초록 ▼

Large composite structures are produced using a vacuum assisted resin transfer molding process incorporating a resin distribution network. The structure includes cores each having a main feeder groove or channel therein. A resin distribution network is provided adjacent the core surface in fluid com

Large composite structures are produced using a vacuum assisted resin transfer molding process incorporating a resin distribution network. The structure includes cores each having a main feeder groove or channel therein. A resin distribution network is provided adjacent the core surface in fluid communication with the feeder groove. In a first embodiment, the resin distribution network comprises a plurality of microgrooves formed in each core surface. In a second embodiment, the resin distribution network comprises a separate distribution medium surrounding each core. Each core and associated resin distribution network is covered with a fiber material. The dry lay-up is placed against a mold and encapsulated in a vacuum bag. Uncured resin is fed under vacuum directly into the main feeder groove in each core via a fitting through the bag. The resin flows from the main feeder groove through the resin distribution network and outwardly into the fiber material and is allowed to cure. The resin distribution network forms an integral part of the finished structure. The fiber material with cured resin between adjacent cores may comprise various structural members.

대표청구항 ▼

[ We claim:] [1.] A method of forming a composite structure comprising:providing a core having a peripheral surface and a feeder channel formed to lie across at least a portion of said peripheral surface of said core, said feeder channel having a first cross-sectional area;providing a resin distribu

[ We claim:] [1.] A method of forming a composite structure comprising:providing a core having a peripheral surface and a feeder channel formed to lie across at least a portion of said peripheral surface of said core, said feeder channel having a first cross-sectional area;providing a resin distribution network adjacent at least a portion of said peripheral surface and in fluid communication with said feeder channel in said peripheral surface, said resin distribution network comprising a network of grooves formed in said peripheral surface of said core extending from said feeder channel, each of said grooves having a second cross-sectional area smaller than the first cross-sectional area of the feeder channel;covering at least a portion of said core and said resin distribution network with a fiber material;providing a forming structure, at least a first portion of said forming structure comprising a mold and at least a further portion of said forming structure comprising a flexible portion collapsible under vacuum against an adjacent portion of said core;sealing said core and said fiber material in said forming structure;connecting a source of uncured resin directly to said feeder channel through said forming structure;connecting an interior of said forming structure to a vacuum outlet;forcing said uncured resin initially through said feeder channel and said resin distribution network to said vacuum outlet to fill the interior of said forming structure between said core and said forming structure to impregnate said fiber material;wherein said feeder channel and said distribution network are sized and arranged to allow said uncured resin to completely fill said fiber material covering said core prior to curing; andcuring said uncured resin to form a composite structure.