Patent ID: 11179901

Abstract:
A method and an apparatus for molding composite articles are disclosed. The method generally involves the saturation of reinforcing fibers (e.g. glass fibers, carbon fibers, etc.) with a matrix (e.g. resin, epoxy, cyanate ester, vinyl ester, polyester, etc.) in/on a mold using a conventional resin transfer molding (“RTM”) process (e.g. “RTM-light”) or a vacuum assisted resin transfer molding (“VARTM”) process (e.g. advanced VARTM or “A-VARTM”), and, once saturation is completed, the vibration of the matrix-infused fibers using controlled ultrasonic sound waves transmitted through the mold. By vibrating the matrix-infused fibers with the ultrasonic sound waves, the method and apparatus allow voids present between fibers to be closed and localized pockets of gases to be dislodged and degassed, and also allow the fibers to compact, thereby producing composite articles with reduced porosity and higher compaction.