Method for direct inline molding of pre-impregnated composites

Patent metadata

Field	Value
Publication number	US-9821497-B2
Application number	US-201314372059-A
Country	US
Kind code	B2
Filing date	Jan 10, 2013
Priority date	Jan 13, 2012
Publication date	Nov 21, 2017
Grant date	Nov 21, 2017

Abstract

A system for fabricating a composite article includes a pre-impregnation station for forming a prepreg comprising a reinforcement impregnated with a resin. The prepreg is provided to a blanking station where a blank is cut from the partially cured prepreg and arranged onto a preforming mold. The blank is then transferred to a forming station, and is formed into the composite article using a compression mold. The pre-impregnation station, the blanking station and the forming station are co-located. During forming of the blank into the composite article using the compression mold, additional prepreg is formed in the pre-impregnation station and passes to the blanking station so as to form a next blank for being formed into a next composite article during a subsequent molding cycle. Optionally, the prepreg is partially cured prior to being cut in the blanking station.

First claim

What is claimed is:

1. A system for fabricating a composite article, comprising:
a pre-impregnation station for forming a prepreg comprising a reinforcement impregnated with a resin, the pre-impregnation station comprising a carrier film unwind and a reinforcement unwind;
a blanking station comprising a cutter for cutting a blank from the prepreg and for arranging the blank on a preforming mold, such that a shape of the blank, when so arranged, corresponds approximately to a final shape of the composite article; and
a forming station comprising a compression mold for forming the composite article from the blank by the application of heat and pressure to said blank,

wherein the pre-impregnation station, the blanking station and the forming station are co-located, such that while the blank is being formed into the composite article in the compression mold, additional prepreg is formed in the pre-impregnation station and passes to the blanking station to form a next blank for being formed into a next composite article in the compression mold during a subsequent molding cycle, and
wherein the reinforcement unwind is disposed for unwinding the reinforcement onto one side of the carrier film, and wherein the prepreg carried by the carrier film extends continuously between the pre-impregnation station to the blanking station.

2. The system of claim 1 wherein the pre-impregnation station and the blanking station cooperate to produce a blank arranged on the preforming mold within a period of time that corresponds approximately to a cycle time of the compression mold, such that a next blank is being produced while the composite article is being formed in the compression mold.

3. The system of claim 1 comprising a curing station disposed between the pre-impregnation station and the blanking station, the curing station comprising one of a heat source and a source of ultraviolet radiation and the curing station for partially curing the prepreg that is formed in the pre-impregnation station.

4. The system of claim 3 comprising a robot disposed between the curing station and the blanking station, the robot for transferring the partially cured prepreg from the curing station to the blanking station.

5. The system of claim 1 comprising a robot disposed between the blanking station and the forming station, the robot for transferring the arranged blank from the blanking station to the forming station.

6. The system of claim 1 wherein the system does not comprise a refrigerated storage unit.

7. The system of claim 1 wherein the system does not comprise a refrigerated transport unit.

8. A method of fabricating a composite article, comprising:
performing a pre-impregnation process at a pre-impregnation station to form a prepreg having a reinforcement impregnated with a resin, the pre-impregnation process performed at a predetermined rate;
molding the prepreg to form the composite article, each cycle of the molding having a known cycle time and comprising:
cutting a blank from the prepreg at a blanking station;
arranging the blank on a preforming mold to form a preformed blank, such that a shape of the blank, when so arranged, corresponds approximately to a final shape of the composite article;
transferring the preformed blank from the preforming mold to a compression mold; and
applying heat and pressure to the preformed blank inside the compression mold so as to form the composite article,

wherein the rate of the pre-impregnation process is predetermined based on the known cycle time of the molding process, such that during each current molding cycle the pre-impregnation process yields a quantity of prepreg to form the blank for use in a corresponding next molding cycle, and
wherein the pre-impregnation station comprises a carrier film unwind and a reinforcement unwind, the reinforcement unwind being disposed for unwinding the reinforcement onto one side of a carrier film, and wherein the prepreg carried by the carrier film extends continuously between the pre-impregnation station to the blanking station.

9. The method of claim 8 wherein the resin is one of a thermosetting resin and a thermoplastic resin.

10. The method of claim 9 further comprising, prior to molding, a step of partially curing the prepreg.

11. The method of claim 10 wherein partially curing the prepreg comprises one of heating the prepreg and irradiating the prepreg with ultraviolet radiation.

12. The method of claim 10 wherein, prior to molding, the partially cured prepreg is not stored for a period of time that exceeds approximately one cycle time of the molding process.

13. The method of claim 10 wherein, prior to molding, the partially cured prepreg is not stored or transported using a refrigerated unit.

14. The method of claim 9 wherein the thermosetting resin is selected from the group consisting of an epoxy resin, vinyl ester, polyester and polyurethane.

15. The method of claim 8 wherein performing a pre-impregnation process comprises:
unwinding the carrier film from the carrier film unwind;
unwinding the reinforcement from the reinforcement unwind onto the one side of the carrier film; and
impregnating the reinforcement with the resin during unwinding of the carrier film and of the reinforcement, such that the prepreg is formed continuously during the pre-impregnation process and at the predetermined rate.

16. The method of claim 8 wherein the reinforcement comprises fibers selected from the group consisting of glass fibers, carbon fibers, aramid fibers and basalt fibers.

Assignees

• Magna Int Inc

Inventors

• Amtmann Maximilian
• Shulkin Boris
• Van Gelder Aldo
• Deaville Todd

Classifications

• B29K2031/00

  Use of polyvinylesters {or derivatives thereof} as moulding material · CPC title

• B29K2075/00

  Use of {PU, i.e.} polyureas or polyurethanes {or derivatives thereof}, as moulding material · CPC title

• B29K2067/00

  Use of polyesters {or derivatives thereof}, as moulding material · CPC title

• B29K2309/00

  Use of inorganic materials not provided for in groups B29K2303/00 - B29K2307/00, as reinforcement · CPC title

• B29K2309/08

  Glass · CPC title