CN108602205A - 通过用遮罩形成初始预成型件来制造三维预成型件的方法 - Google Patents

通过用遮罩形成初始预成型件来制造三维预成型件的方法 Download PDF

Info

Publication number
CN108602205A
CN108602205A CN201780008880.9A CN201780008880A CN108602205A CN 108602205 A CN108602205 A CN 108602205A CN 201780008880 A CN201780008880 A CN 201780008880A CN 108602205 A CN108602205 A CN 108602205A
Authority
CN
China
Prior art keywords
preformed member
polymer
shade
initial
synusia
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201780008880.9A
Other languages
English (en)
Inventor
约翰内斯·特赖贝尔
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Coriolis Composites SAS
Coriolis Group
Original Assignee
Coriolis Group
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Coriolis Group filed Critical Coriolis Group
Publication of CN108602205A publication Critical patent/CN108602205A/zh
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/20—Making multilayered or multicoloured articles
    • B29C43/203—Making multilayered articles
    • B29C43/206—Making multilayered articles by pressing the material between two preformed layers, e.g. deformable layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/04—Making preforms by assembling preformed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/06—Making preforms by moulding the material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/06—Making preforms by moulding the material
    • B29B11/12—Compression moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/002—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/002—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor characterised by the choice of material
    • B29C51/004—Textile or other fibrous material made from plastics fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
    • B29C51/145—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets having at least one layer of textile or fibrous material combined with at least one plastics layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/345—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using matched moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • B29C2043/189—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles the parts being joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/02—Combined thermoforming and manufacture of the preform
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
    • B29C51/082—Deep drawing or matched-mould forming, i.e. using mechanical means only by shaping between complementary mould parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/0072—Orienting fibers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0223—Vinyl resin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0292—Polyurethane fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B32B2262/065—Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/558—Impact strength, toughness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/748—Releasability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/18—Aircraft

Abstract

本发明涉及一种制造三维预成型件的方法，该方法包括：制造包括多个堆叠的层片的初始预成型件(4)，所述层片由单向连续纤维和第一聚合物形成；和在压力机(9)的凸形成型工具(92)和凹形成型工具(91)之间热成型初始预成型件以获得三维预成型件(1)。在成型步骤中，外遮罩被安置在初始预成型件(4)和凸形工具(62)之间的界面处，以及在初始预成型件和凹形工具(91)之间的界面处，所述外遮罩由第二聚合物形成，使得在成型步骤期间，外遮罩保持为固态并变形。

