USOO9649784B2

(12) United States Patent (10) Patent No.: US 9,649,784 B2

Masini et al. (45) Date of Patent: May 16, 2017
(54) MOLD MADE OF A COMPOSITE MATERAL (58) Field of Classification Search
AND PROCESS EMPLOYING THIS MOLD CPC ....... B29C 45/02; B29C 70/548; B29C 70/86;
B29C 33/3807; B29C 33/301; B29C
(71) Applicant: Automobili Lamborghini S.p.A., 70/72; B29C 70/48
Sant'Agata Bolognese BO (IT) See application file for complete search history.
(72) Inventors: Attilio Masini, Monteveglio BO (IT): (56) References Cited
Nicoló Pasini, Taino VA (IT): Luigi De
Sario, Crevalcore BO (IT): Casper U.S. PATENT DOCUMENTS
Steenbergen, Sant'Agata Bolognese BO
(IT) 2,027,165 A * 1/1936 Grubman ...................... 425, 176
2,171,229 A * 8, 1939 Steiner ............................ 164.96
(73) Assignee: AUTOMOBILLAMBORGHN (Continued)
S.P.A., Sant'Agata Bolognese (BO) (IT)
FOREIGN PATENT DOCUMENTS
(*) Notice: Subject to any disclaimer, the term of this
patent is extended or adjusted under 35 CN 1104974 C 4/2003
U.S.C. 154(b) by 480 days. EP O412891 A2 2, 1991
(Continued)
(21) Appl. No.: 13/693,387
OTHER PUBLICATIONS
(22) Filed: Dec. 4, 2012
Woods. B.K.S., et al., Manufacture of Bulk Magnetorheological
(65) Prior Publication Data
Elastomers. Using Vacuum Assisted Resin Transfer Molding, Inter
US 2013 FOO93126 A1 Apr. 18, 2013 national Journal of Modern Physics B, vol. 21, No. 28&29 (2007).
Related U.S. Application Data pp. 5010-5017.*
(Continued)
(63) Continuation-in-part of application No.
PCT/IB2011/052567, filed on Jun. 14, 2011. Primary Examiner — Matthew Daniels
(30) Foreign Application Priority Data (74) Attorney, Agent, or Firm — Lucas & Mercanti, LLP
Jun. 14, 2010 (IT) .............................. MI2O1 OA1072 (57) ABSTRACT
A mold for manufacturing products made of composite
(51) Int. C. materials, which comprises at least one functional portion
B29C 33/38 (2006.01) made of a composite material joined to at least one interface
B29C 33/20 (2006.01) made of a composite material which projects at least par
(Continued) tially around the functional portion, said mold being pro
(52) U.S. C. vided with one or more mechanic fastening devices for the
CPC ............ B29C 33/20 (2013.01); B29C 33/301 coupling with at least another mold.
(2013.01); B29C 33/3807 (2013.01);
(Continued) 15 Claims, 10 Drawing Sheets
 US 9,649,784 B2
Page 2

(51) Int. Cl. 4,756,683 A * 7/1988 Svoboda ................. B29C 45/46

B29C 33/30 (2006.01) 425,557
B29C 70/48 (2006.01) 4,859,528 A * 8/1989 Lee et al. ...................... 442,180
4,920,161 A * 4/1990 Wang et al. 523 220
3. 26 C
(2006.01)
4.944,824. A * 7/1990 Gupta ...
5,039,468 A * 8/1991 Sellers ...
... 156,286
... 264,225
B29C 70/54 (2006.01) 5,114.637 A * 5/1992 Williams ................ B29C 39.32
B29C 70/86 (2006.01) 264/101
B29K 307/04 (2006.01) 5,252,165 A * 10/1993 Fecto et al. ................... 156.228
B29L 3 I/OO (2006.01) 5,470,651 A * 11/1995 Milinkovic et al. ... 428/325
(52) U.S. Cl 5,939,007 A * 8/1999 Iszczyszyn et al. ... 264/258
AV e. we 6,069,319 A * 5/2000 Davis et al. ................ 174,72 A
CPC .............. B29c. 45/02 (2013.01); B29C 70/48 6,309,587 B1 * 10/2001 Gniatczyk et al. ........... 264/510
(2013.01); B29C 70/548 (2013.01); B29C 6,638,466 B1 10/2003 Abbott
70/72 (2013.01); B29C 70/86 (2013.01); B29K 7,628,942 B1* 12/2009 Miller ................. CO4B 35,5622
2307/04 (2013.01); B29K 2913/00 (2013.01); 264/257
B29L 2031/00 (2013.01) 2002fO181224 A1 12/2002 Tahara et al.
