Title of Invention

A MOLD ASSEMBLY AND A METHOD FOR GENERATING A COMPOSITE PART

Abstract The present invention generally relates to a mold assembly (32, 34) and a method of using the mold for the manu- facture of composite parts which, more particularly, are generated from a strengthener in a generally solid phase and a matrix in a generally liquid phase. Various types of molds and processes may be used in order to impregnate a strengthener with a matrix such that a composite part may be manufactured, but the efficiency rate and the duration of the manufacturing process significantly vanes depending on the chosen type of mold and process. The present invention relates to a mold assembly and to the manufacture of composites by using the mold assembly which includes the injection of the matrix in the mold assembly containing the strengthener and a deformable member (36) which favors the impregnation of the matrix toward the strengthener.
Full Text WO 2005/000566 PCT/CA2004/000959
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TITLE OF THE INVENTION
MANUFACTURE OF COMPOSITES BY A FLEXIBLE INJECTION PROCESS
USING A DOUBLE OR MULTIPLE CAVITY MOLD
FIELD OF THE INVENTION
[0001] The present invention generally relates to the manufacture of
composite parts. More specifically, the present invention is concerned with the
manufacture of a composite part by injection of a liquid phase throughout a
porous solid phase.
BACKGROUND OF THE INVENTION
[0002] Composite materials are generally considered engineering
materials made from two or more components. One component is often a fiber
or porous solid phase, generally called the strengthened which gives the
material its tensile strength, while another component is often a resin or liquid
phase, generally called the matrix, which binds the strengthener together and
renders the composite material generally either stiff and rigid or deformable as
a whole.
[0003] Several processes used in the. manufacture of composite
parts consist of impregnating the strengthener with the matrix, which may be a
polymer, (a resin) or any material that is liquid at the injection temperature.
Variants of this family of processes are now grouped, under the generic term
LGM or Liquid Composite Molding. Although they are used principally for the
manufacture of polymer matrix composite parts, LCM processes are also
encountered in biomedical and electronics applications, for example when

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injecting a polymer to insulate microelectronic circuits. A molten metal may be
injected instead of a polymer resin in order to manufacture metal matrix
composite parts.
[0004] Polymer matrix composite manufacturing processes may be.
separated into several categories:
[0005] Contact molding process
[0006] This manual method generally uses a half-mold on which the
dry strengthener is set in layers that are impregnated by hand.
[0007] Autoclave process
[0008] The composite part is generally manufactured by hand from
pre-impregnated strengthened and then cured in an autoplave. This method is
widely used in aeronautics, most notably in the military sector. However, its
cost remains generally high.
[0009] RTM (Resin Transfer Molding) process
[0010] The matrix in its liquid state is generally injected throughout a
strengthener confined in a rigid mold. Liquid injection in the RTM process may
be carried out at ambient temperature or at a higher temperature by heating
either the injected liquid, the mold or both.
[0011 ] VARTM (Vacuum Assisted Resin Transfer Molding) process
[0012] A vacuum is generated inside the mold in order to facilitate

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and accelerate matrix injection.
[0013] CRTM (Compression Resin Transfer Molding) process
[0014] Also called injection-compression, the CRTM process
generally consists of opening slightly the gap between the mold halves during
injection to accelerate the liquid flow, after which the part is consolidated and
sized to specification by lowering the press on the molds or one of the mold
halves on the other.
[0015] VARI (Vacuum Assisted Resin Infusion) processes
[0016] The strehgthener is generally arranged beneath a plastic film
or elastic membrane, creating a compartment which may be placed under
vacuum. The liquid then infuses into the strengthener by gravity.
[0017] RTM Light process
[0018] This variant combines the advantages of deforming one
boundary of the moid, as in the VARI process, with an imposed injection
pressure, as in the RTM process. The mold consists of one or two thin metal or
composite shells, which may be deformed under the pressure of injection. A
first vacuum usually ensures closure of the mold, while a second vacuum is
generated inside the cavity to accelerate injection.
[0019] Other variants
[0020] Numerous other variants of the LCM processes exist, which
may be associated with one or another of the previously described main

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categories. For example, the VEC injection process uses reservoirs containing
a non-compressible fluid to strengthen the walls of a mold that are not in
contact with the part. Preferential flow channels may also be created by various
means in an outer layer of the strengthener (SCRIMP process), in one of the
mold walls or inside the cavity, in order to facilitate liquid infusion or injection.
[0021] The quality of parts manufactured by contact molding is
generally lower on average than that of injected parts. Labor costs are
considerable as well, since each layer of the strengthener must be precisely
positioned in the cavity and the laminate impregnated by hand. During
impregnation by the liquid, air bubbles are often entrapped . inside the
composite part. This constitutes the principal problem with contact molding and
explains notably the large variations observed in part weight. A second
disadvantage stems from the difficulty of ensuring constant part thickness and
uniform fiber content, two critical parameters that govern the quality and
mechanical properties of the composite part. Finally, another problem arises
from increasingly strict government regulations concerning toxic gases or
vapors generated during open moid manufacturing.
[0022] LCM processes based on the use of closed molds
significantly eliminate most gaseous emissions during manufacturing.
Conventional liquid injection molding is done using two rigid half-molds: the
base generally designates the bottom portion of the mold, which remains
immobile and the punch designates the top portion, which is raised in order to
open the mold and free the part at the end of the manufacturing cycle. Between
these two half-molds lies a cavity in which the strengthener is arranged and into
which the injection occurs.
[0023] The RTM process and its variants VARTM and CRTM are
generally appropriate for the manufacture of structural composite parts, but

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constant thickness remains difficult to achieve because of the non uniform
shrinkage of the resirt during the cure. It is not always easy to eliminate porosity
completely in injected parts, even by creating vacuum in the cavity before
injection. Finally, the biggest difficulty is associated with the injection time,
which is generally too long for strengtheners with high fiber content (i.e., more
than 50%).
[0024] Overall, average surface appearance, low geometrical
precision of the parts and limits regarding fiber content and injection time all
reduce the range of applications of RTM process and its derived processes
such as heated RTM, VARTM and injection-compression (CRTM). One
constraint peculiar to CRTM process should also be mentioned. In general, the
punch closes along a vertical axis, which results in practically no compression
of the strengthener in the vertical zones of the cavity, while maximal pressure is
exerted in the horizontal zones. This problem, in addition to difficulties inherent
to the complexity of the process and risks of air entrapment during the
compression phase, significantly limit the applications of CRTM process. It
should be noted that compression of one half-mold over the other may also be
performed by zones, but this significantly complicates the manufacturing of the
mold.
[0025] Recently, new vacuum impregnation processes (VARI) have
been introduced, which present the advantage of not requiring a cover mold. In
these so-called liquid aspiration infusion processes, the strengthener is stiil
arranged in the mold cavities, but' is then covered with an impermeable
membrane sealed to the outer edges of the mold. The air inside the cavity
formed between the membrane and the mold may then be evacuated using a
vacuum pump. Atmospheric pressure then compacts the strengthener, while
the liquid flows from an external source into the strengthener-filled cavity under
vacuum. In this type of VARI process, liquid infusion into the strengthener is

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carried out under vacuum at low flow rate under the single effect of static
pressure due to gravity. The inclusion of air bubbles is thus eliminated, solving
one of the problems encountered in other injection variants. However, the effect
of gravity generally introduces non uniformity into the impregnation of the
strengthener for large parts. In spite of the apparent simplicity of VARi
processes, problems persist because the flow of the viscous matrix, such as for
example resin, is difficult through strengtheners of low permeability. The fiber
contents and dimensional accuracy of parts infused by VARI process are
generally lower than the levels that may be accommodated by RTM process.
Since resistance to resin penetration increases with the distance to be crossed,
portions of certain parts may remain dry while excesses of resin accumulate in
other zones.
[0026] In order to resolve these problems, variants of these
processes have been recently developed, which artificially increase local
permeabilities in the strengthener and thus decrease filling time. These include
resin-dispersing permeable felts on one surface of the strengthener, networks
of tubes to distribute the liquid matrix flow throughout the cavity, preferential
flow channels or grooves incorporated into the surface of the mold and so on.
All of these methods pose particular problems. The use of felt leads to
increased waste of material, which is incompatible with mass production.
Networks of tubes and flow channels generate practical development
difficulties, which can be overcome only at the expense of generally costly trial
periods. Finally, infusion still remains excessively slow compared to injection.
The pressure gradient driving liquid penetration is much greater in an injection
process than the infusion gradient which cannot exceed ambient atmospheric
pressure minus the residual pressure inside the cavity under vacuum.

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[0026.1] As another example, Wassenberg in DE199,26,896 teaches
about a moi impregnation apparatus including a two-part moid configured and
sized as to be sealingly mounted to one another with a flexible membrane in
between. One of the molds receives the strengthener and the other one is
provided with a series of channel for receiving the membrane when vacuum is
provided in the apparatus, generating thereby less restriction during
impregnation of the strengthener. In this apparatus however, no controlling fluid
is provided for controlling the impregnation of the matrix by the strengthener.
[0026.2] As a further example, Cauchois et, al. in FR2.828.130 teach
about a moid impregnation apparatus and method. The apparatus includes a
two-part mold configured and sized as to be sealingly mounted to one another
with a membrane in between. One of the molds receives the strengthener and
the other one is provided with an access to a chamber defined between the
latter mold and the membrane, providing thereby means for compressing, with
air in an autoclave, the membrane and consequently, the strengthener on the
other side of the membrane. In this apparatus however, the compaction by air
is provided after the impregnation of the matrix by the strengthener for
evacuating the excess of matrix already impregnated in the strengthener.

