Method and apparatus for infiltration of a micro/nanofiber film

Abstract

There is provided an apparatus and method for manufacturing of an infiltrated fiber-based composite film. The apparatus comprises two tool blocks arranged opposite each other enabling a fiber-based film to be arranged between the tool blocks. At least one of the tool blocks comprises a recess so that the recess can form a sealed cavity enclosing a portion of the film when the tool blocks are in contact with each other. At least one of the tool blocks comprises a vacuum channel connecting cavity to a vacuum pump for drawing a vacuum in the cavity; a melt channel connecting the cavity to a source of molten material. The melt channel comprises a valve arrangement controlling delivery of the molten material to the cavity; pressure means to achieve an elevated pressure onto the molten material within the cavity such that a fiber film in the cavity is infiltrated by the molten material; and an ejection piston for ejecting an infiltrated fiber film from the cavity.

1 . An apparatus for manufacturing of an infiltrated fiber-based composite film, said apparatus comprising:
 two tool blocks ( 102   a,    102   b ) arranged opposite each other enabling a fiber-based film ( 106 ) to be arranged between said tool blocks, wherein at least one of said tool blocks comprising a recess ( 104   a,    104   b ); wherein at least one of said tool blocks is movable towards the opposing tool block such that said recess forms a sealed cavity configured to enclose a portion of said film when said tool blocks are in contact with each other; and   wherein at least one of said tool blocks comprises:   a vacuum channel ( 116 ) in a first end connected to said recess and in a second end connectable to a vacuum pump for drawing a vacuum in said cavity;   a melt channel ( 110 ) in a first end connected to said recess and in a second end connected to a source of molten material ( 108 ); said melt channel comprising a valve arrangement configured to control delivery of said molten material to said cavity;   a heater configured to heat said cavity to a temperature exceeding a melting temperature of said molten material;   pressure means configured to achieve an elevated pressure within said cavity such that a fiber film in said cavity is infiltrated by said molten material; and   an ejection piston ( 122 ) configured to eject an infiltrated fiber film from the cavity, when the tool blocks are in a retracted position spaced apart from each other.   
     
     
         2 . The apparatus according to  claim 1 , wherein said recess has a depth in the range of 5 to 500 micrometers. 
     
     
         3 . The apparatus according to  claim 1 , wherein said valve arrangement comprises:
 a channel valve ( 112 ) configured to control the delivery of molten material from said source to said melt channel; and   an injector valve ( 114 ) configured to control the delivery of molten material from said melt channel ( 7 ) to said cavity.   
     
     
         4 . The apparatus according to  claim 1 , wherein said pressure means are configured to provide a pressure within said cavity higher than 30 MPa 
     
     
         5 . The apparatus according to  claim 1 , wherein said pressure means comprises an injector piston ( 116 ) connected to said melt channel such that said molten material is infiltrated at an elevated pressure into said film in said cavity by means of actuation of said injector piston. 
     
     
         6 . (canceled) 
     
     
         7 . The apparatus according to  claim 1 , wherein said tool block comprises cooling means configured to cool said cavity to a temperature lower than said meting temperature of said molten material. 
     
     
         8 . The apparatus according to  claim 6 , wherein said cooling means comprises a cooling channel containing a fluidic cooling medium. 
     
     
         9 . The apparatus according to  claim 1 , wherein each tool block comprises a recess, and wherein said tool blocks are arranged such that said recesses face each other. 
     
     
         10 . (canceled) 
     
     
         11 . (canceled) 
     
     
         12 . An assembly for reel-to-reel manufacturing of an infiltrated fiber-based composite film, said assembly comprising:
 an apparatus according to  claim 1 ;   a micro/nanofiber film ( 12 );   a storage reel ( 8 ) holding said film;   a collecting reel ( 9 ) configured to receive said film;   wherein said film is arranged between said storage reel and said collecting reel such that a path of said film from said storage reel to said collecting reel runs between said tool blocks.   
     
     
         13 . The assembly according to  claim 12 , wherein said micro/nanofiber film comprise fibers selected from the group comprising polyimide, polyurethane, nylon, polyimide, polyacrylonitrile, polyaramid, high density polyethylene, PEEK, Kevlar polyester, boron nitride, carbon fibers, carbon nanotubes, inorganic fibers and graphene coated fibers. 
     
     
         14 . The assembly according to  claim 13 , wherein said film has a surface modified to facilitate wetting of the molten material to said film, wherein said surface modification compirses coating fibers of said film with Ag, Cu, Au, Ni, Pd, Ti and/or Pt or a combination thereof. 
     
     
         15 . A method for reel-to-reel manufacturing of a micro/nanofiber-based film infiltrated with metal or metal alloy matrix material, said method comprising the steps of;
 arranging micro/nanofiber-based film between a storage reel holding said film and a collecting reel receiving said film;   enclosing a portion of said film in a cavity formed by pressing together a first and a second tool block arranged opposite each other, wherein at least one of said tool blocks comprises a recess forming said cavity;   providing a molten material to said cavity;   elevating a pressure onto said molten material within said cavity such that a fiber film in said cavity is infiltrated by said molten material; and   cooling said cavity to a temperature below a melting temperature of said molten material; and   releasing said film by moving apart said tool blocks.   
     
     
         16 . The method according to  claim 15 , wherein providing a molten material to said cavity comprises:
 opening a channel valve ( 112 ) to allow molten metal to flow from the source of molten material ( 108 ) into the melt channel ( 110 );   closing the channel valve;   opening an injector valve ( 114 ) such that the molten metal flows into the cavity;   closing the injector valve; and   activating said injection piston ( 117 ) to push liquid melt into the cavity.   
     
     
         17 . The apparatus according to  claim 1 , wherein the valve arrangement comprises an injection piston ( 117 ) arranged to push liquid melt into the tool insert cavity. 
     
     
         18 . The apparatus according to  claim 1 , wherein the valve arrangement comprises a channel valve ( 112 ) configured to be opened to allow molten metal to flow from the source of molten material ( 108 ) into the melt channel ( 110 ). 
     
     
         19 . The apparatus according to  claim 1 , wherein the valve arrangement comprises an injector valve ( 114 ) configured to be opened such that the molten metal flows into the cavity.