2007/0012858 A1 1/2007 Callis ............................ 249,134
(56) References Cited 2007/0017634 A1 1/2007 Stevenson et al. . 156,308.2
2007/0182071 A1* 8, 2007 Sekido et al. ................ 264/511
U.S. PATENT DOCUMENTS
FOREIGN PATENT DOCUMENTS
2,178,774. A * 11/1939 Bogoslowsky ....... B29C 33/126
264/278 EP 0662380 A2 7, 1995
2,392,804 A 1/1946 Basolo FR 2664529 A1 1/1992
2,480,434. A 8, 1949 Askin ........................... 249,169 FR 2675732 A1 10, 1992
2,880,830 A * 4, 1959 Rohe..................... E04B 1.4121 FR 277 1960 A1 6, 1999
411/296 FR 2864801 A1 7, 2005
2.915,789 A * 12/1959 Dykstra et al. ............... 264/246 GB 2134845. A 8, 1984
3,016,578 A * 1/1962 Rohe......................... B64C3,00 GB 2232630 A 12, 1990
264/262 GB 2243107 A 10, 1991
3,056,167 A 10/1962 Knoppel JP O3140213 A 6, 1991
3,082,479 A * 3/1963 Chupa ........................... 249,135 JP O71953.76 A 8, 1995
3,212,181 A * 10/1965 Henle ............................. 29/468 JP O8323870 A 12, 1996
3,305,996 A * 2/1967 Shapiro ..................... F16B 5/O1 JP 2003O14938 A 1, 2003
428,116 WO 985O180 A1 11F1998
ck WO O3O41947 A1 5, 2003
3,309.450 A * 3/1967 Rodgers .................. B2. WO 201200 1660 A2 1/2012
3.421,184. A * 1/1969 Swisher ................ B29C 33/2O2
249, 170 OTHER PUBLICATIONS
3.433,450 A * 3/1969 Garrett ................ B29C 45/4005
ck 249,67 Miracle & S. L. Donaldson D B ED, “Composites, Vacuum Infu
3,636.241 A * 1/1972 Baumgartner ......... Hoss, sion”. Dec. 1, 2001, ASM Handbook, pp. 501-511, XP002619563.
3.945,070 A * 3, 1976 Hauser F16B 37,12 International Search Report for EP121991.03, dated Oct. 28, 2013.
- I- W - W - x - k-1 i w kick-kw uwu 164/111 Office Action for Chinese Patent Application No. 201180028871.9,
4.292.222 A * 9/1981 Grigo .................... CO8L 23, 142 dated May 6, 2014.
524/269 Office Action for Chinese Patent Application No. 201180028871.9,
4,315,887 A * 2/1982 Kubat ................. B29C 45,0001 dated Sep. 24, 2014.
264,328.16 International Search Report for EP14171906.2, dated Jul. 23, 2014.
4,359.443 A : 11, 1982 Michaels ................... 264,328.2 Office Action for Japanese Patent Application No. 2013514818,
4,372.741. A * 2/1983 Cane ..................... PE lated Oct 7, 2014.
4,386,868 A * 6/1983 Bluver .................... B22C 21, 10 Office Action for Russian Patent Application No. 2013 101582,
164/387 dated Dec. 17, 2014.
4.391,579 A 7, 1983 Morrison .............. B29C 45,263 Chinese Office Action for Corresponding Chinese Patent Applica
-- - 42.5/548 tion No. 201410740968.8 issued Jun. 28, 2016 (9 pages).
4,442,060 A * 4, 1984 Bouverot ................. CO8K 3/36
264,328.2 * cited by examiner
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 US 9,649,784 B2
1. 2
MOLD MADE OF A COMPOSITE MATERAL namely a process which is fast, economic and easy to be
AND PROCESS EMPLOYING THIS MOLD automated, and which allows to obtain high quality products
with light and compact devices. Said object is achieved with
CROSS-REFERENCE TO RELATED a mold and a process, whose main features are disclosed
APPLICATIONS herein.
This application is a continuation-in-part of PCT Interna The process according to the present invention provides
tional Application Serial No. PCT/IB2011/052567, filed Jun. for molds obtained by layers of carbon fibers pre-impreg
14, 2011, which claims the benefit of priority from Italian nated with a resin (known also as pre-preg) and for the cure
Patent Application Serial No. MI2010A001072, filed Jun. of the final products with the heating of these molds in an
14, 2010, the contents of each of which are incorporated
10 oven or an autoclave, instead of employing a press with
herein by reference. heated molds. Therefore, the resin can be injected at lower
pressures compared to the RTM process but anyway suffi
FIELD OF THE INVENTION cient for ensuring the correct and complete impregnation of
the dry fibers which made up the substrate of the final
The present invention relates to a mold made of a com 15 product.
posite material, as well as to a process which can employ this Said pressures are preferably higher compared to the
mold. RTM-Light process, especially if the molds are stiffened by
means of ribs or other reinforcing members.
