MOULDING PROCESS AND APPARATUS
Introduction
The invention relates to a moulding process and in particular to a process for moulding of fibre-reinforced composite materials.
Various processes have been developed in an attempt to mould fibre -reinforced composite materials. To date, however, such processes have not been entirely satisfactory because of the complexity of the process and the energy inputs required.
This invention is therefore directed towards providing an improved efficient moulding process for such composite materials.
Statements of Invention
According to the invention there is provided a moulding process comprising the steps of:-
laying a continuous fibre composite material comprising a thermoplastics material co-mingled with fibre over a mould;
applying a flexible material over the composite sheet material;
applying a vacuum between the flexible material and the composite material to draw the flexible material onto the composite material over the contour of the mould;
heating the mould internally to melt the thermoplastics material;
maintaining the vacuum to consolidate the fibre-reinforced thermoplastics material;
force cooling the mould internally to cool the thermoplastics material;
releasing the vacuum; and
removing a moulded article from the mould.
The fibre is a reinforcing fibre of glass, carbon or other high tensile material.
In a preferred embodiment of the invention the flexible material is a nylon bagging film or a silicon rubber sheet.
Preferably the composite material is a co-mingled glass fibre/thermoplastics material. Usually, the thermoplastics material is selected from one or more of polypropylene, polyethylene, polyester or modified polyester.
Preferably, the thermoplastics material melts at a temperature of less than 230°C.
In one embodiment of the invention the mould is an open-topped mould.
In another embodiment the mould includes a top lid.
Preferably the lid forms part of the mould.
In one embodiment of the invention the lid includes heat insulation and/or heat reflecting means.
Preferably the lid includes a heat source. The heat source may be infra-red lamps.
The heat source may include means for heating at least a portion of the surface of the lid.
The process may include circulating heated air over the flexible material.
The flexible film may be in the form of an inflatable bladder.
In one embodiment of the invention the process includes the step of interposing a breather material/release film between the flexible film and the composite material.
In another aspect the invention provides moulding apparatus comprising a first mould part having embedded heating and/or cooling means, a flexible material for application over a composite thermoplastic material laid on the first mould part, sealing means for sealing the flexible material to the first mould part, and a vacuum port for drawing a vacuum between the flexible material and the first mould part for moulding the composite material.
The flexible material may have an integral heating means.
In a preferred embodiment of the invention the apparatus includes means for directing heat to the flexible material.
In one case the apparatus includes a second mould part or lid.
The lid may be at least partially lined with a heat reflective material.
Alternatively or additionally the lid includes heat insulating means such as a block of heat insulation material.
In a preferred arrangement the second mould part includes a heat source. The heat source may comprise infra-red heating lamps. Alternatively the heat source is embedded in the second mould part. Preferably the second mould part includes channels for delivery of heated and/or cooled air to the flexible material.
In one embodiment of this aspect of the invention the apparatus includes circulating means, such as a fan for circulating heated air over the flexible material.
Preferably the flexible material is an inflatable bladder.
The apparatus may include a breather material and/or release film for interposing between the flexible material and the composite material.
The invention further provides a moulded article whenever produced by a process and/or using an apparatus of the invention.
Brief Description of Drawings
The invention will be more clearly understood from the following description thereof given by way of example only with reference to the accompanying drawing in which :-
Fig. 1 is a schematic cross sectional view illustrating a moulding process of the invention;
Figs. 2 to 6 are cross sectional views of modified moulding systems; and
Fig. 7 is a cross sectional view illustrating the moulding of a composite material.
Detailed Description
Referring to Fig. 1 of the drawings there is illustrated a mould 1 with a forming tool which in this case is of upwardly facing open channel shape. The mould has internal heating means provided by heating wires 2 and internal cooling means provided by channels 3 through which a cooling fluid is circulated.
In a first step in the process of the invention a composite material somewhat in the form of a cloth 4 is draped over the mould 1. A flexible nylon bagging film or silicone rubber sheet 6 is then placed over the composite material 4 and sealed around the edges. A vacuum V is then applied between the bagging film 6 and the mould 1. This causes the air to be evacuated from the area occupied by the composite material and a uniform vacuum pressure P of approximately 15 psi is applied over the surface of the composite sheet lay-up 4.
The mould 1 is then heated using the embedded electrical heating wires 2. A vacuum is continuously applied to consolidate the thermoplastics material. The thermoplastics melts to form a fluid with a low enough viscosity to flow within the lay-up and completely wet-out the fibres. After a period of time (typically 20 to 30 minutes) the temperature is reduced by forced cooling using a cooling fluid such as air circulated through the channels 3, the vacuum is removed and a fully moulded part is removed.
Most preferably, the composite material is a co-mingled glass fibre/polypropylene continuous fibre composite material. During the drawing process for the glass fibre, fibres of polypropylene are interwoven with the glass fibres to form a continuous yarn. This yarn is then woven to form a "cloth" which is available in various weave forms, patterns and thicknesses. Polyethylene and other similar thermoplastics materials may be used as an alternative to polypropylene. One preferred product has been developed by Vetrotex S.A. of France and is available under the name Twintex from Europrojects Ltd, UK.
The moulding process of the invention provides a very efficient process for moulding such composite materials at relatively low temperature (typically approximately 200°C) and at low pressures. Energy efficiency is optimised as are the moulding cycle times required.
It will be appreciated that in some cases the mould may include a lid which is placed on the mould. The lid may be flat to reflect heat onto the lay-up material. For thicker lay-up materials (e.g. greater than 4mm), a second heating source may also be provided. Such a heat source may be an infra-red source or the like.
Referring to Fig. 2, in this case the mould includes a lid 20 which has a reflective foil 21. The lid 20 is also insulated to further concentrate the heating effect.
Referring to Fig. 3, in this case a second heating source in the form of infra-red lamps 30 is provided.
In the embodiment illustrated in Fig. 4 the lid 35 has a surface which is heated by embedded heating wires 36 and a fan 37 is provided to circulate heated air and further improve the heating efficiency.
Referring to Fig. 5, in this case a silicon rubber sheet or bag 60 is placed over the composite material and is sealed around the edges. A heating network is provided in the silicon rubber sheet or bag 60 to provide directed localised heating. Heating from both sides is advantageous, especially for relatively large wall thicknesses.
Referring to Fig. 6, in this case the lid includes channels 40 for circulation of heated air directly to the bladder 4.
Another version is illustrated in Fig. 7 which is similar to the arrangement of Fig.
5. In this case the material to be moulded is a composite material comprising a
lower fabric skin 50, an upper fabric skin 51 and an intervening foam insulation layer 52. The heating is arranged to heat only the upper and lower skins 50, 51 to avoid melting of the foam and thereby retaining its integrity.
It will also be appreciated that the mould may be in two halves on which composite material is laid up. An inflatable bladder may be provided in the mould in this case.
Many variations on the specific embodiments of the invention described will be readily apparent and accordingly the invention is not limited to the embodiments hereinbefore described which may be varied in detail.