IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0492115
(2002-10-11)
|
등록번호 |
US-7306761
(2007-12-11)
|
우선권정보 |
AU-PR8214(2001-10-11) |
국제출원번호 |
PCT/AU02/001383
(2002-10-11)
|
§371/§102 date |
20041220
(20041220)
|
국제공개번호 |
WO03/031178
(2003-04-17)
|
발명자
/ 주소 |
- Bannister,Michael Keith
- Paton,Rowan Johnson
|
출원인 / 주소 |
- Advanced Composite Structures Ltd
|
대리인 / 주소 |
Sheldon Mak Rose & Anderson PC
|
인용정보 |
피인용 횟수 :
0 인용 특허 :
2 |
초록
▼
A method of manufacturing a composite sandwich structure, the method comprising a preform assembly method. The method comprises providing a preform (8) comprising at least two sheets (12, 14) connected by a plurality of extensible threads (16), and affixing to the outer face of each sheet (12, 14),
A method of manufacturing a composite sandwich structure, the method comprising a preform assembly method. The method comprises providing a preform (8) comprising at least two sheets (12, 14) connected by a plurality of extensible threads (16), and affixing to the outer face of each sheet (12, 14), a face sheet (18, 22). The adhesion is by a film adhesive (20, 24) placed over the respective sheets (12, 14), and the preform (8) is subjected to pressure or heat to set the film adhesive (20, 24). The method further comprises a method of molding a composite sandwich structure, the method comprising placing a preform (8) in a mold (30), creating pressure differentials between respective chambers (40, 42) within the mold (30), feeding a resinous compound into the mold (30), and allowing the resinous compound to set and cure. The invention also provides composite sandwich structures made in accordance with the methods.
대표청구항
▼
The invention claimed is: 1. A method of molding a composite sandwich structure, the method comprising: (a) placing a preform in a mold, where the preform comprises a first sheet and a second sheet and a plurality of extensible threads extending between the first sheet and second sheet, where the m
The invention claimed is: 1. A method of molding a composite sandwich structure, the method comprising: (a) placing a preform in a mold, where the preform comprises a first sheet and a second sheet and a plurality of extensible threads extending between the first sheet and second sheet, where the mold comprises a first portion and a second portion, and where the first sheet is in the first portion and the second sheet is in the second portion; (b) placing a diaphragm between the first sheet and the first portion of the mold, where the diaphragm extends to at least an outer periphery of the first portion, and where there is a first chamber between the diaphragm and the first portion and a second chamber between the diaphragm and the second portion; (c) non-permanently adhering the first sheet of the preform to the diaphragm and non-permanently adhering the second sheet to the second mold portion; (d) creating a pressure differential between the second chamber and the first chamber by reducing the pressure in the second chamber; (e) using the pressure differential to feed a resinous compound into the second chamber to coat the extensible threads and surfaces of the first sheet and second sheet capable of being infused; (f) ceasing the feeding of the resinous compound into the second chamber; (g) ceasing the reduction of the pressure in the second chamber to substantially equalize the pressures in the first and second chambers; (h) creating a second pressure differential between the second chamber and the first chamber by comprising the pressure in the first chamber below that in the second chamber, thereby causing the diaphragm and, hence, the first sheet, to move away from the second sheet, thereby causing the extensible threads to extend; (i) maintaining the second pressure differential; and (j) allowing the resinous compound to set and cure. 2. A method according to claim 1, where the second pressure differential at step (h) is created by applying a vacuum pressure to the first chamber. 3. A method according to claim 2, where the vacuum pressure is created by a first vacuum source. 4. A method according to claim 2, where vacuum pressure is applied to the first chamber by a first vacuum port in the first portion. 5. A method according to claim 4, where the first vacuum port is substantially centrally located in the first portion. 6. A method according to claim 1, where the second pressure differential is created by applying a positive pressure in the second chamber. 7. A method according to claim 1, where the first chamber is vented during step (d), and where the venting ceases upon the commencement of step (h). 8. A method according to claim 7, where the second chamber is vented during step (h). 9. A method according to claim 7, where reducing the pressure in step (d) comprises applying the first vacuum source. 10. A method according to claim 9, where the first vacuum source is applied to a second vacuum port in the second portion of the mold. 11. A method according to claim 10, where the second vacuum port is located at or adjacent to the center of the second portion; and where the at least one inlet port is located outside the periphery of the preform. 12. A method according to claim 11, where the first vacuum or second vacuum source is connected to the second vacuum port and to the first chamber by separate tubes; and where the separate tubes are separately openable and closable. 13. A method according to claim 10, where the inlet port is at a first end of the second portion and the second vacuum port at a second end of the second portion; and where the preform assembly is located between the first end and the second end. 14. A method according to claim 9, where a second vacuum source is applied to a second vacuum port in the second portion of the mold. 15. A method according to claim 14, where the second vacuum port is located at or adjacent to the center of the second portion; and where the at least one inlet port is located outside the periphery of the preform. 16. A method according to claim 15, where the first vacuum or second vacuum source is connected to the second vacuum port and to the first chamber by separate tubes; and where the separate tubes are separately openable and closable. 17. A method according to claim 14, where the inlet port is at a first end of the second portion and the second vacuum port at a second end of the second portion; and where the preform assembly is located between the first end and the second end. 18. A method according to claim 1, where the resinous compound is fed by at least one inlet port in the second portion. 19. A method according to claim 1, where the resinous compound is fed by at least one inlet port located between the first and second portions. 20. A method according to claims 1, where heat is applied for a predetermined time during step (j). 21. A method according to claim 20, where the heat is applied by heating the first portion or the second portion, or both the first portion and the second portion. 22. A method according to claim 20, where the heat is applied by introducing heated air into the second chamber. 23. A method according to claim 22, where the heated air is introduced through the at least one inlet port or the second vacuum port or a further inlet port or a combination of the preceding. 24. A method according to claim 20, where the heat is applied by placing the mold in a heated oven. 25. A method according to claim 1, where a caul plate is releasably adhered to the diaphragm above the first sheet, and to the preform. 26. A method according to claim 1, where the resinous compound is fed using a positive pressure in step (e). 27. A method according to claim 1, where a carrier mesh is used to feed the resinous compound in step (e); and where the carrier mesh is attached to the inlet ports. 28. A method according to claim 1, where the resinous compound is selected from the group consisting of a vinylester, a phenolin, an epoxy and a resin. 29. A method according to claim 1, where the mold is capable of incorporating a diaphragm and of holding vacuum in a cavity under the diaphragm sufficient to conduct a successful infusion of the preform assembly. 30. A method according to claim 29, where the mold is selected from the group consisting of a sealed, fully closed mold, a base plate-diaphragm combination or an envelope bag. 31. A method according to claim 29, where the mold incorporates means for the infusion of the preform assembly with resin. 32. A method according to claim 29, where the mold comprises means for creating a pressure differential on either side of the diaphragm and is capable of maintaining the pressure differential until the sandwich structure is cured. 33. A method according to claim 29, where the mold comprises means for supporting the predetermined, final component dimensions.
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