A COMPOSITE LAY-UP MOLD PRODUCTION SYSTEM

Abstract

A mandrel is disclosed which is suitable for use in surface metallization process (eiectrodeposition) by electrolysis. The mandrel has at least one inner coating which is metallized on an outer surface of the mandrel by electrolysis method such that it almost entirely covers the outer surface thereof, allowing electrical conductivity to be created on the surface and at least one outer coating which is obtained by almost entirely an electrolytic and/or electroless metallization on the inner coating.

Claims

1. A composite lay-up mold production system (1) comprising a. mandrel (2) suitable for use in electrodeposition process by electrolysis; at least one inner coating (3) which is metallized on an outer surface of the mandrel (2) by electrolysis method such that it almost entirely covers the outer surface thereof, allowing electrical conductivity to be created on the surface; at least one outer coating (4) which is obtained by almost entirely an electrolytic or electroless metal coating on the inner coating (3), wherein the mandrel (2) is produced from high density polyurethane foam material and is suitable for increasing its conductivity by doping with black carbon and/or different derivatives of carbon, CNT (carbon nano tube) or graphene; the inner coating (3) that sensitizes the surface of said mandrel (2) by placing Sn.sup.+2 ions in the pores on the surface of the mandrel (2), which is immersed in a solution containing Sn.sup.+2 , coated on the surface of the mandrel (2) by oxidation of Sn.sup.+2 ions to Sn.sup.+4 in the pores of the mandrel (2), which is immersed in a solution containing Pd.sup.+2 ions and which is used for activation, and reduction of Pd.sup.+2 ions to Pd atoms, and allows to increase the surface conductivity; and a composite lay-up mold (5) which allows a fabric (k) laid thereon to be pre-formed, consists of the inner coating (3) and the outer coating (4), and is obtained by the removal of the inner coating (3) and the outer coating (4) from the mandrel (2) almost entirely as a single piece.

2. A composite lay-up mold production system (1) according to claim 1, configured to apply the curing method under temperature and pressure to the pre-shaped fabric (k) by laying on the composite laying mold (5) to produce the part (p).

3. A composite lay-up mold production system (1) according to claim 1, wherein the composite lay-up mold (5) is suitable for use in a hand lay-up process for prepreg fabrics (k).

4. (canceled).

5. A composite lay-up mold production system (1) according to any claim 1, wherein the mandrel (2) has a conductivity value above a threshold value, allowing the inner coating (3) to be coated on the surface of the mandrel (2) with electrolysis.

6. (canceled)

7. A composite lay-up mold production system (1) according claim 1, wherein the outer coating (4) is obtained by almost entirely coating the nickel and/or nickel alloy on the said inner coating (3) by electroless metallization or electrolytic electroforming method.

Description

[0021] The composite lay-up mold production system realized to achieve the object of the present invention is illustrated in the attached drawings, in which:

[0022] FIG. 1 is a schematic view of the composite lay-up mold production system.

[0023] FIG. 2 is a sectional view of the composite lay-up mold, the fabric and the mandrel.

[0024] FIG. 3 is a schematic view of the composite lay-up mold.

[0025] All the parts illustrated in figures are individually assigned a reference numeral and the corresponding terms of these numbers are listed below: [0026] 1. Composite may-up mold production system [0027] 2. Mandrel [0028] 3. Inner coating [0029] 4. Outer coating [0030] 5. Composite lay-up mold [0031] k. Fabric [0032] p. Part

[0033] The composite lay-up mold production system (1) comprises a mandrel (2) suitable for use in electrodeposition process by electrolysis; at least one inner coating (3) which is metallized on an outer surface of the mandrel (2) by electrolysis method such that it almost entirely covers the outer surface thereof, allowing electrical conductivity to be created on the surface; at least one outer coating (4) which is obtained almost entirely by an electrolytic and/or electroless metal coating on the inner coating (3) (FIG. 1).

[0034] The composite lay-up mold production system (1) of the invention comprises a composite lay-up mold (5) which allows a fabric (k) laid thereon to be pre-formed, consists of the inner coating (3) and the outer coating (4), and is obtained by the removal of the inner coating (3) and the outer coating (4) from the mandrel (2) almost entirely as a single piece (FIG. 3).

[0035] In order for the composite part (p) to take the shape predetermined by the user, there are provided a mandrel (2) that fits into that shape and whose surface conductivity is suitable for metallization (electroplating) process, at least one inner coating (3) which is obtained by coating metal ions predetermined by the user, by the electroplating process, from a solution in order to provide surface conductivity on the surface of the mandrel (2) such that they almost entirely cover the outer surface of the mandrel (2), at least one outer coating (4) which takes the shape of the inner coating (3) by being coated on an outer surface of the inner coating (3) by electrolytic and/or electroless metallization method such that It almost entirely covers the surface thereof (FIG. 1).