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OBJECTS OF THE INVENTION
[0027] An object of the present invention is therefore to provide a
mold and a method of using the mold which allows to rapidly and efficiently
inject under pressure the liquid matrix required to manufacture the composite
part, without having to wait for complete impregnation of the strengthener.
[0028] A further object of the present invention is therefore to
provide a mold and a method of using the mold which allows controlling the
progression of the matrix flow front through the strengthener to increase the
composition, geometrical and mechanical quality of the composite part during
the various manufacturing steps.
[0029] Another further object of the present invention is to provide a
mold and a method of using the moid which allows producing one or more than
one composite part at the same time and with generally the same mold
injection equipment.
SUMMARY OF THE INVENTION
[0030] More specifically, in accordance with the present invention,
there is provided a mold assembly for generating a composite part from a
strengthener in a generally solid phase and a matrix in a generally liquid phase;
the mold assembly including a base mold including a strengthener chamber for
receiving the strengthener and a matrix injection inlet for injecting the matrix in
the strengthener chamber, the mold assembly further including a cover mold
including a compression chamber and a fluid control aperture for injecting a
fluid in the compression chamber; the cover mold being so configured as to be
sealingly mounted on the base mold whereby the strengthener chamber and

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the compression chamber are adjacent; and the mold assembly further
including a deformable member so provided in a gap defined by the
strengthener chamber and the compression chamber as to pressurize the
matrix toward the strengthener upon compression by the fluid.
[0031] There is furthermore provided a moid assembly for
generating a predetermined number of composite parts from strengthened in a
generally solid phase and from matrix in a generally liquid phase; the mold
assembly including a base mold including a strengthener chamber and a cover
mold including a compression chamber; the mold assembly further including at
least one frame assembly, each including a separator defining a further
respective strengthener chamber and a further respective compression
chamber; the at least one frame assembly being so configured as to be
sealingly stacked one next to the other and between the base mold and the
cover mold, whereby each of the strengthener chamber faces one of the
compression chamber to define adjacent pairs of chambers; the mold assembly
further including matrix injection inlets for injecting the matrix in the
trengthener chambers; the mold assembly further including fluid control
apertures for injecting a fluid in the compression chambers'; and the mold
assembly further including deformable members so provided between the
adjacent pairs of chambers as to pressurize the matrix toward the strengthener
upon compression by the fluid.
[0032] There is furthermore provided a mold assembly for
generating a predetermined number of composite parts from strengthened and
matrix; the mold assembly including a base mold including a contact wall; the
mold assembly further including at least one frame assembly so configured as
to be sealingly stacked one next to the other on the base mold defining a
stacking chamber thereby; the mold assembly further including matrix injection
inlets for injecting the matrix in the strengthened trough the base mold and the

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at least one frame assembly; the mold assembly further including deformable
elements, each having a respective compression wait and a further respective
contact wall, the deformable elements being so configured as to be
alternatively stacked with the strengthened in the stacking chamber whereby
each of the contact wall faces one of the compression wall; and the mold
assembly further including a cover mold including a further respective
compression wall and being mounted in the stacking chamber.
[0033] There is furthermore provided a mold assembly for
generating a composite part from a strengthener and a matrix; the mold
assembly including a base mold including a strengthener chamber for receiving
the strengthener and a matrix injection inlet for injecting the matrix in the
strengthener chamber; the mold assembly further including a cover mold
including a compression chamber and a fluid control aperture for injecting a
fluid in the compression chamber; the cover mold being so configured as to be
sealingly mounted on the base mold whereby the strengthener chamber and
the compression chamber are adjacent; and the mold assembly further
including a deformable membrane provided in a gap defined by the
strengthener chamber and the compression chamber; whereby upon operation,
the matrix is injected via the injection inlet in the strengthener located in the
strengthener chamber, a first portion of the matrix impregnates the
strengthener and a second portion of the matrix remains in the strengthener
chamber and deforms the deformable membrane thereby, the second portion
being forced into the strengthener by the fluid pressurizing the deformable
membrane when injected in the compression chamber via the control aperture.
[0034] There is furthermore provided a method for generating a
composite part from a strengthener and a matrix including sealingly positioning
a deformable member in between, a first chamber of a first mold portion and a
second chamber of a second mold portion, the first chamber receiving the

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strengthener; impregnating the strengthener with the matrix injected in the first
chamber; compacting the matrix toward the strengthener by pressurizing a
controlling fluid injected in the second chamber on the deformable member.
[0035] There is furthermore provided a method for generating a pre
determined number of composite parts from strengthened and matrix including
sealingly positioning a deformable member in between a strengthener chamber
of a first mold portion and a compression chamber of a second mold portion,
the strengthener chamber including the strengthened repeating the sealingly
positioning a deformable member by stacking a number of subsequent mold
portions one next to the other determined by a predetermined number of parts
to manufacture; impregnating the strengtheners with matrix injected in the
strengthener chambers; compacting the matrix toward the strengthener by
pressurizing a controlling fluid injected in the compression chamber on the
deformable member.
[0036] There is furthermore provided a method for generating a
predetermined number of composite parts from strengtheners and matrix
including positioning an alternating stack of strengtheners and deformable
members in a stacking chamber generated by sealingly mounting frame
assemblies on a base mold assembly; impregnating the strengtheners with
matrix injected in the stacking chamber; compacting the matrix toward and
along the strengtheners by pressurizing on the stack of strengtheners and
deformable members.
[0037] Other objects, advantages and features of the present
invention will become more apparent upon reading of the following non-
restrictive description of preferred embodiments thereof, given by way of
example only with reference to the accompanying drawings.

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BRIEF DESCRIPTION OF THE DRAWINGS
[0038] In the appended drawings:
[0039] Figure 1 is a side section view of a mold according to a first
embodiment of the present invention;
[0040] Figure 2 is a perspective view of the base moid shown in
Figure 1;
[0041] Figure 3 is a top view of the base mold shown in Figure 2;
[0042] Figure 4 is a side section view of the base mold shown in
Figure 2;
[0043] Figure 5 is a side section view of the cover mold shown in
Figure 1;
[0044] Figure 6 is a side section view of the mold of Figure 1
provided with a strengthener;
[0045] Figure 7 is a side section view of the base mold showing a
first step in a process for manufacturing a composite part;
[0046] Figure 8 is a side section view of the base mold showing a
second step in a process for manufacturing a composite part;
[0047] Figure 9 is a side section view of the mold showing a third

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step in a process for manufacturing a composite part;
[0048] Figure 10 is a side section view of the mold showing a fourth
step in a process for manufacturing a composite part;
[0049] Figure 11 is a side section view of the mold showing a fifth
step in a process for manufacturing a composite part;
[0050] Figure 12 is a side section view of the mold showing a sixth
step in a process for manufacturing a composite part;
[0051] Figure 13 is a side section view of the moid showing a
seventh step in a process for manufacturing a composite part;
[0052] Figure 14 is a side section view of the mold showing an eight
step in a process for manufacturing a composite part;
[0053] Figure 15 is aside section view of the mold showing a ninth
step in a process for manufacturing a composite part;
[0054] Figure 16 is a side section view of the base mold showing a
tenth step in a process for manufacturing a composite part;
[0055] Figure 17 is a side section view of the base mold showing an
eleventh step in a process for manufacturing a composite part;
[0056] Figure 18 is a side section view of the base mold showing a
twelfth step in a process for manufacturing a composite part;

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[0057] Figure 19 is a side section view showing a mold according to
a second embodiment of the present, invention;
[0058] Figure 20 is a side section view showing a mold according to
a third embodiment of the present invention;
[0059] Figure 21 is a side section view showing a step of
compression generated by tubes of the mold of Figure 20;
[0060] . Figure 22 is a partial isometric view showing a cover mold
according to a fourth embodiment of the present invention;
[0061] Figure 23 is a top plan view showing the fluid passage
network of the cover moid of Figure 22;
[0062] Figure 24 is a side section view showing an impregnation
step in the mold according to the fourth embodiment of the invention;
[0063] Figure 25 is a side section view showing a fluid injection step
in the mold of Figure 24;
[0064] Figure 26 is an exploded side section view showing a mold
according to a fifth embodiment of the present invention;
[0065] Figure 27 is a side section view showing a fluid injection step
in the mold of Figure 26;
[0066] Figure 28 is a side section view showing a compression step
in the mold of Figure 26;

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[0067] Figure 29 is a side section view showing a mold according to
a sixth embodiment of the present invention;
[0068] Figure 30 is a side section view showing an impregnation
step in the mold of Figure 29;
[0069] Figure 31 is a side section view showing a compression step
in the mold of Figure 29;
[0070] Figure 32 is a side section view showing a cure step in the
mold of Figure 29;
[0071] Figure 33 is a side section view showing a membrane in the
mold of Figure 29; and
[0072] Figure 34 a moid according to a seventh embodiment of the
present invention.
DETAILED DESCRIPTION
[0073] Generally stated, the present invention relates to the
manufacture of a composite material by injecting in a mold assembly a
generally liquid phase, called the matrix, throughout a strengthener that is in a
generally solid phase with a method of-injection that favors an efficient
impregnation of the matrix in the strengthener. The matrix is generally a resin,
such as for example a thermoset or a thermoplastic polymer or a liquid metal,
and the strengthener is a fibrous, granular or any other type of porous material.
Examples of commonly used thermoset polymers include epoxy, polyester,
vinylester or phenolic resins, and examples of commonly used liquid metals

