Source: http://www.google.es/patents/US5656231?dq=flatulence
Timestamp: 2013-12-12 04:28:39
Document Index: 629241362

Matched Legal Cases: ['art.\n10', 'art.\n18', 'art 38', 'art 38', 'art 38', 'art 38', 'art 38', 'art 38', 'art 38', 'art 38', 'art 38', 'art 38', 'art 38', 'art 38', 'art 38', 'art 38', 'art 62', 'art 62', 'art 62', 'art 62', 'art 62', 'art 62', 'art 62', 'art 62', 'art 62', 'art 62', 'art 62', 'art 62', 'art 62', 'art 62', 'art 62', 'art 62', 'art 62', 'art 62', 'art 96', 'art 96', 'art 96', 'art 96', 'art 96', 'art 86', 'art 96', 'art 96', 'art 96', 'art 120', 'art 120', 'art 132', 'art 120', 'art 120', 'art 120', 'art 120', 'art 120', 'art 120']

Patente US5656231 - Method of forming advanced cured resin composite parts - Google PatentesB�squeda Im�genes Maps Play YouTube Noticias Gmail Drive M�s » B�squeda avanzada de patentes | Iniciar sesi�n B�squeda avanzada de patentesPatentesA unique composite material impregnated with a heat curable resin comprising a layer of conductive fibers and one or more resin carrying layers is utilized to reinforce utility poles by wrapping the material around a portion of the utility pole and causing a current to flow through the conductive fibers...http://www.google.es/patents/US5656231?utm_source=gb-gplus-sharePatente US5656231 - Method of forming advanced cured resin composite parts N�mero de publicaci�nUS5656231 ATipo de publicaci�nConcesi�n N�mero de solicitudUS 08/466,349 Fecha de publicaci�n12 Ago 1997 Fecha de presentaci�n6 Jun 1995 Fecha de prioridad8 Ago 1994TarifaPagadasTambi�n publicado comoUS5591291, US5648137, WO1996005386A1 N�mero de publicaci�n08466349, 466349, US 5656231 A, US 5656231A, US-A-5656231, US5656231 A, US5656231A InventoresRichard D. Blackmore Cesionario originalBlackmore; Richard D.Exportar citaBiBTeX, EndNote, RefManCitas de patentes (53), Otras citas (10), Citada por (24), Clasificaciones (71), Eventos legales (18) Enlaces externos: USPTO, Cesi�n de USPTO, EspacenetMethod of forming advanced cured resin composite partsUS 5656231 A Resumen A unique composite material impregnated with a heat curable resin comprising a layer of conductive fibers and one or more resin carrying layers is utilized to reinforce utility poles by wrapping the material around a portion of the utility pole and causing a current to flow through the conductive fibers to resistively heat the material to the resin. The composite material can also be incorporated into molds to produce cured composite parts. The composite material is also used in the construction of large parts without the need for huge, expensive molds. The conductive fibers in composite parts are oriented in a manner to ensure that the entire part is thoroughly heated during the curing process.
What I claim is: 1. A method of forming a cured composite part comprising the steps of:providing a mold for heat treating materials, said mold having a first mold portion and a second mold portion, said first mold portion having a layer of electrically conductive fibers and said second mold portion having a layer of electrically conductive fibers; placing a part formed from a composite material impregnated with a heat curable resin in said mold, said composite material including a layer of electrically conductive fibers; clamping said composite material between said first and second mold portions; and causing an electric current to flow through said conductive fibers in said first mold portion to resistively heat said first mold portion, causing an electric current to flow through said conductive fibers in said second mold portion to resistively heat said second mold portion, and causing an electric current to flow through said conductive fibers in said composite material to resistively heat said composite material, wherein said currents being of sufficient magnitude to resistively heat said mold and said composite to cure said resin. 2. The method of claim 1 wherein said currents flowing through said conductive fibers in said first and second mold portions resistively heat said first and second mold portions to a temperature such that thermal expansion of said first and second mold portions from said resistive heat substantially corresponds to thermal expansion of said composite material from resistive heat from said current flowing in said conductive fibers in said composite material.
