MANUFACTURE

The present invention relates to a hinge made of composite material, in particular a hinge which may be fixed or integrated into two parts in composite material that must be connected to each other in a rotary manner. The present invention also relates to a process for manufacturing such a hinge.

EP 1738895 describes a hinge comprising two groups of layers of carbon fibers impregnated with epoxy resin, which layers are arranged on and under a substrate of aramid fibers impregnated with a polyurethane resin. Said known hinge is complex and expensive to manufacture, as it requires layers of pre-impregnated fibers.

To solve said problem WO 2012/035465 describes a hinge comprising two groups of layers of fibers arranged on and under two opposite edges of a substrate of material flexible and compatible for adhesion with resins for composite materials, so that a central portion of the substrate is not covered by these layers, wherein the substrate and the layers are embedded in a cured and flexible resin.

The hinges of EP 1738895 and WO 2012/035465 have a relatively clear and sudden fold line between a rigid portion and a flexible portion. If deformed, these known hinges have a very accentuated edge between the two portions, with consequent problems of stress concentration and therefore of rapid wear.

Another problem of such known hinges is represented by their aesthetic finish, since it is not possible to carry out a product in which the two portions appear to be well-defined, almost isolated from each other.

The object of the present invention is therefore to provide a hinge free from said drawbacks. Said object is achieved with a hinge and a manufacturing process whose main features are specified in claims 1 and 18, respectively, while other features are specified in the remaining claims.

Thanks to its particular layered structure, the hinge according to the present invention allows to obtain a flexible portion having a flexural rigidity variable according to the distance from the rigid portion, so as to obtain a hinge relatively more resistant and more versatile than the known hinges. Such resistance can be considerably increased by applying particular layers of reinforcing fibers on the substrate and on the flexible sheets, in particular on holes made in these flexible sheets, so that the latter are "pinched" in the rigid portion of the hinge. The flexural rigidity of the flexible portion can be controlled easily by overlapping the flexible sheets with appropriate arrangements and dimensions.

The aesthetic finish of the hinge is improved thanks to the clear and clean interface between the rigid portion and the flexible portion, which may be accentuated by a slit arranged between these portions.

The substrate of the rigid portion is preferably provided with a particular bevel which facilitates the deployment of the flexible sheets and make less sharp the interface between the rigid portion and the flexible portion of the hinge. On the other hand, it is possible to accentuate this interface by leaving a non-beveled portion on the edge of the substrate and/or by arranging this edge beside a particular rib formed on the mold for the manufacture of the hinge, which rib prevents the passage of resin from the rigid portion the flexible portion.

The substrate described in the Italian patent application MI2012A000307 and fabrics of carbon fiber described in the Italian patent applications MI2012A000244 and MI2012A000245 are particularly suitable for the application in the present hinge.

The hinge can be manufactured with a particular process that is fast and easy to carry out, especially if layers of fibers pre-impregnated with resin are employed as reinforcement layers.

Further advantages and characteristics of the hinge and of the process according to the present invention will become apparent to those skilled in the art from the following detailed and non-limiting description of some of their embodiments with reference to the attached drawings in which:

Figure 1 shows a top view of a first embodiment of the hinge during a first step of the process;

Figure 2 shows the section II-II of Figure 1;

Figure 3 shows the hinge of Figure 2 during a second step of the process;

- Figure 4 shows the hinge of Figure 2 during a third step of the process;

Figure 5 shows the hinge of Figure 2 at the end of the process; Figure 6 shows a top view of a second embodiment of the hinge during a step of the process;

Figure 7 shows the section VII-VII of Figure 6; and

Figure 8 shows the hinge of Figure 7 at the end of the process.

