 shows the disposition of an upper mould half 35 on the lower mould half 34, in principle similar to the arrangement shown in Figure 2. Like features, accordingly, will not be repeated. However, with the upper mould half in place, it is now possible to distinguish on the second mould surface 32 two distinct mould surface areas, which we refer to as first and second mould surface areas 32a, 32b, respectively.
• the first mould surface area 32a is associated with the first fibre preform portion 12
• the second mould surface area 32b is associated with the second fibre preform portion 22, as shown.
• the first mould surface area 32a is designed and shaped to accommodate the fibre loop 18, and the filler 13, while the second mould surface area 32b is essentially as in the prior art, that is it is simply designed to accommodate the fibre preform 11 , and thus conforms to the fibre preform 11 and the first mould surface 31, at those locations.
• a resin mixture 40 can be poured - with or without the help of a positive pressure applied externally of the mould 30 - into the mould cavity 33 directly through the transfer channel 36.
• the cavity 33 is now shaped according to the first and second mould surfaces 31, 32 to accommodate the reinforcing filler 13 at one edge of the finished product.
• the resin mixture then impregnates the fibres in the cavity 33, as shown in Figure 7.
• FIG 7 schematically shows the transfer of the resin mixture 40 into the cavity 33 of Figure 6.
• the resin mixture 40 is made up of a resin 41 and a curing agent 42, as known in the arts of RTM.
• a positive pressure P is imparted to the resin mixture 40 outside of the mould 30, for example by a pump (not shown).
• a vacuum pump could be applied to the cavity 33, for example through the separation between the lower and upper mould halves 34, 35. It is not necessary that the resin mixture 40 be premixed.
• the resin 41 and the curing agent 42 could be mixed locally, just before the mixture is injected into the cavity 33, as schematically represented in Figure 7, or they could in principle mix in the cavity, although this is less preferred.
• a heater H is operatively coupled to the lower mould half 34 (but this could be equally applied to upper mould half 35) to heat the mould 30, thereby helping the transfer of the resin mixture 40 as well as the curing of the resin mixture 40 in the mould 30, if necessary.
• a number of heaters H may be used in place of the single heater H of Figure 7, and any of these heaters may operate according to different principles, for example conduction and/or convection. However, these details are not relevant to the present disclosure.
• the filler material may need to be adequately specified to provide an intended level of expansion at the moulding temperatures. Also, the one or more heaters H will be selected and operated accordingly.
• the demoulded reinforced lightweight composite component is, in this implementation, finished with the application of a number of aesthetic layers 50 of a thin carbon composite (skin).
• a suitable adhesive which may be a different adhesive or the same resin mixture 40 used in the RTM method described herein. Curing may be favoured by increased temperatures as well as by pressure obtained by placing the demoulded part in a vacuum bag VB, as also shown in Figure 8, wherein a vacuum V is formed by a vacuum pump (not shown) operatively connected to the vacuum bag.
• a vacuum V is formed by a vacuum pump (not shown) operatively connected to the vacuum bag.
• Figures 8 and 9 show the expanded filler 15, inside the resin impregnated fibre loop 18.
• the application of the skin may be preceded by sandblasting, if required.
• FIG 9 shows a finished reinforced lightweight composite component 10 manufactured using the improved RTM method described herein.
• This component 10 comprises an edge- reinforced section 10a as well as a non-reinforced section 10b.
• the reinforced section 10a has an increased edge stiffness comparable to that of an equivalently reinforced portion 2a of the prior art component 2 which was previously briefly described in connection with Figures 1 and 2 and is shown in Figure 10B.
• the presently disclosed component 10 does not comprise an edge featuring an open trench OT, as the other component 2, but an edge defined by a ‘close trench’ CT, as shown in Figure 10C.
• the components 2, 10 are manufactured for the same application, i.e. as carbon composite parts of a vehicle seat S, which is shown in Figure 11.
• the two non-reinforced portions 2b, 10b of the two respective composite components 2, 10 being compared are generally equivalent in terms of mechanical performance.
• the composite component 10 described herein retains the advantages of conventional RTM forming (that is the ability to achieve good structural properties while maintaining ease of manufacture and therefore relatively low cost) throughout most of its structure, while it greatly improves the shape of the stiffened edge.
• Figure 10A also shows an equivalent car seat composite component 1 manufactured using a standard autoclave process.
• the finish layer 50 may be disposed around a foam core, as shown in Figure 10A.
• other principles may be followed to allow for a hollow cavity, where needed.
• This prior art method results into components 1 which may be too expensive to produce, since this method, as it can be appreciated, is not really suitable to mass production.
• autoclave manufacturing would be able to confer to these components the required lightness and strength, the latter typically by laying up multiple layers.
• the open trench component 2 achieved using conventional RTM lends itself to the production of robust, light weight structures, which however may not be acceptable due to the presence of the open trench OT, as discussed.