3. The method of claim 1 further comprising the steps of:providing a source of electrical power having a first electrically conductive lead and a second electrically conductive lead; and connecting said first lead to a first end of said first mold portion so that said first lead is in electrical contact with said conductive fibers in said first mold portion and connecting said second lead to a second end of said first mold portion so that said second lead is in electrical contact with said conductive fibers in said first mold portion, wherein said source is utilized to cause an electric current to flow through said conductive fibers in said first mold portion. 4. The method of claim 1 further comprising the steps of:providing a conductor connected at a first end of said first mold portion to said conductive fibers in said first mold portion and at a first end of said second mold portion to said conductive fibers in said second mold portion; providing a source of electrical power having a first electrically conductive lead and a second electrically conductive lead; and connecting said first lead to a second end of said first mold portion so that said first lead is in electrical contact with said conductive fibers in said first mold portion and connecting said second lead to a second end of said second mold portion so that said second lead is in electrical contact with said conductive fibers in said second mold portion, wherein said source is utilized to cause an electric current to flow through said conductive fibers in said first and second mold portions. 5. The method of claim 1 wherein said conductive fibers in said composite material are graphite.
6. The method of claim 1 wherein said conductive fibers in said composite material are conductive polymer-coated polyester.
7. The method of claim 1 wherein said conductive fibers in said first and second mold portions are graphite.
8. The method of claim 1 wherein said conductive fibers in said first and second mold portions are conductive polymer-coated polyester.
9. The method of claim 1 wherein said mold is a cured composite part.
10. The method of claim 1 wherein said placing step includes impregnating said composite material with a resin comprising polyester.
11. The method of claim 1 wherein said placing step includes impregnating said composite material with a resin comprising vinyl ester.
12. The method of claim 1 wherein said placing step includes impregnating said composite material with a resin comprising cyanate ester.
13. The method of claim 1 wherein said placing step includes impregnating said composite material with a resin comprising polyurethane.
14. The method of claim 1 wherein said placing step includes impregnating said composite material with a resin comprising an electrically conductive polymer.
15. A method of forming a cured composite part comprising the steps of:providing a mold for heat treating materials, said mold having a first mold portion and a second mold portion, said first mold portion having a layer of electrically conductive fibers and said second mold portion having a layer of electrically conductive fibers; placing a part formed from a composite material in said mold, said composite material including a layer of electrically conductive fibers; clamping said composite material between said first and second mold portions; injecting a heat curable resin into said composite material; and causing an electric current to flow through said conductive fibers in said first mold portion to resistively heat said first mold portion, causing an electric current to flow through said conductive fibers in said second mold portion to resistively heat said second mold portion, and causing an electric current to flow through said conductive fibers in said composite material to resistively heat said composite material, wherein said currents being of sufficient magnitude to resistively heat said mold and said composite to cure said resin. 16. The method of claim 15 wherein said currents flowing through said conductive fibers in said first and second mold portions resistively heat said first and second mold portions to a temperature such that thermal expansion of said first and second mold portions from said resistive heat substantially corresponds to thermal expansion of said composite material from resistive heat from said current flowing in said conductive fibers in said composite material.
17. The method of claim 15 wherein said mold is a cured composite part.
18. A method of forming a cured composite part comprising the steps of:providing a mold for heat treating materials, said mold having a first mold portion and a second mold portion, said first mold portion having a plurality of zones, each zone having a layer of electrically conductive fibers and said second mold portion having a plurality of zones, each zone having a layer of electrically conductive fibers; placing a part formed from a composite material impregnated with a heat curable resin in said mold, said composite material including a layer of electrically conductive fibers; clamping said composite material between said first and second mold portions; causing electric currents to flow through said conductive fibers in said zones in said first mold portion to resistively heat said first mold portion, causing electric currents to flow through said conductive fibers in said zones in said second mold portion to resistively heat said second mold portion, and causing an electric current to flow through said conductive fibers in said composite material to resistively heat said composite material; monitoring a temperature of each said zone in said first and second mold portion; and providing a controller to separately control each said electric current flowing through each said zone. 19. The method of claim 18 wherein said placing step includes impregnating said composite material with a resin comprising polyester.