BACKGROUND OF THE INVENTION The joining between the molds is obtained by means of
particular mechanic fastening means and gaskets, which
The known RTM (Resin Transfer Molding) process allow to keep the molds hermetically closed at the injection
employs molds made of steel for withstanding the high pressures of the resin.
pressures, even higher than 15 bar, needed for the injection The molds preferably incorporate particular bushings
of the resin. which allow both a precise and resistant mechanic fastening
The shaping of the fiber layers and their subsequent 25 between the molds and the easy and fast addition of par
deposition into the molds can be automated, thus making ticular devices, such as injectors, suction mouths and/or
more repeatable and economic the parts produced with this eXtractOrS.
process, however the molds of the RTM process are heavy, At least one mold comprises particular canals and/or slits
expensive and bulky. Moreover, the metal molds need a for uniformly distributing the resin before it reaches the
complex design which must take their thermal expansion 30 cavities, so as to obtain products free from defects such as
into account during the curing cycle of the resin, to avoid the hollow spaces, pores, delaminations or dry Zones. Particular
molded product being clogged inside a mold. wells arranged in correspondence with the injectors avoid
The RTM-Light process, in which a semirigid mold is the wear of the molds due to the injection pressure of the
arranged on a rigid mold, is known for overcoming these resin.
technical problems. The resin is injected at a pressure lower 35 The production of the molds is preferably obtained in a
than 1 bar and air (0.5 bar) is sucked from a central low point fast and accurate manner by means of particular masters
for favoring the flowing of the resin. The joining between the provided with tridimensional templates of the final product
two molds is obtained by creating vacuum (0.1 bar) along and with mechanic arrangements, such as reference Surfaces
the edges of the two molds. This process, though it is simple for obtaining particular interfaces in the molds, side walls
to be carried out with light and economic devices, does not 40 for obtaining corresponding walls Suitable for strengthening
allow to manufacture products with the same speed and the the molds, pins for arranging the bushings with precision in
same quality of the RTM process, since the injection pres the molds, removable elastomeric sections and/or bulges for
sure is relatively low and the side of the product facing the obtaining canals or wells in the molds. Several identical
semirigid mold has a rough finish. Furthermore, the low molds can be produced with a single master, so as to increase
pressure employed in the RTM-Light process does not 45 in a relatively simple and economic manner the productivity
ensure the correct and complete impregnation of the dry of the process according to the present invention.
fibers, thus causing the manufacture of low quality compo Furthermore, the molds according to the present invention
nentS. are light and not much bulky, so that they can be easily
EP 1721719 and FR 2864801 disclose RTM processes in handled before, during and after use, for example when they
which the molds are made of composite materials. In par 50 are prepared, filled and arranged in the oven or in the
ticular, the molds disclosed in FR 2864801 are in turn made autoclave.
by means of a RTM process in which the resin is injected Since the molds are made of substantially the same
only after the fibers have been arranged between a mold material of the products, they undergo Substantially the same
made of a composite material and a master or a template. thermal expansions, so as to compensate negative effects, if
These known molds are relatively expensive due to the RTM 55 any, due to these expansions.
process employed for their manufacturing and to the need of All the above advantages are remarkably increased if in
arranging a template between a first mold which is already the process a molding unit is employed, in which all the
ready and a second mold during the manufacturing of the molds, namely at least two complementary molds, are
latter. The known molds made of a composite material manufactured according to the present invention.
further require complex Supporting structures and/or must be 60
relatively thick, thus expensive, for withstanding the pres BRIEF DESCRIPTION OF THE DRAWINGS
sures of the RTM process.
Further advantages and features of the process and the
SUMMARY OF THE INVENTION devices according to the present invention will become clear
65 to those skilled in the art from the following detailed and
It is therefore an object of the present invention to provide non-limiting description of two embodiments thereof with
a process which is free from all the above disadvantages, reference to the attached drawings, wherein:
 US 9,649,784 B2
3 4
FIG. 1 shows a perspective view of a product which can plurality of first pins 8 perpendicularly project in turn from
be manufactured with the mold according to the present first reference surface 3a of first master 3 around second
invention; ridge 6. First template 2, first ridges 5, second ridge 6 and/or
FIG. 2 shows a bottom view of the first master according bulges 7 can be made of a single piece of epoxy resin on first
to the first embodiment; reference surface 3a of first master 3 with digital control
FIG. 3 shows section III-III of FIG. 2; cutters or can comprise separate members mutually joined
FIG. 4 shows a top view of the second master according and/or applied onto first reference Surface 3a. In particular,
to the first embodiment; first ridges 5 and/or second ridge 6 are preferably made up
FIG. 5 shows section V-V of FIG. 4; by elastomeric sections glued in a removable manner onto
FIG. 6 shows FIG. 3 partially enlarged with the first mold 10 first reference surface 3a. First template 2 can be an epoxy
according to the first embodiment; resin block shaped by a digital control cutter and then glued
FIG. 7 shows detail VII of FIG. 6; onto first reference surface 3a.
