Europaisches P a t e n t a m t

European Patent Office

Publication number:

Office europeen des brevets

EUROPEAN

123

A1

PATENT

APPLICATION

Int. CI.3: B 29

Application number: 84104139.5

D 3/02

@ Date of filing: 12.04.84

Priority: 20.04.83 US 486725

Applicant: ITT INDUSTRIES INC.

320 Park Avenue
New York, NY 10022(US)

Date of publication of application:

31.10.84 Bulletin 84/44

Designated Contracting States:

FR GB IT SE

Designated Contracting States:

DE FR GB IT SE
_
Qi) Applicant: Deutsche ITT Industries GmbH
Hans-Bunte-Strasse 19 Postfach 840
D-7800 Freiburg(DE)

Inventor: Browning, James Ernest

Route 1, Box 15
Adel Georgia 31620{US)
Inventor: Chamberlin, James Lewis
36110 Congress
Farmington Hills Michigan 48018(US)

^ Designated Contracting States:

DE

Representative: Grau, Ulf

do ALFRED TEVES GMBH Guerickestrasse7
D-6000 Frankfurt (M) 90(DE)

(54) Composite structure machine and method.

u bSubjects
S
j e c t s of the invention are a machine and method, and
the product of the method, for making high-strength composite structures of thermosetting or thermoplastic resin with
reinforcements therein. A continuous longitudinally extending wet charge of resin and reinforcement is formed as an
endless source and maintained under a given tension while it
is advanced toward a mold cavity. Aplurality of reinforcement
elements are continuously placed at predetermined positions
within the cross-sectional area of the wet charge and with the
longitudinal reinforcements being continuously parallel to
one another. The resin and the reinforcements form a composite matrix whose angular reinforcement orientation may
vary 90 with respect to the longitudinal axis of the wet
charge and the ultimate product. The reinforcements also
may change directions or orientations at different levels
within the cross section area. The composite matrix is
advanced into the mold cavity where it is compression
molded and cured within a heated tool under low pressure
without flowing of the matrix.

Croydon Printing Company Ltd.

2 2 5

Of The I n v e n t i o n :

Background

invention

This

relates

structures

or p l a s t i c

a resin

utilizing

and,

having

reinforced

to composite

to

more p a r t i c u l a r l y ,

polymeric

such

reinforcements

selectively

utilizing

a thermosetting

structures

placed

therein.
Composite
having
used
the

components

in the

These

art.

automotive

structural

generally

comprise
fibers

of g l a s s
ments may

partially
mat or

filaments

sheet

fiber

molding

which

polyester,

These members

are

then

materials

reinforcement
In the
at

properties
necessitated
the

structure

with

or the

high

stress

points

of the

This

forcement

materials

geometric

configuration

characteristics
portions

was due to the

of the

of the

at

for

the m a t r i x .

specific

structural

structure

member t h r o u g h o u t

the

composite

structures

of the

overall

homogeneous

nature

of the

prior
a high

device.

within

the

portions

art

wherein

stress

reinforcement

of the

hold

to

composite

reinforcement

in n o n - c r i t i c a l

structure.

need

As a r e s u l t ,

structure.

resin

positions

the

were o v e r - d e s i g n e d

epoxy and p o l y m i d e s .

the

however,

use of the

The r e s i n s

to form a s p e c i f i c

together

selected

like.

form

a fiber

resin,

thermosetting

art,

composite

critical

is p r e - i m p r e g n a t e d

prior

the

a so-called
the

utilizing

in

or c o n t i n u o u s

forming

vinylester,

placed

The r e i n f o r c e -

take

(SMC),

compound

structures

may also

flowable

are

matrix

of f i l a m e n t s

The r e i n f o r c e m e n t s

a tape

and h i g h -

reinforcements

form of a chopped g l a s s

commonly used

composite

with

like.

semi-cured

or

The composite
resin

in

utility

light-weight

and the

like.

of a woven c l o t h ,

particular

of t h e i r

a thermosetting

or a bundle

or the

find

characteristics.

the

filaments

roving,

because

or g l a s s

take

known and have been w i d e l y

are

components

industry

strength

glass

therein

reinforcements

resin

the

point

material

required

dictated
at

re-

the

the

less

This
having

the

device

and by s e l e c t i v e l y

the

critical

selected

physical

the

base

From the

base

structural

a greater

number of

urations.

ment

This method

in the

acceptance

technique

operation

cantly

greater

Another
order

problem

to

lay-up

processing

time

the

liquefy the

ment m a t e r i a l s

such as

pressure

requirement,

relative

to

the

Since

these

tion,

or hand

the

lay-up,

mold c a v i t y

sensitive.

art

they

Moreover,

the

required.
with

layers

two o r
config-

received

wide-

selective

reinforcewith

particularly

problems
is

presented

by t h e

normally

requires

it

that

and t h e r e f o r e
relative

must

semi-cured

or

necessitates

higher

cost.

Further,
times

times

required

techniques

therefore
it

has

are
been

the

in r e i n f o r c e -

to the

in l o w - p r e s s u r e
require

semi-cured

significantly
found

and

tooling
due

in

high

must be u t i l i z e d

normally

to p o s i t i o n

process.

be u t i l i z e d

resin

This

curing

signifi-

to an automated

that

pressure

requires

SMC.

long

curing

prior

high

partially

of r e l a t i v e l y

presses

this

problems

process

or-hand

is

with

by u t i l i z i n g

However,

significant

reinforcement

manual

properties

production.

One of the most

selective

art.

form

layer

up in

and has

That

the

in many d i f f e r e n t

worked well

several

presents

to h i g h - v o l u m e

respect

was b u i l t

disposed

has

over

at

desired

the

property

achieved

properties
layers

varied

layer

structural

structure

the

and took

areas

by o r i e n t i n g

the

point

device.

provided

technique

overall

reinforcements

composite

critical

the m i n i m a l

being

the

material

This

device

different

spread

the

such as SMC.

composite

layer

of

layer

in the

properties

localized

placing

reinforcement
for

use of a base

structural

locations

properties

of m a t e r i a l s
of

minimal

required

anticipated
is,

by the

problem was overcome

that

the

processes.

manual o p e r a materials
operatorselective

into

placement

fails

process

difficult

the

and c o n s i s t e n t

to a s s u r e

void-free,
since

Further,

other

the

to

of

bonding

in

layers

reinforcement

of the

placement

proper

provide

layers. .

must move r e l a t i v e

layers

the mold c a v i t y ,

consistently

between

properties

good-adhesion
one of the

to

the

has b e e n
has

layers

not been a c h i e v e d .
Another
been

the

of

problem

to m a i n t a i n

inability

ous r e i n f o r c e m e n t

it

as

is

in n o n - p a r a l l e l

results

undesired
desired

structural
also

due to the
and r e s i n
failure

structural

member,

tension

of the

wherein

is

and a method

sures.
the

molding

The d e s i r e d

control

individual

of

precise

reinforcement
matrix.

controlled

so as

and c u r i n g
with

properties
quantities

The r e i n f o r c e m e n t s
to change

flowing

to a l i m i t e d

extent,

directions
areas
of

the
the

the

the

of the
resin

by the

throughout
The

stages.

low p r e s -

achieved

and p l a c e m e n t
point

present

in w h i c h

same,

relatively
are

any d e s i r e d

at

cross-sectional

While c o m p r e s s i o n
occur

accomplished

plysical

the

composite

different

is

fibers

structural

a composite

and c o n t a i n e d

and the molding

compression

are overcome

positioned

charging

the

effects

for making

the

areas

Further,

and a machine

are

or u n -

part.

provided

reinforcements
stage

flow

to

adversely

the

with a n

non-parallel

positions.

disadvantages

there

which

in abnormal

utilized

finished

continu-

and r e s i n - v o i d

areas

are

has

fibers

or

undesired

placement

proper

and o t h e r

These

on the

results

resin-rich

final

strength

tension

fibers

This

high-pressures- that

to p r o v i d e

technique

in the mold c a v i t y

further

properties.

