US 4,622,091 A · Resin film infusion process and apparatus

Abstract

A method and apparatus for creating monolithic structures formed of fiber reinforced resin composites, i.e., layers or plies bonded together by a cured resin is disclosed. A plurality of dry plies (13, 15, 17, 19) are stacked to create a dry preform (11). The orientation of the plies is based on the desired directional strength of the resulting structure. The plies may or may not be stitched in the cross-ply direction, as desired. After the dry preform (11) is created, one or more layers of liquid or solid resin (21) are added. The dry preform and the resin layer(s), which are located atop a forming tool (33), are enclosed by resin content control envelope (35) through which breather tape (49) passes. The resin content control envelope (35) is, in turn, enclosed by a vacuum envelope (37). First air and other gases are withdrawn and, then, the composite is heated, causing the resin to flow into the dry preform (11). As the resin (21) enters the dry preform (11), air and other gases remaining in the dry preform (or created as the resin cures) are withdrawn via the conduit created by the dry preform fibers and various regions of breather tape (45, 49, 63).

Claims52

Dependent claims

A method of forming fiber reinforced resin composites comprising the steps of:

creating a dry preform of at least two dry fiber plies, each of said dry fiber plies formed of a plurality of reinforcement fibers;
adding at least one layer of resin to said dry preform;
enclosing said dry preform and said at least one layer of resin in a resin content control envelope;
enclosing said resin content control envelope in a vacuum envelope;
evacuating said vacuum envelope and said resin content control envelope to withdraw air and other gases from said dry preform;
and,
heating said dry preform and said at least one layer of resin simultaneously with the evacuation of said vacuum envelope and said resin content control envelope to cause said resin to melt, fully infuse said dry preform and, then, cure as air and other gases are withdrawn from said dry preform resulting in the creation of a fiber reinforced resin composite.

4 more elements

Apparatus for creating monolithic structures formed of layers of plies joined by a cured resin, said apparatus comprising:

(a) a vacuum envelope including first conduit means for connecting said vacuum envelope to a vacuum source, said vacuum envelope comprising:
(i) a lower tool;
(ii) a gas impervious layer;
and,
(iii) vacuum attachment means for attaching said gas impervious layer to said lower tool such that a vacuum envelope is formed between said gas impervious layer and said lower tool;
(b) a resin content control envelope positioned within said vacuum envelope for enclosing a monolithic structure as it is being formed, said monolithic structure created from a dry preform formed of a plurality of dry plies and at least one layer of resin, said resin content control envelope comprising:
(i) a lower release film located atop said lower tool;
(ii) an upper release film positioned atop said lower release film and beneath said gas impervious layer;
and,
(iii) vacuum attachment means for attaching said upper and lower release films together such that said resin content control envelope is formed between said upper and lower release films;
(c) an upper tool located between said gas impervious layer and said upper release film;
and,
(d) second conduit means positioned inside of said vacuum envelope and said resin content control envelope for providing a path for air and other gases between said dry preform and said first conduit means as said monolithic structure is created.

10 more elements

Apparatus for creating monolithic structures formed of layers of plies joined by a cured resin, said apparatus comprising:

a vacuum envelope including first conduit means for connecting said vacuum envelope to a vacuum source;
a resin content control envelope positioned within said vacuum envelope for enclosing a monolithic structure as it is being formed, said monolithic structure created from a dry preform formed of a plurality of plies and at least one layer of resin;
and,
second conduit means positioned inside of said vacuum envelope and said resin content control envelope for providing a path for air and other gases between said dry preform and said first conduit means as said monolithic structure is created, said second conduit means comprising:
at least one layer of inner breather tape positioned adjacent said dry preform within said resin content control envelope;
at least one layer of vacuum port breather tape extending between the interior of said resin content control envelope and the exterior of said resin content control envelope;
and,
at least one layer of outer breather tape extending between said vacuum port breather tape and said first conduit means.

5 more elements

Dependencies are inferred from the claim text.

Resin film infusion process and apparatus

Life of this patent

Resin film infusion process and apparatus

Life of this patent

Abstract

Claims52