Presented are manufacturing control systems for composite-material structures, methods for assembling/operating such systems, and transfer molding techniques for predicting and ameliorating void conditions in fiber-reinforced polymer panels. A method for forming a composite-material construction includes receiving a start signal indicating a fiber-based preform is inside a mold cavity, and transmitting a command signal to inject pressurized resin into the mold to induce resin flow within the mold cavity and impregnate the fiber-based preform. An electronic controller receives, from a distributed array of sensors attached to the mold, signals indicative of pressure and/or temperature at discrete locations on an interior face of the mold cavity. The controller determines a measurement deviation between a calibrated baseline value and the pressure and/or temperature values for each of the discrete locations. If any one of the respective measurement deviations exceeds a calibrated threshold, a void signal is generated to flag a detected void condition.

A method for producing a part by injecting resin into a woven fiber preform includes the steps of (a) shaping the preform, (b) forming the preform, and (c) injecting resin into the preform. The step of injecting resin into the preform is carried out by means of equipment that includes a mold, a countermold, and resin injecting means. The step of injecting resin into the preform includes the substeps of: partially opening the equipment, injecting resin into the equipment, closing the equipment, and pressurizing and heating the impregnated preform between the mold and the countermold.

A method and apparatus for constructing a tubular assembly (24) comprising an inner portion (21) and a further portion (22) surrounding the inner portion, the further portion being formed from a strip (50) of material comprising two opposed longitudinal marginal side portions (53). The apparatus (100) comprises an assembly station (106) having a wall (122). The apparatus (100) comprises means for advancing the inner portion (21) along a first path (111) extending past the wall, and means for advancing the strip (50) along a second path (112) and causing the strip to encircle the wall and thereby wrap about and surround the inner portion (21). The two marginal side portions (53) are disposed in overlapping relation on the side of the wall opposed to the first path (111). The apparatus (100) further comprises a system (131) for affixing the two longitudinal marginal side portions (53) together in overlapping relation to assemble the strip (50) into a tubular configuration about the inner portion (21), whereby the strip in the tubular configuration provides the further portion (22).

A method for identifying a fiber-reinforced plastic component includes the acts of providing a fiber preform, applying a label to the fiber preform and holding it in place, inserting the preform together with the label in a mold and closing the mold, and infiltrating the preform with a plastic compound and curing it in the closed mold. In order to reliably identify the plastic component, the label comes to rest on a flow aid portion formed on the inner mold wall which has at least one channel-shaped depression. The longitudinal extension of the flow aid portion projects beyond the label.

A method of manufacturing a fibre-reinforced polymer object by means of vacuum-assisted resin transfer moulding (VARTM), wherein fibre material is impregnated with liquid resin in a mould cavity comprising a rigid mould part having a mould surface defining an outer surface of the object, is described. One or more pressure sensors are connected to resin inlets of the VARTM system. A control unit is used for controlling a polymer supply unit based on measured resin pressure and is adapted to adjusting a resin flow rate, if pressure measured by the pressure sensors is below a lower threshold level or above a higher threshold level.

The present invention relates to a method and to a mould system (70) for manufacturing a shear web for a wind turbine blade as well as to a backing plate (66) for such method and mould system. The method involves arranging one or more fibre layers on top of a web mould part (61), arranging backing plates (66) at each end to create a mould cavity between the first and second backing plate (66, 68) and the web mould part (61). Each backing plate (66, 68) comprises an inner moulding surface (80), outer surfaces (98, 100) and a channel (82) or groove (83) extending between at least one of the outer surfaces (98, 100) and the inner moulding surface (80). Resin is supplied to the mould cavity via each channel or groove of the first and second backing plate (66, 68), and subsequently the resin is cured or hardened to form the shear web.

A preform is infused with a resin to form a composite laminate. The preform is placed between a mold and a vacuum bag. An offset tool is placed to permit the vacuum bag to lift away from a surface of the preform in a controlled amount. A charge of the resin is injected between the vacuum bag and the preform to lift the vacuum bag off the surface of the preform and move the vacuum bag toward the offset tool, so that the resin occupies a volume between the vacuum bag and the preform. The preform is infused with the resin by applying a super-atmospheric pressure to an outer surface of the vacuum bag to transport the resin from the volume between the vacuum bag and the preform into a volume within the preform. The resin in the preform is cured, forming the composite laminate.

The invention is directed to a crosshead die for the extrusion of a profile, such as a uniform ply coat for a tire. The crosshead die is used with an extruder, and includes a body. An inlet is formed in the body, and is in fluid communication with the extruder. An outlet and a flow channel are also formed in the body. The flow channel extends between the inlet and the outlet, and is bounded by an upper wall, a lower wall, a first side wall, and a second side wall. The flow channel is formed with a bend and a cross section that includes a trapezoidal shape to align the flow of elastomer with the center of the flow channel.

A pressing tool is provided for producing fiber composite components, including a first tool part and a second tool part moveable relative to the first tool part. In the closed state of the pressing tool, the two tool parts form a shaping cavity for accommodating a fiber semi-finished product to be shaped and each have a tool surface delimiting the cavity. In addition, at least one of the tool surfaces has at least two adjacent flat sections inclined toward each other which are connected to each other by way of a curved transition section. The curved transition section has at least one groove-shaped recess facing the cavity.

A method of manufacturing a structural member includes preheating a plurality of fibers to a first temperature, moving the preheated fibers along an assembly line, applying a binder having a viscosity lower than 25 centipoise to at least one of the preheated fibers, providing a die shaped to receive the preheated fibers, wherein the die moves together with the preheated fibers along at least a portion of the assembly line, maintaining a temperature of the plurality of fibers at a temperature substantially similar to the first temperature, and compressing the plurality of fibers within the die while maintaining a temperature.