WO2012082778A2 - Article composite et son procédé de fabrication - Google Patents

Article composite et son procédé de fabrication Download PDF

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Publication number
WO2012082778A2
WO2012082778A2 PCT/US2011/064703 US2011064703W WO2012082778A2 WO 2012082778 A2 WO2012082778 A2 WO 2012082778A2 US 2011064703 W US2011064703 W US 2011064703W WO 2012082778 A2 WO2012082778 A2 WO 2012082778A2
Authority
WO
WIPO (PCT)
Prior art keywords
microporous membrane
membrane
composite
gas impermeable
microporous
Prior art date
Legal status (The legal status 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 status listed.)
Ceased
Application number
PCT/US2011/064703
Other languages
English (en)
Other versions
WO2012082778A3 (fr
Inventor
James L. Sadlo
James S. Mrozinski
Kim L. Nichum
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
3M Innovative Properties Co
Original Assignee
3M Innovative Properties Co
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 3M Innovative Properties Co filed Critical 3M Innovative Properties Co
Publication of WO2012082778A2 publication Critical patent/WO2012082778A2/fr
Publication of WO2012082778A3 publication Critical patent/WO2012082778A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection

Definitions

  • the present invention is directed to a composite article and the method of manufacturing the composite article.
  • the composite preform can be a woven fabric, a multi-axis interlaid scrim or a warp-thread reinforced unidirectional preform.
  • the preforms are used in the production of components made of fiber-reinforced material, for example airplane wings, boat hulls and wind turbine blades. They represent an intermediate process step before infiltration by resin and curing.
  • the composite preform is then infused with a matrix resin material. This may be accomplished using vacuum infusion.
  • Vacuum infusion utilizes a vacuum to remove air from around a composite preform and a resin is allowed to be infused by the vacuum to completely wet-out all air voids in the composite preform.
  • Typical resins used are polyester, vinyl ester, and epoxy. The resin is then generally cured.
  • the vacuum infusion process is limited by the length of the flow the resin must travel to completely wet all air voids.
  • the vacuum infusion process is limited by the length of the flow the resin must travel to completely wet all air voids.
  • a pressure gradient develops along the part length between the injection and the vacuum lines. Which in turn results in a thickness gradient along the length of the part, the thickness gradient directly creates a variation in the fiber volume fraction.
  • Voids can occur in the final part due to entrapped air in the fiber-bundle, entrapped air during the resin mixing process and due to generation of volatiles during resin curing.
  • Thickness gradient, fiber volume fraction variations and voids can result in significant variation in the mechanical properties of the composite.
  • a membrane is used as an aid to control such variations.
  • the membranes used in these processes are generally semi- permeable, or impermeable to resin while being permeable to a gas.
  • the present application is directed to a method for producing a composite component.
  • the method comprises providing a composite preform on a tool, providing a polymeric microporous membrane encapsulating the composite preform and providing a gas impermeable membrane encapsulating the microporous membrane. Air is removed from between the microporous membrane and the gas impermeable membrane. A matrix material is then introduced in contact with the composite preform and the mircoporous membrane and is infused into the pores of the microporous membrane.
  • the matrix material renders the microporous membrane translucent.
  • a breather layer is between the microporous membrane and the gas impermeable membrane
  • the application is additionally directed to a device for producing composite components.
  • the device comprises a tool configured to hold a composite preform, a microporous membrane encapsulating the preform, and a gas impermeable membrane encapsulating the microporous membrane.
  • the microporous membrane is permeable to a matrix material.
  • Figure 1 is a side view of the apparatus used in the method of the present application.
  • the present application is directed to a composite article and its method of manufacture.
  • the composite article is a multilayer composite.
  • the composite preform (generally, a preform is used for reinforcement layers such as glass fibers, etc.) may be any reinforcement material such as glass fiber, carbon, etc. useful for a desired end application.
  • the composite may be a reinforced plastic component including carbon fibers, glass fibers, aramid fibers, boron fibers or hybrid materials, the geometric shape of which maybe any desired shape.
  • the material is a combination of multiple homogeneous systems. Such embodiments are intended to be described as a composite.
  • the composite may be suitable for the production of wind turbine blades, aircraft components and boat hulls.
  • the composite preform is mounted on a tool.
  • the tool may be made from various suitable materials, e.g., wood, steel, sheet metal, glass, etc.
  • the composite preform is separated from the tool for ease of final separation, for example with a peel-ply and/or a release layer.
  • a flow media is used to facilitate uniform resin flow across the surface of the composite. For example, netted mesh with high permeability available under the name Green Flow 75 at www.airtechonline.com.
  • the resin may be any resin material useful in the desired application.
  • a useful resin is epoxy resin, for example, one commercially available under the trade designation "EPIKOTE RESIN MGS RIMR 135" from Hexion Specialty Chemicals, Columbus, Ohio.
  • the resin is fed to the composite material using an infusion line. A vacuum is created around the composite and the resin flows into the lower pressure void from an attached reservoir.
  • a microporous membrane encapsulates the composite preform.
  • Encapsulation means, for the purpose of the present application, that the membrane is sealed around the composite, for example sealed to the tool with any method known (e.g. vacuum tape).
  • the presence of membrane equalizes vacuum pressure throughout the length of the part reducing the thickness gradient. It also reduces the void content in the final composite thus improving its physical properties.
  • the use of membrane also reduces the overall fill time of a given part geometry.
  • microporous membrane is made as shown in U.S. Patent numbers 5,238,623; 5,120,594; and 4,726,989, the teaching of which are incorporated by reference herein. These microporous membranes contain actual microporous holes.
  • microporous is defined as having an open morphology of a controlled pore size typically ranging from about 0.01 ⁇ to about 10 ⁇ .
