GB2353247A - A method of manufacturing a composite material - Google Patents
A method of manufacturing a composite material Download PDFInfo
- Publication number
- GB2353247A GB2353247A GB0014077A GB0014077A GB2353247A GB 2353247 A GB2353247 A GB 2353247A GB 0014077 A GB0014077 A GB 0014077A GB 0014077 A GB0014077 A GB 0014077A GB 2353247 A GB2353247 A GB 2353247A
- Authority
- GB
- United Kingdom
- Prior art keywords
- mould part
- mould
- vertical
- composite material
- cavity
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 239000002131 composite material Substances 0.000 title claims abstract description 20
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 12
- 239000002657 fibrous material Substances 0.000 claims abstract description 21
- 229920000642 polymer Polymers 0.000 claims abstract description 15
- 238000000034 method Methods 0.000 claims abstract description 13
- 238000000465 moulding Methods 0.000 description 7
- 239000012779 reinforcing material Substances 0.000 description 7
- 238000001746 injection moulding Methods 0.000 description 5
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 230000035515 penetration Effects 0.000 description 2
- 239000012466 permeate Substances 0.000 description 2
- 230000002787 reinforcement Effects 0.000 description 2
- 230000000717 retained effect Effects 0.000 description 2
- 230000006978 adaptation Effects 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 239000012815 thermoplastic material Substances 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
- B29C70/467—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements during mould closing
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
A method of manufacture of a composite material is disclosed, the method comprising providing first 2 and second 22 vertical mould parts defining a mould cavity (30 of fig 3) with a vertical split line, supplying a sheet (32 of fig 2) or stack of sheets of fibrous material which is/are located within the mould by a locating means, the means extending through the sheet (32 of fig 2) or stack of sheets while the first 2 and second 22 mould parts are seperated from each other, the mould parts 2 and 22 are then brought together to form the mould cavity (30 of fig 3) and a polymer is injected into the mould cavity (30 of fig 3) which, with the fibrous sheet(s) (32 of fig 2), forms a composite material, the mould parts 2 and 22 are then separated so that the composite material may be removed from the apparatus. The locating means may extend from one of the mould parts 2 and 22 to the other and may comprise at least one spring biased pin 12.
Description
2353247 Manufacturing MethQ The present invention relates to a
manufacturing method and has particular utility in the production of composite materials, in particular, but not exclusively, composite materials comprising a fibrous material impregnated by a polymer.
In the manufacture of such composite materials it is known to inject a molten thermoplastic material under pressure into a reinforcing mat of the fibrous material. The best results have been obtained by the use of a mould cavity having a horizontal split line. The mat or, more cornmonly, mats of fibrous material are laid up on a first horizontal mould part. It will be understood that gravity will hold the mats in place above one another. A second horizontal mould part is then brought into contact with the first horizontal mould part to form the mould cavity such that the mats of fibrous material are retained in the mould cavity. Typically, the fibres of the mats of fibrous material will be placed in compression. A polymer is then injected into the mould cavity to permeate the fibrous material to produce a moulding of a composite material.
However, most existing injection moulding machines are arranged to inject a polymer into a mould cavity having a vertical split line. It will be understood that adaptation of such injection moulding machines to provide a horizontal split line is an expensive and time consuming task. Attempts have been made to use injection moulding machines in which the mould cavity has a vertical split line. However, difficulty arises in holding the reinforcing material upright in such machines.
In a first such attempt, mats of fibrous material were laid up within a sufficiently deep female vertical mould part and a male vertical mould part entered into the first female mould part to hold the fibrous material in position prior to injection of a polymer into the mould cavity. However, the fibrous material tended to collapse within the mould cavity prior to or during insertion of the male vertical mould part resulting in a composite having an uneven distribution of fibrous material.
In an alternative attempt, a thickness of fibrous material was inserted between a first vertical mould part and a second vertical mould part, the thickness being such that the friction between the mats and the mould parts was sufficient to support the fibrous material between the mould parts when the first and second mould parts were in the open position. The mould parts were then brought together to form the mould cavity, the fibrous material being compressed and retained within the mould cavity. However, it was found that the fibrous material would be over-compressed and efficient penetration of the fibrous material by the molten polymer did not occur. Typically, the result of injecting the molten polymer in this way is a lens of polymer having only partial penetration into the compacted fibres.
Accordingly, there is a need for a method of using an injection moulding apparatus having a vertical split line which allows for an efficient manufacture of a composite material comprising a fibrous material impregnated by a polymer.
