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Publication numberWO1989005717 A1
Publication typeApplication
Application numberPCT/SE1988/000681
Publication date29 Jun 1989
Filing date14 Dec 1988
Priority date15 Dec 1987
Publication numberPCT/1988/681, PCT/SE/1988/000681, PCT/SE/1988/00681, PCT/SE/88/000681, PCT/SE/88/00681, PCT/SE1988/000681, PCT/SE1988/00681, PCT/SE1988000681, PCT/SE198800681, PCT/SE88/000681, PCT/SE88/00681, PCT/SE88000681, PCT/SE8800681, WO 1989/005717 A1, WO 1989005717 A1, WO 1989005717A1, WO 8905717 A1, WO 8905717A1, WO-A1-1989005717, WO-A1-8905717, WO1989/005717A1, WO1989005717 A1, WO1989005717A1, WO8905717 A1, WO8905717A1
InventorsGunnar Westerlund
ApplicantAb Volvo
Export CitationBiBTeX, EndNote, RefMan
External Links: Patentscope, Espacenet
A method of applying a mixture of plastic material and reinforcing fibres in a mould
WO 1989005717 A1
Abstract
A method of applying a batch of material comprising a plastics mixture admixed with reinforcing fibres on a mould surface of a mould half. A foil sheet (7) is held firmly by suction against a suction box (1) whose shape is complementary to the shape of the mould surface (6). The mould batch (8) is sprayed onto the foil sheet, whereafter the mould half (5) is lowered upside down onto the mould batch. The system is then turned the right way up and the suction box removed.
Claims  (OCR text may contain errors)
1. A method of applying a batch of material comprising a plastics mixture admixed with reinforcing fibres to a mould surface on one mould half of a mould tool, charac¬ terized by first placing a mould batch (8) comprising a liquid plastics mixture incorporating fibres onto a sur¬ face of a support element (1) whose shape is complementary to the mould surface (6) on said mould half (5); placing the mould half with mould surface upside down over the mould batch (8), and turning the support element and the mould half together so that the mould half is located beneath the mould batch, and then removing the support element.
2. A method according to Claim 1, characterized- by apply-' ing the mould batch (8) to a foil sheet (7) which is held ' firmly against a perforated suction box (1) by suction.
3. A method according to Claim 2, characterized by spray- : ing a plastics mixture admixed with reinforcing fibres onto the foil sheet (9).
Description  (OCR text may contain errors)

A method of applying a mixture of plastic material and reinforcing fibres in a mould

The present invention relates to a method of applying a batch of material consisting of plastics material admixed with reinforcing fibres to a mould surface of one mould half of a mould tool.

When manufacturing large components, e.g. components having a size in the order of several square meters, from composite materials, such as thermosetting resins rein¬ forced with glass fibre, problems are encountered in charging the material effectively to the cavity of the mould tool so that the material covers the whole of the mould surface. Obvious problems are met with when wishing to charge a large wet, "slippery" batch of fibres and liquid plastic to the cavity of a mould, and hitherto no established technique has been developed which is suitable for rational series production purposes. Instead, the problem has been circumvented by using SMC- aterial which can be handled both manually and by robots.

The SMC-technique (sheet moulding compound) for the manufacture of large reinforced plastic products of uniform thickness with a finish on both sides utilizes leather-like sheets having a thickness of some millimeters and produced from a mixture of fibres, resin and filler with the fibres oriented in the plane of the surface. A number of such sheets are placed on a part of the mould surface of one mould half and move out under the influence of mould pressure, to fill the mould cavity.

The SMC-technique, however, is encumbered with several drawbacks, one of which is the wide spread or variance of mechanical strength values resulting from unfavourable flow of the material. The object of the present invention is to provide an, alternative method to the SMC-method by means of whicftϊ material can be charged effectively to the whole of a mould surface without risk of the charge losing its shape or disintegrating during the handling procedure.

This is achieved in accordance with the invention by first placing a batch of liquid, plastic and fibre mixture onto a surface of a support element whose shape is complemen - ary with the mould surface of said one mould half; placing the mould half over the mould batch with the mould surface facing downwards; turning the support element and the mould half together so that the mould half is located beneath the mould batch, and then removing the support element.