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include aluminum or magnesium. The process of injection of the matrix into the
strengthener is often used for the manufacture of composite parts. For
example, a polymer, a metallic or a ceramic matrix may be reinforced by glass,
carbon, kevlar, metal, ceramic or other strengtheners. In the case of fibrous
strengthened, cloths or mats made of glass fiber, carbon, kevlar, aramide,
natural fibers are generally used. The range of applications for such composite
parts manufactured by such a process covers, amongst others, the field of
transport vehicles (marine, automotive, aeronautical) and may also be used in
the sport, biomedical and electronics sectors.
[0074] The illustrative embodiment of Figure 1 shows a mold
assembly 30 used in the injection of a matrix into the strengthener for the
manufacture of composite parts. The mold assembly 30 is generally rigid and
includes a base mold 32, a cover mold 34 and a deformable member, show in
the illustrative embodiment as a membrane 36.
[0075] The base mold 32 is illustrated in more details in Figures 2, 3
and 4 and includes a strengthener chamber 38 which is defined by a contact
wall 40 and by peripheral walls 42. When in use, the strengthener chamber 38
is generally so configured as to receive a strengthener and to provide the
space into which the matrix is injected to manufacture the composite part.
[0076] The base mold 32 and its strengthener chamber 38 are
generally designed to the dimensions of the strengthener to be injected with the
matrix. It is easily understandable to the skilled reader that in the Figures, the
base mold 32 is presented with a configuration adapted to receive a flat
rectangular strengthener plate, but can be configured to suit various shapes of
strengthener or a combined strengthener with a foamed core.
[0077] The base mold 32 further includes an evacuation outlet 44

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and an injection inlet 46. The evacuation outlet 44 extends from the
strengthener chamber 38 to the external surface of the base mold 32, and is so
configured as to be connected to a vacuum source (not shown) to generate
suction or vacuum in the strengthener chamber 38. More than one evacuation
outlet 44 may be included in the base mold 32 and each of them may be
connected to more than one vacuum source (not shown).
[0078] The injection inlet 46 extends through the base mold 32 with
a first end being so configured as to be mounted to a matrix source (not shown)
and with a second end in communication with the strengthener chamber 38. In
the illustrative embodiment, the second end includes a diffusion passage 50
extending along any desired path in the strengthener chamber 38 to maximize
the diffusion of the matrix therein. Of course, more than one injection inlets 46
may be provided around the strengthener chamber 38 or at its periphery.
[0079] The shoulder 47 of the base mold 32 includes grooves 48
which are represented, as an example, as having a generally triangular cross-
section which helps to hold the membrane 36 and to sealingly mount the cover
mold 34 to the base mold 32. Optionally, additional standard molding elements,
such as for examples o-ring sealants, tubes, guides, or demolding devices (not
shown) may be added to facilitate mold closure and mold opening.
[0080] Turning now to Figures 5 and 6, the cover mold 34 includes a
compression chamber 52 which is defined by a compression wall 54 and by
peripheral walls 56. When in use, the compression chamber 52 is so configured
as to receive a fluid or pressure means and has a geometry which is generally
determined by the configuration of the part to be molded, as will be further
described hereinbelow.
[0081] The cover mold 34 further includes a fluid control aperture 58

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and a vent 60. The fluid control aperture 58 extends from the external surface
of the cover mold 34 to the compression chamber 52, and is so configured as
to be connected to a pressurized fluid source (not shown) to provide pressure
in the compression chamber 52. More than one fluid control aperture 58 may
be included in the cover mold 34 and each of them may be connected to more
than one pressurized fluid source (not shown).
[0082] In the embodiment shown in Figure 6, a single fluid control
aperture 58 is extending in the cover mold 34 in a direction which is generally
along the direction of the injection inlet 46 in the base mold 32.
[0083] The vent 60 also extends from the compression chamber 38
to the external surface of the cover mold 34, and is so configured as to expel
the fluid contained in the compression chamber 52. Alternatively, the vent 60 is
connected to a vacuum source (not shown) to selectively provide suction or a
partial vacuum in the compression chamber 52, or includes valves (not shown)
to regulate the flow of fluid in the compression chamber 52. More than one vent
60 may be included in the cover mold 34.
[0084] The shoulder 61 of the cover mold 34 includes ridges 62
which are so configured as to cooperate with the grooves 48 of the base mold
32 and are represented, as an example, as having a generally triangular cross-
section. The assembly of the ridges 62 and grooves 48 generally extends
around the shoulders 47, 61, in the periphery of the molds 32, 34 to help hold
or locate the membrane 36, to mount the base mold 32 and the cover mold 34
together and fo seal the chambers 38,52.
[0085] In Figure 6, the mold assembly 30 contains the strengthener
66 in the chamber 38 of the base mold 32. When mounted together, the cover
mold 34 and the base mold 32 delimit a gap 64 which includes the two

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chambers 38,52 separated by the membrane 36.
[0086] . The gap 64 is shown in Figure 6 as having a total thickness
or height h, including the compression chamber 52 having a thickness or height
hi and the strengthener chamber 38 having a thickness or height hs. The height
h is adjusted as a function of the thickness of the strengthener being injected
with the matrix, in order to control the filling of the strengthener by the matrix,
as will be further explained hereinbelow. Also the variations of the height h
allow the manufacture of composite parts of variable thickness.
[0087] The membrane 36 is provided in a cavity or gap defined by
the strengthener chamber 38 and the compression chamber 52. The
membrane 36 is generally a thin impermeable layer such as a plastic film, an
elastic membrane, or a generally deformable foam not necessarily having a
uniform thickness, or any type of material impermeable to the matrix used.
Alternatively, the membrane 36 may be permeable to gas only.
[0088] The membrane 36 is sufficiently flexible to be deformed
under pressure induced in the chambers 38,52, such that the height hf and the
height hs are variable. As will be described hereinafter, this has the effect of
facilitating the impregnation of the matrix in the strengthener. The deformation
of the membrane 36 is nevertheless limited by the thickness h of the gap 64
which, as mentioned hereinabove, is not necessarily uniform.
[0089] The surface finish of the contact wall 40 depends on the
desired surface appearance for the composite part to manufacture. Usually, the
base mold 32 is made of metal, but it can also be made of any material
normally used to manufacture injection molds, for example, an epoxy /
aluminum foam or a multi-layer composite mold. The surface finish of the
compression wall 54 does not generally need to be of the same quality as that

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of the contact wall 40 of the base mold 32 since most of the times, the
compression wall 54 is not directly touching the strengthener, but usually
indirectly in communication with the strengthener via the membrane 36.
[0090] In operation, the mold assembly 30 is used to manufacture a
composite part by injecting the matrix throughout the strengthener 66. For
clarity purposes, the manufacturing process will now be described with
reference to a composite plate formed with the following steps: laying of the
strengthener; placement of the membrane; closure of the mold assembly;
application of vacuum to the strengthener chamber, injection of the matrix;
injection of the controlling fluid;' compaction of the composite part; solidification
of the part; and ejection from the mold assembly.
Laving of the strenqthener
[0091] As illustrated in Figure 7, the strengthener 66 is first
positioned in the chamber 38 of the base mold 32. This strengthener 66 is
generally the "skeleton" of the composite material, as opposed to the matrix
provided by injection.to impregnate and fill the strengthener 66. Under
atmospheric pressure Pa, the free thickness of the generally non-compacted
strengthener 66 is denoted as n0.
Placement of the membrane
[0092] As shown in Figure 8, the membrane 36 is positioned on the
base mold 32 in order to cover the strengthener 66 and over the grooves 48.
As stated hereinabove, the base mold 32 and the membrane 36 generally
delimit the strengthener chamber 38 adapted to receive the strengthener 66.

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Closure of the mold assembly
[0093] From Figure 9, the cover mold 34 is fitted to the base mold 32
via the ridges 62 and grooves 48 assembly in order to seal the strengthener
chamber 38 and the compression chamber 52 with the strengthener 66 located
in the strengthener chamber 38.
Application of vacuum to the strenathener chamber
[0094] Optionally, pressure in the strengthener chamber 38 is
changed to facilitate the manufacture of the composite material. As seen in
Figure 10, the pressure in the strengthener chamber 38 is set at a vacuum
pressure Pv, which is generally lower than atmospheric pressure Pa.To change
the pressure in the chamber 38, a vacuum source such as for example a
vacuum pump is generally used through a connection to the evacuation outlet
44 in the base mold 32 (see arrow 45).
[0095] In this case, the resulting pressure applied to the
strengthener 66, that is, the ambient atmospheric pressure Pa minus the
vacuum pressure Pv, generally compresses the strengthener 66 to a thickness
hi which is less than h0.
Injection of the liquid
[0096] In Figure 11, a predetermined quantity of matrix 70 is injected
in the chamber 38 via the injection inlet 46 (see arrow 71). At first, a portion of
the matrix 70 generally impregnates a fraction of the strengthened total
volume 72 near where it is injected, and moves in the strengthener 66 with a
matrix flow front 76. The matrix flow front 76 gradually moves along a

WO 2005/000566 PCT/CA2004/000959
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propagation direction generally defined from the injection inlet 46 to the
evacuation outlet 44.
[0097] After injection, a portion of the matrix 70 impregnates a
fraction of the strengthened total volume 72 and another portion of the matrix
called free matrix generates a deformation zone 74 by swelling the membrane
36 which deforms and occupies a portion of the compression chamber 52. The
free matrix is generally the injected matrix 70 which has permeated across the
strengthener or when the matrix infiltrates on the sides of the strengthened
generally between the strengthener 66 and the strengthener chamber 38.
[0098] Alternatively, the free matrix swells the membrane 36 to
significantly fill the compression chamber 52. Also alternatively, the deformation
zone 74 is generated by tine varying thickness of the strengthener 66 saturated
by the matrix and which, as a result, deforms the membrane 36.
[0099] Due to the injection of the matrix 70, the thickness hi of the
strengthener chamber 38 generally increases, up to the maximal value h
corresponding to the height of the gap 64.
[0100] Once the predetermined quantity of matrix 70 has been
injected Into the strengthener chamber 38, the matrix injection inlet 46 is
closed, the fluid control aperture 58 is generally obstructed by the swollen
portion of the membrane 36, while the vent 60 allows evacuation of the air
contained in the compression chamber 52 (see arrow 61).
[0101] Injection of the controlling fluid
[0102] The controlling fluid may be either a gas or more generally an