According to the present invention there is provided a method of manufacture of a composite material comprising the steps of providing a manufacturing apparatus comprising a first vertical mould part and a second vertical mould part, a mould cavity being defined between the first mould part and the second mould part and having a vertical split line, supplying a sheet or a stack of sheets of fibrous material, providing location means on said apparatus to vertically locate said sheet or stack within the mould cavity, extending the locating means through said sheet or stack while the first and second mould parts are separated from one another, bringing the first mould part and the second mould part together to form the mould cavity, injecting a polymer into the mould cavity to form a composite material and separating the first mould part and the second mould part to allow the composite material to be removed from the apparatus.
Preferably the sheet or a stack of sheets of fibrous material has an uncompressed thickness greater than the depth of the mould cavity. this allows for greater reinforcement of the finished moulding.
Conveniently, the locating means extends from one of the first vertical mould part and the second vertical mould part toward the other of the first vertical mould part and the second vertical mould part, for example from the first vertical mould part. The first vertical mould p art may comprise a female mould part.
Conveniently, the locating means comprise at least one spring biased pin.
One of the first vertical mould part and the second vertical mould part may be provided with means to eject the composite material from the mould cavity.
The invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
Fig. 1 shows a first vertical mould part and a second vertical mould part of an apparatus for performing a method in accordance with the present invention in perspective; Fig. 2 shows a side section through the apparatus shown in Fig. 1 in an open condition; and Fig.3 shows a side section through the apparatus of Fig.2 in a closed condition.
Referring to Figs. 1 and 2, a first vertical mould part 2 comprises a recessed central portion 4 about which runs a frame portion 6 having four recesses 8. Within the central portion 4 there are located a number of ejector pins 10, location means in the form of a number of location pins 12 and a sprue 14 through which a molten polymer may be allowed to flow. The ejector pins 10 are provided with end surfaces 16, which can be seen in Fig. 1.
During moulding, the end surfaces 16 of the ejector pins 10 are flush with the recessed portion 4. The location pins 12 are spring biased to extend through the first vertical mould part 2. When the first vertical mould part 2 and a second vertical mould part 22 are held apart from one another, tips 18 of the location pins 12 extend beyond the recessed portion 4 of the first vertical mould part 2. The second vertical mould part 22 has a surface 24 and locating dowels 26, equal in number to the recesses 8 in the frame portion 6.
In use, sheets 32 (or possibly only one sheet) of a fibrous reinforcing material are placed over the locating pins 12 so that the locating pins extend through the stack of sheets. The locating pins 12 may be used to pierce the reinforcing material sheets 32. Alternatively, each sheet 32 may be provided with openings of suitable size, shape and spacing to allow the locating pins 12 to extend through the stack without deforming or displacing any of the reinforcing material.
When a desired number of sheets 32 have been placed onto the locating pins 12 to form the stack, the first vertical mould part 2 is brought into contact with the second vertical mould part 22. The first vertical mould part 2 is located with respect to the second vertical mould part 22 by the locating dowels 26 entering the recesses 8. As the mould parts 2, 22 are brought together, the tips 18 of the location pins 12 abut the surface 24 of the second vertical mould part 22 and become withdrawn through the first vertical mould part 2.
Each sheet 32 is sized such that it will fit within the periphery of the recessed portion 4 of the first vertical mould part 2. As the locating pins 12 become withdrawn into the first vertical mould part 2, the reinforcing material becomes compressed into the recessed portion 4 of the first vertical mould part 2. The sheets 32 remain located on the location pins 12 and cannot readily become separated thereftom.
When the first vertical mould part 2 and the second vertical mould part 22 abut one another a mould cavity 30 is formed between the recessed portion 4 of the first vertical mould part 2 and the surface 24 of the second vertical mould part 22.
Means (not shown) may be provided fully to withdraw the location pins 12 from the mould cavity 30, since the sheets 32 are now supported in compression within the mould cavity 30. Alternatively, means (again not shown) may be provided to retain the location pins 12 in this partially withdrawn position.
A molten polymer is then injected under pressure through the sprue 14 into the mould cavity 30. This enables the polymer to permeate the reinforcing material and obtain a satisfactory degree of wetting of the material, thereby forming a moulding of a composite material.
The molten polymer is allowed to cool. When the moulding has sufficient integrity, the first vertical mould part 2 and the second vertical mould part 22 are separated from one another. The ejector pins 10 are then actuated to release the moulding from the recessed portion 4 of the first vertical mould part 2. Once the moulding has been ejected from the recessed portion 4 of the first vertical mould part 2, the location pins 12 are allowed to return to the initial position described above.
The location pins are particularly useful where the reinforcing material sheet 32 or the stack of sheets is greater than the depth of the recessed central portion 4 of the first vertical mould part 2, i.e., the depth of the mould cavity. This is the usual situation when a reasonable degree of reinforcement is required.