• the advance presently described is in relation to the provision of the close trench CT in the composite component 10 of Figure 10C.
• the close trench CT is acceptable in shape in that does not result into sharp edges, and still provides the required localised stiffness at the edge-reinforced portion 10a of the reinforced component 10.
• the (non-reinforced) remainder 10b of the component 10 is essentially left unchanged compared to the component 2 obtained using convention RTM.
• Figure 11 shows a car seat S comprising one or more carbon composite components 10 manufactured according to the method described herein.
• Figure 11A is a front partial perspective view of the seat S showing a portion of the entire seat S
• Figure 11 B is a top plan view of the same seat S.
• the seat S comprise two or more parts 10 each manufactured according to the RTM method described herein.
• Figures 11 C and 11 D which correspond, respectively, to cross sections according to planes A-A and B-B, respectively, shown in Figure 11 B.
• the curvature radii R quoted in Figures 11 C and 11 D are expressed in mm, and, as it can be seen, range from a minimum of 5mm in connection with the edge-reinforced portions 10a of the composite components 10.
• the seat will not need extensive padding (as in prior art seats) in order to satisfy relevant regulations. It is also worth noting the presence of an opening or window W in the car seat S, as shown in Figures 11 A, 11 C and 11D. This shows that the reinforced edge 10a of the composite component can equally be an external reinforced edge, provided on an external edge of the seat S, as well as an internal reinforced edge, provided on an internal or inner edge of the seat S.
• a car seat is manufactured by initially providing a lower mould half as described herein.
• the lower mould half defines a groove in correspondence of the edges of the finished composite component.
• a glass fibre layer is disposed on and across the groove, to exceed the width of the groove.
• a foam filler is disposed all along the groove, over the glass fibre layer, which is then wrapped around the foam filler for the whole length of the groove so as to fully encapsulate the foam filler.
• three fibre mats are laid one on top of the other to form a three-layer fibre lay-up.
• a preform is thus ready for impregnation using RTM as described herein.
• An upper mould half is lowered on the lower mould half and a mould cavity is formed which accommodated the preform.
• a resin mixture is poured into the cavity as also described herein.
• the composite component is demoulded and then is forwarded on for further manufacturing operations before being shipped for use.
• the glass fibre initially disposed around the groove is the same as the first layer successively disposed on the lower mould half.
• This is woven glass fibre mat EBX450 supplied by Selcom Multiaxial Technology, a biaxial fabric having a weight of 450 g/m2.
• the second layer which is disposed on the first layer, is woven carbon fibre mat GG 380 T supplied by Angeloni, having a weight of 384 g/m2. This carbon fibre layer provides the required mechanical strength.
• the third layer disposed on the second layer is random-orientation non-woven glass fibre mat Uniconform 600 supplied by OVC Reinforcements, having a weight of 600 g/m2.
• the resin used in the RTM process is a high-performance epoxy vinyl ester resin Arotran 3101 supplied by Ashland, Inc..
• fibre preform we intend any fibre or fibre-based material, or arrangement of materials, suitably prepared for RTM, that is any fibre material or arrangement which is capable of being impregnated by a resin mixture transferred to a mould cavity as known in the RTM arts and as described herein.
• filler has a functional connotation in that it indicates any materials capable of conferring suitable reinforcement to the finished composite component.
• edge ‘region’ of the fibre preform we refer to an edge ‘region’ of the fibre preform.
• edge region we mean a portion of the fibre preform located at or toward a periphery of the fibre preform rather than at or in proximity of a centre of the fibre preform. It is by associating the filler with such an edge region of the fibre preform that it is possible to obtain a reinforced edge in the finished product, manufactured using RTM. Since the final product also has a non-reinforced portion obtained similarly to conventional open-trenched RTM, the final product is in addition lightweight and easy and cost-efficient for mass manufacture.
• a computer program product or computer readable medium may comprise or store the computer executable instructions.
• the computer program product or computer readable medium may comprise a hard disk drive, a flash memory, a read-only memory (ROM), a CD, a DVD, a cache, a random-access memory (RAM) and/or any other storage media in which information is stored for any duration (e.g., for extended time periods, permanently, brief instances, for temporarily buffering, and/or for caching of the information).
• a computer program may comprise the computer executable instructions.
• the computer readable medium may be a tangible or non-transitory computer readable medium.
• the term “computer readable” encompasses “machine readable”.
• Second Mould Surface 32a First Mould Surface Area 32b Second Mould Surface Area
• Curing Agent 50 Finish Layer OT Open Trench CT Close Trench H Heater

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• Mechanical Engineering (AREA)
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• Manufacturing & Machinery (AREA)
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• 2021
  • 2021-07-22 GB GB2110594.5A patent/GB2609219A/en active Pending
• 2022
  • 2022-07-21 WO PCT/GB2022/051911 patent/WO2023002205A1/en active Application Filing
  • 2022-07-21 EP EP22751428.8A patent/EP4373657A1/de active Pending

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