Manufacture om commposites by a flexibel injection process using a double or multiple cavity mold

A mold assembly for generating a predetermined number of composite parts from strengtheners in a generally solid phase and from matrix in a generally liquid phase;

• said mold assembly comprising:
• a) a base mold including a strengthener chamber;
• b) a cover mold including a compression chamber;
• c) at least one frame assembly, each including a separator defining a further respective strengthener chamber and a further respective compression chamber;
• said at least one frame assembly being so configured as to be sealingly stacked one next to the other and between said base mold and said cover mold, whereby each of said strengthener chamber faces one of said compression chamber to define adjacent pairs of chambers;
• d) matrix injection inlets for injecting the matrix in said strengthener chambers;
• e) fluid control apertures for injecting a fluid in said compression chambers;
• and
• f) deformable members so provided between said adjacent pairs of chambers as to pressurize the matrix toward the strengthener upon compression by the fluid.

A mold assembly for generating a predetermined number of composite parts from strengtheners and matrix;

• said mold assembly comprising:
• a) a base mold including a contact wall;
• b) at least one frame assembly so configured as to be sealingly stacked one next to the other on said base mold defining a stacking chamber thereby;
• c) matrix injection inlets for injecting the matrix in the strengtheners trough said base mold and said at least one frame assembly;
• d) deformable elements, each having a respective compression wall and a further respective contact wall, said deformable elements being so configured as to be alternatively stacked with the strengtheners in said stacking chamber whereby each of said contact wall faces one of said compression wall;
• and
• e) a cover mold including a further respective compression wall and being mounted in said stacking chamber.

A mold assembly for generating a composite part from a strengthener and a matrix;

• said mold assembly comprising:
• a) a base mold including a strengthener chamber for receiving the strengthener, a matrix injection inlet for injecting the matrix in said strengthener chamber and an evacuation outlet, said inlet and said outlet defining a propagation direction;
• b) a cover mold including a compression chamber and a fluid control aperture for injecting a controlling fluid in said compression chamber;
• said cover mold being so configured as to be sealingly mounted on said base mold whereby said strengthener chamber and said compression chamber are adjacent and said controlling fluid is an incompressible fluid;
• and
• c) a deformable member provided in a gap defined by said strengthener chamber and said compression chamber, said deformable member generating a deformation zone in said compression chamber from a portion of the matrix permeating the strengthener, said deformable member being pressurized by the controlling fluid in proximity of said deformation zone for redirecting the portion of matrix generating said deformation zone back to the strengthener and for propagating the matrix along said propagation direction.

A method for generating a composite part from a strengthener and a matrix comprising:

• a) sealingly positioning a deformable member in between a first chamber of a first mold portion and a second chamber of a second mold portion;
• said first chamber receiving the strengthener;
• b) impregnating the strengthener with the matrix injected in said first chamber;
• c) propagating the matrix in and along the strengthener by pressurizing a controlling fluid injected in said second chamber on said deformable member.

A method for generating a pre-determined number of composite parts from strengtheners and matrix comprising:

• a) sealingly positioning a deformable member in between a strengthener chamber of a first mold portion and a compression chamber of a second mold portion;
• said strengthener chamber including the strengthener;
• b) repeating said sealingly positioning a deformable member by stacking a number of subsequent mold portions one next to the other determined by a predetermined number of parts to manufacture;
• c) impregnating the strengtheners with matrix injected in said strengthener chambers;
• d) compacting the matrix toward the strengthener by pressurizing a controlling fluid injected in said compression chamber on said deformable member.