20. The method of claim 18 wherein said placing step includes impregnating said composite material with a resin comprising vinyl ester.
21. The method of claim 18 wherein said placing step includes impregnating said composite material with a resin comprising cyanate ester.
22. The method of claim 18 wherein said placing step includes impregnating said composite material with a resin comprising polyurethane.
23. The method of claim 18 wherein said placing step includes impregnating said composite material with a resin comprising an electrically conductive polymer.
RELATED APPLICATION This is a continuation-in-part application under 37 C.F.R. pending prior application Ser. No. 08/287,120 filed Aug. 8, 1994 of Richard Blackmore for "Advanced Cured Resin Composite Parts and Method of Forming Such Parts."
TECHNICAL FIELD The present invention relates generally to advanced composite material parts impregnated with a heat curable resin system and including a conductive layer integrally consolidated into such composite material prior to curing of the resin, and to a method for producing such parts.
BACKGROUND OF THE INVENTION The technology of producing composite material components or parts, which include a heat curable resin system, is polarized. At one end of the scale, there exists low cost, low quality "engineered" composites. While at the other end, high quality "advanced" composite materials are extremely costly to produce. Such advanced composite materials are highly desirable for use in many applications due to their high strength, low weight, and other beneficial physical properties. Accordingly, a genuine need exists for methods of forming advanced composite material parts at a lower cost.
The composite material 10 is formed having one or more resin carrying layers and at least one layer of conductive material. The conductive layer is formed as an integral component of the composite material 10 prior to the curing operation described below. Preferably the conductive layer is in a fabric form and comprises a plurality of generally parallel, electrically conductive fibers. The composite material 10 is previously impregnated with a heat curable resin system. Preferred forms of the composite material and resin systems are described in greater detail below. The composite material 10 is approximately seven feet in length and approximately seven feet wide (for utility poles which have a typical circumference of approximately six feet). The composite material 10 includes a first contact 14 and a second contact 15 at either end of the material. The contacts 14, 15 may be copper bands or other conductive materials, and are in electrical contact with exposed portions of the conductive layer of the composite material. Alternatively, the contacts 14, 15 can be added to the composite material 10 after it is secured to the pole 12. The composite material 10 is wrapped around the four foot exposed portion of the pole 12 as well as approximately three feet of the pole immediately above ground level. The composite material 10 is then secured in place around the pole 12. Preferably, the composite material is secured by stapling it to the pole; however other means, such as, metal bands or plastic ties can be used.
To cure the resin, a power generator (not shown) having a first lead 24 and a second lead 26 is provided. As shown in FIG. 3, the first lead 24 is connected to the first contact 14 and the second lead 26 is connected to the second contact 15 to create an electric circuit. Depending on the size of the bladder, the leads 24, 26 from the power generator may have to be connected to the contacts 14, 15 before the bladder is put in place. The generator is then turned on to cause a current to flow through the conductive layer of the composite material 10 to resistively heat the composite material 10 for a period of 30-90 minutes. A sufficient current is applied to the conductive layer of the composite material 10 in order to heat the composite material 10 to a temperature to cure the impregnated resin. Although either alternating current or direct current may be used, it has been found that direct current provides a more even resistive heating of the composite material.
After the curing cycle, the bladder 16 and the leads 24, 26 can be removed and the evacuated exposed portion of the pole can be filled in.
FIG. 7 discloses a cross-section of a mold 30 in an open position having a first mold half or portion 32, and a second mold half or portion 34. The mold halves 32, 34 are supported and guided by posts 36; however a clam shell type mold, or other known configurations can be used. The mold 30 is configured to hold and compress a part 38 formed from a composite material which includes at least one layer of conductive fibers. The preferred forms of the composite material are described in more detail below.