  • the microporous membrane has an open morphology of a controlled pore size typically ranging from about 0.1 ⁇ to 1 ⁇ .
  • the micropores may be formulated with a tortuous path through the membrane.
  • the tortuous path provides a slow path through the microporous membrane.
  • the membrane is therefore permeable to both gas and fluid. It is therefore surprising that such a membrane can be used in this process, as it has the ability to still contain the resin. Its permeability to the resin allows for the membrane to become transparent/translucent when the resin begins to permeate. Therefore, the operator can see the resin location and note when the part have been completely filled, this helps the operator from over filling the part with excess resin. Excess resin reduces the fiber weight fraction of the composite part which can result in significant loss of its mechanical properties. Therefore the transparency/translucency property of this membrane plays an important to obtain control and repeatability in the current process. Such a process allows for the resin flow to move without inhibition and the resin is still contained so as to not enter the vacuum lines.
  • the use of a transparent or translucent membrane will increase process robustness, which will reduce the risk of dry spot formation in complex part shapes.
  • a breather layer is generally between the microporous membrane and the gas impermeable membrane.
  • the breather layer facilitates the air flow during the vacuum process. It separates the gas impermeable membrane from the microporous membrane, and allows for tangential air flow, which creates the vacuum as air flows out of the area between the microporous membrane and the gas impermeable membrane. Air is further removed from the area between the microporous membrane and the composite preform as the air flows through the microporous membrane to the breather layer.
  • the breather material is a nonwoven material. It may also be laminated to the microporous membrane.
  • the breather layer is a structured surface on the microporous membrane.
  • the breather layer is encapsulated by a gas impermeable membrane.
  • the gas impermeable membrane is any material known to be effective as a vacuum bag or bladder.
  • the resin flows over the top of the composite preform, between the composite preform and the microporous membrane.
  • the resin flows over side of the composite facing the tool.
  • the present application is directed to a process that will limit flow time. For example, the resin will flow over the entire surface of the composite and will flow through the thickness. In embodiments where the resin flow from the tool side to the microporous membrane side, the completion of the flow will be marked by the change of the microporous membrane from opaque to transparent/translucent and indicated above.
  • the present application may allow for faster infusion times. It may also allow for more complex geometries to be filled. Additionally, resin systems with nano-particles may be used, allowing for a higher compression strength without the loss of productivity.
  • the device 10 comprises a tool 12.
  • a flow media 14 and a peel-ply 16 are on the tool.
  • the composite preform 18 is on the tool 12.
  • An additional peel-ply 20 sits over the preform 18.
  • a microporous membrane 22 encapsulates the preform 18 and is attached to the tool 12 around the perimeter of the composite preform.
  • the perimeter is represented by points 24 and 26.
  • a gas impermeable membrane 28 encapsulates the microporous membrane, and is attached to the tool round the perimeter of the microporous membrane, represented by points 30 and 32.
  • a vacuum line 34 is used to pull the vacuum from the space between the gas impermeable membrane 28 and the microporous membrane 22.
  • a resin infusion line 36 delivers resin to the composite preform 18.
  • SCRIMP Seeman Composites Resin Infusion Molding Process
  • the second embodiment was 2 layer laminate with a 38.1 ⁇ thick membrane and average pore size of 0.20 ⁇ thermal bonded to a spun bond
  • polypropylene backing of about 40 grams per square meter (gsm), -180 ⁇ thick from BBA Nonwovens South Carolina, identified as 1.25 oz PP spunbond.
  • the microporous membranes were made accordingly:
  • a sheet of microporous membrane material as taught in U.S. Patent numbers 5,238,623; 5,120,594; and 4,726, 989US, was prepared using a thermally induced phase separation technique combining about 59.9 parts by weight polypropylene (PP) having a melt flow index of 0.8 dg/min ASTM 1238 (available from Sunoco Inc., Philadelphia
  • the PP/NA/MO composition was melt extruded on a twin screw extruder operated at a decreasing temperature profile of 260° to 193° C. through a slip gap sheeting die having an orifice of 35.6 cm x 0.05 cm and quenched on a patterned casting wheel maintained at 49° C.
  • the mineral oil containing film was continuously length stretched 1.8: 1 at 110 ° C and width stretched or oriented (cross direction) in a tenter oven to a 1.8:1 stretch ratio at 120° C. and heat annealed at 130° C resulting in a membrane that was 127 ⁇ thick, had a pore size of 0.50 ⁇ , a 40 % porosity, and a 50 seconds/50cc Gurley value.
  • a second microporous material was made except the PP/NA/MO ratio was
  • the Bubble Point pore size is the bubble point value representing the largest effective pore size in a sample, measured in microns, according to ASTM-F-316-80.
  • Porosity (1 - membrane bulk density/PP density) x 100
  • Gurley resistance to air flow value is the time in seconds for
  • Epoxy resin commercially available under the trade designation "EPIKOTE
  • RESIN MGS RIMPv 135" from Hexion Specialty Chemicals, Columbus, Ohio, was used as the matrix system along with 4 layers of biaxial 800 g/m 2 E-Glass fabric as the reinforcement.
  • the infusion line, flow media and the peel-ply layers were sealed inside the microporous membrane along with the composite preform.
  • the backing of the entire microporous membrane acted as the breather which ensured uniform vacuum distribution on the part.
  • the vent was placed directly on top of the microporous membrane.
  • the vacuum bag gas impermeable membrane sealed all these materials.
  • the peel-ply layers separates the reinforcements from the distribution medium and the membrane respectively.
  • the distribution medium has a much higher in-plane permeability compared to the fabric stack allowing fast surface resin wet-out of the part ensuing resin penetration through the thickness of the fiber reinforcements under vacuum (100 mbar).
  • the microporous membrane turned translucent instantaneously as the resin came in contact after penetrating through the reinforcements. This helped to identify the flow front of the resin throughout the infusion process.
  • the first embodiment turned more transparent than the second as it did not have the addition of the nonwoven layer.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)

