CN111372769A - 中间材料和制造此类材料的方法 - Google Patents

中间材料和制造此类材料的方法 Download PDF

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Publication number
CN111372769A
CN111372769A CN201880075528.1A CN201880075528A CN111372769A CN 111372769 A CN111372769 A CN 111372769A CN 201880075528 A CN201880075528 A CN 201880075528A CN 111372769 A CN111372769 A CN 111372769A
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CN
China
Prior art keywords
prepreg
thermoplastic
length
interleaving
strips
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Pending
Application number
CN201880075528.1A
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English (en)
Inventor
J·埃利斯
A·卡巴列罗
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Hexcel Composites Ltd
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Hexcel Composites Ltd
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Publication of CN111372769A publication Critical patent/CN111372769A/zh
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    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/20—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror"
    • B29C65/2007—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror" characterised by the type of welding mirror
    • B29C65/2038—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror" characterised by the type of welding mirror being a wire
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/22—Heated wire resistive ribbon, resistive band or resistive strip
    • B29C65/221—Heated wire resistive ribbon, resistive band or resistive strip characterised by the type of heated wire, resistive ribbon, band or strip
    • B29C65/222—Heated wire resistive ribbon, resistive band or resistive strip characterised by the type of heated wire, resistive ribbon, band or strip comprising at least a single heated wire
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81433—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined being toothed, i.e. comprising several teeth or pins, or being patterned
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

公开了用于制造复合部件的中间材料(132)，其具有预浸料层(116)和交错层(120)，所述交错层由至少两个热接合的热塑性交错材料区段(120a，120b)构成。本发明涉及制造此类中间材料的方法。

