Fibre-reinforced composite moulding and manufacture thereof

1. A method of manufacturing a fibre-reinforced composite moulding, the method comprising the steps of:

(a) disposing at least one layer of fibrous reinforcing material within a mould;

(b) disposing at least one pre-preg layer adjacent to the fibrous reinforcing material, the pre-preg layer comprising fibrous reinforcement at least partially impregnated with uncured first resin material, to form a laminar assembly of the at least one layer of fibrous reinforcing material and the at least one pre-preg layer within the mould;

(c) applying a vacuum to the assembly;

(d) infusing a flowable uncured second resin material, under the vacuum by vacuum assisted resin transfer moulding, into the at least one layer of fibrous reinforcing material; and

(e) curing the first and second resin materials at least partially simultaneously to form the fibre-reinforced composite moulding which comprises at least one first structural portion formed from the fibrous reinforcement and the cured first resin material bonded to at least one second structural portion formed from the at least one layer of fibrous reinforcing material and the cured second resin material, wherein the second infused resin material has a curing temperature range that is lower than the curing temperature range of the first pre-preg resin material, the curing step is carried out at a temperature within the curing temperature range of the second infused resin material, and the curing of the second resin material is exothermic and generates heat to raise the temperature of the first resin material to within the curing temperature range of the first resin material,

the method further comprising the step, before step (a), of disposing a surfacing layer on the mould surface, the surfacing layer comprising a third uncured resin material and being in the form of at least one solid sheet, and in steps (a) and (b) the laminar assembly of the at least one layer of fibrous reinforcing material and the at least one pre-preg layer is disposed over the surfacing layer within the mould, and in the curing step (e) the third resin material is cured at least partially simultaneously with the first and second resin materials, and wherein in the curing step (e) the curing reaction of the second resin material is exothermic which generates heat which accelerates the curing of the third resin material.

2. A method according to claim 1 wherein in the at least one pre-preg layer the fibrous reinforcement is fully impregnated with uncured first resin material.

3. A method according to claim 2 wherein the pre-preg layer comprises a pre-consolidated slab of a plurality of layers of fibrous reinforcement fully impregnated with uncured first resin material.

4. A method according to claim 1 wherein the at least one pre-preg layer is partially impregnated and comprises a sandwich structure of a pair of fibrous reinforcement layers on opposed sides of a layer of the uncured first resin material.

5. A method according to claim 1 wherein the laminar assembly comprises a plurality of the layers of fibrous reinforcing material interleaved with a plurality of the pre-preg layers.

6. A method according to claim 1 wherein the surfacing layer comprises a plurality of surfacing layer segments assembled together to form a continuous surfacing layer.

7. A method according to claim 6 wherein each surfacing layer segment has at least one edge thereof that partially overlaps an adjacent surfacing layer segment.

8. A method according to claim 1 wherein the third resin material of the surfacing layer has at least one or both of (i) a thickness of from 100 to 300 microns and (ii) an applied weight thickness of from 100 to 400 grams per square meter (gsm).

9. A method according to claim 8 wherein the third resin material of the surfacing layer is supported on a carrier of a sheet material.

10. A method according to claim 9 wherein the sheet material of the surfacing layer has a weight of from 10 to 90 gsm.

11. A method according to claim 10 wherein the sheet material of the surfacing layer comprises a polyester spun bonded scrim material.

12. A method according to claim 9 wherein the sheet material of the surfacing layer is located at or proximal to a first face of the surfacing layer.

13. A method according to claim 12 wherein the first face of the surfacing layer is remote from the mould surface so that a majority of the third resin material is between the sheet material and the mould surface.

14. A method according to claim 1 wherein the second resin material and the third resin material have different viscosities.

15. A method according to claim 1 wherein the third resin material has a higher viscosity than that of the second resin material at room temperature (20 degrees Centigrade).

16. A method according to claim 15 wherein the ratio of the viscosity, measured at 20° C. ambient temperature, of the third resin material and of the second resin material is at least 100/1.

17. A method according to claim 16 wherein the ratio of the viscosity, measured at 20° C. ambient temperature, of the third resin material and of the second resin material is at least 1000/1.

18. A method according to claim 1 wherein in the curing step (e) the second resin material is adapted to initiate curing before the third resin material.

19. A method according to claim 1 wherein the curing step (e) is carried out at a temperature of from 40 to 90 degrees Centigrade.

20. A method according to claim 1 wherein the fibre-reinforced composite moulding is a wind turbine blade.