their

layer

reinforcement

permits

into

invention

proper

placed

This

curvature.

placement

selective

the

through
of e a c h

within

the

can be a c c u r a t e l y
or o r i e n t a t i o n
composite
in the

invention

does

within

part.

matrix
not

may

rely

upon

of

flowing

the

of the

positioning
coincide

matrix

with

the

to

reinforcements
desired

reinforcements.

the

disperse

is

location

controlled

precisely

once

The

the wet c h a r g e

to

has

cured.

completely

Summary Of The I n v e n t i o n :
a method and a machine

Briefly,
ducing
or

high-strength

thermoplastic

initial

wet charge

fiberglass
is

and a d v a n c e d

predetermined

thereof.
uous

A composite

with

area

and e x t e n d i n g

given

area

may vary
into

advanced

and the
under
from
Brief

composite

matrix

continuous

source

when t a k e n

tensioned

location

length

is

to

and t h e

provided

matrix

in the mold c a v i t y
being m a i n t a i n e d

The cured

and e j e c t e d

the

cross-sect-

The c o m p o s i t e

while

contin-

can b e

0 + 90

of

a given

molded

area

of an a n g u l a r

having

cured

charge

product

is

severed

from the m a c h i n e .

Of The D r a w i n g :

appreciated
by r e f e r e n c e

is

range

length.

tension.

The a d v a n t a g e s

stood

the

and c o m p r e s s i o n

Description

readily

a given

along

a predetermined
the

the

A plural-

formed w h e r e i n

thereby

A mold c a v i t y

ional

is

in

which

source

cross-sectional

reinforcements

which can vary

direction.

length

the

of p r e d e t e r m i n e d

rovings

in c o m b i n a t i o n

orientation

is

matrix

in the

placed

within

positions

longitudinal

placed

then

are

as

the machine.

through

pro-

An

such

as a c o n t i n u o u s

provided

of r e i n f o r c e m e n t s

ity
at

is

therein.

and r e i n f o r c e m e n t s

of r e s i n

rovings

pre-tensioned

reinforcements

with

for

provided

of t h e r m o s e t t i n g

structures

composite

resin

are

of

this

as the
to

the

in c o n j u n c t i o n

invention
same becomes

following
with

the

will

become more

completely

detailed

under-

description

accompanying

drawing

wherein:
Figure

1 is

a plan

view of

an a u t o m o b i l e

bumper member

with

in a c c o r d a n c e

constructed

the

of the

principles

present

invention;
2 is

Figure
of F i g u r e

1 taken

2--2:

3 is

a top view of

Figure

4 is

a plan view of a r e p r e s e n t a t i v e

composite

structures

materials

posite

and composite

member

relative

7 and

Figures

operational

9 is

com-

and Figure

4c

squeeze-

bath;

in Figure
axis

biaxial
4 as

of the m a c h i n e

views

structure

member

representation

5a;

of a c o m p o s i t e

of the

utilization

principles

of d i f f e r e n t

workpiece;
plan

and top views

of

4;
sequence

chart

plan,

an a l t e r n a t i v e

illustrate

in accordance

which

illustrates

the

and,

11 and 12a and 12b are

which

of F i g u r e

applicator

diagrammatic

of the machine;

10,

sectional

Detailed

of the

view of one of the

in a s i n g l e

a timing

steps

Figures

present

invention;

traversina

applications

to the

8 are

of Figure

Figure

resin

producing

present

plates

depicted

a diagrammatic

of r e i n f o r c e m e n t s

the machine

the

machine

views

wet charge

view of the

illustrating

invention

of the

the

common l o n g i t u d i n a l

a side

is

6 is

Figure

with

1;

matrix;

Figure 'Sb

structure

after

applicators

down the

for

assembly

carding

view of the

reinforcement
looking

the

an e l e v a t i o n a l

5a is

bumper member of F i g u r e

cross-sectional

traversing

immediately

Figure
rotary

and p r e s s

4b are

a cross-sectional

out b u s h i n g s

the

in a c c o r d a n c e

4a and

Figure

types

line

Figure

a mold c a v i t y

seen

the

along

including

is

end view of the member

a cross-sectional

with

the

side

and c r o s s -

composite

principles

of t h e

invention.
Description:

Referring
10 a composite

now to Figure
structure

1,

in the

there

is

shown g e n e r a l l y

form of an automotive

at

bumper

invention.

present
of

11 and which

tions
as

illustrated

in F i g u r e

2 and

and

3,

As w i l l

cross

section

ments

utilizing

glass,

each

composed

from the

filaments

strand
to

mats.

the

of

axis

may vary
the

in c o m b i n a t i o n
compatible
system

and 15% r e s i n

and may comprise

and c o n t i n u o u s

structure

use o f

10 is

not

limited

in a c c o r d a n c e

and,

cross-sectional

configuration

any p o i n t

the

10.

That

along

while

is,

constant,

accomodate

a given

structural

of a given

to a square

volume

of

to a group

remains

from a round

invention,

present

configuration

section

cap-

composite

portion

cross

cross-sectional

of r e i n f o r c e -

use of chopped

at

to

the

of g l a s s

form of

structure

the

the

can be v a r i e d

the

with

cross

and on t h r o u g h

the

may vary

fibers

a uniform

placed

invention,

of bumper

example,

the

the

cross-sectional

any c r o s s - s e c t i o n a l

section
For

and

matrix

85% r e i n f o r c e m e n t

a roving

U-shaped

by a r e s i n

into

of a f i l a m e n t

Further,

present

advantageously
inal

size

or v a r y i n g

and any o t h e r

in p l a c e

precisely

materials

a constant

with

is

illustrated

hereinafter,

fully

and s t e e l

In a c c o r d a n c e

of bumper

a tapered

a composite

materials

comprising

woven c l o t h

held

surface

generally

more

stampings

of up to

reinforcement

fiber

is

these

by w e i g h t .

system

the

carbon,

metal

which

of bonding

material

14 of

legs

end p o r -

cross-section

as b e s t

includes

further

may i n c o r p o r a t e

reinforcement

12,

form

in the

curved

U-shaped

The forward

be d e s c r i b e d

w i t h woven f i b e r s ,

able

2.

of t h e

teachings

illustrated

a generally

a depression

in the

section

section.

of

in F i g u r e

10 i n c l u d e s

the

bumper member having

is

structure

cross

10 is

Structure

automotive

a curved

with

in a c c o r d a n c e

member c o n s t r u c t e d

remains

the

the
the

same.

volume
cross

requirement.

structure

configuration

longitud-

or p a r t

provided

that

100 for

making

with

ance

an e n d l e s s
in the

illustrated

in a s u i t a b l e

form of

rack.