FIG. 8 shows a top view of the first mold of FIG. 6, Referring to FIGS. 4 and 5, it is seen that a second
removed from the first master; operating step of the process comprises the manufacturing,
FIG. 9 shows section IX-IX of FIG. 8: 15 for example with a CAD/CAM system, of a second template
FIG. 10 shows FIG. 5 with the second mold according to 9 which has substantially the same tridimensional shape and
the first embodiment; the same sizes of at least one second portion of product 1.
FIG. 11 shows a bottom view of the second mold of FIG. In the present embodiment, second template 9 has substan
10, removed from the second master; tially the same width W and the same depth D, but a height
FIG. 12 shows section XII-XII of FIG. 11; H2 lower than height H of product 1, so that the sum of
FIG. 13 shows a molding unit with the molds of FIGS. 10 height H1 of first template 2 with height H2 of second
and 12 during the use: template 9 substantially corresponds to height H of product
FIG. 14 shows section XIV-XIV of FIG. 13: 1. Second template 9 is joined or integral with at least one
FIG. 15 shows an enlarged longitudinal section of an second reference surface 10a of a second master 10, in
injector, 25 particular Substantially parallelepiped-shaped. Second ref
FIG. 16 shows an enlarged longitudinal section of an erence Surface 10a is Substantially planar, wider and deeper
eXtractor, than second template 9. So as to project around it. One or
FIG. 17 shows an enlarged longitudinal section of a pair more second walls 11, for example of aluminum, wood or
of centering devices; and epoxy resin, Substantially perpendicular to second reference
FIG. 18 shows a vertical section of a second embodiment 30 Surface 10a are fastened around second master 10, so as to
of the molding unit. surround second reference surface 10a. A plurality of second
pins 12 project from second reference surface 10a of second
DETAILED DESCRIPTION OF THE master 10 around second template 9. The position of first
INVENTION pins 8 on first master 3 is substantially equal to the position
35 of second pins 12 on second master 10. One or more third
Referring to FIG. 1, it is seen that a product 1 made of a pins 13 project from second reference surface 10a of second
composite material has in a known way a tridimensional master 10 at substantially the same positions of bulges 7 on
shape, for example parallelepiped, with a height H, a width first reference surface 3a of first master 3. At least one fourth
W and a depth D. In practice, product 1 generally has more pin 14 and one or more fifth pins 15 project from second
complex shapes, also curved and/or irregular, according to 40 template 9 of second master 10.
the required function, such as for example frames, body Referring to FIGS. 6 and 7, it is seen that a third operating
works, covers, accessories and other structural, fluid step of the process comprises a spraying of first master 3
dynamic and/or aesthetic parts of land, sea and air vehicles. with a sealing liquid which closes the present porosities for
Referring to FIGS. 2 and 3, it is seen that a first operating obtaining a smooth and regular Surface, as well as the
step of the process comprises the manufacturing, for 45 cleaning of these surfaces with a detaching Substance, after
example with a CAD/CAM system, of a first template 2 which a first mold 16 is made by applying onto first template
which has substantially the same tridimensional shape and 2, onto first reference surface 3a and onto first walls 4 of first
the same sizes of at least one first portion of product 1. In the master 3 a plurality of fiber layers, in particular carbon
present embodiment, first template 2 has substantially the fibers, pre-impregnated with a resin, known also with the
same width W and the same depth D, but a height H1 lower 50 name of pre-preg. In the figures, for simplicity's sake, first
than height H of product 1. First template 2 is joined or template 2 and first reference surface 3a are shown turned
integral with at least one first reference surface 3a of a first downward, but it is preferable that during this operating step
master 3, in particular Substantially parallelepiped-shaped. they are turned upward for facilitating the arrangement of
First reference surface 3a is substantially planar, wider and these layers. In particular, first mold 16 comprises a first
deeper than first template 2, so as to project around it. One 55 inner layer 17 and/or a second inner layer 18. Preferably,
or more first walls 4, for example of aluminum, wood or first inner layer 17 comprises pre-preg with fibers of the type
epoxy resin, Substantially perpendicular to first reference 1K (1000 threads per fiber), PW (Plain Weave), 100 g/m
Surface 3a are fastened around first master 3, so as to basis weight and 0.1 mm thickness, while second inner layer
surround first reference surface 3a. One or more first ridges 18 comprises fibers of the type 3K (3000 threads per fiber),
5 are arranged on first reference surface 3a of first master 3 60 TW (Twill Weave) 2x2, 200 g/m basis weight and 0.25 mm
around first template 2, while at least a second ridge 6 is thickness. The fibers of inner layers 17 and/or 18 are
arranged on first reference surface 3a around first ridges 5. substantially parallel or perpendicular to each other. Strips
First ridges 5 are connected to one or more bulges 7, in of pre-preg (not shown in the figures) can be arranged
particular having a hemispherical shape. The cross-section between inner layer 17 or 18 and the corners of first template
of first ridges 5 is convex, in particular Substantially semi 65 2 and/or the corners comprised between first reference
circular or semielliptical, while the cross-section of second surface 3a and first template 2, first walls 4 and/or second
ridge 6 is substantially rectangular, in particular square. A ridge 6. So as to make these corners sharper.