Description

通过用遮罩形成初始预成型件来制造三维预成型件的方法
技术领域
本发明涉及一种制造由复合材料制成的三维预成型件的方法。
背景技术
用于制造三维预成型件的方法是已知的，并且其包括制造由多个堆叠的纤维层片形成的初始预成型件，以及在压力机的凸形成型工具和凹形成型工具之间形成初始预成型件，以便获得具有期望的最终形式的三维预成型件。然后，使用三维预成型件形成由复合材料制成的部件。
可以使用预浸渍有热塑性或热固性聚合物的织造或非织造的单向纤维制造初始预成型件。成型步骤通常是热成型步骤，在所谓的成型温度下进行，以增加初始预成型件的成型性。在所述成型步骤期间，会发生多个变形机械作用，特别是层片间摩擦机械作用、预成型件和工具之间的摩擦机械作用、层片内剪切机械作用和弯曲机械作用。
根据最终预成型件的形状，特别是在具有复杂形状(例如具有双曲线)的预成型件的情况下，纤维织物易于起皱。
发明内容
本发明的目的是提出一种旨在限制具有复杂形状的三维预成型件中的缺陷的方案。
为此，本发明涉及一种用于制造三维预成型件的方法，该方法包括：制造包含多个堆叠层片的初始预成型件，所述层片由单向连续纤维和第一聚合物形成；以及在压力机的凸形成型工具和凹形成型工具之间使所述初始预成型件热成型，以便获得三维预成型件，其特征在于，在成型步骤中，外遮罩被安置在初始预成型件和凸形工具之间的界面处以及在初始预成型件和凹形工具之间的界面处，所述外遮罩由第二聚合物形成，该第二聚合物与第一聚合物不同，使得在成型步骤期间，所述外遮罩保持固态并变形。
根据本发明，将遮罩安置在预成型件和压制工具之间，在成型步骤期间预成型件的温度(称为成型温度)被限定为使得遮罩能够变形，以便吸收遮罩和工具之间的摩擦应力。遮罩在成型过程中保持固态，通过伸长或断裂而变形，并允许预成型件在压力机中滑动而不粘连。外遮罩通过限制或甚至消除预成型件的局部变形来稳定预成型件的外表面，从而提供预成型件的纤维的均匀变形。遮罩限制了第一聚合物和工具表面之间的接触。遮罩和工具之间的干摩擦力似乎弱于具有聚合物的纤维和工具之间的粘性摩擦力。
因此，根据本发明的方法增强了成型工具和预成型件之间的滑动机械作用，从而限制或甚至消除了在现有的成型方法中的由于预成型件和成型工具之间的摩擦导致的预成型件外层片的纤维缺陷。
该初始预成型件可以是二维的，通过在工具的平坦表面上铺设而获得，或者它可以是三维的，由此可以进行成型步骤以获得具有复杂形状的，不能通过铺设、特别是布置纤维而获得的三维部件。
根据本发明的方法可以有利地用于制造由复合材料制成的部件，特别是在汽车或航空领域。
此外，所述遮罩限制了，或者甚至消除了第一聚合物和所述工具之间的直接接触，并因此消除了预成型件和工具之间的粘合问题，从而使脱模更容易。
在其生产之后，可以以自动或手动的方式将遮罩施加在初始预成型件的外层片上，优选施加热量以保证在随后的预成型件处理操作期间将该遮罩保持在预成型件上。根据另一个实施方式，第一层片铺设在先前安置在铺设工具上的第一外遮罩上。在铺设了所有层片之后，将第二外遮罩施加到最后层片上。根据另一个实施方式，遮罩被安置在预成型件上和/或压力机的一个或多个工具上。优选通过纤维布置施加的单向连续纤维是，例如，碳纤维，玻璃纤维，合成纤维(如芳族聚酰胺纤维、聚乙烯纤维)，和/或天然纤维(如亚麻纤维)。
所述成型步骤是热成型步骤，由此在成型步骤之前和/或在成型步骤期间将初始预成型件加热到成型温度以增加预成型件的成型性。初始预成型件可以在成型步骤之前通过在炉子或通道中通过而被预热，和/或预成型件可以在成型步骤期间通过加热凸形成型工具和/或凹形成型工具来加热。优选地，特别是在干燥预成型件的情况下，所述预成型件仅通过在炉子或通道中通过而被预热，由此压力机的工具不被加热，从而简化了压制工具。
第二聚合物可以是热塑性或热固性聚合物，优选热塑性聚合物。
根据一个实施方式，外遮罩由第二热塑性聚合物形成，其中，成型步骤在成型温度下进行，该成型温度低于第二聚合物的熔融温度，并且优选低于第二聚合物的玻璃化转变温度。
