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Method of fabricating fibre reinforced composite articles by resin transfer moulding
Absf~ac~sof patents US patent abstracts prepared by Dr R.J. Hand, Department of Engineering Materials, Unioersity
Method of manufacturing a composite implant prosthesis Devanathan, T.N.C. (Zimmer, Inc., Warsaw, ID, USA) US Pat 4 978 360 ( 18 December 1990 ) A number of continuous fibre strands are pulled through a series of work stations to form a core. The strands are impregnated with a polymer material at the first station and a casing is braided over all the strands at a second station ; this braided casing is partially embedded into the strands. The braided, impregnated strands are cut into discrete elements at a third station and each discrete element is enclosed in a second casing to define an outer contour for the composite implant prosthesis at a fourth station. Method for making a fibr~reinforc~ pipe flange Bordner, D.W. (Ameron, Inc., Monterey Park, CA, USA) US Pat 4 980 006 ( 25 December 1990 f A number of fibres are placed transversely in a circumferentially extending slot in a mandrel. Each fibre has a central portion which carries warp fibres and end portions which extend radially adjacent to each face of the slot which do not carry warp fibres. The whole is used in forming a fibre-reinforced annular pipe flange. Methods for producing composite materials of metal matrix containing tungsten grain Kapoor, D. (The Secretary of the Army, Washington, D.C., USA) US Pat 4 %I 512 ( I January i99i ) Tungsten powders containing SO-100 weight% tungsten and O-20 weight% of at least one of moly~enum, tantalum, niobium, rhenium or chromium are produced by plasma rapid solification. The surface of the powders are cleaned and the oxide surface reduced and they are then coated with at least one of the following: copper, nickel, cobalt, hafnium and tantalum. The coated powders are formed into a less than fully dense sintered preform, which is subsequently fully densified by using hot isostatic pressing, rapid omni-directional compaction or hot extrusion to produce the composite. HIPing method for composite structures Siemers, P.A. and Rutkowski, S.F. (General Electric Company, Schnectady, NY, USA) US Pat 4 981643 ( I January 1991) A metal matrix composite sample is placed into a HIPing chamber. The temperature of the article and the HIPing gas are raised to the HIPing temperature and the pressure is then increased to the HIPing pressure. Both the temperature and the pressure are then maintained for the time prescribed for the said composite.
Composites
Manufacturing
No.
3 1992
Fibre reinforced composite product having a hollow interior Sargent, L.R. (4345 Applecross Dr., Indianapolis, ID 46254, USA) US Par 4 983 430 ( 8 January 1991) A tubular body which includes a reinforcement has tubular shaped bladder inserted in it so that the ends of the bladder extend out of the two ends of the tube. An opening is created in the side of the tube away from the two ends and one end of the bladder is passed into the opening. The other end of the bladder is then passed into the opposite end of the tubular body and through the side opening to form a hollow continuous preform with an annular configuration which is then placed in a mould where it is moulded to shape by curing the mould whilst inflating the bladder thereby forming a hollow reinforced composite product. Moulding process for fibre reinforced plastics Komiya, K. and Nakamura, Y. (Takeda Chemical Industries, Ltd., Osaka, Japan) US Pat 4 986 948 (22 January 199f f 60-80 weight%, based on the final product weight, of fibre reinforcements are placed in one half of a mould with positive pinch off edges. The mould halves are positioned near each other in such a fashion that the fibres are grasped between the pinch off edges so that the resin cannot escape from the mould whilst it is being injected. Following resin injection and impregnation of the fibres the mould is closed and pressure applied to form the article. Method of making composite bicycle frames Trimble, B.J. (PO Box 246, Berryville, Ark. 72616, USA) US Pat 4 986 949 (22 January 1991)
At least two wall sections comprised of at least one layer of fibrous material impregnated with a synthetic resin are arranged in opposite relation to each other the resin of at least one part being substantially uncured. Opposing parts are traversely overlapped to form a generally hollow shell which extends between the at least two of the supports for the forks, seat, pedals and rear wheel. The interior of this shell is placed under compression whilst the uncured parts are also placed under external compression so that the whole is pressed together and the uncured parts shaped. The uncured parts are then cured whilst the compression is maintained to form a substantially continuous hollow frame component with at least one pressure moulded junction in it.