 US 9,649,784 B2
5 6
First master 3 comprises at least one protruding portion 3b and substantially perpendicular to first interface 16a. As it
between first ridges 5 and first template 2 which projects can be seen from the figures, first side walls 16b project from
from first reference surface 3a with a height difference H3 first interface 16a so that first mold 16 is substantially
comprised between 0.1 mm and 1 mm. vat-shaped. One or more first canals 25 substantially
One or more first intermediate layers 19, in particular complementary to first ridges 5 of first master 3 are arranged
from four to six intermediate layers, are then applied onto on first interface 16a of first mold 16 around first cavity 24,
inner layers 17 and/or 18, after which first bushings 20 are while at least a second canal 26 Substantially complementary
inserted onto first pins 8 and one or more second interme to second ridge 6 of first master 3 is arranged on first
diate layers 21, in particular from four to six intermediate interface 16a around first canals 25. First canals 25 are
layers, are applied onto first intermediate layers 19 and first 10 connected to one or more wells 27 substantially comple
bushings 20, so as to incorporate the latter in first mold 16. mentary to bulges 7 of first master 3. A plurality of first holes
Intermediate layers 19 and/or 21 comprise pre-preg with 28 is arranged on first interface 16a of first mold 16 in
fibers of the type 12K (12000 threads per fiber), TW (Twill correspondence with first bushings 20, namely with first pins
Weave) 2x2, 700 g/m basis weight and 0.4 mm thickness. 8 of first master 3.
The fibers of intermediate layers 19 and/or 21 are substan 15 When first mold 16 is separated from first master 3, first
tially parallel, diagonal (t25') or perpendicular to each canals 25 and/or second canal 26 may still include the
other. At least one outer layer 22 is applied onto second sections employed for first ridges 5 and/or second ridge 6.
intermediate layers 21 and comprises pre-preg with fibers of since the sections can come off first master 3. In this case,
the type 3K (3000 threads per fiber), TW (Twill Weave) 2x2, the sections are extracted from first canals 25 and/or second
200 g/m basis weight and 0.25 mm thickness. The basis canal 26 for being reused or substituted. At least one tubular
weight and/or the thickness of intermediate layers 19, 21 are gasket 29, resistant to temperatures comprised between -60°
thus greater than the basis weight and/or the thickness of and 220° C. and having a rigidity up to 60 Shore, is arranged
inner layers 17, 18 and/or of outer layer 22. First bushings in second canal 26.
20 are provided with an inner thread 23. First interface 16a is provided with at least one slit 30
During the application, in particular after two, three or 25 substantially complementary to protruding portion 3b of first
four layers are applied one on the other, inner layers 17, 18. master 3 between first canals 25 and first cavity 24. Thick
intermediate layers 19, 21 and/or outer layer 22 are com ness H3 of slit 30 is comprised between 0.1 and 1 mm, while
pressed onto first master 3 by means of compacting steps in length L1 of slit 30 is comprised between 5 and 300 mm.
which the most external layer is covered by an anti-adhesive One or more ribs 31, preferably made of a composite
sheet and by a layer of a ventilating material, after which 30 material, in particular with carbon fibers, are fastened to first
first master 3 is inserted into a vacuum bag which presses the mold 16 on the side opposite to first interface 16a, in
layers already arranged on first master 3 by effect of the particular by means of adhesive and/or further pre-preg
outer pressure acting onto the vacuum bag. These compact layers 32 applied astride first ribs 31 and first mold 16, as
ing steps may comprise the insertion of first master 3 with well as pressed and cured with a vacuum bag in an auto
the vacuum bag into an autoclave at a pressure comprised 35 clave. First ribs 31 form a network and are preferably joined
between 1 and 10 bar for creating an additional pressure onto to first side walls 16b of first mold 16. First centering devices
the vacuum bag. 33 and/or first mechanic fastening devices 34, for example
Inner layers 17 and/or 18, intermediate layers 19, 21 toggle fasteners, are fixed outside first side walls 16b of first
and/or outer layer 22 cover also first ridges 5, second ridge mold 16.
