Compression-molded fiber-composite parts and methods of fabrication
AssigneeArris Composites Inc.
InventorsEthan Escowitz, Erick Davidson
Life of this patent
Estimating the term…
Abstract
Fiber-reinforced composite parts include select portions containing a plurality of co-aligned fiber. The parts are fabricated by placing substantially preforms into a mold cavity to form a layup, and compression molding the layup to consolidate the preforms to provide a fiber-reinforced composite part. Different sections of the part can be derived from preforms having different shapes and different compositions.
Claims17
A method for fabricating a fiber-composite part via compression molding, wherein the method comprises:
- forming a plurality of fiber-bundle-based (FBB) preforms, each FBB preform being a single bundle of continuous, co-aligned fibers impregnated with a thermoplastic resin and having a substantially circular cross section, each FBB preform characterized by an external architecture, wherein, within the plurality of FBB preforms, a first group includes FBB preforms that each have a first bend, defining a non-linear external architecture;
- forming a preform charge consisting of the plurality of FBB preforms by, prior to placement in a mold cavity, tacking together the plurality of FBB preforms, wherein the external architecture of the FBB preforms is maintained;
- placing the preform charge in the mold cavity;
- compression molding the preform charge, thereby consolidating the thermoplastic resin and the fibers from the FBB preforms;
- and
- cooling, in the mold cavity, the consolidated thermoplastic resin and fibers, fabricating a fiber-composite part.
A method for fabricating a fiber-composite part via compression molding, wherein the method comprises:
- forming a plurality of fiber-bundle-based (FBB) preforms, each a single bundle of co-aligned fibers impregnated with a thermoplastic resin and having a substantially circular cross section, and characterized by an external architecture, wherein at least some of FBB preforms of the plurality have a non-planar external architecture, having two bends that do not fall in a single plane;
- placing the FBB preforms in a mold cavity, wherein the external architecture of the FBB preforms is maintained;
- compression molding the FBB preforms, thereby consolidating the thermoplastic resin and the fibers from the FBB preforms;
- and
- cooling, in the mold cavity, the consolidated thermoplastic resin and fibers, fabricating a fiber-composite part.
Dependencies are inferred from the claim text.