Abstract

Cette invention concerne un procédé de production d'un composant composite, ledit procédé consistant à fournir une préforme composite sur un outil, à fournir une membrane microporeuse polymère encapsulant la préforme composite et à fournir une membrane imperméable aux gaz encapsulant la membrane microporeuse. L'air présent entre la membrane microporeuse et la membrane imperméable aux gaz est éliminé. Un matériau matriciel est ensuite introduit en contact avec la préforme composite et la membrane microporeuse et se diffuse dans les pores de la membrane microporeuse. L'application concerne par ailleurs un dispositif de production de composants composites. Le dispositif comprend un outil conçu pour tenir une préforme composite, une membrane microporeuse encapsulant la préforme, et une membrane imperméable aux gaz encapsulant la membrane microporeuse. La membrane microporeuse est perméable à un matériau matriciel.
PCT/US2011/064703 2010-12-17 2011-12-13 Article composite et son procédé de fabrication Ceased WO2012082778A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201061424158P 2010-12-17 2010-12-17
US61/424,158 2010-12-17

Publications (2)

Publication Number Publication Date
WO2012082778A2 true WO2012082778A2 (fr) 2012-06-21
WO2012082778A3 WO2012082778A3 (fr) 2012-08-09

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PCT/US2011/064703 Ceased WO2012082778A2 (fr) 2010-12-17 2011-12-13 Article composite et son procédé de fabrication

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Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2124130B (en) * 1982-07-24 1985-11-27 Rolls Royce Vacuum moulding fibre reinforced resin
DE10013409C1 (de) * 2000-03-17 2000-11-23 Daimler Chrysler Ag Verfahren und Vorrichtung zur Herstellung von faserverstärkten Bauteilen mittels eines Injektionsverfahrens
JP4160771B2 (ja) * 2002-04-18 2008-10-08 三菱レイヨン株式会社 繊維強化プラスチック成形体の成形装置とその成形方法
ES2628600T3 (es) * 2002-10-09 2017-08-03 Toray Industries, Inc. Método de moldeo de RTM

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Publication number Publication date
WO2012082778A3 (fr) 2012-08-09

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