Method of manufacturing a fiber-reinforced composite molding, the method comprising the steps of: (a) disposing a surfacing layer on a portion of a mold surface, the surfacing layer comprising a first resin material and being in the form of at least one solid sheet; (b) disposing at least one layer
Method of manufacturing a fiber-reinforced composite molding, the method comprising the steps of: (a) disposing a surfacing layer on a portion of a mold surface, the surfacing layer comprising a first resin material and being in the form of at least one solid sheet; (b) disposing at least one layer of fibrous reinforcing material on the surfacing layer to provide, on the portion of the mold surface, an assembly of the surfacing layer and a structural layer comprising the at least one layer of fibrous reinforcing material; (c) applying a vacuum to the assembly; (d) infusing a flowable second resin material, under the vacuum, into the at least one layer of fibrous reinforcing material; and (e) curing the first and second resin materials to form the fiber-reinforced composite molding which comprises a surface portion formed from the surfacing layer laminated to a structural portion formed from the at least one layer of fibrous reinforcing material and the second resin material.
대표청구항▼
1. A method of manufacturing a fibre-reinforced composite moulding, the method comprising the steps of: (a) disposing a surfacing layer on a portion of a mold surface, the surfacing layer comprising a first resin material and being in a form of at least one solid sheet, the first resin material of t
1. A method of manufacturing a fibre-reinforced composite moulding, the method comprising the steps of: (a) disposing a surfacing layer on a portion of a mold surface, the surfacing layer comprising a first resin material and being in a form of at least one solid sheet, the first resin material of the surfacing layer being supported on a carrier of a sheet material, wherein the surfacing layer comprises a plurality of surfacing layer segments assembled together to form a continuous surfacing layer;(b) disposing at least one layer of dry fibrous reinforcing material on the surfacing layer to provide, on the portion of the mould surface, an assembly of the surfacing layer and a structural layer comprising the at least one layer of dry fibrous reinforcing material;(c) applying a vacuum to the assembly;(d) in a vacuum assisted resin transfer moulding step, a resin feed infusion system feeds a liquid resinous compound from a source of such resinous compound into the assembly, the liquid resinous compound comprising a second resin material, wherein the second resin material is infused, under the vacuum, into the at least one layer of dry fibrous reinforcing material; and(e) curing the first and second resin materials to form the fibre-reinforced composite moulding which comprises a surface portion formed from the surfacing layer laminated to a structural portion formed from the at least one layer of dry fibrous reinforcing material and the second resin material, wherein the first resin material of the surfacing layer has an applied weight thickness of from 100 to 400 grams per square meter (gsm). 2. A method according to claim 1, wherein each surfacing layer segment has at least one edge thereof that partially overlaps an adjacent 2 surfacing layer segment, wherein the overlap between adjacent surfacing layer segments has a width of from 10 to 75 mm. 3. A method according to claim 2, wherein the surfacing layer segments overlap on opposing edges. 4. A method according to claim 1, wherein the first resin material of the surfacing layer has a thickness of from 100 to 300 microns. 5. A method according to claim 1, wherein the sheet material of the surfacing layer has a weight of from 10 to 90 gsm. 6. A method according to claim 1, wherein the sheet material of the surfacing layer comprises a polymer or glass scrim material. 7. A method according to claim 1, wherein the sheet material of the surfacing layer is located at or proximal to a first face of the surfacing layer. 8. A method according to claim 7, wherein the first face of the surfacing layer is remote from the mould surface in disposing step (a) so that a majority of the first resin material is between the sheet material and the mould surface. 9. A method according to claim 1, wherein the first resin material and the second resin material cure at least partially simultaneously in the curing step (e). 10. A method according to claim 1, wherein the first resin material and the second resin material have different viscosities. 11. A method according to claim 10, wherein the first resin material has a higher viscosity than that of the second resin material at room temperature (20 degrees Centigrade). 12. A method according to claim 11, wherein a ratio of the viscosity, measured at 20° C. ambient temperature, of the first resin material and of the second resin material is at least 100/1. 13. A method according to claim 10, wherein in the curing step (e) the second resin material is adapted to initiate curing before the first resin material. 14. A method according to claim 10, wherein the curing step (e) is carried out at an elevated temperature above room temperature. 15. A method according to claim 14, wherein the curing step (e) is carried out at a temperature of from 40 to 90 degrees Centigrade. 16. A method according to claim 10, wherein in the curing step (e) the curing reaction of the second resin material is exothermic which generates heat which accelerates the curing of the first resin material. 