112 i n c l u d e s

seven

doffs.

separate
are

provided

the

rovings

and

225 y i e l d .
ends of

The l e a d i n g
and guided
carding

112.

carding

through

may take

plates

type

holes

of a p e r t u r e s

or

apertures

are

in a p r e d e t e r m i n e d

the

emerging

provided

form of woven c l o t h

illustrated
stock
of

in

itself

the

a belt
machine

100.

composite

suitable
charge

for

support

product--and
the

matrix

That

if

and,

the

which

as

they
of

the

geometry

therefore

the

cross-sectional

carrier

charge--may

stock

preparation.

for

of the

the

in

are

The c a r r i e r

forms

an e l e m e n t

functions

advance

necessitate

transporting

The ends

width

also

the

is,

matrix

118a and 118b

necessary,

rovings

having

cross-sectional

of a given

material

The

so t h a t

pattern

stock

in

The

by way of example.

a reinforcement

composite
or

or tape

embodiment

this

is

mats

received

or disk

on a p r e d e t e r m i n e d
of c a r r i e r

Two r o l l s

configuration.
the

take

rovings

through

113 y i e l d

30,

therein.

plurality

twelve

rovings

116b and 116c.

form of a p l a t e

the

each

embodiment,

114 are

rovings
116a,

plates

in

fiberglass

Fiberglass

each of

source

with

provided

In one c o n s t r u c t e d

Owens Corning

were

practice,

420 s e p a r a t e

Accordingly,

by source

is

shelves

thirty-five

on a n d

provided

five'shelves

having

112

Source

doffs

preferred

Machine

materials

rovings.

fiberglass

racks

separate

in a c c o r d -

invention.

of r e i n f o r c e m e n t

fiberglass
of

shown a m a c h i n e

structures

present

In c u r r e n t l y

Each of the

rack.

the

source

form of a c r e e l

the

takes

of

principles

is

composite

high-strength

the

includes

100

4 there

now to F i g u r e

Referring

as

through

ultimate

part

or

configuration

of

the

use

charge

woven c l o t h

of

during

or tape

the
are

the

after
fed

the

onto

placed

resin

function

carrier

baths

to

stock

through

120b and

120a,

embodiment,

Fiberglass

E987-2

type

the

which

The r e s i n

of r o v i n g s

and

materials

reinforcements.

resin

is

then

are

of c o m p o s i t e

and f i b e r g l a s s

one c o n s t r u c t e d

immediately

120c.

each group

form a wet charge

to

or

The r o v i n g s

plate.

impregnate

wet r e s i n

comprising

rovings

carding

adjacent

through

baths

adjacent

In

was Owens C o r n i n g

a low-shrink

polyester

resin.
In c u r r e n t l y
under

tension

This is

after

they

pulleys

it

hereinafter,
the

tension

lbs)of

(2

the

found

in each

4b p r o v i d e
axis

of the

R or r o v i n g

a final

plates
to

carding

116a--c

accomodate

composite

bundles

selecting

through

matrix,

wet c h a r g e .

only

axis

of

the

longitudinal

is

124.

Carding

shape

and c r o s s - s e c t i o n a l

plate

or r e i n f o r c e m e n t s

charge

are

configuration

wrapped.

Further,

number

The i m p r e g n a t e d

similar

seen

in

122b a n d '
to c a r d i n g
bushinqs

a view of t h e

traversing

124 may be p r o v i d e d

116a

plates

a limited

4c is
r,

looking

materials,

squeeze-out

Figure

the

views

122a and

rollers

.907kc

good r e s u l t s .

shown.

wet r e s i n

including

to p r o v i d e

from c a r d i n g

and which may i n c l u d e

the

or a d j u s t i n g

device

124 which

plate

more f u l l y

reinforcement

are

and

spring-loaded

As d e s c r i b e d

For c l a r i t y ,

guided

of

cross-sectional

of r o v i n g s

into

rovings

provides

respectively.

into

the

a pair

roving

and 116c,

then

plates.

tensioning

woven mats W, emerging

are

carding

that

including

rovings

from the

baths.

the

of

longitudinal

are p l a c e d

through

resin
been

4a and

Figure
into

has

constant

spring

emerge

path

the

to

prior

rovings

and l o o p i n g

done by r o u t i n g

from an S - s h a p e d

out

the

practice

preferred

looking
carding

into
plate

a predetermined
which

fibers

a mandrel

can b e

over

used

this

at

finished

so t h a t

stage

is

product,

The charge
advanced

through

Each b i a x i a l

126 and 128.

member c o a x i a l w i t h
matrix
tion

in r e s p e c t i v e l y

more

fully

the

receiving

its

charge

tive

advances

through

of the

composite

lenath

direction

can vary

in the

in the

upon the

depending
and the

speed

the

of the

speed

of r o t a t i o n

of the

composite

a pair

of b i a x i a l

in an a d d i orientation

matrix

90

charge

(i.e.,

of the

charge

composite

extending

results

an a n g u l a r

0 t o +

of

range

for

so as to w r a p

rate

composite

of

a source

126 and 1 2 8 ,

longitudinally

having

rota-

be d e s c r i b e d

therein

As the

This

for

As w i l l

applicators

matrix.

pattern

mounted

opening

a given

composite

includes

charge.

at

around

reinforcement

which

and a c e n t r a l

is r o t a t e d

are

applicator

matrix

reinforcements

rovings

each

then

a rotary

of the

directions.

composite

applicator

axis

members

opposite

thereon

includes

applicator

rotary

124 is

plate

reinforcement 'applicators

longitudinal

hereinafter,

reinforcements

each

the

and the

charge

matrix

of b i a x i a l

ultimate

configuration.

of c a r d i n g

output

a pair

and the

charge,

of a hollow

formed

the

at

the

biaxially)

applicators

advancing

through

the

applicators.
By using
wrap

in r e s p e c t i v e l y

balanced
into

charge

the

charge

out by the
is

by one a p p l i c a t o r

the

is,

of the

products

should

without

the

longitudinally

composite

mandrel.

It

other.

accomplished

That

matrix

Of course,
where

wherein

also
use

there

are

a conventional

offset

be noted

and b a l a n c e d that

the

and t e n s i o n e d
the

certain

applications
could

wrapping

mandrel.

provide

mandrel

or

introduced

of a c o n v e n t i o n a l

extending

charge

a symmetrical

any s t r e s s e s
are

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applicators,

directions,

opposite

is p r o v i d e d

rotary

function

be used

rovings
of a
and
such

as

for

a hollow

suitable
those

structure

invention

not

type

provided

require

for

ready
into

can
of

upper

be f i x e d

the

dies

closed

are

without

die

in

that

the

the

use of r o t a r y

that

many p r o d u c t s
of t h e

pattern

126 and 128 p r o v i d e

matrix

press
is

130.

C is

Press

fastened

130 f u r t h e r

includes

and

then

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130 i n c l u d e s
fixed

mechanically

suitably

a compo-

setup

A lower male die

134.
is

is

The charge

molding.

or movable

is utilized

138 which

be a p p r e c i a t e d

composite

ram 132 which

female

applicator.

molding

130..Press

press

the

hand,

can be u t i l i z e d

and r e i n f o r c e m e n t

rotary

compression

a reciprocating

also

other

contemplated

of a p p l i c a t o r s

a compression

movable

is

a charge

C wherein

charge

it

is,

by the

The o u t p u t

should

also

can be p r a c t i c e d

That

applicators.

site

It

applications.

will

On the

such as a foam core

core

present

or a tube.

to

which

136,

to the

frame
device

a clamping

to clamp and t e n s i o n

C when

charge

mold and form the

to c o m p r e s s i o n

final

part.
Machine

100 f u r t h e r

ejection

station

which

movably mounted

is

which

140 which

142 includes

device

are

adapted

product

once d i e s

pression

molding

functions

includes

dies

over

male die

and to

sever

opened,

136 to

the

C by means of a p a i r

cured

144.

Clamping
142b

finished

following

device

142

142a and

cured

opened

tensioning

are

clamps

the

Clamping

proper

is

charge

and hold

operation.

