Continuous channel resin transfer molding with rapid cycle time

Patent metadata

Field	Value
Publication number	US-11407187-B2
Application number	US-201716472740-A
Country	US
Kind code	B2
Filing date	Dec 20, 2017
Priority date	Dec 27, 2016
Publication date	Aug 9, 2022
Grant date	Aug 9, 2022

Abstract

A process for resin transfer molding (RTM) with injection and overflowing of a resin through one or more troughs is provided that includes the injection of resin into a plurality of injection ports feeding the one or more troughs and overflowing the resin in into a mold. The temperature and pressure are controlled as applied to the mold. The injection ports are activated for injecting the resin in any order of individually, in groups, or pairings. A resin transfer molding (RTM) system for performing the process includes a mold having a cavity. A set of injection ports feed one or more continuous channels between the cavity and a reservoir of resin. A numerical controller selectively activates the injection ports to overflow the resin into the cavity in any order of individually, in groups, or pairing.

First claim

The invention claimed is:

1. A process for resin transfer molding (RTM) with injection and overflowing of a resin through one or more troughs, the process comprising:
injecting said resin into a plurality of injection ports that collectively feed one of said one or more troughs and overflowing said resin into a mold from said one or more troughs at a flow rate of injection of 1 to 10 liters per minute and a pressure of injection between 80 and 100 bars; and
controlling temperature and pressure applied to said mold;
wherein said plurality of injection ports are activated for injecting said resin in any order of individually, in groups, or pairings; and
wherein said resin is at least one of an epoxy resin, an unsaturated polyester resin, a polyvinylester resin, a phenolic resin, a guanamine resin, a polyimide resin, a bismaleimide triazine resin, a furan resin, a polyurethane resin, a polydiarylphthalate resin, a melamine resin, a urea resin, or an amino resin.

2. The process of claim 1 , wherein said resin further comprises fibers that are injected into said mold with said resin.

3. The process of claim 2 , wherein said fibers are at least one of glass, carbon, or other synthetic fibers.

4. The process of claim 2 , wherein said fibers are natural fibers.

5. The process of claim 4 , wherein said natural fibers are at least one of coconut fibers, bamboo fibers, sugar cane fibers, or banana skin fibers.

6. The process of claim 1 , wherein said plurality of injection ports are activated for injecting resin in a sequential clockwise or counter clockwise order.

7. The process of claim 1 , wherein said plurality of injection ports are activated based on a computer program.

8. The process of claim 1 , wherein said plurality of injection ports are from 2 to 6 injection ports.

9. The process of claim 1 , wherein said plurality of injection ports are 3 injection ports.

10. The process of claim 1 , further comprising repeating the steps of the injecting and the controlling with a cycle time of 1 to 5 minutes.

11. The process of claim 1 , wherein the controlling limits a decline of pressure and temperature during formation of a molded part in said mold.

Assignees

• Continental Structural Plastics Inc
• Teijin Automotive Tech Inc

Inventors

• Boyer Dominique
• Bonte Philippe
• Toitgans Marc-Philippe

Classifications

• B29C70/48 Primary

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

• B29C70/443

  and impregnating by vacuum or injection · CPC title

• B29C70/546

  Measures for feeding or distributing the matrix material in the reinforcing structure · CPC title

• B29C70/548

  using distribution constructions, e.g. channels incorporated in or associated with the mould · CPC title