WO 2005/000566 PCT/CA2004/000959
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incompressible liquid such as water, oil or any other liquid meeting specified
requirements. As seen in Figure 12 the fluid 78 is injected in the compression
chamber 52, through the control aperture 58 (see arrow 59), at a temperature
7/and a pressure Pf.
[0103] The pressure applied by the controlling fluid 78 on the
membrane 36 progressively reduces the deformation of the membrane 36,
compacts the strengthener 66 and forces both the matrix which is already in the
impregnated strengthener volume 72 and the free matrix in the deformation
zone 74 along its longitudinal extension.
[0104] This step has the effect of bringing the penetration of the
matrix toward the un-impregnated strengthener volume 80 and enables to
control the progression of the matrix flow front 76 through the strengthener 66
. along the propagation direction.
[0105] By heating the controlling fluid 78 and/or the base mold 32,
the temperature inside the strengthener chamber 38 is regulated. Usually,
higher temperatures generally decrease the viscosity of the matrix 70 and
facilitate its penetration into the strengthener 66. Increasing the controlling fluid
temperature 7} also generally facilitates the progression of the matrix flow front
76 through the strengthener 66.
[0106] Compaction of the composite part
[0107] As seen in Figure 13, when the compression chamber 52 is
filled by the controlling fluid 78, pressure is increased up to a compaction
pressure Pc in order to compress the impregnated strengthener 72 via the
membrane 36. This step generally completes the impregnation of the

WO 2005/000566 PCT/CA2004/000959
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strengthener 66, increases its saturation, brings the strengthener to a given
thickness h and helps to maintain the contact of the impregnated strengthener
72 with the base mold 32.
[0108] Indeed, since the application of the compaction pressure Pc is
isotropic (i.e. in all directions), the impregnated strengthener 72 is generally
. compacted uniformly, regardless of its geometrical particularities. Furthermore,
it is possible to maintain the compaction pressure Pc during the cure and/or
solidification phase, as will be discussed in more details in the next step, to
increase the saturation of the injected part and help impart the surface finish of
the contact wall 40 to the injected part.
[0109] The compaction pressure Pc being generally greater than
atmospheric pressure, the final thickness h of the molded part may be
controlled and parts with greater fiber contents can be manufactured. It should
be noted that the compaction pressure Pc nevertheless remains below the level
that would cause permanent deformation of the cover mold 34. Accordingly, the
cover mold 34 is designed to withstand the compaction pressure Pc.
[0110] Cure and/or Solidification of the part
[0111] The base mold 32 is brought to the desired temperature for
the cure and/or solidification of the part 82 by means of thermal resistors 84,
schematically illustrated in Figure 14, or by any other suitable heating system
or cooling system (not shown). The thermal resistors 84 are so configured as to
radiate heat to the base mold 32 to provide means for regulating the
temperature of the contact wall 40 of the mold 32.
[0112] During this phase, the compaction pressure Pc applied in the

WO 2005/000566 PCT/CA2004/000959
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compression chamber 52 helps provide a generally continuous contact of the
composite part 82 with the contact wail 40 of the base moid 32. This contact
has the effect of providing the part 82 with a generally conformed reproduction
of the geometrical and surface finish of the contact wall 40, and is further
optionally used in conjunction with a heating or cooling of the fluid 78, as stated
hereinabove.
[0113] During the cure and/or solidification of the composite part, the
mold helps to provide a generally continuous contact of the injected part 82
with the contact wall 40 which minimizes the surface waviness and roughness
of the part 82 on its surface adjacent to the contact wall 40. These phenomena
sometimes result from polymerization shrinkage in the case of heat-cured
polymers, or from matrix contraction during cooling or solidification of the part
82.
[0114] The mold assembly 30 therefore helps to control the cure
and/or the solidification of the injected part 82 such that its generated surface
appearance is of a generally better quality, since the surface of the injected part
82 that is adjacent to the base mold 32 optimally reproduces the finish quality
of the contact wall 40. This cure and/or solidification step also helps to solidify
the matrix and to control matrix cross-linking and/or micro-structure, which are
the physico-chemical phenomena generally occurring during cure and/or
solidification, in general, cure and/or solidification determines some physico-
chemical properties of the composite part 82 such as for example mechanical
resistance, anti-wear properties and so on.
[011.5] Depending on the properties desired for the composite part
82 as well as the means available, the cure method alternatively uses ultra-
violet (UV) light. In this case, the base moid 32, the cover mold 34 and the
membrane 36 are transparent to this type of radiation.

WO 2005/000566 PCT/CA2004/000959
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[0116] Ejection from the mold assembly
[0117] Once the cure and/or solidification are completed, the
temperature of the base mold 32 is lowered by shutting off the thermal resistor
elements 84 and/or by using a cooling system (not shown) so configured as to
decrease the temperature in the strengthener chamber 38.
[0118] In the example shown in Figure 15, ejection of the controliing
fluid 78 (see arrow 81) by cold air injected at the vent 60 (see arrow 83)
contributes at the same time to the cooling of the part 82 before its removal
from the mold assembly 30. The fluid 78 is therefore evacuated from the
compression chamber 52 by pump means (not shown) connected to the vent
60 and expelled at the fluid control aperture 58. The cooling of the composite
part 82 is also alternatively achieved by conduction of cold through the base
mold 32 and the cover mold 34.
[0119] Once this fluid evacuation is completed, the moid assembly
30 is opened by removing the cover mold 34 from the base mold 32, as shown
in Figure 16. At that stage, the composite part 82 is still enclosed in the
strengthener chamber 38 by the membrane 36 and has a composite thickness
h2. The membrane 36 is then removed (see arrow 85) from the base mold 32
containing the composite part 82, as shown in Figure 17.
[0120] Next, by means of usual methods of de-molding such as for
example compressed air jets or mechanical ejectors (not shown), the
composite part 82 is extracted from the base mold 32, as illustrated in Figure
18 (see arrow 87). In general, de-molding is facilitated by the use of a releasing
agent applied to the contact wall 40 and the peripheral walls 42 of the base
mold 32 prior to placing the strengthener therein.

WO 2005/000566 PCT/CA2004/000959
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[0121] According to the present invention, the mold assembly 30
may be optionally configured by pre-determining the optimal thickness h of the
gap 64 defined by the chambers 38, 52. This gap 64 may be determined by
means of a computer simulation that helps to achieve optimal impregnation rate
conditions throughout the strengthener 66, while generally minimizing the filling
time.
[0122] Optionally, the total thickness h of the gap 64 does not need
to be uniform along the dispersion of the strengthener 66 in the strengthener
chamber 38. Indeed, a variable and adjustable thickness h helps to provide a
more uniform control over the matrix progression in some portions of the
strengthener 66 and allows injecting strengthened of non uniform thickness.
[0123] For example, the adjustability of thickness h is used in cases
where the strengthened permeability characteristics need to be regulated or
changed locally during injection, in cases where the final thickness of the
composite part is not uniform, in cases where divergent or convergent flow
zones exists within the strengthener chamber 38 or in cases where inserts (not
shown) are included in the gap 64 or mounted on the base mold 32 and the
cover mold 34.
[0124] Also optionally, the mold assembly 30 including the base
mold 32, the cover mold 34 and the membrane 36 is further provided with a
means for achieving dynamic consolidation of. the liquid-saturated strengthener
as in the VRTM (Vibration Resin Transfer Molding) variation of the RTM
process for example, or by transmitting the mechanical vibration energy directly
to the fluid.
[0125] If dynamic consolidation is used as in the VRTM process
during the "compaction of the part" step described hereinabove, the vibration so

WO 2005/000566 PCT/CA2004/000959
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imposed on the impregnated strengthener 66 contributes to expel the residual .
gaseous phase which is sometimes entrapped in the pores of the fibrous
strengthener at the end of the compaction phase, before total solidification of
the matrix.
[0126] Also optionally and as introduced in the steps of "Injection of
the controlling fluid" and "Solidification of the part", heating and cooling systems
may be included into the mold assembly 30. The heating and cooling systems
generally involve one or both molds 32, 34 or the controlling fluid 78 during the
manufacture of the composite part and may be achieved by heat transfer such
as for example conduction, convection and radiation.
[0127] A mold assembly and a method of using the mold assembly
according to various embodiments of the present invention will now be
described with respect to Figures 19 to 32. For concision purposes, only the
differences between the mold assemblies and processes of the various
following embodiments and the mold assembly and process illustrated in
Figures 1 to 18 will be described hereinbelow.
[0128] A mold assembly 130 and a process of manufacturing a
composite part according to a second embodiment of the present invention are
illustrated in Figure 19.
[0129] In this embodiment, the mold assembly 130 includes a
deformable member, show in the illustrative embodiment as a membrane 136
and a deformable element 131. The deformable element 131 is provided in the
compression chamber 152 and has the effect of generally reducing the volume
of controlling fluid injected into the compression chamber 152 via the fluid
control aperture 158 and ejected via the vent 160.