Referring to Figures 1 and 2, it is seen that in a first step of the process at least one substrate 1 , in particular having a substantially prismatic shape, of rigid composite material is arranged on at least one functional surface of a mold 2 for composite materials. A release sheet 3, known as peel-ply, may be arranged between mold 2 and substrate 1. The thickness of substrate 1 is greater than 1 mm, in particular comprised between 1 and 5 mm. An edge la of substrate 1 is provided with a bevel lb on the opposite side to mold 2. Bevel lb forms an angle a comprised between 1 ° and 45° with the surface of edge la of substrate 1 opposite to bevel lb, i.e. the surface of substrate 1 in contact with mold 2, the width wl of bevel lb is comprised between 5 and 60 mm, and/or the height h of bevel lb is comprised between 50% and 100% of the thickness of substrate 1. End lc of edge la provided with bevel lb preferably comprises also a non- beveled portion which has a height between 0,3 and 0,7 mm, in particular 0,5 mm, and is rounded or substantially perpendicular to the surface of substrate 1 in contact with mold 2.

Substrate 1 is preferably a sheet of CFRP (Carbon-Fiber-Reinforced Polymer) manufactured with a SMC (Sheet Molding Compound) process, as the product and the process described in Italian patent application MI2012A000307, which is incorporated herein by reference. In particular, substrate 1 is a sheet containing carbon fibers having a length between 5 and 50 mm and embedded in a random manner in a matrix of vinylester-phenolic resin that has already been cured. The flexural rigidity of substrate 1 is greater than 0, 1 Nm/rad, in particular greater than 100 Nm/rad.

Referring to Figure 3, it is seen that in a second step of the process at least one first layer 4 (indicated with a bold line) of resin for composite materials is applied on the surface of substrate 1 opposite to mold 2, so as to cover at least partially bevel lb. Width w2 of the first resin layer 4 is comprised between 5 and 50 mm. The first resin layer 4 is applied onto edge la of substrate 1 so as to leave preferably uncovered by the first resin layer 4 a portion Id of edge la adjacent to end lc. Distance dl between end lc of edge la of substrate 1 and the first resin layer 4, i.e. the width of said uncovered portion Id, is preferably comprised between 1 and 15 mm, in particular comprised between 3 and 5 mm.

A first flexible sheet 5 comprising fibers is arranged on mold 2, i.e. on the release sheet 3, and covers at least partially edge la of substrate 1, so that edge la of substrate 1 is comprised between mold 2 and the first flexible sheet 5. The first resin layer 4 is in turn comprised between substrate 1 and the first flexible sheet 5, which is, however, in direct contact with substrate 1 in said first portion Id of edge la not covered by the first resin layer 4.

A second layer 6 (always indicated with a bold line) of resin for composite materials is applied onto the first flexible sheet 5, so that the two surfaces of at least one first portion 5 a of the first flexible sheet 5 in contact with substrate 1 are provided respectively with the first resin layer 4 and/or the second resin layer 6. The second resin layer 6 is applied also on a second portion 5b of the first flexible sheet 5, having a width substantially equal to distance dl, which is adjacent to portion Id of substrate 1 and is free form the first resin layer 4. The second resin layer 6 is applied also onto a third portion 5c of the first flexible sheet 5 which is in contact with mold 2 or with release sheet 3, namely protrudes beyond edge la of substrate 1.

A second flexible sheet 7 comprising fibers is arranged at least partially on the first flexible sheet 5, so that at least one portion of the second resin layer 6 is comprised between the first flexible sheet 5 and the second flexible sheet 7. In the present embodiment the second flexible sheet 7 is entirely arranged on the first flexible sheet 5, however in an alternative embodiment a portion of the second flexible sheet 7 may extend beyond the first flexible sheet 5 and be arranged on a first portion 1 e of substrate 1 adjacent to edge la, in which case the first resin layer 4 and/or the second resin layer 6 extend between the second flexible sheet 7 and the portion le of substrate 1 for joining the second flexible sheet 7 to substrate 1. Distance d2 between end lc of edge la of substrate 1 and the end of the edge of the second flexible sheet 7 arranged on substrate 1 is greater than 5 mm, in particular comprised between 5 and 50 mm, more in particular comprised between 15 and 25 mm. A portion 7a of the second flexible sheet 7 is joined to the third portion 5c of the first flexible sheet 5 by means of the second resin layer 6. Width w3 of said portion 7a is greater than 2 mm, in particular comprised between 3 and 30 mm, more particularly between 3 and 5 mm.