在第一热塑性聚合物的情况下，第一聚合物在成型温度下优选为液态或粘性液态，并且成型温度优选大于第一聚合物的玻璃化转变温度，优选接近第一聚合物的熔融温度，例如略高于第一聚合物的熔融温度，从而改善预成型件的成型性，由此第二聚合物的熔融温度大于第一聚合物的熔融温度。根据另一个实施方式，根据第一聚合物的性质，该成型温度高于所述第一聚合物的玻璃化转变温度，并且低于所述第一聚合物的熔融温度。
在第一热固性聚合物的情况下，第一聚合物在成型温度下优选为液态或粘性液态，并且成型温度优选大于第一聚合物的玻璃化转变温度且小于第一聚合物的固化或交联温度。
根据另一个实施方式，外遮罩由第二热固性聚合物形成，其中，成型步骤在成型温度下进行，在该成型温度下第二聚合物保持固态，且该成型温度优选低于第二聚合物的玻璃化转变温度。
在热塑性聚合物的情况下，所述第一热塑性聚合物和/或第二热塑性聚合物为，例如，选自聚酰胺、如聚对苯二甲酸乙二醇酯的聚酯、聚醚砜、聚醚醚酮、聚亚苯基硫醚、聚氨酯、环氧化物、聚烯烃、聚乳酸或一种或多种所述聚合物的混合物。
在热固性聚合物的情况下，所述第一热固性聚合物和/或第二热固性聚合物为，例如，选自环氧化物、聚酯、乙烯基酯、酚醛树脂、聚酰亚胺或双马来酰亚胺。
根据一个实施方式，外遮罩是由第二聚合物制成的长丝以随机方式取向形成的非织造遮罩。在此实施方式中，遮罩的非织造结构增加了预成型件的渗透性，从而促进了输注和/或注射，由此遮罩提供了穿流效应(draining effect)，更特别是在输注的情况下。遮罩还可以增加预成型件的冲击强度和/或改善预成型件的表面外观。
根据一个实施方式，外遮罩是由热塑性聚合物制成的非织造遮罩。
根据另一个实施方式，遮罩由聚合物膜，特别是热塑性聚合物膜形成。
根据一个实施方式，所述方法包括生产所谓的干燥初始预成型件，其包含具有由第一聚合物形成的粘合剂的纤维，所述预成型件包含小于10wt％的粘合剂，优选小于5wt％的粘合剂，将在热成型之后得到的所谓干燥三维预成型件经历如下操作：其中与第一聚合物相容的浸渍聚合物通过注入和/或输注浸渍，以形成由复合材料制成的部件。具有粘合剂的干燥预成型件包含少量粘合剂，通常小于5％，由此保持预成型件的内聚力，同时允许其随后的浸渍。干燥预成型件是通过施加设置有粘合剂的干纤维和/或通过施加没有粘合剂的干纤维而获得的，以及，所述粘合剂的施加，例如，通过喷射液体粘合剂和/或通过喷射粉末形式粘合剂在施加表面上和/或先前铺设的干燥纤维上形成。
根据另一个实施方式，初始预成型件由预浸渍有第一热塑性或热固性聚合物的纤维制成，其量足以形成最终复合材料部件的基质，该方法包括制备包含至少30wt％，优选至少40wt％的第一聚合物的初始预浸渍预成型件，由此，在可能的固结或者固化操作后，第一聚合物构成由三维预成型件获得的复合材料制成的部件的基质。
根据一个实施方式，外遮罩具有4至100g/m2的单位面积重量。
根据一个实施方式，外遮罩具有4至35g/m2，优选至少10g/m2的单位面积重量。
根据一个实施方式，遮罩是聚酰胺(PA)遮罩，特别是共聚酰胺遮罩。
根据一个实施方式，形成步骤在第一聚合物处于液态或粘性液态的成型温度下进行，由此成型温度高于第一聚合物的玻璃化转变温度。
根据一个实施方式，所述初始预成型件包括插入在初始预成型件的两个层片之间的至少一个内遮罩，所述内遮罩由第三聚合物形成，所述第三聚合物优选在成型步骤期间处于固态以便提升两个层片之间的滑动机械作用。内遮罩限制两个层片之间的接触，并因此限制两个层片通过第一聚合物的粘合。因此，这样的内遮罩增加了预成型件的成型性。所述第三聚合物是热塑性或热固性聚合物，其中，成型温度低于第三聚合物的玻璃化转变温度。
此外，在干燥预成型件的情况下，内遮罩增加了渗透性并且增强了输注和/或注射操作。
