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Apparatus-and-method-for-forming-fiber-reinforced-composite-articles

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Apparatus and method for forming fiber reinforced composite articles

Details

Inventors: Alanko, John Sulo Matias;
Assignee: Arctek Inc. (Aurora, CA)
Primary Examiner: Davis; Robert
Assistant Examiner:
Attorney, Agent or Firm:

A unitary vacuum bag for forming of a fiber reinforced composite article, made of a fabric mesh reinforced curable elastomer, having a smooth surface on both sides. The bag is constructed upon the surface of the article which is to be reproduced and upon a planar flange extension of the mold for said article. A rigid vacuum chamber assembly consisting of a planar fiber reinforced composite or equivalent sheet is sealed on the outer periphery to the mold flange extension and on the inner periphery to the top surface of the bag by rubber seals which are attached to the vacuum chamber assembly under surface. A vacuum port through the vacuum chamber assembly between the rubber seals allows vacuum to be applied to the chamber causing it to be pressed by atmospheric pressure to the mold flange extension and bag periphery thus sealing the bag to the mold periphery and simultaneously providing a continuous vacuum source around the entire periphery of the bag. The vacuum is connected to the fiber reinforcement in the mold via multiple self sealing micro porous conduits passing under the bag periphery between the vacuum chamber and the mold cavity containing the fiber reinforcement for the article. The bag is constructed within integral multiple injection ports positioned at strategic locations for introduction of catalysed thermoset resins into the reinforcement. Optionally, a series of tubular air pressure channels are made integral to the bag which, when inflated, cause the bag to distort, resulting in resin flow channels forming under the bag on both sides of the inflated air channel. Deflation of the air channel returns the bag to it's original contour with no trace of the flow channel evident on the surface of the completed article.

DETAILED DESCRIPTION The apparatus of the invention as shown in FIG.
1, contains a mold surface (1) suitable for producing fiber reinforced articles and having attached an integral planar mold flange (2) for the purpose of sealing the open mesh fabric reinforced elastomeric form fitting bag (3) which has integral sealable resin inlet(s) (9), A separate rigid vacuum clamping assembly (5) with integral vacuum outlet (10) has attached an outer rubber seal (6) which contacts with the outer peripheral top surface of the integral planar mold flange (2) and an inner rubber seal (7) which contacts with the upper peripheral surface of the open mesh reinforced elastomeric form fitting bag (3) defining a peripheral vacuum chamber (8) having rigid vacuum clamping assembly (5) as the top surface, outer rubber seal (6) and inner rubber seal (7) as sides and integral planar mold flange (2) as the bottom surface.
The apparatus of this invention in addition to the features (1) to (10) inclusive has a self sealing micro porous transition conduit (11) in fluid communication with the peripheral vacuum chamber (8) and the fiber reinforcement bundle (4) between the mold surface (1) and the open mesh reinforced elastomeric form fitting bag (3).
A further apparatus of this invention is the air lifter tube (12) with air inlet (13) integral with the upper surface of the open mesh fabric reinforced elastomeric form fitting bag (3).
The dry fiber reinforcement bundle (4) is applied to the mold surface (1) followed by the placement of the open mesh fabric reinforced elastomeric form fitting bag (3).
The self sealing micro porous transition conduits (11) are placed strategically around the mold surface (1) periphery in contact with the fiber reinforcement bundle (4) to be at the terminus of the resin flow through the fiber reinforcement bundle (4) and to be in fluid communication with the fiber reinforcement bundle (4) and the peripheral vacuum chamber (8).
The vacuum clamping assembly (5) is placed on top of the integral planar mold flange (2) so that the outer rubber seal (7) contacts intimately with the outer periphery of mold flange (2) and the inner rubber seal (6) contacts intimately with the peripheral top surface of the open mesh fabric reinforced elastomeric form fitting bag (3)

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