The first flexible sheet 5 and/or the second flexible sheet 7 are preferably provided with one or more holes 8, 9, wherein a hole 8 of the first flexible sheet 5 is arranged at least partially on a hole 9 of the second flexible sheet 7. Holes 8, 9 preferably lead onto bevel lb of substrate 1 and are preferably made on the flexible sheets 5, 7 before the latter are arranged onto substrate 1.

In another embodiment, one or more further flexible sheets (not shown in the figure) comprising fibers, which may be provided with further holes arranged on holes 8, 9, may be arranged one above the other on the first flexible sheet 5, on the second flexible sheet 7 and/or on substrate 1 , at least one layer of resin for composite materials being applied between two adjacent flexible sheets.

Referring to Figure 4, it is seen that in a third step of the process one or more layers 10 of fibers preferably impregnated with a resin which is not yet cured, also known as pre-preg layers, are arranged onto substrate 1 , onto the first flexible sheet 5, onto the second flexible sheet 7 and/or onto any further flexible sheets arranged on the first flexible sheet 5 and/or on the second flexible sheet 7, so as to cover holes 8, 9. The first flexible sheet 5 and the second flexible sheet 7 are then comprised between substrate 1 and the fibers layers 10. In particular, four layers 10 of impregnated carbon fibers having a thickness comprised between 0,1 and 1 mm, in particular between 0,2 and 0,4 mm, and substantially the same shape are arranged at least partially one on the other on substrate 1, the first flexible sheet 5 and the second flexible sheet 7. Width w4 of layers 10 of impregnated carbon fibers is comprised between 20 and 50 mm.

A sealing tape 11 is preferably applied onto an edge of the upper layer of fibers 10 and onto the upper flexible sheet, in particular the second flexible sheet 7, to create a barrier to the resin of layers 10.

In a subsequent step of the process, not shown in the figures, mold 2 provided with substrate 1, the flexible sheets 5, 7 and layers 10 of impregnated fibers is sealed in a vacuum bag and introduced into an autoclave, in which it is subjected to a pressure comprised between 3 and 6 bar and to a temperature comprised between 100 and 120 °C for a time comprised between 1 and 3 hours, so as to cure the first resin layer 4, the second resin layer 6 and the resin of layers 10 of impregnated fibers.

Referring to Figure 5, it is seen that at the end of the process said whole, once extracted from the autoclave, cooled and separated from mold 2 and from the release sheet 3, comprises a rigid portion 12 corresponding to substrate 1 and to the portion of the flexible sheets 5, 7 joined in one piece to substrate 1 by means of the resin layers 4, 6. The rigid portion 12 is thus integral with a flexible portion 13 corresponding to the portion of the flexible sheets 5, 7 which is not joined to substrate 1 and can be bent with respect to the rigid portion 12 as indicated by the dashed lines. The flexural rigidity in a section of the flexible portion 13, namely the radius of curvature in this section when the flexible portion 13 is bent, is inversely proportional to its distance from the rigid portion 12. Substrate 1 forms a single piece also with layers 10 of impregnated fibers both through the portion of these layers which are joined to substrate 1 and through the resin that has penetrated into holes 8, 9 of the flexible sheets 5, 7. A slot 14 is arranged between the rigid portion 12 and the flexible portion 13, namely between portion 5b of the first flexible sheet 5 not provided with the first resin layer 4 and portion Id adjacent to end lc of edge la of substrate 1.