根据一个实施方式，初始预成型件通过所谓的纤维布置方法12生产，由此，初始预成型件的生产包括，在铺设工具上使用施加(application)或压实辊通过接触施加单向连续纤维在限定方向上的堆叠层片的生产，其中每个层片通过在铺设工具上或在前一层片的带上以一个方向施加(application)一个或多个带来生产，由此每个带由一个或多个纤维形成。纤维布置通过已知的纤维铺设头而有利地自动化，所述纤维布置头包括：压实辊，其意图与工具接触以施加由一个或多个连续扁平纤维形成的带，和引导系统，其用于根据不同轨迹通过施加头相对于铺设表面的相对位移引导所述辊上的一个或多个纤维。
所述单向连续纤维优选采用扁平单向连续纤维的形式，通常称为丝束，包括多个长丝。例如，纤维具有八分之一英寸、四分之一英寸或半英寸(1/8”、1/4”或1/2”)的宽度。在本文中使用的术语“纤维”也用于表示更大宽度的、超过1/2英寸的纤维，其在布置技术中通常称为带(tape)。铺设的纤维可以是设置有粘合剂的干燥纤维，或用热固性或热塑性聚合物预先浸渍的纤维。
根据其他实施方式，通过堆叠织物获得预成型件的层片。
附图说明
通过参考附图阅读本发明的以下具体的说明性描述以及本发明当前优选的实施方式，将更好地理解本发明，并且更清楚地显现其他目的、细节、特征和优点，其中：
-图1是根据本发明的方法生产的三维预成型件的一个实例的示意性剖视图；
-图2是表示初始预成型件的铺设操作的示意侧视图；
-图3是表示在初始预成型件上施用外遮罩的示意侧视图；
-图4和5是压力机的示意剖视图，其显示出了图3中初始预成型件的成型操作；以及
-图6是根据第二实施方式的初始预成型件的层片堆叠的示意图，其除了两个内遮罩之外还设置有两个外遮罩。
具体实施方式
图1显示了三维预成型件1的一个实例，该三维预成型件1可以使用根据本发明的方法，通过连续纤维的铺设并通过成型来生产。预成型件具有带有环形边缘12的球冠11的形状。
图2至5示出了生产所述三维预成型件1的方法的步骤。
如图2所示，在第一步骤中，将单向连续纤维层片以不同方向的平铺铺设工具2上，以形成板或二维初始预成型件4。
通过已知的纤维布置头3完成铺设，以通过接触自动铺设由一根或多根纤维构成的带。纤维F以两个纤维层的形式进入头部3，并且头部包括引导系统31，以用于以纤维带的形式引导纤维朝向压实辊32，其中，所述纤维并排放置，例如，基本上边缘对边缘。在引导系统的任一侧，头部包括切割装置33，用于单独切割穿过引导系统的每根纤维，阻挡装置34，用于阻挡刚刚被切割的每根纤维，以及重新选择路径装置35，用于单独地重新递送每根纤维，从而能够随时停止和恢复纤维的施加，以及选择带的宽度。通过头部相对于铺设工具的基本平坦的铺设表面的相对位移来完成带的铺设。例如，头部包括支撑结构(未示出)，引导系统安装在该支撑结构上并且头部可以通过该支撑结构组装到位移系统，该位移系统能够使头部在彼此垂直的至少两个方向上位移。例如，头部期望接收八根纤维，并允许测量的宽度为6.35mm(1/4英寸)的1至8根纤维的带的施加。
出于说明的目的，头部用于由设置有粘合剂的干纤维生产干预成型件，以便在铺叠步骤期间为纤维提供粘合性并确保预成型件的内聚力。粘合剂由粉末形式的第一聚合物和/或一个以上的遮罩构成。例如，纤维是扁平的、连续的、丝束型碳纤维，包括多个碳丝或长丝，具有粉末形式的热塑性粘合剂，其含量为约2wt％。例如，初始预成型件4通过以根据以下叠层的不同取向铺设七个纤维层片制成：+45°/-45°/0°/90°/0°/-45°/+45°。
头部3设置有加热系统(未示出)，例如，IR灯或激光类型的加热系统，以便在纤维的施加期间加热粘合剂，并因此允许不同层片的纤维的至少一次粘合，并确保预成型件的所有的层片的内聚力，以便随后转移和其成型。加热系统在施加到施加表面上之前加热纤维，此外还加热施加表面或相对于头部向前移动的方向在辊的上游预先铺设的纤维。
如图3所示，在制造初始预成型件之后，将外遮罩51、52施加在初始预成型件的两个表面上。在这种情况下，外遮罩是由第二热塑性聚合物制成的长丝形成的非织造类型，所述第二热塑性聚合物的熔点高于构成预成型件的粘合剂的第一热塑性聚合物的熔点。
