Methods for manufacturing resin-infused parts having integral protective coatings
A method of manufacturing a resin-infused part, may include: preparing a laminate by layering a curable protective film onto a fibrous preform; infusing resin into the laminate under a vacuum, such that the resin impregnates the fibrous preform and the protective film adheres to the fibrous preform; and curing the laminate at a curing temperature.
1 . A method of manufacturing a resin-infused part, the method comprising:
preparing a laminate by layering a curable protective film comprising a prepolymer layer and a resin blocking layer onto a fibrous preform, such that the resin blocking layer is disposed between the prepolymer layer and the fibrous preform;
infusing resin into the laminate under a vacuum, such that the resin impregnates the fibrous preform and the curable protective film adheres to the fibrous preform; and
curing the laminate at a curing temperature.
2 . The method of claim 1 , further comprising sealing the laminate within a vacuum bag.
3 . The method of claim 1 , wherein preparing the laminate further comprises:
disposing a porous release film beneath the fibrous preform; and
covering the curable protective film with a released caul plate.
4 . The method of claim 1 , wherein the curable protective film further comprises a reinforcement layer.
5 . The method of claim 4 , wherein the prepolymer layer comprises epoxide resins.
6 . The method of claim 5 , wherein the prepolymer layer further comprises an ultraviolet-visible light (UV-vis)-blocking additive.
7 . The method of claim 5 , wherein curing the laminate causes the epoxide resins to polymerize to form a thermosetting polymer coating layer.
8 . The method of claim 4 , wherein the prepolymer layer comprises at least one isocyanate and at least one polyol.
9 . The method of claim 8 , wherein curing the laminate causes the prepolymer layer to polymerize, such that a polyurethane thermosetting coating layer is formed.
10 . A method of manufacturing a resin-infused part, the method comprising:
applying a first curable film comprising a prepolymer layer and a resin blocking layer to a caul plate;
installing the caul plate over a fibrous preform, such that the resin blocking layer is disposed between the prepolymer layer and the fibrous preform;
infusing resin into the fibrous preform under vacuum, such that the fibrous preform is impregnated by the resin and the first curable film adheres to the fibrous preform; and
curing the fibrous preform and the first curable film.
11 . The method of claim 10 , wherein the first curable film comprises epoxide resins, and wherein curing the fibrous preform and the first curable film forms an epoxy surfacing layer.
12 . The method of claim 10 , wherein the first curable film comprises polyurethane prepolymers, and wherein curing the fibrous preform and the first curable film forms a polyurethane paint replacement layer.
13 . The method of claim 10 , wherein the first curable film further comprises a tack layer.
14 . The method of claim 10 , further comprising applying a second curable film to the first curable film.
15 . The method of claim 14 , wherein the first curable film comprises polyurethane prepolymers and wherein the second curable film comprises epoxide resins.
16 . A method of manufacturing a resin-infused part, the method comprising:
applying a first curable film comprising a prepolymer layer and a resin blocking layer to a fibrous preform, such that the resin blocking layer is disposed proximate the fibrous preform;
installing a caul plate over the first curable film;
infusing resin into the fibrous preform under vacuum, such that the resin permeates the fibrous preform and the first curable film adheres to fibrous preform; and
curing the fibrous preform and the first curable film.
17 . The method of claim 16 , further comprising sealing the caul plate and the fibrous preform within an airtight tool.
18 . The method of claim 16 , wherein the caul plate further comprises a release layer.
19 . The method of claim 16 , wherein the first curable film comprises epoxide resins, and wherein curing the fibrous preform and the first curable film forms an epoxy surfacing layer.
20 . The method of claim 16 , wherein the first curable film comprises polyurethane prepolymers, and wherein curing the fibrous preform and the first curable film forms a polyurethane paint replacement layer.