6 and bulges 7, while they are provided with holes for being 40 Referring to FIG. 10, it is seen that a fourth operating step
crossed by first pins 8 of first master 3. First mold 16 of the process comprises a spray sealing and a cleaning with
comprises at least ten layers in total, namely at least one a detaching agent of the second master 10, as well as the
inner layer 18, eight intermediate layers 19, 21 and an outer creation of a second mold 36 by applying onto second
layer 22. Before the application, each layer 17, 18, 19, 21 template 9, onto second reference surface 10a and onto
and/or 22 is shaped with a digital control device on the basis 45 second walls 11 of second master 10 a plurality of pre-preg
of data obtained according to the shape and the sizes of first layers, some of which are provided with holes for pins 12,
master 3. 13 and 14. In particular, second mold 36 comprises a first
First mold 16 is then completed by a curing step under inner layer and/or a second inner layer, a plurality of
pressure, in which first master 3 provided with first bushings intermediate layers, in particular at least eight intermediate
20 and layers 17, 18, 19, 21 and 22 is inserted into a vacuum 50 layers, as well as at least one outer layer of the same kind of
bag, always with an anti-adhesive sheet and with a layer of the layers of first mold 16. Strips of pre-preg can be arranged
a ventilating material, in turn arranged into an autoclave, so between an inner layer and the corners of second template 9
that the layers are joined to each other with a pressure and and/or the corners comprised between second reference
with a temperature which are suitable for curing the resin surface 10a and second template 9 and/or second walls 11,
which impregnates them. 55 So as to make these corners sharper.
Referring to FIGS. 8 and 9, it is seen that first mold 16, Second bushings 37, one or more third bushings 38 and at
once removed from the autoclave, cooled and separated least one fourth bushing 39 are inserted onto second pins 12,
from first master 3, comprises at least one first cavity 24 onto third pins 13 and onto fourth pin 14, respectively, of
substantially complementary to first template 2 of first second master 10, between two intermediate layers, in
master 3, with substantially the same width W, the same 60 particular between a group of four first intermediate layers
depth D and the same height H1. First mold 16 comprises at and a group of eight second intermediate layers. One or
least one first interface 16a made of a single piece with first more fifth bushings 40 are instead arranged onto fifth pins 15
cavity 24. First interface 16a projects entirely, or at least of second master 10 before applying the layers on the latter,
partially, around first cavity 24 and is substantially comple so that fifth bushings 40 are flush with second template 9.
mentary to first reference surface 3a of first master 3. First 65 Third bushings 38 and fourth bushing 39 are substantially
mold 16 comprises also one or more first side walls 16b the same. Third bushings 38, fourth bushing 39 and fifth
substantially corresponding to first walls 4 of first master 3 bushings 40 are inwardly threaded. The distance between
 US 9,649,784 B2
7 8
two adjacent first bushings 20 or second bushings 37 is particular carbon fibers, which are dry, namely coupled with
comprised between 35 and 100 mm, preferably 70 mm. a quantity of resin from 0 to 10%, preferably 5%, by weight.
The layers of second mold 36 are compressed onto second First mold 16 is then aligned with second mold 36 by
master 10 by means of compacting steps of the above means of centering devices 33, 47, after which first mold 16
mentioned kind for the first mold 16, with or without is tightened to second mold 36 by means of screws 55
autoclave. inserted into second bushings 37 and screwed into first
Second mold 36 is then completed with a curing step bushings 20, as well as by mutually coupling mechanic
under pressure, in which second master 10 provided with the fastening devices 34, 48, so as to made up a molding unit
pre-preg layers and with bushings 37, 38, 39, 40 is inserted comprising first mold 16 and second mold 36. Other
into a vacuum bag, always with an anti-adhesive sheet and 10 embodiments can comprise bushings 20, 37 only, mechanic
with a layer of a ventilating material, in turn arranged into fastening devices 34, 38 only and/or other mechanic fasten
an autoclave, so that the layers are joined to each other with ing devices. Molds 16, 36 are then urged one against the
a pressure and with a temperature which are suitable for other, so that interfaces 16a and 36a contact each other,
curing the resin which impregnates them. thereby pressing gasket 29, so as to hermetically close molds
Referring to FIGS. 11 and 12, it is seen that second mold 15 16, 36.
