Process for the rapid fabrication of composite gas cylinders and related shapes

Abstract

A method of fabricating a composite vessel encompassing rapid manufacturing. The process includes using a liner, of metal or plastic materials, over which a braided or developed preform is wrapped. The dry fiber wrapped liner is placed in a mold and resin injected into the cavity formed between the liner and the mold outer walls. The liner is flooded with heated and/or cooled pressurized fluid thus enabling complete and independent process control from within the liner for both the resin injection and the cure phases. Fiber placement control is determined through combined biaxial and triaxial braid/preform design, and by wrapping at controlled tension onto the supporting liner. Fiber tension control is further enhanced by the methodology of mold loading whereby tensioning forces are enacted during actual load and close. The process may use thermoset or thermoplastic resins and any of a variety fibrous reinforcements.

What is claimed is: 
     
         1 . A process of rapid manufacturing of a composite hollow article comprising:
 providing a liner;   applying a dry fiber over-wrap around the liner;   placing the liner with over-wrapped fiber into a mold cavity corresponding to the outer shape of the composite hollow article and providing a cavity between the liner and the mold wall;   delivering a fluid into the liner capable of heating or cooling the liner;   injecting resin into the cavity between the liner and the mold wall to permeate the fiber over-wrap;   removing the composite hollow article from the mold cavity; and
 a) wherein the liner is subsequently removed, or 
 b) wherein the over-wrapped fiber is in the form of a stitched fabric material, or woven fabric material, or filament wound tow material, or 
 c) wherein the resin used for the composite is thermoplastic resin. 
   
     
     
         2 . The process of  claim 1  wherein the liner is subsequently removed via melting. 
     
     
         3 . The process of  claim 1  wherein the liner is subsequently removed via dissolution. 
     
     
         4 . The process of  claim 1  wherein the over-wrapped fiber is in the form of a stitched or woven fabric material. 
     
     
         5 . The process of  claim 1  wherein the over-wrapped fiber is in the form of a filament wound tow material. 
     
     
         6 . The process of  claim 4  wherein the fabric material is constructed of bi-axial fibers. 
     
     
         7 . The process of  claim 4  wherein the fabric material is constructed of tri-axial fibers. 
     
     
         8 . The process of  claim 4  wherein the fabric material is constructed of a combination of bi-axial and tri-axial fibers. 
     
     
         9 . The process of  claim 1  wherein the resin used for the composite is thermoplastic resin. 
     
     
         10 . The process of  claim 9  further comprising
 during the step of injecting resin, controlling the temperature of the fluid inside the liner during injection; and 
 wherein the step of heating the fluid comprises heating the fluid in the liner to a temperature higher than the melt temperature of the resin.