可以以自动、半自动或手动方式施加遮罩。为了保证遮罩保持在预成型件上，例如，将遮罩放置在预成型件的形成了预成型件的两个主要表面的外层片上，然后在加热时压在该预成型件上，以便至少软化该预成型件的粘合剂，并将第一外遮罩51粘合到预成型件的第一45°取向的层片上，并将第二外遮罩52粘合到预成型件的最后45°取向的层片上。优选地，在低于第二聚合物熔点，优选低于其玻璃化转变温度的温度下进行加热。遮罩的非织造结构在遮罩和预成型件之间提供了良好的连接，由此第一聚合物进入遮罩的长丝之间。
然后将设置有外遮罩的初始预成型件转移到用于成型操作的压力机，也称为冲压操作。
如图4所示，压力机9包括凹形成型工具91或模具，其具有凹口，其形状对应于待制造的预成型件的球冠12的形状，以及凸形成型工具92或冲头，其包括具有互补形状的凸起。通过凸形成型工具和凹形成型工具的彼此接近的相对位移，即，从图4所示的压力机的打开位置到图5所示的压力机的闭合位置来进行成型。
成型步骤是热成型步骤，其中，预成型件处于大于或等于第一聚合物的熔融温度并且小于遮罩的熔融温度的成型温度，使得遮罩在成型步骤期间保持固态。在成型步骤中，外遮罩通过伸长或撕裂而变形。粘合到预成型件的外层片的遮罩稳定所述层片，由此，遮罩分散了摩擦应力并限制了所述层片的纤维的局部变形。预成型件的成型温度是在将预成型件安置在压力机中之前预热预成型件和/或通过加热两个工具91、92而获得的。例如，通过使初始预成型件在预热炉或隧道的斜坡的上下红外灯之间通过来进行此预热。优选地，在成型步骤期间，预成型件通过张力系统(例如坯料夹持器类型，如附图标记8所示)保持在张力下。
出于说明的目的，预成型件的第一聚合物由熔点为约130℃的热塑性环氧聚合物形成。外遮罩各自由非织造的共聚酰胺，单位面积重量为12g/m2，熔点为约180℃的热塑性遮罩形成，例如由Spunfab或Protechnic公司销售的那些。将遮罩在140℃的温度下施加在初始预成型件上，并在140℃的温度下进行成型。
然后，工具91、92彼此分开移动到打开位置，以便从压力机中使三维预成型件脱模，外遮罩简化了此脱模操作。
然后，将所得到的三维预成型件经历添加操作，其中，通过注入和/或输注方法添加热固性或热塑性浸渍聚合物，然后进行修整操作，以形成由复合材料制成的部件。
根据另一个替代实施方式，初始预成型件由预浸渍有热塑性树脂的纤维制成。例如，纤维是扁平的、连续的、丝束型碳纤维，包括多个碳丝或长丝，具有热塑性聚合物，其含量为约40wt％，所述聚合物构成最终部件的模头。
图6示出了根据另一个实施方式的初始预成型件，其主要不同于先前的预成型件之处在于，内遮罩被安置在0°和-45°层片之间。对于前述情况，预成型件包括以45°/-45°/0°/90°/0°/-45°/+45°取向的七个层片堆叠，其由设置有粘合剂或第一热塑性聚合物的干纤维形成。
将第一非织造热塑性外遮罩151施加到铺设工具的铺设表面上，并且通过在所述第一外遮罩上的纤维布置直接铺设预成型件的第一40°取向层片。在以-45°取向的第二层片的铺设之后，由第三热塑性聚合物形成的第一非织造内遮罩61被安置在所述第二层片上。铺设分别以0°、90°和0°取向的以下的第三、第四和第五层片，并且与第一内遮罩相同的第二非织造内遮罩62被安置在第五层片上。铺设-45°和+45°的第六和第七层片，并且将第二非织造热塑性外遮罩152被安置在最后的层片上。
在成型步骤期间，预成型件的温度达到了超过第一聚合物熔点，并且低于第二聚合物和第三聚合物的熔点的温度。举例来说，如在前面的情况一样，外遮罩是非织造的共聚酰胺遮罩，其熔点为180℃，单位面积重量为12g/m2，内遮罩也是非织造的共聚酰胺，其熔点为180℃，单位面积重量为15g/m2。
成型在150℃的温度下进行，从而使得内遮罩和外遮罩保持固态。内遮罩促进以0°和45°取向的层片之间的滑动，而外遮罩促进在成型工具上滑动。在成型之后，三维预成型件经历其中注入或输注浸渍聚合物的操作，由此内遮罩保持层片分开并因此促进输注或注入。
尽管已经关于不同的具体实施方式描述了本发明，但是显然本发明决不限于此，并且它包括所描述的装置的所有技术等同物，以及落入本发明的范围内的任何其组合。