36, once removed from the autoclave, cooled and separated In a sixth operating step of the process, molds 16, 36 are
from second master 10, comprises at least one second cavity heated at a temperature comprised between 25° C. and 70°
41 substantially complementary to second template 9 of c., preferably 60° c., after which resin heated at a tempera
second master 10, with substantially the same width W, the ture comprised between 40° C. and 70° c., in particular 60°
same depth D and the same height H2. Second mold 36 c., is injected at a pressure comprised between 0.5 bar and
comprises at least one second interface 36a made of a single 3.5 bar, in particular comprised between 1.5 and 2.5 bar, into
piece with second cavity 41. Second interface 36a projects cavities 24, 41 between first mold 16 and second mold 36
entirely, or at least partially, around second cavity 41 and is through inlets 51, injectors 50, wells 27, first canals 25 and
Substantially complementary to second reference Surface slit 30. In another embodiment, the heated resin is injected
10a of second master 10. Second mold 36 comprises also 25 at a pressure equal to or greater than 0.5 bar and less than 2
one or more second side walls 36b substantially comple bar. The arrows of FIG. 14 show the path followed by the
mentary to second side walls 11 of second master 10 and resin till it reaches and completely impregnates Substrates
Substantially perpendicular to second interface 36a. As it can 49. Simultaneously, air is sucked from suction mouth 52 and
be seen from the figures, second side walls 36b project from from outlet 53, until the resin does not reach suction mouth
second interface 36a so that second mold 36 is substantially 30 52, after which the injection of resin is interrupted. When the
vat-shaped. Second holes 42 and third holes 43 are arranged resin is injected into cavities 24, 41, the inflow Zones of the
on second interface 36a of second mold 36 in correspon resin, namely slit 30, are at a lower level with respect to the
dence with second bushings 37 and third bushings 38. evacuation Zones, namely to Suction mouth 52. During said
respectively, namely with second pins 12 and third pins 13 evacuation, the pressure in cavities 24, 41 in the spaces not
of second master 10. Fourth holes 44 and fifth bushings 40 35 reached by the resin is lower than 0.5 bar, in particular
lead instead to second cavity 41, with fifth bushings 40 flush comprised between 0.001 and 0.02 bar.
with second cavity 41. Once the resin injection is competed, molds 16, 36 are
The distances between interfaces 16a, 36a, and bushings arranged into an oven or an autoclave and are slowly heated
20, 37 or 38, or between cavity 41 and fourth bushing 39, are (from 2 to 4°C. per minute) from the injection temperature
greater than 0.2 mm. 40 up to a cure temperature comprised between 90° and 100°
One or more second ribs 45, preferably made of a C., which is kept for about one hour, after which it is
composite material, in particular with carbon fibers, are increased to a post-cure temperature comprised between
fastened to second mold 36 on the side opposite to second 120° and 160° C., which is kept for about two hours. At the
interface 36a, in particular by means of adhesive and/or end of the cure cycle, molds 16, 36 are cooled down to a
further layers 46 of pre-preg applied astride second ribs 45 45 temperature comprised between 40° and 70° C. and are
and second mold 36, as well as pressed and cured with a opened, so that final product 1, comprising Substrates 49
vacuum bag in an autoclave. Second ribs 45 form a network incorporated in the cured resin, can be extracted, in particu
and are preferably joined to second side walls 36b of second lar by means of extractors 54, for being trimmed and
mold 36. Second centering devices 47 and/or second cleaned. The cure and post-cure cycle depends on the
mechanic fastening device 48, for example toggle fasteners, 50 chemical features of the resin employed for impregnating
are fixed outside second side walls 36b of second mold 36 the dry fabric.
at positions Substantially corresponding to first centering Referring to FIG. 15, it is seen that during the preparation
devices 33 and to first mechanic fastening devices 34, of second mold 36, an outwardly threaded injector 50 is
respectively, of first mold 16. screwed into a third bushing 38 already incorporated in
Ribs 31, 45 are preferably applied to molds 16, 36 before 55 second mold 36. So as to urge a first annular gasket 56
removing the latter from the respective masters 3, 10. arranged between injector 50 and third bushing 38. Inlet 51
Referring to FIGS. 13 and 14, it is seen that a fifth is then inserted into injector 50 and locked by means of a
operating step of the process comprises the preshaping and ring 57 which is screwed onto injector 50, so as to urge a
the arrangement of one or more substrates 49 into first cavity second annular gasket 58 against inlet 51. Suction mouth 52
24 of first mold 16 and/or into second cavity 41 of second 60 and outlet 53 have the same structure and the same working
mold 36. Third bushings 38 of second mold 36 are provided of injector 50 and of inlet 51.
with injectors 50 connected to inlets 51. The distance Referring to FIG. 16, it is seen that during the preparation
between two adjacent injectors 50 is comprised between 400 of second mold 36, a piston 59 provided with a stem 60 is
and 1500 mm. Fourth bushing 39 of second mold 36 is inserted into a fifth bushing 40 already arranged in second
provided with a suction mouth 52 connected to an outlet 53. 65 mold 36, so as to urge a third annular gasket 61 housed in
Fifth bushings 40 of second mold 36 are provided with a cylindrical seat made in fifth bushing 40 for the head of
extractors 54. Substrates 49 comprise layers of fibers, in piston 59. Stem 60 of the piston is connected to a threaded
 US 9,649,784 B2
10
ring 62 which is screwed into fifth bushing 40, so that by placing the closed and tightened mold and further mold
rotating threaded ring 62 the head of piston 59 moves axially into an oven or an autoclave;
for projecting from second mold 36. heating the mold and further mold to cure the resin of the
Referring to FIG. 17, it is seen that first centering device one or more impregnated Substrates arranged in the
33 comprises a first conical or frustoconical head 63 which 5 cavity to form a final product,
can be adjusted axially by means of a screw 64. A spring 65 wherein said process does not employ a press.