[0036] A composite lay-up mold (5) production is provided, which is obtained by removal of the inner coating (3) and the outer coating (4) from the surface of the mandrel (2) as one piece, consists of both the inner coating (3) and the outer coating (4), and preforms the fabric (k) when the fabric (k) is laid thereon. In this way, molds resistant to expansion with high pressure and temperature can be produced with an effective and easy method (FIG. 3).

[0037] In an embodiment of the invention, the composite lay-up mold production system (1) comprises a part (p) obtained by curing the fabric (k), which has been pre-formed by being laid on the composite laying mold (5), under temperature and pressure. in order to form the parts (p) made of composite material, the fabric (k) is pre-formed by laying it on the composite laying mold (5). The pre-formed fiber fabrics (k) are cured in a furnace to form the final form of the piece (p). In this way, part (p) made of a composite material can be produced effectively (FIG. 2).

[0038] In an embodiment of the invention, the composite lay-up mold production system (1) comprises a composite lay-up mold (5) used in a hand lay-up process for prepreg fabrics (k). In the production of the part (p) made of composite material, its fabrics (k) are produced by hand lay-up method. Thus, more efficient production of composite parts (p) is provided.

[0039] In an embodiment of the invention, the composite lay-up mold production system (1) comprises a mandrel (2) which is obtained from high-density polyurethane foam with a pore diameter varying between 1-2 m, and has a form-fitting structure with the part (p). The mandrel (2) with high density, where the diameters of the pores vary between 1-2 m, is used for the production of composite lay-up mold (5). Thus, it can be used as a cost-effective and robust substrate with higher electrical conductivity for electrolysis process, for which the conductivity can be increased.

[0040] In an embodiment of the invention, the composite lay-up mold production system (1) comprises a mandrel (2) made of high-density polyurethane foam material with a suitable structure to increase the conductivity by doping with black carbon and/or different derivatives of carbon, CNT (carbon nano tube) or graphene. In addition to having a high-density structure, a mandrel (2) which is made suitable for surface metal coating with electrolysis by increasing its conductivity by doping with carbon derivatives such as black carbon, CNT (carbon nanotube) or graphene is used. Thus, it is easily subjected to metal coating process by electrolysis and an efficient composite lay-up mold (5) is produced.

[0041] In an embodiment of the invention, the composite lay-up mold production system (1) comprises a mandrel (2) with a conductivity value above a threshold value that allows the inner coating (3) to be coated on the surface of the mandrel (2) with electrolysis. A mandrel (2) which has a surface with an electrical conductivity required to form the inner coating (3) is used. In this way, the inner coating (3) can be coated on the surface of the mandrel (2) in a cost-effective manner by providing an effective coating with electrolysis.

[0042] In an embodiment of the invention, the composite lay-up mold production system (1) comprises a mandrel (2) on which surface cleaning can be performed with alkaline solutions, wherein a porous structure can be formed on the surface of the mandrel (2) by surface treatment with sulfuric acid. The porous structure (surface roughness) required for the formation of the inner coating (3) on the surface of the mandrel (2) is formed on purpose by the surface treatment using sulfuric acid after the cleaning process with alkali solutions on the surface of the mandrel (2). Thus, the inner coating (3) can be adsorbed on the surface of the mandrel (2) in a more cost-effective manner.

[0043] In an embodiment of the invention, the composite lay-up mold production system (1) comprises an inner coating (3) which is coated on the mandrel (2) surface such that it provides an increase in the surface conductivity thereof, wherein the mandrel (2) immersed in a solution containing Sn.sup.+2 ions is sensitized by deposition of Sn.sup.+2 ions to the pores on the surface on the mandrel (2), and the mandrel (2), whose surface has been sensitized, is immersed in an activation solution containing Pd.sup.+2 ions such that Sn.sup.+2 ions in the pores are oxidized to Sn.sup.+4 ions and Pd.sup.+2 ions are reduced to Pd atom. After the sensitization process of the mandrel (2) by exposing it to a solution containing Sn.sup.+2 ions and filling the pores opened on its surface, the mandrel (2) is immersed in an activation solution containing Pd.sup.+2 ions, Sn.sup.+2 ions in the pores are oxidized to Sn.sup.+4 ions and the Pd.sup.+2 ions are reduced to Pd atom, so that the surface of the mandrel (2) is coated by the inner coating (3) which increases the surface conductivity. Thus, the outer coating (4), which is a part of the coating composite lay-up mold (5), will be allowed to take the shape of the mandrel (2).

[0044] In an embodiment of the invention, the composite lay-up mold production system (1) comprises an outer coating (4) which is obtained by almost entirely coating the nickel and/or nickel alloy on the inner coating (3) by electroless metallization and/or electrolytic electroforming method, The outer coating (4) is obtained by coating the nickel and/or nickei alloys, which are required to obtain the composite lay-up mold (5) and predetermined by the user, on the inner coating (3) with an electroless and/or electrolytic method, Thus, the composite lay-up mold (5) is effectively produced.