WO 2005/000566 PCT/CA2004/000959
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[0130] The deformable element 131 is generally porous and made
from elastic material such as, for example, a foam polymer or any other type of
open or closed-pore material. By being machined on its surface facing the
strengthener 166, the deformable element 131 helps impose a shape on the
composite part being manufactured. The other surface of the deformable
element 131 faces the compression wall 154 of the cover mold 134.
[0131] In operation, when injected in the mold assembly 130 by an
orifice in the cover mold (not shown), the deformable element 131 occupies a
certain volume of the compression chamber 152 while still facilitating, due to its
deformability, the flow of the matrix 170 through the strengthener 166.
[0132] Once the matrix 170 injection is completed, a minimized
quantity of controlling fluid 178 is then injected into the compression chamber
152 to control the penetration of the matrix 170 into the strengthener 166. The
pressure applied to the fluid 178 is transmitted to the strengthener 166 through
the deformable element 131. In the case of closed-pore deformable elements
131, the fluid control aperture 158 and the vent 160 are in communication with
the membrane 136 via the deformable element 131. Injection of the controlling
fluid 178 may generate a film (not shown) in the compression chamber 152,
either between the deformable element 131 and the compression wall 154 or
between the membrane 136 and the deformable element 131.
[0133] Alternatively, a series of grooved channels (not shown) are
machined on the surface of the deformable element 131 that is closest to the
strengthener 166 to participate in transmitting pressure to the strengthener 166.
In that case, the membrane 136 deforms in operation and cooperates with the
grooves (not shown) of the deformable element 131.
[0134] It is to be noted that the deformable element 131, instead of

WO 2005/000566 PCT/CA2004/000959
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being shaped, is also alternatively injected directly into the cavity created by the
base mold 132 and the cover mold 134 via the fluid control aperture 158. The
mold 132 would nevertheless already have to contain a first strengthener 166 In
order for the injected deformable element 131 to take the imprint of the
strengthener 166.
[0135] In this embodiment generally, if the membrane 136 is
removed, the placement or the injection of the deformable element 131 in the
compression chamber 152 may be used to produce a composite sandwich part
with the deformable element 131 as core, in that case, a strengthener 166 is
placed next to the deformable element 131 and the controlling fluid 178 is
replaced by the matrix 170.
[0136] A mold assembly 230 and a process of manufacturing a
composite part according to a third embodiment of the present invention are
illustrated in Figures 20 and 21.
[0137] In this embodiment, the strengthener 266 is located in the
base mold 232 and covered with the membrane 236 under which a vacuum
may be drawn. The cover mold 234 includes a compression chamber 252
. which allows pressurizing at greater than atmospheric pressure, with the aid of
either a gas or a liquid.
[0138] The cover mold 234 needs not be machined in the
compression chamber 252 and may include compartmentalized portions (not
shown) delimited by the compression wall 254 which are so configured as to be
independently movable toward the compression chamber 252 and the
strengthener 266.

WO 2005/000566 PCT/CA2004/000959
30
[0139] In operation, the strengthener 266 is first pressurized by
compressed gas injected in the compression chamber (see arrow 259), by
incompressible fluid or by a combination of incompressible fluid and
pressurized tubes, which will further be described hereinbelow. The
compressed gas generally compresses the strengthener 266 and controls the
membrane 236 deformation during injection. If the cover mold 234 includes
compartmentalized portions (not shown), they may be positioned at various
levels with respect to the membrane 236 to control the deformation of the
membrane 236 after injection of the matrix in the strengthener 266 and via the
pressure exerted on the compressed gas or control fluid.
[0140] With the incompressible fluid, isotropic compression is
exerted on the strengthener 266. Due to the non-compressibility of the fluid
278, local deformations of the membrane 236 in the saturated zone of the
strengthener 266 generally imply a deformation in the opposite direction and of
equivalent volume in the non-saturated zone of the strengthener 266.
[0141] With the combination of an incompressible fluid 278 and
pressurized tube 235 extending in the compression chamber 252, as illustrated
in Figure 21, a controllable isotropic pressure is exerted on the strengthener
266 and the compression chamber 252 by a tube 235 provided into specific
locations above the strengthener 266. The tube 235 is deformable under
pressure and includes at least one tube closable on both extremities. At least
one extremity of the tube 235 is mounted through the cover mold 234 for
operability while composite parts are being manufactured.
[0142] In operation, the pressure of the control fluid 278 is controlled
by changing the pressure in the tube 235. By deforming under pressure while
injected by a fluid source 278a, the tube 235 either directly physically
compresses the membrane 236 and the strengthener 266 or indirectly

WO 2005/000566 PCT/CA2004/000959
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compresses the membrane 236 and the strengthener 266 via the pressure
exerted on the control fluid 278 in the compression chamber 252.
[0143] It should be noted that in the second embodiment, the
temperature in the compression chamber 252 may also be modified and
controlled via the pressurization fluid. With the use of the tubes 235, the
heating and cooling of the strengthener 266 may be achieved through the
incompressible fluid, while the tubes 235 provide means for evacuating or
dissipating a certain amount of heat or cold from the mold assembly 230.
[0144] A mold assembly 330 and a process of manufacturing a
composite part according to a fourth embodiment of the present invention are
illustrated in Figures 22 to 25.
[0145] In this embodiment, the cover mold 334 includes a machined
or imprinted channel network on the compression wall 354 which faces the
strengthener 366 when the cover'mold 334 is mounted on the base mold 332.
The network is so configured as to allow the matrix to spread over an optimized
surface of the strengthener 366, before using the controlling fluid 378.
[0146] The network includes a plurality of passages 339 which are
shown in the illustrative embodiment as a generally rectangular grid or a set of
channels including longitudinal passages 339a and transversal passages 339b.
The distance between the compression wall 354 and the membrane 336 is
sufficiently small to limit the space in which the matrix flows above the
strengthener 366.
[0147] It is to be noted however that the geometry of the network,
including the shape and configuration of the passages 339, is generally

WO 2005/000566 PCT/CA2004/000959
32
designed to adapt to the part to manufacture, in order to favor matrix
penetration into specified zones and zones of complex shape of the
strengthener 366 and to minimize the average movement of the matrix from the
time it is injected in the mold assembly 330 to the moment it impregnates the
strengthener 366. Generally, the passages 339 are of dimensions such that
they can receive a significant portion of the amount of matrix 370 required to
wet the strengthener 366 completely. Optionally, the transversal passages
339b are generally extending in alignment with the diffusion passages 350 and
at least one longitudinal passage 339a is generally extending in alignment with
an injection inlet 346.
[0148] In operation and during injection of the pressurized matrix
370 via the injection inlet 346 (see arrow 371) and the diffusion passages 350
(only one shown), a portion of the strengthened total volume 372 is
impregnated by the matrix. The free matrix generates the deformation zone 374
and deforms the membrane 336 which mates with the passages 339 of the
network, expelling the excess of air from the cover mold 334 through the vents
360 (see arrow 361), as seen in Figure 24.
[0149] From Figure 25, it is shown that the injection of the controlling
fluid 378 via the fluid control aperture 358 (see arrow 359) propagates in the
passages 339 and above the membrane 336 to force the free matrix into the
strengthener 366 and favor a complete impregnation of the strengthener in the
composite part 382.
[0150] A mold assembly 430 and a process of manufacturing a
composite part according to a fifth embodiment of the present invention are
illustrated in Figures 26 to 28.
[0151] In this embodiment, the mold assembly 430 allows the

WO 2005/000566 PCT/CA2004/000959
33
simultaneous manufacture of several composite parts using a base mold 432
and a plurality of rigid frame assemblies 441a, 441b, 441c, 441 d, 441 e so
configured as to define a plurality of superimposed double-chamber layers.
Each layer includes a strengthener chamber 438a, 438b, 438c, 438d, 438e, a
respective membrane 436a, 436b, 436c, 436d, 436e and a respective
compression chamber 452a, 452b, 452c, 452d, 452e.
[0152] In the illustrative embodiment, each frame assemblies 441a,
441 b, 441 c, 441 d, 441 e includes a separator 443 made of metal or of a more or
less rigid foam, defining on one side the contact wall 440 and on the other side
the compression wall 454 as described hereinabove. On the side of each
compression wall 454, at least one fluid control aperture 458 and at (east one
vent 460 extend through each frame assemblies 441 a, 441 b, 441 c, 441 d, 441 e..
Also, on the side of each contact wall 440, at least one injection inlet 446 and at
least one evacuation outlet 444 extend through each frame assemblies 441 a,
441b, 441c, 441 d, 441 e. The base mold 432 and the frame assemblies 441a,
441b, 441c, 441 d, 441 e are mounted or stacked one on top of the other as
described hereinabove.
[0153] In the illustrative embodiment of Figure 26, the last frame
assembly 441 e includes a cover reinforcement 434a which is mounted over its
separator 443 to provide for additional rigidity and integrity of the mold
assembly 430 during the manufacturing of the composite parts. Alternatively,
as illustrated in Figures 27 and 28, the last frame assembly 441 e is replaced by
a cover mold 434b' which has a similar configuration as the previously
described cover molds.
[0154] In operation, each strengthener 466a, 466b, 466c, 466d,
466e is placed in one strengthener chamber 438a, 438b, 438c, 438d, 438e and
impregnated with matrix injected via the injection inlets 446 of each frame

WO 2005/000566 PCT/CA2004/000959
34
assemblies 441a, 441b, 441c, 441 d, 441 e, as illustrated in Figure 27. The
matrix 470 is optionally injected simultaneously into all strengthener chambers
438a, 438b, 438c, 438d, 438e, or with a delay between each sequential
injection of matrix in the strengthened.
[0155] The controlling fluid 478 is then injected into the compression
chambers 452a, 452b, 452c, 452d, 452e via the fluid control apertures 458
(see arrows 459). The excess of fluid contained In the compression chambers
452a, 452b, 452c, 452d, 452e Is expelled via the vents 460 (see arrows 461).
The principle of matrix flow front 476 progression and the movement of the
membranes 436a, 436b, 436c, 436d, 436e due to the free matrix in the
deformation zone 474 remains the same, as described in the previous
embodiments and for each layer of the mold assembly 430. Injection of the fluid
478 proceeds until the latter compression chamber 452e has been completely
filled.
[0156] As seen in Figure 28, each composite part 482e is then
compressed between the separator 443 on one side and the membrane 336e
pressurized by the controlling fluid 478 on the other side. This step therefore
provides a generally similar degree of compression for all composite parts,
which are at the same time more protected against the risk of defects due to
warping, since each face of the strengthener generally sees a similar
compression force.
[0157] For the cure and/or the solidification step, the base mold 432
is brought to the desired temperature as in the general case. Once initiated, the
polymerization of the liquid matrix is generally accompanied by heat
dissipation, which participates in upward heat flux diffusion, such that this
exothermic polymerization reaction occurring in the base mold 432 initiates the
cure of the composite part located in the frame assembly immediately above.