The mould parts 2, 22 are easily mounted on a conventional injection moulding machine so that existing plant can be utilised.
Claims (8)
- -6CLAIMSL. A method of manufacture of a composite material comprising the steps of: providing a manufacturing apparatus comprising a first vertical mould part and a second vertical mould part, a mould cavity being defined between the first mould part and the second mould part and having a vertical split line; supplying a sheet or a stack of sheets of fibrous material; providing location means on said apparatus to vertically locate said sheet or stack within the mould cavity; extending the locating means through said sheet or stack while the first and second mould parts are separated from one another; bringing the first mould part and the second mould part together to form the mould cavity; injecting a polymer into the mould cavity to form a composite material; and separating the first mould part and the second mould part to allow the composite material to be removed from the apparatus.
- 2. A method according to claim 1 wherein the sheet or a stack of sheets of fibrous material has an uncompressed thickness greater than the depth of the mould cavity.
- 3. A method according to claim 1 or claim 2 wherein the locating means extends from one of the first vertical mould part and the second vertical mould part toward the other of the first vertical mould part and the second vertical mould part.
- 4. A method according to claim 3 wherein the locating means extends from the first vertical mould part.
- 5. A method according to claim 4 wherein the first vertical mould part comprises a female mould part.
- 6. A method according to any previous claim wherein the locating means comprise at least one spring biased pin.
- 7. A method according to any previous claim wherein one of the first vertical mould part and the second vertical mould part is provided with means to eject the composite material from the mould cavity.
- 8. A method of manufacture of a composite material substantially as described herein with reference to the accompanying drawings.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GBGB9917782.6A GB9917782D0 (en) | 1999-07-30 | 1999-07-30 | Manufacturing assembly |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB0014077D0 GB0014077D0 (en) | 2000-08-02 |
| GB2353247A true GB2353247A (en) | 2001-02-21 |
Family
ID=10858139
Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GBGB9917782.6A Ceased GB9917782D0 (en) | 1999-07-30 | 1999-07-30 | Manufacturing assembly |
| GB0014077A Withdrawn GB2353247A (en) | 1999-07-30 | 2000-06-10 | A method of manufacturing a composite material |
Family Applications Before (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GBGB9917782.6A Ceased GB9917782D0 (en) | 1999-07-30 | 1999-07-30 | Manufacturing assembly |
Country Status (1)
| Country | Link |
|---|---|
| GB (2) | GB9917782D0 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2016020430A1 (en) * | 2014-08-08 | 2016-02-11 | Ako Kunststoffe Alfred Kolb Gmbh | Device and method for producing a fibre composite component |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113954391B (en) * | 2021-10-13 | 2024-03-12 | 上海复合材料科技有限公司 | S-shaped composite material air inlet passage forming die and preparation method thereof |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH01309721A (en) * | 1988-01-19 | 1989-12-14 | Sumitomo Electric Ind Ltd | Multi-cable winding method using a drum |
| JPH0768589A (en) * | 1993-09-03 | 1995-03-14 | Mitsui Toatsu Chem Inc | Method for producing composite molded article by injection molding and mold apparatus thereof |
| JPH0839607A (en) * | 1994-07-29 | 1996-02-13 | Nissha Printing Co Ltd | Patterned molded product manufacturing apparatus |
| JPH08267504A (en) * | 1995-03-30 | 1996-10-15 | Nissha Printing Co Ltd | Manufacture of insert-molded article and insert mold |
-
1999
- 1999-07-30 GB GBGB9917782.6A patent/GB9917782D0/en not_active Ceased
-
2000
- 2000-06-10 GB GB0014077A patent/GB2353247A/en not_active Withdrawn
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH01309721A (en) * | 1988-01-19 | 1989-12-14 | Sumitomo Electric Ind Ltd | Multi-cable winding method using a drum |
| JPH0768589A (en) * | 1993-09-03 | 1995-03-14 | Mitsui Toatsu Chem Inc | Method for producing composite molded article by injection molding and mold apparatus thereof |
| JPH0839607A (en) * | 1994-07-29 | 1996-02-13 | Nissha Printing Co Ltd | Patterned molded product manufacturing apparatus |
| JPH08267504A (en) * | 1995-03-30 | 1996-10-15 | Nissha Printing Co Ltd | Manufacture of insert-molded article and insert mold |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2016020430A1 (en) * | 2014-08-08 | 2016-02-11 | Ako Kunststoffe Alfred Kolb Gmbh | Device and method for producing a fibre composite component |
Also Published As
| Publication number | Publication date |
|---|---|
| GB9917782D0 (en) | 1999-09-29 |
| GB0014077D0 (en) | 2000-08-02 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |