A resin barrier device for connection in a vacuum line, for use in resin infusion during composite manufacture, includes a housing having an inlet port for connection to a resin source and an outlet port for connection to a vacuum source. A flow path extends between the inlet and outlet ports. A gas-permeable membrane is disposed across the flow path to prevent resin from flowing to the vacuum pump. A gasket supports the membrane and is adapted to prevent resin leakage. A method of infusing a preform with a resin also is provided.

The present invention addresses the problem of providing a method for molding, using a honeycomb core, a composite material structure that is high-quality, low cost, and leaves less voids. The present disclosure addresses the problem of providing a method for molding, using a honeycomb core, a composite material structure with which it is possible to reduce dimples in a composite material skin at low cost. According to a method for molding a composite material structure of the present disclosure, an uncured composite material honeycomb sandwich panel in which prepreg is laminated on upper and lower surfaces of a honeycomb core via an adhesive is covered with a vacuum bag and placed in an autoclave. After that, the vacuum bag is evacuated and, while the evacuation is being continued, is heated and pressurized by the autoclave to cure a matrix resin of the prepreg and achieve adhesion to the honeycomb core.

The present invention addresses the problem of providing a method for molding, using a honeycomb core, a composite material structure that is high-quality, low cost, and leaves less voids. The present disclosure addresses the problem of providing a method for molding, using a honeycomb core, a composite material structure with which it is possible to reduce dimples in a composite material skin at low cost. According to a method for molding a composite material structure of the present disclosure, an uncured composite material honeycomb sandwich panel in which prepreg is laminated on upper and lower surfaces of a honeycomb core via an adhesive is covered with a vacuum bag and placed in an autoclave. After that, the vacuum bag is evacuated and, while the evacuation is being continued, is heated and pressurized by the autoclave to cure a matrix resin of the prepreg and achieve adhesion to the honeycomb core.

The invention relates to a method for manufacturing a composite aircraft window frame; the method comprises the steps of: a) positioning in a mold a preform made of pre-impregnated material including dispersed fibers, with a predefined orientation, in a thermosetting resin matrix; b) closing the mold so as to define a gap between at least one surface of said preform and a portion of said mold; c) injecting thermosetting resin into the closed mold through an inlet opening of the mold itself, so as to fill the gap and completely lap said surface of the preform; and d) applying a uniform hydrostatic pressure on the surface by the injection of the resin.

Forming systems and methods for drape forming a composite charge are disclosed herein. The forming systems include a forming die having a forming surface configured to receive the composite charge and a collapsible support having a support surface. The forming surface has a forming surface edge that extends along a length of the forming surface, and the support surface has a die-proximate support surface edge that extends along the length of the support surface. The forming surface edge and the die-proximate support surface edge define a gap therebetween. A shape of the die-proximate support surface edge corresponds to a shape of the forming surface edge such that a gap width of the gap is at least substantially constant along a length of the gap. The collapsible support is configured to transition from an extended conformation to a collapsed conformation. The methods include methods of utilizing the systems.

Forming systems and methods for drape forming a composite charge are disclosed herein. The forming systems include a forming die having a forming surface configured to receive the composite charge and a collapsible support having a support surface. The forming surface has a forming surface edge that extends along a length of the forming surface, and the support surface has a die-proximate support surface edge that extends along the length of the support surface. The forming surface edge and the die-proximate support surface edge define a gap therebetween. A shape of the die-proximate support surface edge corresponds to a shape of the forming surface edge such that a gap width of the gap is at least substantially constant along a length of the gap. The collapsible support is configured to transition from an extended conformation to a collapsed conformation. The methods include methods of utilizing the systems.

A method for positioning wrinkling of a cured composite material at a predetermined location in fabricating a composite part, which includes positioning a caul plate in contact with an uncured composite material. The uncured composite material has a geometric change in shape and the caul plate has a first slit which extends through and along the caul plate. The method further includes positioning a fiber and a resin of a portion of the uncured composite material within the first slit and curing the uncured composite material positioning a wrinkle within the first slit of the caul plate.

A method for positioning wrinkling of a cured composite material at a predetermined location in fabricating a composite part, which includes positioning a caul plate in contact with an uncured composite material. The uncured composite material has a geometric change in shape and the caul plate has a first slit which extends through and along the caul plate. The method further includes positioning a fiber and a resin of a portion of the uncured composite material within the first slit and curing the uncured composite material positioning a wrinkle within the first slit of the caul plate.

A stitched multi-axial reinforcement and a method of producing a stitched multi-axial reinforcement. The stitched multi-axial reinforcement may be used in all such applications that reinforcements are generally needed and especially in such applications where either Vacuum Infusion technology or Resin Transfer Molding (RTM) technology for distributing the resin in the mold is used. The stitched multi-axial reinforcement is especially applicable in the manufacture of wind turbine blades, boats, sporting equipment, storage tanks, bus, trailer, train and truck panels, etc., and generally in all such structures that are subjected to stress in more than one direction

The invention relates to a method for producing molded parts from fiber composite material, including the following steps: a) providing a press having a first press tool, a second press tool and a membrane. The first press tool and the second press tool are movable relative to each other. The membrane is connected to one of the press tools, a cavity for a working medium being formed between the membrane and the press tool connected thereto, a working chamber for a workpiece being formed in the other press tool, and the volume of the working chamber being modifiable by a movement of the membrane when the press is closed, b) providing at least one workpiece having a workpiece volume. The workpiece has a matrix and fibers inserted therein, c) inserting the workpiece into the working chamber of the press, d) closing the press. The working chamber takes up a first volume, e) applying pressure and/or temperature to the workpiece by means of the membrane. The working chamber takes up a second volume, a hardened molded part being created from the workpiece, and f) opening the press and removing the molded part. In order to ensure continuous and uniform pressure distribution, according to the invention the first volume of the working chamber is smaller than the workpiece volume, and therefore the workpiece is already compressed at step d) and before step e).