WO 2005/000566 PCT/CA2004/000959
35
The composite parts are therefore sequentially cured in the stack of frame
assemblies 441a, 441b, 441c, 441 d, 441 e.
[0158] . The energy used to heat any lower frame assembly is
generally transferred from one layer to the next one rather than being used for
cure only a single composite part. It should be noted that heating elements are
optionally included in the vicinity of compression chambers 452a, 452b, 452c,
452d, 452e or in intermediate combinations of frame assemblies 441a, 441b,
441 c, 441 d, 441 e to accelerate the cure process.
[0159] A mold assembly 530 and a process of manufacturing a
composite part according to a sixth embodiment of the present invention are
illustrated in Figures 29 to 33.
[0160] In this embodiment, the mold assembly 530 includes a base
mold 532, a cover mold 534 and a plurality of frame assemblies 541a, 541b,
541c, 541 d. The number of frame assemblies 541a, 541b, 541c, 541 d varies
depending on the number of parts to be manufactured simultaneously.
[0161] The mold assembly 530 is also provided with injection inlets
546 and evacuation outlets 544 in order to allow injection of the matrix over the
strengthened 566a, 566b, 566c, 566d as well as evacuation of air and excess
matrix. In the illustrative embodiment, the evacuation outlet 544 and the
injection inlet 546 are extending through the plurality of frame assemblies 541a,
541b, 541c, 541 d that are stacked on the base mold 532 and covered by the
cover mold 534.
[0162] When mounted one on top of the other as described
hereinabove, the base mold 532, and the plurality of frame assemblies 541a,

WO 2005/000566 PCT/CA2004/000959
36
541b, 541c, 541 d define a stacking chamber 545 in which layers of
.strengtheners 566a, 566b, 566c, 566d, separators 543a, 543b, 543c and the
cover mold 534 are to be alternatively placed one on top of the other.
[0163] The separators 543a, 543b, 543c participate in providing the
shape during the manufacture of the composite parts and include on one side a
machined compression wall 554 and on the other side, a machined contact wall
540. The compression wall 554 faces the contact wall 540 of the base mold
532 or the contact wall 540 of the separator located just below.
[0164] The separators 543a, 543b, 543c are made from sufficiently
compressible material to allow themselves to generally deform upon injection of
matrix into the strengtheners 566a, 566b, 566c, 566d, but sufficiently rigid at
the same time to transmit the effect of the pressure of the matrix injected into
' one strengthener to neighboring strengtheners in the stacking chamber 545.
[0165] • The cover mold 534 includes a compression wall 554 facing
the contact wall 540 of the separator 543c located below and a punch 547
adapted to compress via the cover mold 534 the strengtheners 566a, 566b,
566c, 566d and the separators 543a, 543b; 543c contained between the base
mold 532 and the cover mold 534. The shapes of the contact walls 540 and the
compression walls 554 are so configured as to define the composite part to
manufacture.
[0166] Using this mold assembly 530, several replicates of a same
part may be obtained during one manufacturing process, without significantly
diminishing the final composite part quality. This process may also be adapted
to the mass production of structural parts, since the surface finish obtained by
this approach on one side of the composite part is generally less critical and
does not have to be of the same quality as for the parts manufactured by the

WO 2005/000566 PCT/CA2004/000959
37
other embodiments described hereinabove using a compression chamber, a
strengthener chamber and a membrane.
[0167] . In operation, the first strengthener 566a is slidably placed
over the base mold 532 and laterally held in place by the first frame assembly
541 a. The first separator 543a is then placed above the first strengthener 566a.
This procedure is repeated the number of times necessary to obtain the desired
number of composite parts, then the stack of strengtheners 566a, 566b, 566c,
566d and separators 543a, 543b 543c are covered with the cover mold 534.
[0168] As seen in the illustrative embodiment of Figure 30, the
method includes a successive injection of the matrix 570 into the strengtheners
566a, 566b, 566c, 566d via the injection inlets 546, with a slight delay between
each injection.
[0169] The matrix 570 is injected (see arrows 571) under pressure
into the first strengthener 566a, which brings about a deformation of the first
separator 543a, as described hereinabove. Since no significant force opposes
the movement of the first separator 543a, the latter presses the second
strengthener 566b along the same direction.
[0170] The matrix flow front 576a progresses along the strengthener
566a. After the matrix flow front 576a reaching an optimized progression in the
strengthener 566a, injection begins in the second, strengthener 566b. The
matrix 570 injected under pressure produces the same effect as described in
the previous paragraph for the first injection, and generally deforms the
. separators located above 543b and beneath 543a the second strengthener
566b. The first strengthener 566a is thus generally compressed over the
distance of propagation of the matrix flow front 576b into the second
strengthener 566b. All the other injections of matrix in subsequent

WO 2005/000566 PCT/CA2004/000959
38
strengtheners are performed in a similar manner.
[0171] The last strengthener 566d has the particularity of not
allowing the matrix under pressure injected therethrough to deform the rigid
cover mold 534 located above the strengthener 566d. As a result, the matrix
570 compresses the layers of strengthener 566a, 566b, 566c located
underneath.
[01721 The impregnation of the matrix in the strengthened 566a,
566b, 566c, 566d and the progression of the matrix flow front 576a, 576b,
576c, 576d are thus regulated by the pressure applied by the contact wall 540
on the strengtheners 566a, 566b, 566c, 566d and generally corresponds to the
pressure applied on the strengthener located above. During this impregnation
step, the excess of fluid or gas in the vicinity of strengtheners 566a, 566b,
566c, 566d or the excess of matrix may be expelled via the evacuation outlet
544 (see arrows 545).
[0173] The compaction step generally increases the fiber content of
the composite parts manufactured and improves the reproducibility of the parts
manufactured in a stack according to this embodiment. This step is usually
performed by applying a compression force to the cover mold 534 via the
punch 547 (see arrow 549), as illustrated in Figure 31. The stiffness of the
separators 543a, 543b, 543c is generally sufficient to cause compaction of the
impregnated strengtheners 582a, 582b, 582c, 582d, in compliance with the
geometry of the separators 543a, 543b, 543c. For this reason, the crushing of
the separators 543a, 543b, 543c remains generally minimal.
[0174] . In this embodiment, the consolidation of the composite parts
582a, 582b, 582c, 582d generally occurs in one direction, which is not
necessarily a direction normal to the surfaces of the composite parts 582a,

WO 2005/000566 PCT/CA2004/000959
39
582b, 582c, 582d. In the previous embodiments, the compaction of the parts is
usually performed by the controlling fluid proving a compression loading normal
to the surface of the composite part.
[0175] However, a controlling fluid 578 may be optionally injected
between the cover mold 534 provided or not with a membrane covering the last
strengthener 582d. Alternatively, as illustrated in Figure 33, each strengthener
566a, 566b, 566c, 566d is covered with a membrane 536 so configured as to
interact with a controlling fluid injected simultaneously between each separator
543a, 543b, 543c. in.these cases, the controlling fluid can be injected either
into a porous separator 543a, 543b, 543c, or as illustrated in Figure 33, directly
between the separators 543a, 543b, 543c and an added membrane covering
the strengtheners 582a, 582b, 582c, 582d.
[0176] Also alternatively, the membrane 536 is inserted between the
separators 543a, 543b, 543c and the strengtheners 582a, 582b, 582c, 582d,
such that the controlling fluid can still be injected either into the porous
separators 543a, 543b, 543c, or directly between the separators 543a, 543b,
543c and the strengtheners 582a, 582b, 582c, 582d.
[0177] The cure step generally corresponds to the cure step
described in the fourth embodiment of the present invention. As shown in
Figure 32 of the illustrative embodiment, the compression force is maintained
on the mold assembly 530 during the cure and/or the solidification step which
more particularly involves cure and/or solidification of the first composite part
582a followed by the subsequent cure and/or solidification of the remaining
composite parts 582b, 582c, 582d (see arrow 551). Once cure is completed, a
finishing step is sometimes required to meet final composite part specifications.
[0178] A mold assembly 630 and a process of manufacturing a

WO 2005/000566 PCT/CA2004/000959
40
composite part according to a seventh embodiment of the present invention are
illustrated in Figure 34.
[0179] In this embodiment, the mold assembly 630 includes a
porous medium 653 provided in the compression chamber 652 of the cover
mold 634 which generally controls or reduces the speed at which the fluid
injected from the fluid control aperture 658 to the vent 660 progresses in the
compression chamber 652. Alternatively, the porous medium is replaced by a
granular medium such as for example sand or by a fibrous medium.
[0180] The porous medium 653 is a generally deformable element
131 which in operation, allows the passage of the fluid through itself, but its
porous composition significantly helps to control or restrain the propagation of
the flow of control fluid. In some instances, depending on the physical
properties of the strengthened of the chemical properties of the matrix, of the
nature of the control fluid and on the pressure and temperature conditions while
the mold assembly 630 is in operation, the flow propagation of control fluid may
need to be controlled with respect to the flow propagation of the matrix in the
strengthened
[0181] For instance, a control fluid flowing in the compression
chamber 652 from the fluid control aperture 658 to the vent 660 generally
provides an efficient and non-uniform compression of the membrane 636 in the
region swollen by the free matrix so as to facilitate the flow of the free matrix
toward the strengthener. By having a porous medium 653 in the compression
chamber 652, the propagation of the control fluid in the compression chamber
652 may be delayed such that the control fluid flow front (not shown) does not
go beyond the matrix flow front, in order to efficiently help impregnate the
strengthener with the matrix.