When the

part

of movable

134 and 136 are

operation.

cured

rack

and

device

a clamping

on a s t a t i o n a r y

to clamp

to p r o v i d e

advanced

includes

a pair

cutoff

a clamping,

a com-

142 a l s o

during

the m o l d i n g

clamping

device

142

clamp

and then

remove

part

from the

balance

of c u t t e r s

146 and 147.

the
of

In o n e

embodiment

constructed
vided

each cured

between

As each

part

advanced

cutters

severed

and removed
the

sized,

136 of p r e s s

130 include

which

facilitate

As w i l l

the machine

finished

of

be e x p l a i n e d

the

first

adjacent

from a p p l i c a t o r

apart

in p a r t ,

to

advance

the

is

curing

part

dies

are

opened

within

applicator

Once the

dies

press

is

advance

130 is

press

adjacent

the

curing

C into

Further,

while

dies

clamping

device

close,

slip

a predeternined

through

the

side

other

predetermined

clamp when the

rovings
This

also

in charge

then

intended

of the d i e s .
tension

precisely
nositions

programed

to close

128

is

the

so as to p u l l

and

for

slowly

trapped

thereby

assuring

a void-free

air

the

allows

charge

the

before

and excess

C to

C exceeds

to m a i n t a i n

.907ka

on
the

extending
molding

operation.

in t h e i r

The dies
they

resin

part

the

charge

tension

reinforcements

finished

onto

on charge

done

molding

and b e f o r e

moving

compression

just

next

and clamps

tension

the

wet c h a r g e .

begins,

operation

is

and

moved and p o s i t i o n e d

the mold c a v i t y .

to allow

distribution.

when t h e

longitudinally

the

done

is

is,

142 m a i n t a i n s

maintains
within

That

which

This

on the

C during

closed

138 c l o s e s

pressure

provided,

are

stationary

press

position

is

movement

position

the

(two pounds.) . Clamping device

the

the

moved away from a p p l i c a t o r

a new wet charge

from a

dies

initially

and the

close,

oneration.

C under

press.

128 and over

press

on a t r a c k

This

C when the

charge

C.

128 to a second

128.

(not

means

charge

140 are movably mounted

spaced

134 a n d

hereinafter,

more f u l l y

applicator

charge.

of

pair

heating

130and station
position

the

The dies

part.

conventional
curing

the

of

from each end o f ,

offal

the

was p r o -

balance

and the

part

through

and p r o p e r l y

shown)

amount of o f f a l

a small

are

meet.

This

to e s c a p e

with

proper

resin

It

should

in v a r i o u s

provided

limited

not

the

to

illustrated

extruded-type

4c.

or a f t e r

U-shaped,

of the

L-shaped

is

138 to p r o v i d e

pulled

and t h e r e f o r e

the

a generally

of a number of d e s i r e d

or any one

an

the

through

can take

charge,

can b e

a plate-die

plate-die,

resulting

is

configuration

device

which

of the

and

configurations

example,

clamping

section

cross

section

For

C can b e

charge

rectangular

generally

The shape

plate-die.

that

cross-sectional

in F i g u r e

before

provided

cross

be a p p r e c i a t e d

also

con-

figurations.

elevation
It

and side

can be seen

is mounted

frame

150 is

ring

154.

154 is
36

spaced

in c o n t a c t

of twenty

doffs.

reinforcement
from a doff

delivery

with

guided

holes

of d e l i v e r y

drag

or p r e d e t e r m i n e d

wet charge
currently
orovide
that

preferred

applicator

kg

holder

along

set

each

the

of t e n s i o n
adapted

axis
the

through
ring

screws

R as it

are
It

The

166 on e a c h

to provide

of a p p l i c a t o r

set

radially

164.

164 toward

in each r o v i n g .
for

of

a source

screws

roving
ring

delivery

practice,

128 is

delivery

adjusted

are

to

drive

154 or a t o t a l

ring

inwardly

transverse

tension

of

R which are p a i d - o u t

radially

164 which

surface

160 e q u a l l y

provides

rovings

through

extending

0.907

ten

ring

and advanced

of d r i v e

156 of a m o t o r

practice,

holders

162 of an inner

includes

side

pulled

side

150

is r o t a b l y

outer

radially

doff

128.

Disposed w i t h i n

wheel

preferred

ten

fiberglass

and are

ring

the

Each doff

or

bore

extending

with

on each

apart

drive

rubber

a frame

154 which

ring

In c u r r e n t l y

provided

152.

shown

are

applicator

rotary

base

drive

by the

5b t h e r e

128 i n c l u d e s

applicator

a floating

is

ring

of b i a x i a l

to a s u i t a b l e

and d r i v e n

158 which
drive

views

that

which

mounted

5a and

now to F i g u r e s

Referring

is
the

128.
adjusted

In
to

can be s e e n

counter-clockwise

rotation

as viewed

in F i g u r e

rovings

R are

bundles

of

the

wet charge
in Figure

around

side

downstream
a run out

5b,

about

are wrapped

the

128.

to a p p l i c a t o r

wrap c o n t r o l

wet charge

It

around

128.

advancing

speed

of a p p l i c a t o r s

without

with
such

structures

Referring
grammatic

the

ment m a t e r i a l s .
bundles,

roving
winding
axis.
the

form of

in

a roving

the

a woven c l o t h
applied

axis

of the

only

or

material

reinforcement

rovings

it

Further,
or wrapping
used

is

as

is

in t h e

facilitate

171,

in
certain

with

170 a d i a -

the

to

along

reinforceor f i v e

rovings,

wrapping

illustrated

comprise

172 is
also

angular

respect
between

to

in

a woven c l o t h
also

could

illus-

comprise

Reinforcement

tape.

or

a longitudinal

171 as

material

and the

R, can vary

shown at

of composite

but which

a reinforcement
applicator

is

Prior

but which could

material

C and t h e

charge

to

five

extend

rovings

form of a roving

by a f i r s t

reinforcement

of a charge

reinforcement

A second

or tape.

6 there

clarity,

the

appli-

structures.

illustrated.

are

operation,
A first

trated

For

that

can be employed

invention

now t o - F i g u r e

representation

close

reinforcement

winding

a mandrel

present

as hollow

the

and

and in a p a t t e r n

use of a mandrel

however,

Again,

conjunction

the

with

as

relatively

126 and 128.

be a p p r e c i a t e d t h a t

art.

prior

in an area

bundles

rotational

accomplished

R make c o n t a c t

the wet roving

speed of the

hoop 167 on t h e

to wrap or wind

by the

also

direction.

now be a p p r e c i a t e d

should

determined

should

or r o v i n g

Hoop 167 f u n c t i o n s

rovings

128 f u n c t i o n

126 and

materials

so t h a t

rovings

twenty

128 i n c l u d e s

applicator

of a p p l i c a t o r

control

the

the

of

in a c o u n t e r - c l o c k w i s e

elliptically-shaped

generally

each

Accordingly,

wound or wrapped

As i l l u s t r a t e d

cators

5a.

171 i s

orientation

the

0 and +

of

longitudinal
90 as a

function

of the

speed
is

same p a r a m e t e r s .

reinforcement
filaments

or any o t h e r

of the

ability
material

at any p o i n t

graphite

filaments
matrix

composite
additional
generally
2.

in the

U-shaped

angle

then

45

selectively

final

for

12".
certain

strengthen

also

of t h e

to p r o v i d e
14 of t h e

10

This,

then,

areas

of

of t h e

angularity

such t h a t

charge

12" then

in F i g u r e
to t h e

applies

the

a given

for

location

illustrated

example,

within

can be m a i n t a i n e d
again

section

cap-

For e x a m p l e ,

portions

leg

the

6 so as

capability

By way of

can be v a r i e d

45

the

bumper c r o s s

placement.

windings

for

placement

the

in F i g u r e

additional

materials.

matrix.

at

of

reinforcement

place

composite

of r e -

form of g r a p h i t e

to d e m o n s t r a t e

G can be p r o v i d e d

reinforcement

the

reinforcement

selectively

illustrated

The s e l e c t i v e

angular

to

172

as a f u n c t i o n

illustrates

which may t a k e

suitable

process

orientation

0 and 90

illustrated

G are

reinforcement

and the

6 further

Figure

and t h e

applicator

Similarly,

between

materials G

Reinforcements

R.

applicator

172 can vary

inforcement

of the

speed

rovings

moving

by a second

applied

the

rotational

of the

for

12" and

functions

the

to
such a s

product

a bumper.

grammatic
Figure

and

plan

9 provides

in e x p l a i n i n g

the

LOAD POSITION,
rovings

top views

composite

matrix

The completed

timing

operational

line

R which

of machine

a simplified

illustrated

matically

7 and 8 t h e r e

now to F i g u r e s

Referring

are

180 in F i g u r e

C at

the

C extends

8.

the

up i n t o

Figure

chart

In the

represents

output

into

shown d i a -

the machine

and set

established

charge

charge

7 and

in F i g u r e

100 of

sequence

of

steps

is

useful

diagram-

initial
the

initial

a completed

of a p p l i c a t o r

and a c r o s s

4.