of Shejield, UK
constructing a steel frame form from channel shaped members and then transversely mounting reinforcing members between the channel shaped members. A backing form is secured via spaced connectors to the frame and concrete is pneumatically applied against the backing form in sufficient thickness to cover the reinforcement frame. The backing form is removed after the concrete has set. Method of fabricating fibre reinforced composite articles by resin transfer molding Reavely, R.T. and Kim, W. (United Technologies Corporation, Hartford, CN, USA) US Pat 4 988 469 (29 January 1991) A number of dry fabric plies are stacked on a shaped perforated mandrel. Between each pair of plies 5-20 g of polymeric binder per square metre of fabric ply is distributed. Compaction pressure is applied by a conforming tool made of low heat conductive marterial and whilst this pressure is applied hot air at 120-205°C is passed through the preform followed by relatively cool air at room temperature or below thereby shaping and stabilising the preform. The stabilized preform is injected under pressure with a thermosetting resin by resin transfer moulding. The impregnated preform is then heated to cure the resin to produce the fibre reinforced article. Automated tape laminator head for thermoplastic matrix composite material Brown, CL., Ashcraft, H.C., Tichenor, D.R. and Garcia, R.M. (Northrop Corporation, Hawthorne, CA, USA) US Pat 4 990 213 (5 February 1991) An apparatus for dispensing thermoplastic composite tape onto a mandrel. The apparatus includes means for unwinding the tape from a reel and advancing it to the mandrel; a heated pressure roller, which is separated from the tape by a high temperature interference film to prevent the tape sticking to it. for heating the tape above its glass transition tem~rature and applying pressure to laminate the tape onto the recipient surface; means for maintaining tension on the heated tape as it is applied to the mandrel ; a cooling shoe both to reduce the heat of the laminated tape to prevent delamination and to smooth the tape. Method and spraying apparatus for applying a layer of air-sprayed concrete Mueller, K.-H. and Barthel, W. (Degussa Aktiengesellschaft, Frankfurt am Main, Germany) IJS Pat 4 993 884 ( 19 February 1991)
Reinforced concrete building construction and method of forming same Goodson, A.A. (13923 Myrtlea, Houston, TX 77079, USA) US Pat 4 987 719 (29 January I991 ) A method of constructing a non-modular concrete wall in situ. The method consists of
A pumpable and sprayable mix of cements, aggregates and water is fed at a given rate through a concrete feed, where propelling air is introduced at a pressure above atmospheric pressure, to a spraying means. Precipitated silica with an inner surface of 35-700 m2 g-’ is mixed with the cement so that when the
215
Method of manufacturing a composite implant prosthesis Devanathan, T.N.C. (Zimmer, Inc., Warsaw, ID, USA) US Pat 4 978 360 ( 18 December 1990 ) A number of continuous fibre strands are pulled through a series of work stations to form a core. The strands are impregnated with a polymer material at the first station and a casing is braided over all the strands at a second station ; this braided casing is partially embedded into the strands. The braided, impregnated strands are cut into discrete elements at a third station and each discrete element is enclosed in a second casing to define an outer contour for the composite implant prosthesis at a fourth station. Method for making a fibr~reinforc~ pipe flange Bordner, D.W. (Ameron, Inc., Monterey Park, CA, USA) US Pat 4 980 006 ( 25 December 1990 f A number of fibres are placed transversely in a circumferentially extending slot in a mandrel. Each fibre has a central portion which carries warp fibres and end portions which extend radially adjacent to each face of the slot which do not carry warp fibres. The whole is used in forming a fibre-reinforced annular pipe flange. Methods for producing composite materials of metal matrix containing tungsten grain Kapoor, D. (The Secretary of the Army, Washington, D.C., USA) US Pat 4 %I 512 ( I January i99i ) Tungsten powders containing SO-100 weight% tungsten and O-20 weight% of at least one of moly~enum, tantalum, niobium, rhenium or chromium are produced by plasma rapid solification. The surface of the powders are cleaned and the oxide surface reduced and they are then coated with at least one of the following: copper, nickel, cobalt, hafnium and tantalum. The coated powders are formed into a less than fully dense sintered preform, which is subsequently fully densified by using hot isostatic pressing, rapid omni-directional compaction or hot extrusion to produce the composite. HIPing method for composite structures Siemers, P.A. and Rutkowski, S.F. (General Electric Company, Schnectady, NY, USA) US Pat 4 981643 ( I January 1991) A metal matrix composite sample is placed into a HIPing chamber. The temperature of the article and the HIPing gas are raised to the HIPing temperature and the pressure is then increased to the HIPing pressure. Both the temperature and the pressure are then maintained for the time prescribed for the said composite.
Composites
Manufacturing
No.