WO 2005/000566 PCT/CA2004/000959
41
[0182] Although the present invention has been described
hereinabove by way of embodiments thereof, it can be modified, without
departing from the spirit and nature of the subject invention as defined in the
appended claims.

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42
Claims
1. A mold assembly for generating a composite part from a strengthener in a
generally solid phase and a matrix in a generally liquid phase; said mold
assembly comprising:
a) a base mold including a strengthener chamber for receiving the
strengthener, a matrix injection inlet for injecting the matrix in said
strengthener chamber and an evacuation outlet, said inlet and said
outlet defining a propagation direction;
b) a cover mold including a compression chamber and a fluid control
aperture for injecting a controlling fluid in said compression
chamber; said cover mold being so configured as to be sealingly
mounted on said base mold whereby said strengthener chamber
and said compression chamber are adjacent; and
c) a deformable member provided in a gap defined by said strengthener
chamber and said compression chamber, said deformable member
being so configured as to pressurize the matrix toward the
strengthener and propagate the matrix along said propagation
direction upon compression exerted on said deformable member
by the controlling fluid.
2. A mold assembly as recited in claim 1, wherein said deformable member is
able to be swollen in said compression chamber from the matrix
permeating the strengthener to generate a deformation zone, said
deformable member receiving pressure from the controlling fluid in
proximity of said deformation zone for redirecting the matrix towards the
strengthener.

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3. A mold assembly as recited in claim 2, wherein said deformation zone is
adjacent to a matrix flow front corresponding to a portion of the
strengthener impregnated by the matrix, said matrix flow front propagating
in the strengthener along said propagation direction as the matrix in said
deformation zone is redirected to the strengthener.
4. A mold assembly as recited in claim 1, wherein said controlling fluid is an
incompressible fluid.
5. A mold assembly as recited in claim 1, wherein said matrix injection inlet
includes a diffusion passage provided on a contact wall of said
strengthener chamber.

6. A mold assembly as recited in claim 1, wherein said evacuation outlet is
connectable to a vacuum source to selectively generate at least a partial
vacuum in said strengthener chamber.
7. A mold assembly as recited in claim 1, wherein base mold includes a
contact wall, peripheral wails extending around said contact wall and
shoulders extending around said peripheral walls; said cover moid includes
a compression wall, peripheral walls extending around said compression
wall and shoulders extending around said peripheral walls, said cover mold
being sealingly mounted to said base mold through a complementary ridge
and groove arrangement provided along said shoulders Of said base mold
and said cover mold.
8. A mold assembly as recited in claim7, wherein said ridge and groove

28-04-2005 CA0400959
44
arrangement has a generally triangular cross-sectional profile.
9. A mold assembly as recited in claim 1, wherein said fluid control aperture is
connectable to a fluid source to generate pressure in said compression
chamber.
10. A mold assembly as recited in claim 1, wherein said fluid control aperture
extends in said cover mold and said matrix injection inlet extends in said
base mold in a generally similar direction.

11. A mold assembly as recited in claim 1, wherein said cover mold includes a
vent extending from said compression chamber and through said cover
mold.
12. A mold assembly as recited in claim 11, wherein said vent is connected to
a vacuum source to selectively generate at least a partial vacuum in said
compression chamber.
13. A moid assembly as recited in claim 11, wherein said vent comprises a
valve to regulate the flow of the controlling fluid through said vent.

14. A mold assembly as recited in claim 1, wherein said gap has a variable
thickness.
15. A mold assembly as recited in claim 14, wherein said compression
chamber has a first thickness, said strengthener chamber has a second

28-04-2005 CA0400959
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thickness, said first and second thickness being variable upon deformation
of said deformable member.
16. A mold assembly as recited in claim 1, wherein said deformable member
includes a membrane sealingly mounted between said strengthener
chamber and said compression chamber.
17. A mold assembly as recited in claim 16, wherein said membrane is
impermeable to liquid.
18. A mold assembly as recited in claim 16, wherein said membrane is
permeable to gas.

19. A mold assembly as recited in claim 1, wherein said mold assembly
includes a means for inducing vibrations to the controlling fluid injected in
said mold assembly to expel residual gases entrapped in the strengthener.
20. A mold assembly as recited in claim 1, wherein said mold assembly
includes temperature controlling means.
21. A mold assembly as recited in claim 1, wherein said strengthener chamber
comprises a contact wall for locating the strengthener, said contact wall
having a controlled surface finish.
22. A mold assembly as recited in claim 1, wherein said base mold and said
cover mold are rigid.

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23. A moid assembiy as recited in claim 1, wherein said deformable member
includes a deformable element and a membrane, said membrane being
sealingly mounted between said strengthener chamber and said
compression chamber, said deformable element being provided in at least
a portion of said compression chamber.
24. A mold assembly as recited in claim 23, wherein a surface of said
deformable element is so machined as to be complementary to the shape
of the composite part.

25. A mold assembly as recited in claim 24, wherein said machined surface of
said member includes a series of grooved channels so configured as to
receive said membrane.
26. A mold assembly as recited in claim 23, wherein said deformable element
is injected directly into said gap via said fluid control aperture.
27. A mold assembly as recited in claim 23, wherein said deformable element
includes a generally porous and elastic material.

28. A mold assembly as recited in claim 1, wherein said deformable member
includes an elastic material being provided in at least a portion of said
compression chamber and adjacent to said strengthener chamber.
29. A mold assembly as recited in claim 1, wherein said cover mold includes

28-04-2005 CA0400959
47
compartmentalized portions so configured as to independently move with
respect to one another toward and away from said strengthener chamber
for providing a gap of variable thickness.
30. A mold assembly as recited in claim 1, wherein said mold assembly further
includes a tube provided in said compression chamber and adjacent to said
strengthener chamber, said tube being connected to a pressure source and
deformable under pressure generated from the pressure source, said tube
including at least one extremity mounted through said cover mold for
controlling the pressure in said tube.
31. A mold assembly as recited in claim 1, wherein said cover mold includes a
compression wall including a plurality of passages provided adjacent to
said deformable member.

32. A mold assembly as recited in claim 31, wherein said plurality of passages
includes longitudinal passages and transversal passages configured in a
grid so as to cooperate with said deformable member.
33. A mold assembly as recited in claim 31, wherein said matrix injection inlet
of said base mold includes a diffusion passage extending on a contact wall
of said strengthener chamber; said diffusion passage being generally
aligned with at least one transversal passage and said matrix injection inlet
of said base mold being generally aligned with at least one longitudinal
passage.
34. A mold assembly as recited in claim 1, wherein said mold assembly

28-04-2005 CA0400959
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includes a porous medium provided in said compression chamber for
controlling the propagation of the fluid injected in said compression
chamber.
35. A mold assembly as recited in claim 34, wherein said porous medium is
made from a generally deformable element.
36. A mold assembly for generating a predetermined number of composite
parts from strengtheners in a generally solid phase and from matrix in a
generally liquid phase; said mold assembly comprising:

a) a base mold including a strengthener chamber;
b) a cover mold including a compression chamber,
c) at least one frame assembly, each including a separator defining a
further respective strengthener chamber and a further respective
compression chamber; said at least one frame assembly being so
configured as to be sealingly stacked one next to the other and
between said base moid and said cover mold, whereby each of
said strengthener chamber faces one of said compression
chamber to define adjacent pairs of chambers;
d) matrix injection inlets for injecting the matrix in said strengthener
chambers;
e) fluid control apertures for injecting a fluid in said compression
chambers; and
f) deformable members so provided between said adjacent pairs of
chambers as to pressurize the matrix toward the strengthener upon
compression by the fluid.

28-04-2005 CA0400959
49
37. A mold assembly as recited in claim 36, wherein each of said deformable
members is a membrane sealingly mounted between said adjacent pairs of
strengthener chamber and compression chamber.
38. A mold assembly as recited in claim 36, wherein said mold assembly
further includes evacuation outlets and vents, said evacuation outlets
extending from said strengthener chambers and through said mold
assembly; said vents extending from said compression chambers and
through said mold assembly.

39. A moid assembly as recited in claim 36, wherein said cover mold is one of
said at least one frame assembly.
40. A mold assembly as recited in claim 36, wherein said cover moid is one of
said at least one frame assembly including a cover reinforcement so
configured as to be rigidly mounted in its respective strengthener chamber.
41. A mold assembly as recited in claim 36, wherein said separator is rigid.
42. A mold assembly for generating a predetermined number of composite
parts from strengtheners and matrix; said mold assembly comprising:
a) a base mold including a contact wall;
b) at least one frame assembly so configured as to be sealingly stacked
one next to the other on said base mold defining a stacking
chamber thereby;
c) matrix injection inlets for injecting the matrix in the strengtheners

28-04-2005 CA0400959
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trough said base mold and said at least one frame assembly;
d) deformable elements, each having a respective compression wall and
a further respective contact wall, said deformable elements being
so configured as to be alternatively stacked with the strengthened
in said stacking chamber whereby each of said contact wall faces
one of said compression wall; and
e) a cover mold including a further respective compression wall and
being mounted in said stacking chamber.
43. A mold assembly as recited in claim 42, wherein each of said deformable
elements.is porous elastic material.
44. A mold assembly as recited in claim 43, wherein each of said at least one
frame assembly includes a fluid control aperture for injecting a fluid in said
stacking chamber to said deformable elements.
45. A mold assembly as recited in claim 42, wherein each of said at least one
frame assembly and said base mold are sealingly stacked in adjacent pairs
and said mold assembly further includes membranes sealingly mounted
between said adjacent pairs.

