Composite-material molding method and molding device

Patent metadata

Field	Value
Publication number	US-10105878-B2
Application number	US-201415516761-A
Country	US
Kind code	B2
Filing date	Oct 22, 2014
Priority date	Oct 22, 2014
Publication date	Oct 23, 2018
Grant date	Oct 23, 2018

Abstract

A composite material molding method is provided for forming a composite material. The molding includes disposing carbon fiber in a cavity inside an openable and closable mold, injecting resin into the cavity in a state in which a clamping pressure is exerted on the mold and curing the resin. When a threshold value of the pressure inside the cavity is set to a pressure that is lower than the clamping pressure and the resin is injected into the cavity while exerting an injection pressure that is equal to or greater than the clamping pressure on the resin until the pressure inside the cavity reaches the threshold value. Then, after the pressure inside the cavity has reached the threshold value, the inside of the cavity is suctioned.

First claim

The invention claimed is:

1. A composite material molding method for forming a composite material comprising:
disposing a reinforcing base material in a cavity inside an openable and closable mold,
injecting resin into the cavity in a state in which a clamping pressure is exerted on the mold, and
curing the resin, wherein
a threshold value of pressure inside the cavity is set to a pressure that is lower than the clamping pressure, and
when the resin is injected into the cavity, the resin is injected while exerting on the resin an injection pressure that is equal to or greater than the clamping pressure until the pressure inside the cavity reaches the threshold value, and the inside of the cavity is suctioned after the pressure inside the cavity has reached the threshold value.

2. The composite material molding method according to claim 1 , wherein
at least a portion of the resin that is injected into the cavity is suctioned when suctioning the inside of the cavity.

3. The composite material molding method according to claim 1 , wherein,
the pressure inside the cavity is gradually lowered when suctioning the inside of the cavity.

4. The composite material molding method according to claim 1 , wherein
an inside of the mold is in a vacuum state before injecting the resin.

5. The composite material molding method according to claim 1 , wherein
the reinforcing base material is formed from carbon fibers.

6. The composite material molding method according to claim 1 , wherein
the composite material is used for an automobile part.

7. A composite material molding device, comprising:
an openable and closable mold in which is formed a cavity for disposing a reinforcing base material;
a pressing part configured to exert a clamping pressure on the mold;
a resin injection unit configured to inject resin into the cavity; and
a suction unit configured to apply suction to an inside of the cavity,
until a pressure inside the cavity reaches a threshold value that is set lower than the clamping pressure, the resin injection unit being configured to inject the resin while exerting an injection pressure on the resin that is equal to or greater than the clamping pressure, and after the pressure inside the cavity has reached the threshold value, the suction unit suctions the inside of the cavity, and the resin injection unit being further configured to inject the resin inside the cavity without exerting the injection pressure on the resin.

8. The composite material molding device according to claim 7 , wherein
the suction unit is configured to apply suction to at least a portion of the resin that is injected into the cavity.

9. The composite material molding device according to claim 7 , wherein
the suction unit is configured to gradually lower the pressure inside the cavity.

10. The composite material molding device according to claim 7 , wherein
the suction unit is configured to create a vacuum state inside of the mold before the resin is injected.

11. The composite material molding device according to claim 7 , wherein
a reinforcing base material is formed from carbon fibers.

12. The composite material molding device according to claim 7 , wherein
the composite material is used for an automobile part.

Assignees

• Nissan Motor

Inventors

• Usui Katsuhiro
• Arai Naoki

Classifications

• B29C70/48 Primary

  and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM] {, e.g. by vacuum} · CPC title

• B29C2791/002

  Making articles of definite length, i.e. discrete articles (B29C53/40 takes precedence) · CPC title

• B29C45/0005

  using fibre reinforcements · CPC title

• B29C67/246

  Moulding high reactive monomers or prepolymers, e.g. by reaction injection moulding [RIM], liquid injection moulding [LIM] (casting monomers B29C39/006, mixing construction B29B7/74) · CPC title

• B29C39/44

  Measuring, controlling or regulating · CPC title