US 11,478,978 B2Granted

Systems and methods of making a composite article

AssigneeGM Global Technology Operations LLC

InventorBradley A. Newcomb

Life of this patent

Estimating the term…

Loading patent…

Abstract

Methods of making a composite article are provided herein. The method can include an unwinding step including unwinding a fiber substrate material from a creel at an unwinding velocity and an impregnation step including applying an uncured resin composition to the fiber substrate material to form a resin-fiber material. The method further includes a winding step comprising applying the resin-fiber material onto a shaped surface at a winding velocity and a solidifying step comprising applying heat to the resin-fiber material to initiate an exothermic reaction comprising polymerization, cross-linking, or both of the uncured resin composition. Temperature of the resin-fiber material can be monitored during operation of the method and a polymerization front velocity set point (vpfs) and an operating polymerization front velocity (vpfo) can be determined. Parameters can be adjusted to maintain a vpfo that is substantially the same as the vpfs. Systems for performing said methods are also provided.

Claims18

Dependent claims

A method of making a composite article, the method comprising:

an unwinding step comprising unwinding a fiber substrate material from a creel at an unwinding velocity (ω1) with a first motor operably connected to the creel and configured to rotate the creel at the unwinding velocity (ω1);
an impregnation step comprising applying an uncured resin composition to the fiber substrate material to form a resin-fiber material;
a winding step comprising applying the resin-fiber material onto a shaped surface at a winding velocity (ω2) with a second motor operably connected to the shaped surface and configured to rotate the shaped surface at the winding velocity (ω2);
a solidifying step comprising applying heat indirectly or directly to the resin-fiber material to initiate an exothermic reaction comprising polymerization, cross-linking, or both of the uncured resin composition to form the composite article;
monitoring the resin-fiber material and determining a polymerization front velocity set point (vpfs) and an operating polymerization front velocity (vpfo) via a polymerization front monitoring system;
and
adjusting via a controller in communication with the unwinding step, the winding step, and the polymerization front monitoring system one or more of the following parameters to maintain a vpfo that is substantially the same as the vpfs:
(i) the unwinding velocity (ω1) and/or the winding velocity (ω2);
and
(ii) the heat applied to the resin-fiber material.

7 more elements

A system for making a composite article, the system comprising:

an unwinding component comprising:
a creel wound with a fiber substrate material;
and
a first motor operably connected to the creel and configured to rotate the creel at an unwinding velocity (ω1);
a resin bath component for impregnating the fiber substrate material received therein with an uncured resin composition to form a resin-fiber material, wherein the resin bath component comprises:
a single container for containing the uncured resin composition;
or
a first container for containing a resin component and a second container for containing a hardener component, a catalyst component, or both;
a winding component comprising:
a mandrel for receiving the resin-fiber material;
a second motor operably connected to the mandrel and configured to rotate the mandrel at a winding velocity (ω2);
and
a heat source for solidifying the uncured resin composition to form the composite article;
a polymerization front monitoring system configured to determine a polymerization front velocity set point (vpfs) and an operating polymerization front velocity (vpfo);
and
a controller in communication with the unwinding component, the winding component, and the polymerization front monitoring system, wherein in order to maintain a vpfo that is substantially the same as the vpfs, the controller is configured to adjust one or more of the following parameters:
(i) the unwinding velocity (ω1) and/or the winding velocity (ω2);
and
(ii) the heat source.

16 more elements

Dependencies are inferred from the claim text.

Facts

Application: 16/593,584Filed 4 Oct 2019
Published: US 2021/0101326 A18 Apr 2021
Granted: 25 Oct 2022
Term ends: Not estimatedThe source records don’t support an estimate.

Classification10 codes

B29C 53/8066
Specially adapted for winding and joining: impregnating
B29C 53/582
Using sheets or strips consisting principally of plastics material: comprising reinforcements, e.g. wires, threads
B29C 53/60
Helically: using internal forming surfaces, e.g. mandrels
B29C 53/84
Component parts, details or accessories; Auxiliary operations: heating or cooling