When practicing this method, the mould batch is preferably sprayed onto a foil sheet which is held by suction ag;ainst a perforated suction box. The foil may consist of a mate- rial which will adhere firmly to the mould batch and can be allowed to remain on the final moulded product. Alter¬ natively, the foil may be prepared from or consist of material which can be readily torn lose.

The present invention ensures that a mould surface will be covered completely without risk of the mould batch losing its shape or disintegrating.

The invention will now be described in more detail with reference to Figures 1-6 of the accompanying drawing, which illustrates the mould charging procedure in greater detail.

In Figures 1-4, the reference numeral 1 identifies a suction box having perforations 2 and an outlet 3 for connection to a fan. The suction box 1 has a configuration which is complementary to the shape of a mould cavity 4 of one mould half 5 of a mould tool which is intended for pressure moulding composite material components, such as thermosetting resins reinforced with glass fibre.

The following procedure is taken when charging a batch of material to the mould surface 6 of the mould cavity 4.

A thin plastic foil sheet 7 is placed over the suction box 1 and held firmly thereagainst by suction, whereafter fibres and matrix material {liquid plastics mixture) is sprayed over the foil 7 with the aid of a spray/fibre cutter 9 (Figure 1), The mould half 5 is lowered upside down over the mould batch (Figure 2) so that the mould surface 6 will finally rest against the mould batch. The whole system, i.e. suction box 1, mould half 5 and the intermediate mould batch, is then turned so that the mould half 5 is turned the right way up (Figure 3).

The suction box 1 is now lifted away (Figure 4), wherewith air is optionally blown out through the perforations 2 to facilitate removal of the suction box. An upper mould half 10 is then lowered over the mould half 5 (Figure 5) and pressure is applied so as to compact the mould batch. When the mould batch has set (hardened), the mould halves 5 and 10 are separated and the moulded article removed from the mould.

Patent Citations
Cited PatentFiling datePublication dateApplicantTitle
DE1202977B *29 Jul 195814 Oct 1965Goodyear Aerospace CorpSpritzvorrichtung zum Verarbeiten eines Fasermaterials mit einem Bindemittel
FR1175022A * Title not available
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CN102458805B *25 May 201029 Jul 2015Lm 玻璃纤维制品有限公司制造带有预制增强构件的复合结构的方法
CN102834247A *22 Dec 201019 Dec 2012Lm 玻璃纤维制品有限公司Method of producing a composite shell structure
CN102834247B *22 Dec 20102 Sep 2015Lm 玻璃纤维制品有限公司制造复合壳体结构的方法
DE4442858A1 *2 Dec 19945 Jun 1996Inst Verbundwerkstoffe GmbhProdn. of sandwich mouldings from fibre-reinforced thermoplastic
EP0426317A2 *11 Oct 19908 May 1991Ford Motor Company LimitedA resin transfer moulding preform and a method of making the preform
EP0426317A3 *11 Oct 199025 Nov 1992Ford Motor Company LimitedA resin transfer moulding preform and a method of making the preform
EP2338668A1 *22 Dec 200929 Jun 2011Lm Glasfiber A/SMethod of producing a composite shell structure
US63833203 Dec 19997 May 2002Lear CorporationMethod of forming a headliner
US673691518 Apr 200218 May 2004Lear CorporationMethod of forming a headliner
US9133817 *25 May 201015 Sep 2015Lm Glasfiber A/SMethod of manufacturing a composite structure with prefabricated reinforcement element
US9234500 *22 Dec 201012 Jan 2016Fm Glasfiber A/SMethod of producing a composite shell structure
US20120067515 *25 May 201022 Mar 2012Lm Glasfiber A/SMethod of manufacturing a composite structure with prefabricated reinforcement element
US20120257984 *22 Dec 201011 Oct 2012Lm Glasfiber A/SMethod of producing a composite shell structure
Classifications
International ClassificationB29C41/08, B29C43/14, B29C70/34, B29C31/08, B29C43/00, B29C70/30, B29C43/18, B29C70/08
Cooperative ClassificationB29C43/183, B29C43/14, B29K2105/128, B29C41/08, B29C70/345, B29C31/08, B29K2105/253, B29C43/006, B29K2105/06, B29C70/086, B29K2105/12, B29C70/305
European ClassificationB29C31/08, B29C43/18B, B29C70/34B, B29C43/14, B29C70/30A, B29C70/08C
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