17. A method according to claim 1, wherein the surfacing layer is previously affixed to a layer of the fibrous reinforcing material whereby the surfacing layer and at least one layer of fibrous reinforcing material are disposed on a portion of a mould surface in a common step. 18. A method according to claim 1, wherein the first resin material of the surfacing layer has a viscosity of from 0.1×105 to 5×105 Pa.s measured at 20° C. 19. A method according to claim 1, wherein the second resin material has a viscosity of from 0.1 to 2 Pa.s measured at 20° C. 20. A method of manufacturing a fibre-reinforced composite moulding, the method comprising the steps of: (a) disposing a surfacing layer on a portion of a mould surface, the surfacing layer comprising a first resin material and being in a form of at least one solid sheet, the first resin material of the surfacing layer being supported on a carrier of a sheet material, wherein the surfacing layer comprises a plurality of surfacing layer segments assembled together to form a continuous surfacing layer;(b) forming an assembly comprised of the surfacing layer and a structural layer comprised of at least one layer of dry fibrous reinforcing material;(c) applying a vacuum to the assembly;(d) in a vacuum assisted resin transfer moulding step, a resin feed infusion system feeds a liquid resinous compound from a source of such resinous compound into the assembly, the liquid resinous compound comprising a second resin material, wherein the second resin material is infused, under the vacuum, into the at least one layer of dry fibrous reinforcing material; and(e) curing the first and second resin materials to form the fibre-reinforced composite moulding which comprises a surface portion formed from the surfacing layer laminated to a structural portion formed from the at least one layer of dry fibrous reinforcing material and the second resin material, and wherein each surfacing layer segment has at least one edge thereof that partially overlaps an adjacent surfacing layer segment, wherein the overlap between adjacent surfacing layer segments has a width of from 10 to 75 mm. 21. A method of manufacturing a fibre-reinforced composite moulding, the method comprising the steps of: (a) disposing a surfacing layer on a portion of a mould surface, the surfacing layer comprising a first resin material and being in a form of at least one solid sheet, the first resin material of the surfacing layer being supported on a carrier of a sheet material, wherein the surfacing layer comprises a plurality of surfacing layer segments assembled together to form a continuous surfacing layer;(b) disposing at least one layer of dry fibrous reinforcing material on the surfacing layer to provide, on the portion of the mould surface, an assembly of the surfacing layer and a structural layer comprising the at least one layer of dry fibrous reinforcing material;(c) applying a vacuum to the assembly;(d) in a vacuum assisted resin transfer moulding step, a resin feed infusion system feeds a liquid resinous compound from a source of such resinous compound into the assembly, the liquid resinous compound comprising a second resin material, wherein the second resin material is infused, under the vacuum, into the at least one layer of dry fibrous reinforcing material; and(e) curing the first and second resin materials to form the fibre-reinforced composite moulding which comprises a surface portion formed from the surfacing layer laminated to a structural portion formed from the at least one layer of dry fibrous reinforcing material and the second resin material, and wherein the first resin material of the surfacing layer has a thickness of from 100 to 300 microns. 22. A method of manufacturing a fibre-reinforced composite moulding, the method comprising the steps of: (a) disposing a surfacing layer on a portion of a mould surface, the surfacing layer comprising a first resin material and being in a form of at least one solid sheet, the first resin material of the surfacing layer being supported on a carrier of a sheet material, wherein the surfacing layer comprises a plurality of surfacing layer segments assembled together to form a continuous surfacing layer;(b) disposing at least one layer of dry fibrous reinforcing material on the surfacing layer to provide, on the portion of the mould surface, an assembly of the surfacing layer and a structural layer comprising the at least one layer of dry fibrous reinforcing material;(c) applying a vacuum to the assembly;(d) in a vacuum assisted resin transfer moulding step, a resin feed infusion system feeds a liquid resinous compound from a source of such resinous compound into the assembly, the liquid resinous compound comprising a second resin material, wherein the second resin material is infused, under the vacuum, into the at least one layer of dry fibrous reinforcing material; and(e) curing the first and second resin materials to form the fibre-reinforced composite moulding which comprises a surface portion formed from the surfacing layer laminated to a structural portion formed from the at least one layer of dry fibrous reinforcing material and the second resin material, and wherein the sheet material of the surfacing layer has a weight of from 10 to 90 gsm. 23. A method of manufacturing a fibre-reinforced composite moulding, the method comprising the steps of: (a) disposing a surfacing layer on a portion of a mould surface, the surfacing layer comprising a first resin material and being in a form of at least one solid sheet, the first resin material of the surfacing layer being supported on a carrier of a sheet material, wherein the surfacing layer comprises a plurality of surfacing layer segments assembled together to form a continuous surfacing layer;(b) disposing at least one layer of dry fibrous reinforcing material on the surfacing layer to provide, on the portion of the mould surface, an assembly of the surfacing layer 9 and a structural layer comprising the at least one layer of dry fibrous reinforcing material;(c) applying a vacuum to the assembly;(d) in a vacuum assisted resin transfer moulding step, a resin feed infusion system feeds a liquid resinous compound from a source of such resinous compound into the assembly, the liquid resinous compound comprising a second resin material, wherein the second resin material is infused, under the vacuum, into the at least one layer of dry fibrous reinforcing material; and(e) curing the first and second resin materials to form the fibre-reinforced composite moulding which comprises a surface portion formed from the surfacing layer laminated to a structural portion formed from the at least one layer of dry fibrous reinforcing material and the second resin material, and wherein a ratio of viscosity, measured at 20° C. ambient temperature, of the first resin material and of the second resin material is at least 100/1.
연구과제 타임라인
LOADING...
LOADING...
LOADING...
LOADING...
LOADING...
이 특허에 인용된 특허 (6)
Godbehere, Andrew P; Williams, Stephen; Spear, Robert D, Composite material construction.
※ AI-Helper는 부적절한 답변을 할 수 있습니다.