Claims (11)

1.用于制造三维预成型件(1)的方法，包括：
-制造包含多个堆叠层片的初始预成型件(4)，所述层片由单向连续纤维和第一聚合物形成，以及
-在压力机(9)的凸形成型工具(92)和凹形成型工具(91)之间使所述初始预成型件热成型，以便获得三维预成型件(1)，
其特征在于，在成型步骤中，外遮罩(51，52；151，152)被安置在所述初始预成型件(4)和所述凸形工具(92)之间的界面处以及在所述初始预成型件和所述凹形工具(91)之间的界面处，所述外遮罩由第二聚合物形成，使得在成型步骤期间，所述外遮罩保持固态并变形，所述外遮罩是由所述第二聚合物的长丝形成的非织造遮罩。
2.根据权利要求1所述的方法，其特征在于，所述外遮罩(51，52；151，152)由第二热塑性聚合物形成，由此，所述成型步骤在低于所述第二聚合物的熔融温度的成型温度下进行。
3.根据权利要求1所述的方法，其特征在于，所述外遮罩(51，52；151，152)由第二热固性聚合物形成，由此，所述成型步骤在第二聚合物保持为固态的成型温度下进行。
4.根据权利要求1至3中任一项所述的方法，其特征在于，所述方法包括：生产干燥的初始预成型件(4)，所述干燥的初始预成型件(4)包含设置有由所述第一聚合物形成的粘合剂的纤维；在热成型之后获得的所述干燥的三维预成型件经历这样的操作，其中浸渍聚合物通过注入和/或输注浸渍，以形成由复合材料制成的部件。
5.根据权利要求1至4中任一项所述的方法，其特征在于，所述方法包括制备包含至少30wt％的所述第一聚合物的初始预浸渍预成型件，由此，所述第一聚合物构成由所述三维预成型件获得的复合材料制成的部件的基质。
6.根据权利要求1至5中任一项所述的方法，其特征在于，所述外遮罩(51，52；151，152)具有4至35g/m2的单位面积重量。
7.根据权利要求2所述的方法，其与权利要求4至8中任一项组合，其特征在于，所述外遮罩是聚酰胺遮罩。
8.根据权利要求1至7中任一项所述的方法，其特征在于，所述成型步骤在所述第一聚合物处于液态或粘性液态的成型温度下进行。
9.根据权利要求1至8中任一项所述的方法，其特征在于，所述初始预成型件包括插入在所述初始预成型件的两个层片之间的至少一个内遮罩(61，62)，所述内遮罩由第三聚合物形成，所述第三聚合物在成型步骤期间处于固态。
10.根据权利要求1至9中任一项所述的方法，其特征在于，所述初始预成型件(4)的生产包括：在铺设工具(2)上使用施加辊(32)通过接触施加单向连续纤维来生产堆叠层片，其中每个层片通过在铺设工具上或在前一层片的带上的一个或多个带的一个方向的施加来生产，由此每个带由一个或多个纤维形成。
11.根据权利要求1至10中任一项所述的方法，其特征在于，在成型步骤之前预热所述初始预成型件。
CN201780008880.9A 2016-02-02 2017-01-23 通过用遮罩形成初始预成型件来制造三维预成型件的方法 Pending CN108602205A (zh)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
FR1670024 2016-02-02
FR1670024A FR3047196B1 (fr) 2016-02-02 2016-02-02 Procede de realisation de preformes tridimensionnelles par formage de preformes initiales avec des voiles
PCT/FR2017/000017 WO2017134356A1 (fr) 2016-02-02 2017-01-23 Procédé de réalisation de préformes tridimensionnelles par formage de préformes initiales avec des voiles

