Unidirectional fiber-random mat preform
AssigneesGKN Westland Aerospace, Inc., The Dow Chemical Company
InventorsBrenda T. Colegrove, Warren D. White, Johnny P. Gendreau, Larry N. Varholak, Curt G. Wilkinson
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Abstract
A preform suitable for use in a resin transfer molding process comprising (1) one or more layers of a non-woven random mat and (2) one or more layers of a series of tows of unidirectional fibers held together by a polymeric curable resin film grid. The polymeric resin film is in the form of a grid, such that only a fraction of the surface area of the fibers contacts the resin film.
Claims16
A preform suitable for use in a resin transfer molding process comprising (1) at least one layer of a non-woven random mat and (2) at least one layer of a series of tows of unidirectional fibers held together by a polymeric curable resin film grid presented on at least one side of the unidirectional fibers in an amount sufficient to hold the fibers in the desired shape and position but small enough to leave the resulting preform porous so that the preform can be impregnated with matrix resin during subsequent molding processes.
A single-ply preform suitable for use in a resin transfer molding process comprising a first layer of a non-woven random mat and a second layer of a series of tows of unidirectional fibers held together by a polymeric curable resin film grid.
A two-ply preform suitable for use in a resin transfer molding process, each ply comprising a layer of a non-woven random mat and a layer of a series of tows of unidirectional fibers held together by a polymeric curable resin film grid, the layer of unidirectional fibers of one-ply laminated to the layer of non-woven random mat of the other ply.
A process for preparing a preform which comprises (1) providing a resin film grid, (2) forming a resin-fiber tape by applying a layer of the resin film grid on at least one side of a plurality of unidirectionally aligned fibers in an amount sufficient to hold the fibers in the desired shape and position but small enough to leave the resulting preform porous so that the preform can be impregnated with matrix resin during subsequent molding processes, (3) heating the resin-fiber tape to melt the resin on the fibers and (4) adhering a non-woven random mat to one side of the resin-fiber tape using heat and pressure.
A preform for use in a resin transfer molding process, the preform comprising a plurality of layers of oriented fiber material assembled and shaped prior to insertion into a mold, the preform additionally containing one or more unidirectional fiber layers, each unidirectional fiber layer having a series of tows of unidirectional fibers held together by polymeric curable resin film grid present on at least one side of the unidirectional fibers in an amount sufficient to hold the fibers in a desired shape and position but small enough to leave the resulting preform porous so that the preform can be impregnated with a matrix resin during the resin transfer molding process, at least one layer of a non-woven random mat adhered to at least one side of at least one unidirectional fiber layer.
Dependencies are inferred from the claim text.