128.

the p r e s s

At t h i s

positions.

point,

PRESS CLOSE n o s i t i o n
for

Line

1.

Step

machine

during
the

over

trated

by arrow

2,

and t o l l

then

opens

and with

and t r a v e r s e s

back

formed

186 of Figure

line

new c e n t r a l l y
by l i n e

ted

form the

to

moves to

the

Figure

which can be added

is

principles

to

applicators

motion
applied

202.

adapted
Again,

of charge
mats

press

are

illustra-

open p o s i t i o n
cut

and s e v e r e d

C.

wrapping

to the machine

or w i n d i n g

in a c c o r d a n c e

invention.

present

That

is,

a mat a p p l i c a t o r

200 which

is

126 and 128 p r e v i o u s l y

described

but

illustrates

specifically

material

of the

its

of charge

portion

parts

and as

4,

190 is

part

an a d d i t i o n a l

8 illustrates

8 further

similar

completed

the

3,

As i l l u s t r a t e d

and completed

again

or upstream

The p r e s s

In Step

part.

press

balance

operation

completed

the

from the

with

next

9 two cured

first

9.

PRESS CLOSE p o s i t i o n ,

In Step

the

to a d v a n c e

new p o s i t i o n .

187.

time

press

PRESS CLOSE p o s i t i o n

as at

at which

the

functions

joined
188,

Figure

the

part.

PRESS OPEN p o s i t i o n

184 of F i g u r e

to

on t h e

completed

and while

then

in i t s

charge

130 now in i t s

press

closes

again
in

in l i n e

the

leaving

This

closed.

its

to

charge

illustrated

C as

charge

time of the

still

are

advanced

are

138 i l l u s -

tension

mold and form the

130 is

dies

the

clamp

9 maintains

183 in F i g u r e

curing

that

C--while

charge

of t h e

operation

can be seen

It

completed

press

the

during

1.

the

its

C in p r e p a r a t i o n

and below charge

132 i l l u s t r a t e s

compression

rovings--to
In Step

above

Step

closed

130 is moved into

press

for

the

the

application

rotational

C determine

the

speed

angular

of a wider

mat

and l o n g i t u d i n a l

orientation

of

the

202.

As p r e v i o u s l y

described,

machine

100 f u r t h e r

includes

a controlled
ermined

tension

rovings

in

the

on the

is

tension

wise,
radii

of the

a part

on the

out

undesirable

In a c c o r d a n c e

with

the

138 and 142 in F i g u r e

movement of machine
Station

therewith

the

130.
the

As the

itself

press

this

During

movement

pressure.

therein,
charge,

to

slip

can t r a n s l a t e

the

112.

Thus,

that

forcements

the

the

are

as

130 for

142 is

the

extends

over

therein
proper

tension

maintained .

the wet c h a r g e ,

to

upstream

of the

dies,

predetermined
individual

when the
rovings

close,

cannot

inde-

closed

slippage

dies

further

138 is

pressure

rovings

tension

on t h e
exceeds

therein,

0.907

of one or more r o v i n g s

way back or u p s t r e a m
the

movement

PRESS CLOSE p o s i t i o n .

This

individual

as

and away from p r e s s

closed

the d i e s

controlled

all

reinforcements

ensures

the

This

(two p o u n d s ) .

source

toward

or any of

toward

or any of the

charge,

function

PRESS OPEN a n d

the

device

devices

controlled

the

tensioning

device

clamping

with

in

areas.

clamping

to p r e s s

into

under

the wet

the

being

which

allows

and r e s i n - r i c h

invention,

clamp the wet c h a r g e ,

a predetermined

shorter

resulting

Clamping

are

the

along

resin

resin-void

is moving

movement,

fibers

and between

dies

press

Other-

surrounding

100 p r o v i d e

for

workpieces.

4 in c o n j u n c t i o n

a track

mounted

respect

up and i n c r e a s e

present

PRESS CLOSE p o s i t i o n .
pendently

with

build

140 is mounted

along

molding

would

configuration

squeeze

having

follows:

or c o n t o u r e d

reinforcement

extending

compression

significant

particularly

curved

and t h e r e b y

the

during

curved

longitudinally

a predet-

longitudinally

generally

wet charge

This

operation.
to

movement to m a i n t a i n

or programed

the

exceed

to the

doffs

induced

Simultaneously,

tension

on

kg-

and t h i s

of the

rein-

0.907

and p l a c e m e n t

a t

the

clamping

kg

142 of

device

device

clamping

side

an a l t e r n a t i v e

the

in a u t o m o t i v e

with

equal

of

the

volume

longitudinal

in

of

areas

each

in the

is wrapped

it

wet charge.

The f i b e r

flange

is

illustrative

40%-45

of the

those

locations

system

orientation
diagonal.

in

Other-

materials
with

are
the

Spring

of p r o d u c t s

com-

the
that

in i t s
section

is

300 is

spring

are

longof

flange

areas.
100%

desired
provided

using

the

in accordance

invention.

304 which

many types

304.

end mounting

areas

spring

areas

can be seen

composite

flange

and winding

wear r i n g s

flange

300 v a r i e s

the

leaf

can be any other

of the p r e s e n t

around

areas

at

It

main body of

The end mounting

features

steel

in a c c o r d a n c e

except

of c o u r s e ,

wrapping

300 which p r o v i d e s

wear ring

spring

However,

up the m a t e r i a l

rotational

The s t r u c t u r e

The end mounting

steel

illustrate

is made in a c c o r d a n c e

spring

invention.

shape

all

and,

orientation.

certain

in

invention.

and r e s i n

orientation

building

reinforcements

is made of composite

present

direction.

The f i b e r

to

of a c o n v e n t i o n a l

an i n s e t

spring

cross-sectional

itudinal

so as

views which

which

present

applications.

entire

principles
the

13C

11 and 12a and 12b t h e r e

10,

structure

of the

reinforcements

prising

controlled

on the

form of a c o m p o s i t e

provided

the

wise,

tension

and s t r e n g t h

function

302 are

movement o f

to the movement of p r e s s

and c r o s s - s e c t i o n a l

composite

teachings

shown t a k e s
the

relative

oreciscly

now to F i g u r e s

shown p l a n ,

the

is

which

wet charge

dies.

closinq

with

on the

and the

respect

predetermined

the

Referring
are

with

142,

closed

dies

140 t h e r e w i t h ,

and s t a t i o n
maintain

140 is

of the

downstream

extends

the

station

with

The m a t e r i a l
placed

in t h e

end m o u n t i n g
300 is m e r e l y
which can be

by

made in

accordance

examples
seat

door

are

frames,

examples
pole

with

hollow

the
means

heating

in

provided
150C
and

While

which

is

relatively

lifetime

of

the

(cure)

at

tively

short

less.

By u t i l i z i n g
described

viously
of the

resins
will

It
the

process

a relatively
art

prior

utilized

tons

tonage

(20,000
its

which

is

in a c c o r d a n c e

such

embodiment

for

pounds)and

the

Further,

the
it

bath

will

set

in hours
resins
the

that

in

press

the

For e x a m o l e , i n

made of

order

a press

aluminum

constructed

life

art

that

to

which

lbs).