Publications (1)

Publication Number Publication Date
CN108602205A true CN108602205A (zh) 2018-09-28

Family

ID=56119696

Family Applications (1)

Application Number Title Priority Date Filing Date
CN201780008880.9A Pending CN108602205A (zh) 2016-02-02 2017-01-23 通过用遮罩形成初始预成型件来制造三维预成型件的方法

Country Status (5)

Country Link
EP (1) EP3411207B1 (zh)
CN (1) CN108602205A (zh)
ES (1) ES2785666T3 (zh)
FR (1) FR3047196B1 (zh)
WO (1) WO2017134356A1 (zh)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114434676A (zh) * 2020-10-30 2022-05-06 通用汽车环球科技运作有限责任公司 三维表面上的预成型纤维放置

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
BR112021012875A2 (pt) * 2018-12-31 2021-09-08 Cytec Industries Inc. Método para conformar um material compósito
FR3093669B1 (fr) 2019-03-12 2021-03-19 Lineo Procédé de fabrication d’un renfort fibreux pré-imprégné à partir d’un non-tissé thermoplastique et d’un renfort de fibres naturelles
CN112848368B (zh) * 2019-11-12 2022-05-24 航天特种材料及工艺技术研究所 一种热隔膜预成型方法

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SE418162B (sv) * 1978-10-19 1981-05-11 Berstorff Gmbh Masch Hermann Forfarande och anordning for kontinuerlig tillverkning av kabelforsterkta transportband
CN104011275A (zh) * 2011-10-19 2014-08-27 霍尼韦尔国际公司 用于防弹应用的高性能层压带&相关产品
CN104812556A (zh) * 2012-12-20 2015-07-29 塞特工业公司 用于形成成形的预成型物的方法
CN105190222A (zh) * 2013-03-15 2015-12-23 霍尼韦尔国际公司 在不降低防弹性能的情况下减轻创伤

Family Cites Families (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2051655A (en) * 1979-03-30 1981-01-21 Storey Brothers & Co Method of making a shaped structure
DE3109424A1 (de) * 1981-03-12 1982-10-28 Herbert 7140 Ludwigsburg Schreiber Verfahren zur herstellung faserverstaerkter kunststoffgegenstaende und prepreg zu seiner durchfuehrung sowie danach hergestellte gegenstaende
EP0195562B1 (en) * 1985-03-21 1992-10-28 Imperial Chemical Industries Plc Method of producing shaped articles from reinforced composites
GB8811057D0 (en) * 1988-05-10 1988-06-15 Ici Plc Method of shaping blanks of thermoformable material
US5037599A (en) * 1989-06-26 1991-08-06 Basf Aktiengesellschaft Single diaphragm forming of drapeable thermoplastic impregnated composite materials
DE69612798T2 (de) * 1995-03-01 2001-08-30 Kawasaki Steel Co Mit der papierherstellungstechnik hergestellte verpressbare folie und verfahren zum herstellen von verpressten folien mit geringen gewicht
US6818159B2 (en) * 2000-03-17 2004-11-16 Deutsches Zentrum Fuer Luft-Und Raumfahrt E.V. Process for the production of a composite consisting of a fiber reinforced material
DE10203975C1 (de) * 2002-01-31 2003-01-23 Eads Deutschland Gmbh Verfahren und Vorrichtung zur Herstellung von faserverstärkten Bauteilen
US20080136060A1 (en) * 2006-12-08 2008-06-12 Gkn Westland Aerospace, Inc. System and method for forming and curing a composite structure
DE102010013131A1 (de) * 2009-12-21 2011-06-22 REHAU AG + Co., 95111 Verfahren zur Herstellung von endlosfaserverstärkten Formteilen aus thermoplastischem Kunststoff sowie Kraftfahrzeugformteil
FR3020779B1 (fr) * 2014-05-09 2016-06-03 Coriolis Composites Procede de realisation de preformes par application et formage de fibres orientees