Similar to the composite material part 38, each of the mold halves 32, 34 include at least one layer of conductive fibers 44, 46. The conductive layers 44, 46 in the mold halves 32, 34, along with the conductive layer in the composite material part 38 are utilized to provide resistive heating during the curing process.
Once the composite material 38 is placed in the mold 30, the mold halves 32, 34 are clamped shut as shown in FIG. 8. At this point resin would be injected into the composite material 38 if it was not preimpregnated with the resin. A power generator 54 (not shown) is used to supply Current to the conductive layers 44, 46 in the mold halves 32, 34 and to the conductive layer in the composite material 38. The composite material part 38 includes exposed sections 40, 42 of the conductive fibers in the part 38 which are placed in line with electrical contacts 52, 54 in the mold in order to allow for electrical contact with the power generator 54. Preferably, the mold 30 includes connections so that the conductive layers 44, 46 in the mold 30 and the conductive layer in the composite material 38, are placed in series. Alternatively, separate connections can be made to these layers. This is important when it is necessary to supply different currents to the layers as described below.
The currents flowing through the conductive layers 44, 46 of the mold 30 and the composite material resistively heat the mold and the composite material in order to cure the resin in the material. Once cured, the part may be removed from the mold.
In the preferred form of this embodiment of the invention, the mold 30 is constructed from the same or similar material as the composite material part 38. This ensures that the thermal characteristics of the mold 30 match those of the composite material part 38 being cured. This helps ensure a more uniform part production with less rejects. If the thermal characteristics of the mold 30 match that of the part 38 (i.e., have approximately the same coefficient of thermal expansion), then during the curing process where the mold 30 and part 38 are resistively heated, the mold will stay in close contact with the part 38 throughout the process since it will expand and contract at the same rate as the part 38. This ensures that a uniform pressure is applied to the part 38 throughout the curing cycle, and that the part will not pull away from the mold 30 or warp. Such warpage may happen in those cases where the mold does not expand and contract at the same rate as the part 38. By providing conductive layers 44, 46 in the mold, this helps ensure that the heat distribution in the mold 30 is similar to that of the part 38.
The mold halves 32, 34 can be further controlled by providing a plurality of discrete sections or zones of conductive fibers. Each zone can be monitored and separately controlled to achieve a particular temperature. In this manner, the mold halves 32, 34 can be more readily controlled to match the characteristics of the composite part to enhance the cure. This may advantageous for composite parts having non-uniform shapes, or having portions constructed from different materials. In such instances it may be necessary increase or otherwise vary the temperature of different portions of the mold halves 32, 34.
FIG. 9 discloses an open mold 60 having a lower portion 68 configured to support a composite material part 62 in the shape of a boat hull. The mold includes electrical contacts 64, 66 built into the mold 60 at opposite ends.
A composite material part 62 which includes a layer of conductive fibers is preformed into the boat hull shape and impregnated with a heat curable resin having a high cure temperature (e.g., 125 The conductive fibers are integrally consolidated into the composite material. The composite material part 62 is placed in the lower portion 68 of the mold 60. The composite material part 62 includes two exposed portions 70, 72 of the conductive layer which coincide with the contacts 64, 66 in the mold 60.
A top portion 74 of the mold 60 which supports a flexible membrane 76 is placed over the composite material part 62. A vacuum is created by a pump (not shown) between the membrane and the composite material part 62 through ports (not shown) in the mold 60. The vacuum allows atmospheric pressure to compress and hold the part 62 during the curing operation. To cure the part, a power generator (not shown) having first and a second lead 78, 80 is connect to the mold 60 so that it is in electrical contact with the conductive fibers in the composite material part 62. The power generator is used to cause a current to flow through the conductive fibers of the composite material part 62 sufficient to resistively heat the part 62 to cure the resin. After the cure cycle is complete, the vacuum is released and the finished part is removed from the mold.