(5,000

kg

utilize

pot

one

was a 25 ton p r e s s

on the

as p r e -

as compared

technique

2,268

or

utilizes

invention

present

up

in a r e l a -

and

skilled

the

life"
state

liquid

is measured

found

operation

"pot

by t h o s e

SMC.

in one

curing

days.

typically
is

the

several

an SMC p r o c e s s i n

which

a suitable

of

weighing

press

a given

having

short,

been

molding
as

is v a r i a b l e

of

and s t a n d a r d

order

with

low-pressure

such p r e s s e s

weight.

has

on the

approximately

a so-called

resin

the

mold

it

herein,

to

since

is,

typically

be a p p r e c i a t e d

a steel

and

relatively

a heated

used

have

is

processes

constructed

press

period

Means a r e

process.

perform

That

in

includes

requirements

to

resins

room t e m p e r a t u r e

preferred

preferably

structure

short.

resin

telephone

like.

formulation

so as

Other

The t e m p e r a t u r e

a resin

such

room t e m p e r a t u r e ,

that

specific

can be p r o v i d e d

like.

in c u r r e n t l y

curing

process.

the

to meet

the

heat

to

curing

chemistry.

catalyst
at

the

varied

resin

dies

and

mold p r e s s

facilitate

to

the

during

is

campression

and the

to,

rails,

such as t u b i n g ,

box bumpers
alluded

As p r e v i o u s l y
practice,

and the

components

Further
frame

supports,

constructions

closed or

invention.

present

radiator

frames,

suspension

are

arms,

the

of

Comparable

200-300

weighing 9,072

so as

kg

to m i n i m i z e

embodiment,

the

curing

time

the

of

was on the
most

.that
in

the

with

order

of

present

from the

follow

resins

cured

30 s e c s .

to

of

it

of

in a c c o r d a n c e

the

compress

and flow them as is

liquefy

semi-

flowable

need to

the

can be c u r e d

characteristics

for

need

anticipated

mm (1 inch)

Again,

desirable

elimination

is

up to2-.54

the

invention

present

and

seconds

these

elimination

to

the

3 minutes.

invention,

and the

the

case

an SMC-type p r o c e s s .
In t h i s

utilize
touch

and p l a c e d

in the

materials

materials

utilized

so-called

"C s t a g e . "

in o r d e r

also

and p r e s s u r e

"A s t a g e "
and is

is

in a f u l l
to

applies
reaction
ciated
process

a set

state.

an i m p r e g n a t e d

has begun

by those

skilled

in a c c o r d a n c e
materials

beginning

of

stage

at very

resin

leading

this

stable

in

been

in

the

art

with

the

present

the A

and the

low p r e s s u r e s .

that

Again,

so-called

"wetted

It

will

the

chemical
be a p p r e -

composite

invention

are

out"

"B s t a g e "

and B s t a g e s

materials

the

molding

an i n t e r n a l

the

are

therefore,

cause

the

The s o - c a l l e d
wherein

in t h e

state

and,

compression

has

composite

worked

in

to m a t u r a t i o n .

between
B,

the

are

or r e s i n

which

up c h a r g e

liquid

composite

molded

material

establish

to

must be a p p l i e d t o

subsequent

the

the

liquefy

art,

materials

the

t h e

to

Accordingly,

must

the

techniques

cured

flowing

dimensionally

flow in the
A composite

operation.

known in

While

tremendous

to

state.

in an SMC-type p r o c e s s

are

materials

which is

to p e r m i t

As is

art

prior

operation

molding

deformable they
heat

in t h a t

mold

matrix.

composite

material

composite

compression

maturated

SMC and r e l a t e d

the

regard,

a maturated

subsequent

the

with

in t h i c k n e s s e s

materials

composite
with

of 1 m i n u t e - 4 5

structures

range

the

in a c c o r d a n c e

process

works
at

then

need

to

the

structure
the
very

compression
liquefy

and flow the

high

relatively

is

and

cavity

the

the

tool

will

It
that

the
art

prior

invention
other

with

of

hand

The l a y e r s

fiberglass.

a staggered or
desired

tool

the

and does

automated

system.
also

art,

that

of the

will

not

thermoplastic

Further,

combined

in the

same mold

example,

a base

layer

bonded
the

to

mold c a v i t y .

cavity

of

a decorative
It

thermosetting

also

has

coated

of

volumes of an

skilled

materials
part.

material

thermoplastic

been

found

in t h e

the method

out

a given

to t h e

of t h e

thermosetting

these

to p r o v i d e

layer

can be s u i t a b l y

to c a r r y

and i n

up is o p e r a t o r

lay

production

can be both

materials.

layers

on a h e a t e d

applied

by those

utilized

molding

in a die

hand

the

over

bumpers

corresponding

then

be a p p r e c i a t e d

invention

out"

configuration

the

provide

the m a t e r i a l s

present

"wetted

hand-placed

However,

part.

advantages

wet c o m p r e s s i o n

is

to.

in the a r t

For example,

fully

are

High p r e s s u r e

sensitive

It

SMC.

and c r o s s - s e c t i o n a l

part.

to cure

of

skilled

configuration

stepped

shape

finished

lay-up

therein.

designed

distinct

provides

a "pre-preg"

as t h e

closes.

by those

than

as t h e

utilized

charge

placed

are

in

areas

same size

nrecisely

tool

as the

other

the

the

can be and o f t e n

be a p p r e c i a t e d

have been made using

technique

and is

cavity

techniques

is

same size

into

thereto,

preferably

edges

present

the

not

the

Further,

pressures.

is

In c o n t r a s t

edge-trim

automatically

necessitates

so as to flow

placed

molding

the

However,

molding
charge

invention

present

compression

SMC p r o c e s s

compression

of the mold c a v i t y .
in

the

SMC p r o c e s s

a typical
mold

of

charge

that

so as to p r o v i d e

and
can be
For

can be

material
the mold
in-mold

in

of

coloring
found
vide

that

finished

the

mold c a v i t y

the

resin

polvester
finish.

of

application

in Figure

113b

is

This

jell

or

dispensed

4.

it

noted

Finally,
4 is

What has been

with

resin

part

constant

depend

are

continuous

composite

and the

flowing

inventions

within

modifications
the

scope

of

of c u r e d

of

of the
and

of

is

appended

is

to

compression

does not

composite

primarily

matrix.

and d e s c r i b e d

these

and a l t e r a t i o n s
the

limited

not

process

is

of a f i n i s h e d
the

The p a r t

the

The

and in which

teachings.

inventive
it

therein.

provision

illustrated

embodiments

than by way o f l i m i t a t i o n

structures

contour

low p r e s s u r e

on c o m p r e s s i o n

and m e t h o d

placed

the

section.

present.invention

a machine

precisely

The p a r t

shown as i l l u s t r a t i o n s

various

is

cross

but p r e f e r r e d

of m a c h i n e s

thereunder.

can vary.

The forms of the

a variety

structures

reinforcements

molded using

the m a c h i n e

composite

high-strength

section

that

the

then,

the

at 118a a n d

practicing

taught,

and a b e t t e r

for

which can be of a curved

cross

one of

only

facilitates,notably,

invention

is

to p r o -

with

conjunction

veil"

producing

for making

in

color

a "surfacing

which would be s u i t a b l e
and for

done

been

as by u t i l i z i n g
both

for

ccating,

typically

in F i g u r e

illustrated

such

has

coated

be s u i t a b l y

A" f i n i s h

"Class

a superior

can

further

It

workpiece.

concepts,

pointed

out

They a r e
however, r a t h e r
that

may be i n d u l g e d

claims.

herein

in

A method

1.
structures

said

longitudinally
mined

tension

with

impregnated

rovings

through

nally
to

cross-sectional

in

each

direction

to

form a c h a r g e

while

provide

a predeter-

having

around

said

a pair

cross-sectional

of a given

and into

the

cross-sectional

maintaining

a press

providing

and

rovings;

said

in

rovings

bushings

bushings

materials

reinforcement

extending

cavity

said

said

of

resin;

liquid

configuration;

through

rovings

extending

applying

rovings

fiberglass

rovings

a predetermined
pulling

continuous

guided

the

the

guiding

of:

steps
of

composite

plate;

impregnating

into

the

a plurality

a carding

high-strength

producing

comprising

guiding
through

for

longitudi-

configuration

tension;

of d i e s

defining

and e x t e n d i n g

area

a mold
a given

length;
closing
charge
the

said

opening
severing

step

cured

The p r o d u c t

3.