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SE418162B (sv) * 1978-10-19 1981-05-11 Berstorff Gmbh Masch Hermann Forfarande och anordning for kontinuerlig tillverkning av kabelforsterkta transportband
CN104011275A (zh) * 2011-10-19 2014-08-27 霍尼韦尔国际公司 用于防弹应用的高性能层压带&相关产品
CN104812556A (zh) * 2012-12-20 2015-07-29 塞特工业公司 用于形成成形的预成型物的方法
CN105190222A (zh) * 2013-03-15 2015-12-23 霍尼韦尔国际公司 在不降低防弹性能的情况下减轻创伤

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114434676A (zh) * 2020-10-30 2022-05-06 通用汽车环球科技运作有限责任公司 三维表面上的预成型纤维放置

Also Published As

Publication number Publication date
WO2017134356A1 (fr) 2017-08-10
EP3411207B1 (fr) 2020-02-26
ES2785666T3 (es) 2020-10-07
FR3047196A1 (fr) 2017-08-04
FR3047196B1 (fr) 2018-09-28
EP3411207A1 (fr) 2018-12-12

Similar Documents

Publication Publication Date Title
CN108602205A (zh) 通过用遮罩形成初始预成型件来制造三维预成型件的方法
US5560985A (en) Molding sheet material and toe puff for safety shoe
CN102574334B (zh) 梁材的制造方法和制造装置
JP6721042B2 (ja) プリプレグシート、その製造方法、表皮材付き単位層、繊維強化複合材料成形品の製造方法、及び繊維強化複合材料成形品
US9821509B2 (en) Method and device for producing an interior covering part
US20190224925A1 (en) Process for producing composite material parts by impregnating a specific preform
CN112313055B (zh) 预浸片及其制造方法、纤维增强复合材料成型品及其制造方法以及预塑型坯的制造方法
JPWO2012172982A1 (ja) 繊維強化プラスチックの製造方法
RU2015105815A (ru) Однонаправленный армирующий наполнитель и способ получения однонаправленного армирующего наполнителя
JP6229881B2 (ja) 繊維強化複合成形品の製造方法
US20200189207A1 (en) Method for producing a composite material part by oriented needling of a preform
JP5909062B2 (ja) 賦形成形方法
JP6802047B2 (ja) 賦形成形型及び賦形成形方法
CN109843564A (zh) 复合片材及其制造方法
JP7344472B2 (ja) 強化繊維テープ材料およびその製造方法、強化繊維テープ材料を用いた強化繊維積層体および繊維強化樹脂成形体
JP5712038B2 (ja) 賦形成形方法
CN107283875A (zh) 一种基于可热塑性纤维复合材料的箱包及其制备方法
CN203864132U (zh) 增强复合材料制成的半成品及模压成型件
JP6967130B2 (ja) 賦形成形型及び賦形成形方法
JP2011057767A (ja) 繊維強化複合材用プリフォームの製造方法と製造装置
CN204452268U (zh) 内衬部件
CN110116522B (zh) 包含主层和加强层的预浸渍部件
CN109591336A (zh) 一种基于热塑性碳纤维复合材料汽车外饰件的制备方法
CN109397725A (zh) 一种基于热塑性碳纤维复合材料汽车内饰件的制备方法
JP5671314B2 (ja) 織物基材と熱可塑性樹脂との積層方法及び賦形成形方法

Legal Events

Date Code Title Description
PB01 Publication
PB01 Publication
SE01 Entry into force of request for substantive examination
SE01 Entry into force of request for substantive examination
WD01 Invention patent application deemed withdrawn after publication
WD01 Invention patent application deemed withdrawn after publication

Application publication date: 20180928