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Abstract

A process for manufacturing simple or complex reinforcement preforms for use in resin transfer molding (RTM), structural reaction injection molding (SRIM) or similar molding processes includes applying a thermosetting binder, which is sensitive to selected ultraviolet or microwave radiation, to planar woven or non-woven reinforcing materials, the binder-bearing reinforcing material being placed into a three-dimensional mold and pressed into a desired shape, cured in the mold by applying a corresponding selected ultraviolet or microwave energy thereto to cure and rigidize the binder and hold reinforcement material in the three-dimensional shape resulting in a rigid three-dimensional preform to be used in subsequent molding operations. Structural reinforcements, sub-assemblies and the like may be applied to the preform to enhance the final properties of the final composite structure. A tool, including an integral ultraviolet light source, and a tool, including an integral microwave waveguide, are employed for pressing the binder-bearing reinforcing material into the desired shape and for supporting the transmission of the appropriate, corresponding electromagnetic energy thereto. The process provides rapid curing of the binder without involving heating of the reinforcement material to any significant degree.

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First Claim