In a second embodiment similar to the matched mold operations described above, an open mold 82, shown in cross-section in FIGS. 10-11 may include a layer of conductive fibers 85 and is preferably formed from the same material as a composite material part 62' to be cured. The open mold 82 also includes electrical contacts 84, 86. The composite material part 62' includes a layer of conductive fibers and is impregnated with a heat curable resin. The conductive fibers in the composite material part 62' are exposed at either end to coincide with the contacts 84, 86. A flexible membrane 88 is placed over the part 62' and a vacuum is effected between the part 62' and the membrane 88.
A power generator (not shown) is connected by leads 90, 92 to the mold. The generator causes a current to flow through the conductive layer 84 of the mold 82 and the conductive fibers of the composite material part 62' to resistively heat the part 62' to cure the resin. As in the matched molds described above, the open mold 82 will thermally expand and contract at the same rate as the composite material part to ensure that close contact is maintained between the mold 82 and the part 62' during the cure cycle.
A composite material part 96, shown in FIG. 12, is preformed into tubular shape and is position over an expandable mandrel or bladder 98, shown in FIG. 13. The composite material part 96 includes a layer of conductive fibers 100 which are integrally consolidated as part of the composite material. The conductive fibers 100 are exposed at opposite ends 99, 101 of the part 96, and the composite material is impregnated with a heat curable resin system.
The mandrel 98 and part 96 are then placed in an outer cylindrical forming shell 102 shown in FIG. 14. The shell includes a first portion 104 and a second portion 106 which are secured by clasps 108. The mandrel 98 is then inflated through a hose 110, to compress the composite material between the mandrel 98 and the shell 102. Electrical contact bands 112, 114 of copper, or other suitable conducting material, are connected to the exposed portions 99, 101 of the conductive fibers in the composite material part 96.
A power generator (not shown) is connected to the bands 112, 114 by a first and second lead 116, 118 to form an electric circuit. The generator is utilized to cause an electric current to flow through the conductive fibers 100 of the composite material part 86 to resistively heat the part to cure the impregnated resin. After the cure cycle, the part 96 is removed from the shell 98 and the mandrel 98 is collapsed and removed from the interior of the part 96. If desired, the part 96 can be injected with a hardening foam, such as an epoxy or urethane or polyester foam.
This principle can be illustrated by examining a composite material part 120 having a parallelogram shape as shown in FIG. 17, which runs from one side 121 of a rectangular piece of conductive fabric 122 to the other 123. Electrical contacts 124, 126 are connected to opposing parallel sides 128, 130 of the part 120. The opposing sides 128, 130 are smaller than the remaining two sides of the part 132, 134, and thus smaller contacts are needed. In this situation, the cross-machine fibers 136 are acting as conducting fibers. However, if the cross-machine fibers 136 are perpendicular to the machine fibers 138 of the fabric 122, the effective conductive path through the part 120 is limited, which results in an ineffective cure. Although it is possible to place electrical contacts along the remaining sides 132, 134, of the part 120, which would provide a conductive path throughout the entire fabric using the machine direction fibers 138, which would be the conducting fibers, the larger size of the contacts would require greater power to effectively resistively heat the part 120.
One way to obtain an effective cure with less power consumption is to orient the fabric 122 so that the crossmachine fibers 136 are parallel to the remaining sides 132, 134 of the part 120, as shown in FIG. 18. This provides a conductive path throughout the part 120 while using the contacts 124, 126. However, this method requires a wider piece of fabric 140 (shown in phantom) in order to cover the entire part 120. An alternative method, which would not require a larger sized fabric, is too create a piece of fabric 142 having conducting fibers oriented at an oblique angle with respect to machine direction fibers such as that shown in FIG. 19. Various combinations of these techniques can be used to minimize the number and size of electrical contacts necessary to provide for the most effective conductive path for parts of even more complex shapes.
FIG. 20 discloses an exploded view of a composite material 150 having a first resin carrying layer 152, a second layer 154 of a conductive material, and a third resin carrying layer 156. The conductive second layer 154 is sandwiched between the first and third resin carrying layers 152, 156.