The method

position
into

the

said
4.

applying

said

when s a i d
first

reinforcement

of

to

closed

said
and c u r e

therein;
and

from

Claim

from a f i r s t
are

of

compress

said

charge.

method of Claim

according

dies

to

length

dies;

press

the

on a p o r t i o n

rovings

structure

press

1,

1.
the

including

position

to advance

to a s e c o n d
said

charge

position.

The method
step

of

pair

2.

of moving

given

and r e i n f o r c e d

said

dies

press

said

to

corresponding

impregnated

of

pair

according

includes

the

applicators

step

to Claim

1,

of r o t a t i n g

comprising

first

wherein
a pair
and

said
of b i a x i a l

second

rotary

members

coaxial

and adapted

with

for

the

rotation

and each member having

for

rotation
5.

a carding

of

a charge

said

composite

tension

producing

a high-strength

composite

of:

steps
of

continuous

fiberglass

guided

rovings

with

impregnated

rovings

through

a predetermined

rovings

to

corresponding

resin;

liquid

and

bushings
and c r o s s -

pattern

rovings

said

through
direction

the

cross-section

said

rovings;

a press

having

a pair

of a given

bushings

to p r o v i d e

in each of

of dies

cross-sectional

and

into

a predeter-

defining

and e x t e n d i n g

area

length;
said

advancing
maintaining

said

to

corresponding
impregnated

pair

said

opening

said

severing

the

given

pair of
cured

6.

The p r o d u c t

7.

The method

axis

of dies

and r e i n f o r c e d

of wrapping
of

relative

charge

to said

press

while

tension;

said

closing

tudinal

thereon

extending

providing

step

opposite.directions,

structure;

said

a longitudinally

a given

rovings

of r e i n f o r c e m e n t s

configuration

mold c a v i t y

said

a source

the

the

having

pulling

mined

of

plate;

the

guiding

sectional

in r e s p e c t i v e l y

a plurality

impregnating

into

for

comprising

guiding
through

axis

therewith.

A method

structure

longitudinal

of

length
rovings

structure
the

charge.

said

charge

and cure

the

therein;
and

from said

method of Claim

according

of

to compress

dies;

cress

reinforcement
said

on a p o r t i o n

to Claim 5,
materials

charge.
5.

including

around

the

the
longi-

A method

8.

resin

structure

of

including

steps

with

continuously
at

charge

sectional

method

impregnated

extend-

longitudinally

with

resin

and having

in

the

direction

longitudinal

tension;

predetermined

in

of r e i n f o r c e m e n t s

a plurality

placing

said

within

positions

cross-

area;
a final-wet

forming
whose

of

wet charge

wet charge

a predetermined

wet

said

therein,

area;

said

advancing

the

reinforcements

rovings

cross-sectional

under

composite

a high-strength

of:

fiberglass

given

producing

an i n i t i a l

forming
ing

for

reinforcement

orientation

in

charge
is

pattern

the

with

provided

direction

length

matrix

a composite
with

in the

an a n g u l a r
0 t o

of

range

+ 90;
a mold c a v i t y

providing
and

area

extending
the

advancing

having

a given

length;

final

wet charge

a given

of

said

cross-sectional

resin

into

said

mold c a v i t y ;
compression
while

cavity
thereby

maintaining

9.

A machine
components

of

source

rovings

of

therein

said

final

process

making

matrix;

tension

and,

of Claim

composite

8.

fiberglass

reinforced

in c o m b i n a t i o n :

comprising,
fiberglass

said mold

under

wet c h a r g e

composite

in

charge

matrix.

of the
for

wet

rovings

comprising

a plurality

doffs;

a carding
holes

said

composite

The p r o d u c t

10.
plastic

said

final

said

flow of said

inhibiting

curing

of

molding

plate
for

rovings

having

a predetermined

respectively

paid-out

receiving

from said

source

pattern

and g u i d i n g
into

of g u i d e
the

ends

a generally

longitudinally
nal

axis

extending

and having

predetermined

extending

said

members c o a x i a l

reinforcements
a press
therein

direction

to

for

mounted

means for

dies

are

portion

means for

another

dies

when said

dies

said

press

from a f i r s t

final

between

closed

are
said

dies;
to

position

said

axis

when said

dies

are

opening

said

dies

when said

press

is

closed;
moved

and
the

cured

portion

of

said

final

charge.
11.
charge
press.

The machine

is p u l l e d

along

according

to Claim 10,

said

by the movement of

axis

apart;

charge

severing

in

said

receiving

final

second p o s i t i o n ;

of

a pair

along

a second p o s i t i o n

said

to one

for

said

charge;

relative
axis

said

receiving

applying

of said

means for moving

means for

for

for

and having

spaced

said

heating

means

of r e i n f o r c e -

a source

axis

said

to

perpendicular

to cure the

said

along

in r e s p e c t i v e l y

rotation

form a f i n a l

to

charge

first

longitudinal

therein

opening

which are movable

charge when said

said

each member having

said

wet r e s i n

with

comprising

with

mounted

and a c e n t r a l

longitudinally

rovings

dispenser

and each member i n c l u d i n g

charae,

said

materials:

reinforcement

directions,

thereon

ments

of

impregnating

said members being

opposite

said

to

corresponding

axis

of composite

and second r o t a r y

into

said

along

for

rovings

a biaxial

axis,

a longitudi-

defining

pattern;

to form a charge

dies

a cross-section

located

means

configuration

wherein

said

said

The machine

12.

reinforcements

include

a woven c l o t h ,

tape,

13.

members
14.

said

rotary

radially

said

wherein

a fiberglass

roving,

or g l a s s .

to Claim

10,

wherein

said

from said

inwardly

to Claim 13,

according
said

reinforcements

in a c c o r d a n c e

rotary

with

wherein

with

to

respect

rotational

the

the

speed

of

members.

The machine

to Claim 14,

according
said

of

reinforcement

is

wherein

the

variable

from

90.
16.

located

The machine
said

between

reinforcement
each of

for

applying

for

said

The machine

to

with
said

fiberglass

applying

including

rovings

means
said

and

a predetermined

said

to Claim

according

a predetermined

cooperating

of

10,

tension

rovings.

applying

18.

tension

source

dispenser

said

to Claim

according

The machine

17.
means

boron

10,

charge.

of

orientation

angular

to

said

varies

15.

one of

according

guided

orientation

axis

least

graphite,

The machine

said

0 to

are

and onto

angular

at

The machine

reinforcements

to Claim

according

reinforcements
tension

to

16,

wherein

includes

said

said
for

means

reinforcements.

according

to Claim

10,

for

applying

a predetermined

press

portion

of said

charge

including

when s a i d

dies

means

are

closing.
19.
means

for

resin

bath

rovings.