46. A mold assembly as recited in claim 45, wherein each of said at least one
frame assembly includes a fluid control aperture extending for injecting a
fluid between each of said deformable elements and each of said
membranes in said stacking chamber.
47. A mold assembly for generating a composite part from a strengthener and

38-04-2005 CA0400959
51
a matrix; said mold assembly comprising:
a) a base mold including a strengthener chamber for receiving the
strengthener; a matrix injection inlet for injecting the matrix in said
strengthener chamber and an evacuation outlet, said inlet and said
outlet defining a propagation direction;
b) a cover mold including a compression chamber and a fluid control
aperture for injecting a controlling fluid in said compression
chamber; said cover mold being so configured as to be sealingly
mounted on said base mold whereby said strengthener chamber
and said compression chamber are adjacent; and
c) a deformable member provided in a gap defined by said strengthener
chamber and said compression chamber said deformable member
generating a deformation zone in said compression chamber from
a portion of the matrix permeating the strengthener, said
deformable member being pressurized by the controlling fluid in
proximity of said deformation zone for redirecting the portion of
matrix generating said deformation zone back to the strengthener
and for propagating the matrix along said propagation direction.
48. A method for generating a composite part from a strengthener and a matrix
comprising:
a) sealingly positioning a deformable member in between a first chamber
of a first mold portion and a second chamber of a second mold
portion; said first chamber receiving the strengthener,
b) impregnating the strengthener with the matrix injected in said first
chamber,
c) propagating the matrix in and along the strengthener by pressurizing a

28-04-2005 CA0400959
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controlling fluid injected in said second chamber on said
deformable member.
49. A method as recited in claim 48, wherein said impregnating the
strengthener is performed at a vacuum pressure which is lower than
atmospheric pressure.
50. A method as recited in claim 48, wherein said propagating the matrix in and
along the strengthener is performed while heating said controlling fluid.

51. A method as recited in claim 48, wherein said propagating the matrix in and
along the strengthener is performed at a compaction pressure greater than
atmospheric pressure.
52. A method as recited in claim 48, wherein said propagating the matrix in and
along the strengthener by pressurizing a controlling fluid injected in said
second chamber on said deformable member is delayed after said injecting
the impregnating the strengthener with the matrix injected in said first
chamber is performed.
53. A method as recited in claim 48, further including vibrating the impregnated
strengthener to expel a significant portion of residual gases entrapped in
the strengthener.
54. A method as recited in claim 48, further including a solidification of the
composite part at a compaction pressure greater than atmospheric
pressure.

28-04-2005 CA0400959
53
55. A method as recited in claim 48, further including a cure of the strengthener
with heat transfer applied to said mold and the solidification of the
composite part at a compaction pressure greater than atmospheric
pressure.
56. A method as recited in claim 55, wherein said cure of the strengthener
uses ultra-violet light.
57. A method as recited in claim 54, wherein said solidification of the
composite part is performed while decreasing the temperature of the
strengthener.

58. A method as recited in claim 48, further including a positioning of a
deformable element in a second chamber of a second mold portion
adjacent to said deformable member.
59. A method as recited in claim 48, further including a positioning of a tube in
a second chamber of a second mold portion adjacent to said deformable
member.
60. A method as recited in daim 59, wherein said propagating the matrix in and
along the strengthener by pressurizing a controlling fluid is performed while
pressurizing said tube whereby said tube deforms and compresses said
member by compressing said controlling fluid.
61. A method as recited in claim 59, wherein said propagating the matrix in and
along the strengthener by pressurizing a controlling fluid is performed while

28-04-2005 CA0400959
54
pressurizing said tube whereby said tube deforms and compresses said
member.
62. A method as recited in claim 48, wherein said propagating the matrix in and
along the strengthener by pressurizing a controlling fluid is performed while
varying the position of compartmentalized portions of said second mold
portion with respect to said member.
63. A method as recited in claim 48, further including a deformation of said
member mating with passages in said second mold portion provided
adjacent to said member.
64. A method as recited in claim 48, further including a positioning of a porous
medium in a second chamber of a second mold portion adjacent to said
deformable member.
65. A method for generating a pre-determined number of composite parts from
strengtheners and matrix comprising:
a) sealingly positioning a deformable member in between a strengthener
chamber of a first mold portion and a compression chamber of a
second mold portion; said strengthener chamber including the
strengthener;
b) repeating said sealingly positioning a deformable member by stacking
a number of subsequent mold portions one next to the other
determined by a predetermined number of parts to manufacture;
c) impregnating the strengtheners with matrix injected in said
strengthener chambers;

28-04-2005 CA0400959
55
d) compacting the matrix toward the strengthener by pressurizing a
controlling fluid injected in said compression chamber on said
deformable member.
66. A method as recited in claim 65, wherein said impregnating the
strengthened with matrix injected in said strengthener chambers is
performed with a delay between each sequential injection of matrix in
consecutive strengtheners.
67. A method as recited in claim 65, further including a cure of the
strengtheners performed by heating said first mold portion; whereby said
second mold portions and said subsequent mold portions are sequentially
heated by heat transfer from a previously heated mold portion.
68. A method for generating a predetermined number of composite parts from
strengtheners and matrix comprising:
a) positioning an alternating stack of strengtheners and deformable
members in a stacking chamber generated by sealingly mounting
frame assemblies on a base mold assembly;
b) impregnating the strengtheners with matrix injected in said stacking
chamber;
c) compacting the matrix toward and along the strengtheners by
pressurizing on said stack of strengtheners and deformable
members.
69. A method as recited in claim 68, wherein said impregnating the
strengtheners with matrix is performed while successively injecting the

28-04-2005 CA0400959
56
matrix into consecutive strengtheners with a slight delay between each
injection.
70. A method as recited in claim 69, wherein said compacting the matrix is
performed while said successively injecting the matrix, said successively
injecting the matrix including at least a first injection in a first strengthener
and a second injection in a second strengthener with a delay from said first
injection; said second injection compressing said first strengthener by
pressurizing said deformable member provided in between said first and
second strengthener.
71. A method as recited in claim 68, wherein said positioning an alternating
stack of strengtheners and deformable members further provides for a
membrane provided in between the strengtheners and the deformable
members.
72. A method as recited in claim 71, wherein said compacting the matrix
toward and along the strengthener is performed while pressurizing a
controlling fluid injected in said stacking chamber on said membrane.

The present invention generally relates to a mold assembly (32, 34) and a method of using the mold for the manu-
facture of composite parts which, more particularly, are generated from a strengthener in a generally solid phase and a matrix in a
generally liquid phase. Various types of molds and processes may be used in order to impregnate a strengthener with a matrix such
that a composite part may be manufactured, but the efficiency rate and the duration of the manufacturing process significantly vanes
depending on the chosen type of mold and process. The present invention relates to a mold assembly and to the manufacture of
composites by using the mold assembly which includes the injection of the matrix in the mold assembly containing the strengthener
and a deformable member (36) which favors the impregnation of the matrix toward the strengthener.


Documents:

02681-kolnp-2005-abstract.pdf

02681-kolnp-2005-claims.pdf

02681-kolnp-2005-description complete.pdf

02681-kolnp-2005-drawings.pdf

02681-kolnp-2005-form 1.pdf

02681-kolnp-2005-form 3.pdf

02681-kolnp-2005-form 5.pdf

02681-kolnp-2005-international publication.pdf

2681-KOLNP-2005-(02-04-2013)-ASSIGNMENT.pdf

2681-KOLNP-2005-(02-04-2013)-CORRESPONDENCE.pdf

2681-KOLNP-2005-(02-04-2013)-FORM-1.pdf

2681-KOLNP-2005-(02-04-2013)-FORM-13.pdf

2681-KOLNP-2005-(02-04-2013)-FORM-2.pdf

2681-KOLNP-2005-(02-04-2013)-FORM-3.pdf

2681-KOLNP-2005-(02-04-2013)-FORM-5.pdf

2681-KOLNP-2005-(02-04-2013)-FORM-6.pdf

2681-KOLNP-2005-(02-04-2013)-OTHERS.pdf

2681-KOLNP-2005-(02-04-2013)-PA.pdf

2681-KOLNP-2005-(14-02-2013)-CORRESPONDENCE.pdf

2681-KOLNP-2005-(14-02-2013)-OTHERS.pdf

2681-KOLNP-2005-(15-10-2012)-CORRESPONDENCE.pdf

2681-KOLNP-2005-CORRESPONDENCE 1.1.pdf

2681-KOLNP-2005-CORRESPONDENCE-1.2.pdf

2681-KOLNP-2005-CORRESPONDENCE.pdf

2681-KOLNP-2005-FORM 13.pdf

2681-KOLNP-2005-FORM 6.pdf

2681-KOLNP-2005-OTHERS.pdf

abstract-02681-kolnp-2005.jpg


Patent Number 257566
Indian Patent Application Number 2681/KOLNP/2005
PG Journal Number 42/2013
Publication Date 18-Oct-2013
Grant Date 15-Oct-2013
Date of Filing 23-Dec-2005
Name of Patentee POLYVALOR, LIMITED PARTNERSHIP
Applicant Address 3535 CHEMIN QUEEN-MARY, BUREAU 220, MONTREAL, QUEBEC H3V 1H8, CANADA
Inventors:
# Inventor's Name Inventor's Address
1 TROCCHU, FRANCOIS 4562 BULLION, MONTREAL, QUEBEC H3C 3A7CANADA
2 RUIZ, EDUARDO 256 GALT, VERDUN, QUEBEC H4G 2P4 CANADA
PCT International Classification Number B29C 70/44
PCT International Application Number PCT/CA2004/000959
PCT International Filing date 2004-06-25
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2, 434, 447 2003-06-27 Canada