A unique preferred form of the conductive layer can be formed by combining bundles of graphite fiber and bundles of conductive polymer coated fibers into a single fabric. For instance, five bundles of graphite can be combined with five bundles of polymer coated glass or nylon, to create a fabric having ten bundles per inch. The polymer is preferably polypyrrole or polyaniline which have a resistance of approximately 125-175 ohms.
Such conductive layers are less expensive than pure graphite weaves, and require less current to resistively heat due to the higher resistance of the polymer coated fibers than that of the graphite.
Improved strength in the cured composite part is achieved in the unique structure of the composite materials 160 and 160' disclosed in FIGS. 21 and 22. In the embodiments disclosed in FIGS. 21 and 22, the third resin carrying layers 166 and 166' act as a bulker layer which separates the second 164, 164' and fourth 168, 168' conductive layers. Since the conductive layer is formed from a high performance fabric such as woven graphite, it functions structurally as a load bearing layer in the composite material 160, 160' Separating the conductive layers has been found to increase the overall strength of the composite above that of a composite material where the two conductive layers are in close contact with each other. Accordingly, this bulker layer can be formed with relatively inexpensive materials while increasing the strength of the finished composite part.
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IncFluorocarbon repair bladderWO2001087571A2 *5 Feb 200122 Nov 2001Ihc Rehabilitation ProductsComposite structures and method for their manufactureWO2002092332A1 *10 May 200221 Nov 2002Hardcore CompositesApparatus and method for use in molding a composite structure* Citada por examinadorClasificaciones Clasificaci�n de EE.UU.264/408, 264/258, 264/478, 264/496, 264/450, 264/404, 264/453 Clasificaci�n internacionalB29C70/86, B29C33/06, B29C33/38, B29C33/48, B29C65/34, B29C33/02, B29C35/02, E04G23/02, B29C73/00, B29C65/50, B29C65/00, B29C70/88, E04H12/22, B29C41/50, E04C5/07, B29C41/20 Clasificaci�n cooperativaB29C65/3488, B29C65/3476, B29C65/3492, B29C65/3468, Y10S428/902, B29C66/81455, B29C35/02, B29C70/882, B29C73/00, B29L2031/766, B29C33/38, E04G23/0218, B29C35/0272, B29C41/20, E04C5/07, B29C2035/0211, B29C65/3436, B29C2037/903, B29C66/1122, E04H12/2292, B29C70/86, B29C33/06, B29C33/02, B29C41/50, B29C33/48, B29C70/34, B29C66/45, B29C65/344, B29C66/4329, B29C66/4322, B29C66/81471, B29C66/494 Clasificaci�n europeaB29C66/81455, B29C66/1142, B29C66/5221, B29C66/1122, B29C65/50B, B29C33/06, B29C41/50, B29C70/88A, E04G23/02C, E04H12/22E, B29C41/20, B29C70/86, B29C35/02L, B29C35/02, B29C65/34, E04C5/07Eventos legales FechaC�digoEventoDescripci�n25 Jul 2013ASAssignmentOwner name: ENERGY MAINTENANCE SERVICES GROUP I, LLC, TEXASEffective date: 20130703Free format text: MERGER;ASSIGNOR:ENERGY MAINTENANCE SERVICES GROUP I, INC.;REEL/FRAME:030875/0606Owner name: EMS USA HOLDINGS I INC., TEXASFree format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:ENERGY MAINTENANCE SERVICES GROUP I, LLC;REEL/FRAME:030879/09866 Ene 2012ASAssignmentOwner name: ENERGY MAINTENANCE SERVICES GROUP I, INC., TEXASFree format text: CONVERSION FROM A LIMITED LIABILITY COMPANY TO A CORPORATION;ASSIGNOR:ENERGY MAINTENANCE SERVICES GROUP I, LLC;REEL/FRAME:027491/0285Effective date: 2011123028 Dic 2011ASAssignmentEffective date: 20111227Owner name: VICTORY PARK MANAGEMENT, LLC, AS AGENT, ILLINOISFree 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