3 1992
Fibre reinforced composite product having a hollow interior Sargent, L.R. (4345 Applecross Dr., Indianapolis, ID 46254, USA) US Par 4 983 430 ( 8 January 1991) A tubular body which includes a reinforcement has tubular shaped bladder inserted in it so that the ends of the bladder extend out of the two ends of the tube. An opening is created in the side of the tube away from the two ends and one end of the bladder is passed into the opening. The other end of the bladder is then passed into the opposite end of the tubular body and through the side opening to form a hollow continuous preform with an annular configuration which is then placed in a mould where it is moulded to shape by curing the mould whilst inflating the bladder thereby forming a hollow reinforced composite product. Moulding process for fibre reinforced plastics Komiya, K. and Nakamura, Y. (Takeda Chemical Industries, Ltd., Osaka, Japan) US Pat 4 986 948 (22 January 199f f 60-80 weight%, based on the final product weight, of fibre reinforcements are placed in one half of a mould with positive pinch off edges. The mould halves are positioned near each other in such a fashion that the fibres are grasped between the pinch off edges so that the resin cannot escape from the mould whilst it is being injected. Following resin injection and impregnation of the fibres the mould is closed and pressure applied to form the article. Method of making composite bicycle frames Trimble, B.J. (PO Box 246, Berryville, Ark. 72616, USA) US Pat 4 986 949 (22 January 1991)
At least two wall sections comprised of at least one layer of fibrous material impregnated with a synthetic resin are arranged in opposite relation to each other the resin of at least one part being substantially uncured. Opposing parts are traversely overlapped to form a generally hollow shell which extends between the at least two of the supports for the forks, seat, pedals and rear wheel. The interior of this shell is placed under compression whilst the uncured parts are also placed under external compression so that the whole is pressed together and the uncured parts shaped. The uncured parts are then cured whilst the compression is maintained to form a substantially continuous hollow frame component with at least one pressure moulded junction in it.
of Shejield, UK
constructing a steel frame form from channel shaped members and then transversely mounting reinforcing members between the channel shaped members. A backing form is secured via spaced connectors to the frame and concrete is pneumatically applied against the backing form in sufficient thickness to cover the reinforcement frame. The backing form is removed after the concrete has set. Method of fabricating fibre reinforced composite articles by resin transfer molding Reavely, R.T. and Kim, W. (United Technologies Corporation, Hartford, CN, USA) US Pat 4 988 469 (29 January 1991) A number of dry fabric plies are stacked on a shaped perforated mandrel. Between each pair of plies 5-20 g of polymeric binder per square metre of fabric ply is distributed. Compaction pressure is applied by a conforming tool made of low heat conductive marterial and whilst this pressure is applied hot air at 120-205°C is passed through the preform followed by relatively cool air at room temperature or below thereby shaping and stabilising the preform. The stabilized preform is injected under pressure with a thermosetting resin by resin transfer moulding. The impregnated preform is then heated to cure the resin to produce the fibre reinforced article. Automated tape laminator head for thermoplastic matrix composite material Brown, CL., Ashcraft, H.C., Tichenor, D.R. and Garcia, R.M. (Northrop Corporation, Hawthorne, CA, USA) US Pat 4 990 213 (5 February 1991) An apparatus for dispensing thermoplastic composite tape onto a mandrel. The apparatus includes means for unwinding the tape from a reel and advancing it to the mandrel; a heated pressure roller, which is separated from the tape by a high temperature interference film to prevent the tape sticking to it. for heating the tape above its glass transition tem~rature and applying pressure to laminate the tape onto the recipient surface; means for maintaining tension on the heated tape as it is applied to the mandrel ; a cooling shoe both to reduce the heat of the laminated tape to prevent delamination and to smooth the tape. Method and spraying apparatus for applying a layer of air-sprayed concrete Mueller, K.-H. and Barthel, W. (Degussa Aktiengesellschaft, Frankfurt am Main, Germany) IJS Pat 4 993 884 ( 19 February 1991)
Reinforced concrete building construction and method of forming same Goodson, A.A. (13923 Myrtlea, Houston, TX 77079, USA) US Pat 4 987 719 (29 January I991 ) A method of constructing a non-modular concrete wall in situ. The method consists of
A pumpable and sprayable mix of cements, aggregates and water is fed at a given rate through a concrete feed, where propelling air is introduced at a pressure above atmospheric pressure, to a spraying means. Precipitated silica with an inner surface of 35-700 m2 g-’ is mixed with the cement so that when the
215