WO1989005717A1 - A method of applying a mixture of plastic material and reinforcing fibres in a mould - Google Patents

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

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Publication number
WO1989005717A1
WO1989005717A1 PCT/SE1988/000681 SE8800681W WO8905717A1 WO 1989005717 A1 WO1989005717 A1 WO 1989005717A1 SE 8800681 W SE8800681 W SE 8800681W WO 8905717 A1 WO8905717 A1 WO 8905717A1
Authority
WO
WIPO (PCT)
Prior art keywords
mould
batch
reinforcing fibres
applying
support element
Prior art date
Application number
PCT/SE1988/000681
Other languages
French (fr)
Inventor
Gunnar Westerlund
Original Assignee
Ab Volvo
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Ab Volvo filed Critical Ab Volvo
Publication of WO1989005717A1 publication Critical patent/WO1989005717A1/en

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/30Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/345Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using matched moulds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C31/00Handling, e.g. feeding of the material to be shaped, storage of plastics material before moulding; Automation, i.e. automated handling lines in plastics processing plants, e.g. using manipulators or robots
    • B29C31/04Feeding of the material to be moulded, e.g. into a mould cavity
    • B29C31/08Feeding of the material to be moulded, e.g. into a mould cavity of preforms to be moulded, e.g. tablets, fibre reinforced preforms, extruded ribbons, tubes or profiles; Manipulating means specially adapted for feeding preforms, e.g. supports conveyors
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/14Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles in several steps
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • B29C43/183Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles the preformed layer being a lining, e.g. shaped in the mould before compression moulding, or a preformed shell adapted to the shape of the mould
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06Fibrous reinforcements only
    • B29C70/08Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/086Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/30Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/305Spray-up of reinforcing fibres with or without matrix to form a non-coherent mat in or on a mould
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/08Coating a former, core or other substrate by spraying or fluidisation, e.g. spraying powder
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/006Pressing and sintering powders, granules or fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • B29K2105/128Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles in the form of a mat
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/25Solid
    • B29K2105/253Preform

Definitions

  • 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.
  • the SMC-technique 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 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 whicft ⁇ 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.
  • 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.
  • 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 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.
  • 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.
  • the mould batch has set (hardened), the mould halves 5 and 10 are separated and the moulded article removed from the mould.

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.

Description

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.

Claims

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).
PCT/SE1988/000681 1987-12-15 1988-12-14 A method of applying a mixture of plastic material and reinforcing fibres in a mould WO1989005717A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE8705003-5 1987-12-15
SE8705003A SE459798B (en) 1987-12-15 1987-12-15 SET TO APPLY A MATERIAL KIT OF PLASTIC WITH REINFORCEMENT IN A FORM TOOL

Publications (1)

Publication Number Publication Date
WO1989005717A1 true WO1989005717A1 (en) 1989-06-29

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/SE1988/000681 WO1989005717A1 (en) 1987-12-15 1988-12-14 A method of applying a mixture of plastic material and reinforcing fibres in a mould

Country Status (2)

Country Link
SE (1) SE459798B (en)
WO (1) WO1989005717A1 (en)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0426317A2 (en) * 1989-10-30 1991-05-08 Ford Motor Company Limited A resin transfer moulding preform and a method of making the preform
DE4442858A1 (en) * 1994-12-02 1996-06-05 Inst Verbundwerkstoffe Gmbh Prodn. of sandwich mouldings from fibre-reinforced thermoplastic
US6383320B1 (en) 1999-12-03 2002-05-07 Lear Corporation Method of forming a headliner
EP2338668A1 (en) * 2009-12-22 2011-06-29 Lm Glasfiber A/S Method of producing a composite shell structure
US20120067515A1 (en) * 2009-05-25 2012-03-22 Lm Glasfiber A/S Method of manufacturing a composite structure with prefabricated reinforcement element

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1175022A (en) * 1957-05-13 1959-03-19 Renault Improvements in the manufacture of fiber preforms
DE1202977B (en) * 1957-10-17 1965-10-14 Goodyear Aerospace Corp Spray device for processing a fiber material with a binding agent

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1175022A (en) * 1957-05-13 1959-03-19 Renault Improvements in the manufacture of fiber preforms
DE1202977B (en) * 1957-10-17 1965-10-14 Goodyear Aerospace Corp Spray device for processing a fiber material with a binding agent

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0426317A3 (en) * 1989-10-30 1992-11-25 Ford Motor Company Limited A resin transfer moulding preform and a method of making the preform
EP0426317A2 (en) * 1989-10-30 1991-05-08 Ford Motor Company Limited A resin transfer moulding preform and a method of making the preform
DE4442858A1 (en) * 1994-12-02 1996-06-05 Inst Verbundwerkstoffe Gmbh Prodn. of sandwich mouldings from fibre-reinforced thermoplastic
US6383320B1 (en) 1999-12-03 2002-05-07 Lear Corporation Method of forming a headliner
US6736915B2 (en) 1999-12-03 2004-05-18 Lear Corporation Method of forming a headliner
CN102458805B (en) * 2009-05-25 2015-07-29 Lm玻璃纤维制品有限公司 Manufacture the method with the composite construction of prefabricated reinforcement element
US9133817B2 (en) * 2009-05-25 2015-09-15 Lm Glasfiber A/S Method of manufacturing a composite structure with prefabricated reinforcement element
US20120067515A1 (en) * 2009-05-25 2012-03-22 Lm Glasfiber A/S Method of manufacturing a composite structure with prefabricated reinforcement element
CN102458805A (en) * 2009-05-25 2012-05-16 Lm玻璃纤维制品有限公司 Method of manufacturing a composite structure with prefabricated reinforcement element
WO2011076857A1 (en) 2009-12-22 2011-06-30 Lm Glasfiber A/S Method of producing a composite shell structure
CN102834247A (en) * 2009-12-22 2012-12-19 Lm玻璃纤维制品有限公司 Method of producing a composite shell structure
US20120257984A1 (en) * 2009-12-22 2012-10-11 Lm Glasfiber A/S Method of producing a composite shell structure
CN102834247B (en) * 2009-12-22 2015-09-02 Lm玻璃纤维制品有限公司 Manufacture the method for composite shell structure
EP2338668A1 (en) * 2009-12-22 2011-06-29 Lm Glasfiber A/S Method of producing a composite shell structure
US9234500B2 (en) * 2009-12-22 2016-01-12 Fm Glasfiber A/S Method of producing a composite shell structure

Also Published As

Publication number Publication date
SE459798B (en) 1989-08-07
SE8705003D0 (en) 1987-12-15
SE8705003L (en) 1989-06-16

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