The machine

according

impregnating
for

receiving

said

to Claim

rovings

said

10,

includes

longitudinally

wherein
at

the

least

extending

one

The machine

20.

between

bushings

of

configuration
21.
plastic

comprising

the

of:

of r o v i n g

ends

of

said

rovings

configuration

paid-

having

plate

therein

holes

a cross-section

said

of composite

reinforcement

and

a pre-

into

defining

a generally

a longitudito

corresponding

said

coaxial

comprising

said

with
for

with wet

resin

of r e i n f o r c e m e n t s

a source

dispenser

mounted

rovings

form a

to

materials;

first

lonqitudinaly

rotation

and each member having

on a b i a x i a l
and

second

rotary

axis,

said

members

in r e s p e c t i v e l y

directions

opposite
therein

a central

opening

for

reinforcements

to

said

charge

along

said

axis

receiving

charge;
said

applying

to

form a

charge;
providing
of dies

charge
heating

portion

mounted

a press

therein

in a d i r e c t i o n
final

comprising

pattern;

providing

pair

rovings

a carding

through

extending

and into

the

of guide

impregnating

final

fiberglass

and g u i d i n g

pattern

steps

reinforced

doffs;

source

predetermined

said

of

a source

longitudinally

being

charge.

components

determined

members

cross-sectional

fiberglass

from said

charge

the

reinforce-

composite

receiving

axis

biaxial

and c o n t r o l l i n g

guiding

said

and said

bath

including

for making

a plurality

nal

resin

19,

A method

providing

out

said

for

ment d i s p e n s e r

to Claim

according

which

are

perpendicular

when said
said

of said

dies

dies

final

to
are

movable
said

charge

axis

spaced

when said

dies

between

relative
for

and having
to

one a n o t h e r

receiving

said

apart;
are

said

closed
dies;

to cure

the

said

moving
position

said

along

said

opening
second

ents

The p r o d u c t

23.

A machine

for

is

moved into

said

of the method

for

making

final

of Claim

composite

rovings

said

charge.
21.

reinforced

comprising

and g u i d i n g

receiving
from said

dinally

extending

cross-sectional

compon-

a plurality

the

into

source

of

said

a generally

and having

configuration

to

corresponding

pattern

ends

longitu-

a predetermined

the

cross

section

components;

means

of c o m p o s i t e
means

said

for

mounted

to one a n o t h e r
said

along

dies

charge

closing
said

form a c h a r g e

to

a generally

said

opening

means

for

severing

The machine
advanced
said

axis

therein

said

and having

which

are-movable

dies

to

are

spaced
the

cure

of

relative

said

to

perpendicular
dies

a pair

axis

for

apart;

portion

of s a i d

dies;

for

movement of

and g u i d i n g

receiving

along

charge

when said

means

is

said

in a d i r e c t i o n

for

between

24.

for

with wet r e s i n

rovings

advancing

molding

means

means

axis;

a press

receiving

said

materials;

longitudinal

compression

to

adjacent

impregnating

charge

press

doffs:

paid-out

charge

closed;

of

portion

of fiberglass

rovings

said

are

in c o m b i n a t i o n :

comprising,

means

for

cured

22.

of r o v i n g

dies

when said
when said

dies

the

a source

of

axis

to a s e c o n d

position

and

position;
severing

from a f i r s t

press

said

dies;

and

the

cured

portion

according

by p u l l i n g

press.

to Claim

said

charge

of

23,

said

charge.

wherein

said

said

axis

along

by

The machine

25.
for

applying

to Claim

according

23,

tension

longitudinal

a predetermined

including
to

means
said

charge.
The.machine

26.
for

said

heating

dies

heated

are

provides

to

means

of

The machine

for m a i n t a i n i n g
said

including

according

to Claim

wherein

approximately

a pressure

28.

to C l a i m 2 5 ,

when said

dies

29.

The machine

of

first

and second

movement toward

press

tension

clamping
said

located

said

along

to Claim

when said

between

said

and s e c o n d

axis

on o p p o s i t e

said

first

and wherein

means is

movably mounted

independently

which

source

at.a

rate

movement of

said

first

The machine
of

than

said

rate

33.

The machine

plate

therein

corresponding

having

clamping

said

according

closing.

means

clamping

movement

than

said

the

toward
of

rate

first

to Claim

31,

wherein

means

is

clamping
23,

said

greater
means.

wherein

said

said

rovings

includes

a predetermined

pattern

of guide

holes

and g u i d i n g

carding

for

for

wherein

30,

second

to Claim

second

of movement of

receiving

said

said

clamping m e a n s .

said

of movement

are

clamping

is d i f f e r e n t

according

rate

wherein

29,

dies

to Claim

according

is movably mounted with

means for

first

means are movably mounted

source

The machine

32.

means

charge

wherein

comprises

for movement t h e r e w i t h

said

including

to Claim 28,

The m a c h i n e ' a c c o r d i n g

31.

press

dies.

said

30.

said

closing.

are

said

23,

on said

tension

according

for m a i n t a i n i n g

said

25 t o n s .

to Claim

according

a predetermined

dies

26,

300F and wherein

approximately

clamping means r e s p e c t i v e l y
sides

means

dies.

The machine

27.

according

to

said

cross

section

of

said

components.

34.

A method
resin

structure

of

including

steps

at

cavity
area

a mold c a v i t y

to

tation

said

charge.

The method

in the

is

37.

The method

according

varies

method

said

39.

The p r o d u c t

40.

A method

contour

resin

structure

of

including

steps

providing

given

for

said

matrix;
tension

to

said
matrix
orien-

an a n g u l a r
of

and

0 t o +

90.

of Claim 3 4 .
wherein

34,

said

to Claim
said

mold c a v i t y ;

a composite

range

along

of

given

given

length.

wherein

37,

said

the

cross-sectional

length.

of the

method

producing

having

reinforce-

wherein

34,

with

Claim

to

method a c c o r d i n g

over

cross-sectional

said

forming

in the

of the

configuration

in

provided

The p r o d u c t

cross-sectional

into

Claim

to
of

step

direction

a curved

mold

length;

charge

36.

has

said

a predetermined

said

the

length

38. The

area

given

according

includes

within

in said

cavity;

reinforcement pattern

mold c a v i t y

area

said

in

molding

step

reinforcements

and m a i n t a i n i n g

compression

placing

method

cross-sectional

and form a c o m p o s i t e

a charge

reinforcements

35.

said

therein,

a given

of wet r e s i n

a quantity

applying

whose

of

said

over

complete

having

positions

predetermined

curing

composite

length;

a plurality

charging

said

a given

and e x t e n d i n g

ments

a high-strength

reinforcements

having

and e x t e n d i n g
placing

producing

of:

providing
area

for

of Claim

38.

a high-strength

reinforcements

therein,

composite
said

method

of:
a mold c a v i t y

and e x t e n d i n g

a given

having

length;

a given

cross-sectional

providing
at

least

charging
ments

to c o m p l e t e

said

given

and

said

at

cross-sectional

into

forming

said

in

charge

of r e i n f o r c e m e n t s

plurality
within

of wet r e s i n

a charge

of a l e n g t h

length;

given

a quantity

placing

said

matrix;

a composite

mold c a v i t y

with

said

positions

predetermined

area

reinforce-

and e x t e n d i n g

said

over

length;
and m a i n t a i n i n g

applying
said

said

to

equal

of r e i n f o r c e m e n t s

a plurality

reinforcements

in

said

compression

molding

said

charge.

tension to

a predetermined

cavity;

said

in

charge

said

mold c a v i t y ;

and
curing
41.
placing

The method

step

includes

whose r e i n f o r c e m e n t
orientation

in

the

to Claim

according
the

is

pattern
length

of forming

step

said

a composite

with

provided

direction

wherein

40,

in the

matrix

an a n g u l a r
of

range

0 t o

+ 90.
42.

The p r o d u c t

of the

43.

The method

according

mold c a v i t y
44.

has

The method

cross-sectional
area

step

a curved

varies

over

configuration
said

given

The p r o d u c t

46.

The method

placing

step

said

so t h a t

of

of

The p r o d u c t

to Claim
along

to Claim
said

wherein

40,

said

40.

given

said

length.

wherein

43,

the

cross-sectional

given

the method of Claim

charge
said

of Claim

length.

according

mined c r o s s - s e c t i o n a l
47.

contour

according

45.

of p u l l i n g

method

to Claim

through

charge

is

40,

43.
including

said

a die-plate

prior

formed

a predeter-

into

configuration.
of the method

the

of Claim

46.

to

48.
step

The method

of wrapping

placing

step.

said

according
charge

to C l a i n

about

40,

a mandrel

including
prior

to

the
said