allows an axial compression of first head 63 with respect to 2. The process according to claim 1, wherein the mold is
screw 64 for absorbing possible impacts during the coupling heated to a temperature of between 25° C. and 70° C., before
of molds 16, 36. Second centering device 47 comprises a injecting the resin.
second head 66 with a conical or frustoconical seat Substan- 10
3. The process according to claim 1, wherein the resin is
tially complementary to first head 63. Also second head 66 injected
can be adjusted axially by means of a screw 67. First head equal to into or
the cavity at a pressure lower than 2 bar and
greater than 0.5 bar.
63 and second head 66 can further be moved transversely by 4. The process according to claim 1, wherein during the
moving a first plate 68 of first centering device 33 and/or a
second plate 69 of second centering device 47, so as to 15 evacuation, the pressure in the spaces of the cavity which are
obtain, together with the axial adjustment, a perfect coupling not reached by the resin is lower than 0.5 bar.
of molds 16, 36 in the three dimensions. Plates 68, 69 are 5. The process according to claim 1, wherein after the cure
provided with a hole for containing screws 64, 67 in an of the resin, the mold is cooled and opened at a temperature
axially sliding manner. of between 40° and 70° C.
In alternative embodiments, the functional portion of the 20 6. The process according to claim 1, wherein in a pre
first mold or of the second mold, namely the portion of the liminary step the mold is manufactured by arranging and
mold which comprises the surfaces turned toward substrates curing a plurality of layers of fibers on at least one master
49 and which contacts at least one portion of final product comprising a template of at least one portion of a product to
1 at the end of the process, may not comprise a cavity, but be manufactured with the mold, wherein the fibers of said
can be flat or even comprising a protuberance complemen- 25 layers are pre-impregnated with a resin before they are
tary to the cavity of the other mold. In these cases, the arranged on the master.
templates of the masters can be flat and/or have cavities. In 7. The process according to claim 6, wherein one or more
other embodiments, the second mold may be provided with bushings are arranged on the master before arranging the
the first canals and/or with the second canal, while the first layers or are arranged between two layers during their
mold may be provided with the extractors, the injectors 30 arrangement on the master.
and/or the Suction mouth. Molding units according to further
embodiments may comprise more than two complementary are8.inserted The process according to claim 7, wherein the bushings
on one or more pins projecting from the master
molds mutually joined by means of mechanic fastening or from a reference Surface which projects at least partially
devices.
Referring to FIG. 18, it is seen that for example in a 35 around the master.
second embodiment of the present invention first mold 16 is 9. The process according to claim 1, wherein the further
provided with extractors 54 and is substantially flat, namely mold is comprised of a composite material.
lacking a cavity for substrates 49, while second mold 36 is 10. The process of claim 1, wherein the injecting of the
provided with the cavity for substrates 49 and with canal 26 resin into the cavity is at a pressure of between 1.5 and 2.5
for gasket 29. 40 bar.
Further modifications and/or additions may be made by 11. The process of claim 4, wherein the pressure is
those skilled in the art to the hereinabove disclosed and between 0.001 and 0.02 bar.
illustrated embodiments while remaining within the scope of 12. The process according to claim 6, wherein the plu
the following claims. rality of layers of fibers is carbon fibers.
The invention claimed is: 45 13. The process according to claim 1, further comprising
1. A process for manufacturing products made of com injecting the resin through one or more injectors screwed
posite materials, comprising the steps of into one or more additional threaded bushings incorporated
arranging one or more Substrates in-a cavity formed in the mold before injecting resin into the cavity.
between at least one mold made of a composite mate 14. The process according to claim 1, further comprising
rial and a further mold; 50 evacuating the cavity through at least one Suction mouth
hermetically closing and tightening the at least one mold screwed into at least one additional threaded bushing incor
and further mold together with screws inserted into
bushings incorporated in the mold and further mold, porated in the mold before evacuating the cavity.
wherein the bushings in either the mold or the further extracting process
15. The
the
according to claim 1, further comprising
final product from the cavity using one or
mold are threaded; 55 more extractors screwed into one or more additional
evacuating the cavity and injecting resin into the cavity at threaded bushings incorporated in the mold before heating
a pressure of between 0.5 bar and 3.5 bar, so that the the mold.
one or more Substrates are impregnated by the injected
res1n;