Referring to Figures 6 and 7, it is seen that in a second embodiment, similar to the first embodiment if not disclosed and/or shown otherwise, at least one edge 21a of a substrate 21 is arranged beside a rib 22a which protrudes from the functional surface of a mold 22. Rib 22a presents a substantially prismatic shape with a trapezoidal section, with base angles comprised between 80° and 90°. The height of rib 22a is preferably greater than the thickness of substrate 21. A portion 25a of a first flexible sheet 25 is applied onto substrate 21 by means of at least one first resin layer 24 which covers the surface of edge 21a of substrate 21 opposite to mold 22 up to its end adjacent to rib 22a. The first flexible sheet 25 protrudes from edge 21a of substrate 21 , overcomes rib 22a and continues on the functional surface of mold 22. A second flexible sheet 27 is applied onto the first flexible sheet 25 by means of a second resin layer 26 which covers the first flexible sheet 25 up to a portion adjacent to mold 22, i.e. arranged beyond rib 22a. Also the second flexible sheet 27 protrudes from edge 21a of substrate 21, overcomes rib 22a and continues on a second portion 25c of the first flexible sheet 25 arranged on the functional surface of mold 22. The second flexible sheet 27 covers portion 25 a of the first flexible sheet 25 and a portion 21e of substrate 21 adjacent to its edge 21a. The second flexible sheet 27 is joined to portion 21e of substrate 21 by means of a layer of resin for composite materials, for example the first resin layer 24 which extends beyond edge 21a of substrate 21 toward portion 21e.

In a subsequent step of the process, not shown in the figures, mold 22 provided with substrate 21 and the flexible sheets 25, 27 is sealed in a vacuum bag and introduced into an autoclave to be subjected to a pressure comprised between 3 and 6 bar and to a temperature comprised between 100 and 120 °C for a time comprised between 1 and 3 hours, so as to cure the first resin layer 24 and the second resin layer 26.

Referring to Figure 8, it is seen that at the end of the process such a whole, once extracted from the autoclave, cooled and separated from mold 22, comprises a rigid portion 32 corresponding to substrate 21 and to the portion of the flexible sheets 25, 27 joined to substrate 21. The rigid portion 32 forms a single piece with a flexible portion 33 corresponding to the portion of the flexible sheets 25, 27 that is not joined to substrate 21 and can be bent with respect to substrate 21 in the manner indicated by the dashed lines.

The thickness of the first resin layer 4, 24 and/or the second resin layer 6, 26 is comprised between 0,01 and 2 mm. The first resin layer 4, 24 and/or the second resin layer 6, 26 preferably comprise a thermosetting resin, in particular an epoxy resin such as the resin Cytec FM87-1.

The thickness of the first flexible sheet 5, 25 and/or of the second flexible sheet 7, 27 is comprised between 0,1 and 0,5 mm, in particular comprised between 0,2 and 0,3 mm. The flexural rigidity of the first flexible sheet 5, 25 and/or of the second flexible sheet 7, 27 before the polymerization of resins 4, 6, 24, 26 is less than 0,1 Nm/rad.

The first flexible sheet 5, 25 and/or the second flexible sheet 7, 27 and/or any further flexible sheets preferably comprise a fabric of carbon fiber that can be dry, i.e. not impregnated with resins, or impregnated with resins which are flexible when cured. Said carbon fiber fabric is laminated with a polyurethane or acrylic film, as the fabric described in Italian patent application MI2012A000244 which is incorporated herein by reference, and/or is impregnated with a silicone or acrylic emulsion as the fabric described in the application Italian patent MI2012A000245 which is incorporated herein by reference.

It is obvious that the term hinge should be interpreted in the broadest sense of the present invention, given that the external profiles of substrate 1, 21 and the flexible sheets 5, 7, 25, 27 may have different shapes and sizes.

Possible variants and/or additions may be made by those skilled in the art to the embodiment of the invention here described and illustrated remaining within the scope of the following claims. In particular, further embodiments of the invention may include the technical features of one of the following claims with the addition of one or more technical features, taken individually or in any mutual combination, described in the text and/or illustrated in the drawings.