Description

中间材料和制造此类材料的方法
本发明涉及用于复合制造件的中间材料，其包括预浸料层和交错层，所述交错层意在防止预浸料层的自粘结，特别是此类中间材料的相对长和窄的条带。本发明也涉及制造中间材料的方法。
复合材料是公知的，其经常用于制备坚固且轻质的部件。在一种制造技术中，纤维组分(例如碳纤维或玻璃纤维)用基质材料(通常为聚合物，例如热塑性聚合物)预浸渍。基质材料当用于浸渍时并未固化，由此保持一定的柔韧性。该“预浸料”材料可以在切割和成型、和甚至在固化以形成最终(硬化)产品前被处理或储存。预浸料材料通常为卷筒的形式，以易于储存和运输。
越来越流行的制造技术利用自动纤维铺放(AFP)设备将预浸料沉积到表面(例如三维模具)上。使用AFP可避免由从大片材切割预制件带来的浪费。AFP通常涉及通过可移动的自动头部沉积预浸料带材。
将预浸料的窄条带或带材(通常为3至50mm宽)进料到AFP头部，以进行沉积。这些带材可以源自主预浸料的大的宽的(通常为米的数量级，例如2米)片材。在这样的情况中，可以使用切割机器将主预浸料片材切割成带材，所述切割机器配置为同时进行多次切割(例如对2m宽的主片材进行49次切割，产生50个40mm条带)。然后可以将各带材卷绕在例如线轴上，用以运输到AFP机器。
待切割成窄条带的主预浸料可以提供为预制造的片材，通常为卷筒的形式，在这种情况中其可以包括一个或多个背衬层或交错层，在将片材裁切成窄条带之前可以移除所述背衬层或交错层。或者，主预浸料的裁切可以在形成主预浸料时进行，即，无需介入期间的卷绕和储存，使得主预浸料的生产及其裁切可以为单一连续法的一部分。
预浸料通常具有至少一定程度的表面粘性，因此为了防止在将预浸料的切割条带卷绕起来时预浸料会粘附于其自身，可以使条带设置有背衬片，也称为交错材料。背衬片可以由聚合物材料或其共混物(例如聚烯烃，更特别为聚乙烯，例如LDPE或HDPE)形成，并且可以为单层或多层聚合片。通常，交错材料为30至70微米厚。交错材料通常以卷筒或线轴的形式提供，其宽度经常比预浸料带材宽3至12mm。将交错材料与预浸料带材卷绕在线轴上。所得层状预浸料和交错材料的组合代表了制造方法中的中间步骤，因此在本申请称为“中间材料”。
对长度相对较长的预浸料条带的需求日益增长，特别是用于AFP方法中以减少对停止施加材料以用新鲜卷筒代替用完的预浸料卷筒的需求。特别地，需要窄/裁切预浸料的长度为至少3000m，且经常是比这长得多。具有这样长度的预浸料条带可以直接制备，例如如下制备：裁切预浸料的连续成型片材作为一体式制造方法中的一个步骤，或裁切作为卷筒储存的长度长的预成型的预浸料。但是，在后一种情况中，卷筒将非常大且重，因此难以制备、运输和处理。或者，窄预浸料的长条带可以如下形成：裁切短长度的宽预成型的预浸料的相对多个卷筒，将由各卷筒形成的条带接合在一起。已知用于接合预浸料的窄条带的长度的装置。
由这样长窄的预浸料条带形成卷筒产生的问题是预浸料条带的长度和交错衬料的提供长度之间的差异，该差异通常要短得多。特别地，交错材料的卷通常不长于2,500m，而预浸料条带可以为至少3,000m长，经常也为比这长得多。这意味着交错材料的多个长度必须接合在一起以覆盖预浸料带材的整个长度。目前使用的将两种或更多种交错材料长度接合的方法是使用胶带将这些长度在它们的末端处接合。这些“拼接块”可以通过对接机头或交叠的(搭接)接头产生。
同样的技术也可以用于交错材料破裂的这种不太可能出现的事件。
该技术带来的一个问题是，胶带容易吸取异物-称为异物碎片(FOD)。另外，胶带的位置错误或松散的碎片也可成为FOD。这种FOD可被转移至预浸料条带(其为本身发粘的)，这是一个重大的问题，因为它可能会干扰条带的卷绕和/或其后续使用。特别地，FOD可能干扰AFP头部的操作，此外可能会不利地影响最终复合材料的机械性质。
本发明旨在总地消除或至少减轻上述问题和/或提供改进。
根据本发明，提供了本申请所述和/或所附权利要求中任一项所限定的中间材料和方法。
本发明提供用于制造复合部件的中间材料，所述中间材料包括：
平坦且细长的预浸料层；和
与预浸料层的至少一侧接触的交错层，所述交错层包括至少两个热塑性交错材料区段，热塑性交错材料区段的每一个通过热量与至少一个其它热塑性材料区段接合以形成连续长度的交错材料；
其中将中间材料卷绕，使得交错层减少或消除预浸料层的自接触。
本发明进一步提供制造中间材料的方法，其包括以下步骤：
a)提供一定长度的具有第一宽度的主预浸料；
b)将主预浸料切割成多个纵向预浸料条带，所述条带的每一个具有的宽度小于主预浸料的宽度；
c)提供第一热塑性交错材料区段，所述第一热塑性交错材料区段具有的长度小于每一个预浸料条带的长度；
d)将第一热塑性交错材料区段的第一末端放置为与预浸料条带之一的第一末端接触，所述第一热塑性交错材料层区段具有的宽度等同于或大于预浸料条带的宽度；
e)使所述第一热塑性交错材料区段的长度逐渐与所述预浸料条带的长度接触；
f)在第一热塑性交错材料区段的第二末端接触预浸料条带之前，提供具有的宽度等同于或大于预浸料条带的宽度的第二热塑性交错材料区段，和通过施加热量将第一热塑性交错材料区段的第二末端接合于第二热塑性交错材料区段的第一末端，以形成连续长度的热塑性交错材料；
g)一旦第一热塑性交错材料区段的第二末端接触预浸料条带，则使第二热塑性交错材料区段的长度逐渐接触预浸料条带的长度；
h)如果必要，重复步骤f)和g)，直到预浸料条带的全部长度均与热塑性交错材料的连续长度接触；和
i)将与热塑性交错材料的连续层接触的所述预浸料条带卷绕，使得交错材料减少或消除预浸料层的自接触。
有利地，用加热、和优选也为压力的情况下热塑性背衬/交错材料的接合使其熔化。当熔化区段冷却时，不存在剩余粘性(不同于带接合)，由此吸取FOD的风险显著降低。
优选地，两个交错材料区段之间的接合配置为经受在机器方向上至少500psi的拉伸力，根据ISO 527-3标准在无分离的情况下测得。拉伸强度的优选范围为500至40,000psi。
优选地，交错材料接合区应该足够坚固以顺利通过后续处理而保持完整：
·与预浸料材料共同卷绕；
·通过进料系统向AFP头部处张紧；
·进料通过AFP头部；
·在AFP头部处与预浸料材料分隔。
在本发明的中间材料中，交错层包括至少两个热塑性交错材料区段，每个热塑性交错材料区段通过热量接合于至少一个其它热塑性交织材料区段，形成连续长度的交错材料。因此，应该理解，当交错层仅包括两个热塑性交错材料区段时，这些区段通过单个接合区接合在一起。或者，当交错层包括多于两个热塑性交错材料区段时，两个末端区段各自接合于另一个区段，而各中心(非末端)区段接合于两个其它区段(通过在各末端的接头)。
当本发明的中间材料包括多于两个接合在一起以形成连续长度的交错材料的热塑性交错材料区段时，可以使用不同形式的接合区和/或接合的方法，但是优选地，每个接合区通过加热形成，最优选地，每个接合区按大致相同的方式形成。
在本发明的方法中，通过使热塑性交织材料区段的长度“逐渐”接触预浸料条带的长度，这意味着，一旦已经使热塑性交织材料区段的第一末端与预浸料条带、例如在预浸料条带的第一末端处接触，接着使热塑性交织材料区段紧邻第一末端的区域与预浸料条带紧邻第一接触点的区域接触，且该方法沿热塑性交织材料区段的长度继续进行，直到到达热塑性交织材料的长度的第二末端，在该点预浸料条带连接于第二热塑性交织材料区段，且该方法从该点继续进行。可以如下按该方式使热塑性交错材料的区段和预浸料条带相接触：例如，使两种材料穿过起轧点，例如穿过施加压力以接合两种材料的两个辊之间。
在本发明的方法中，热塑性交错材料区段的每一个具有的宽度与预浸料条带的宽度相同或大于预浸料条带的宽度，且优选热塑性交错层的区段的每一个都具有相同的宽度。
在本发明的一种实施方式中，施加热量以在热塑性交错材料区段之间形成接合区引起两个热塑性交错材料区段的接合末端的至少一个、和优选为两个的部分熔融。特别地，优选加热不引起热塑性交织材料的任一个末端的完全熔融，因为这将会减小接合区的强度或甚至使得无法形成接合区。
在本发明的一种实施方式中，施加热量以在热塑性交错材料区段之间形成接合区的步骤也包括施加压力。在该实施方式中，优选以下述方式释放压力，该方式使得接合区的完整度不会显著降低。这可以通过使接头足够冷却以形成来实现，例如通过当还在施加压力时停止加热来进行，或通过缓慢释放压力由此在完全移除压力施加装置之前接头冷却来进行。释放速度取决于众多因素，但是释放压力的时间和速度是通过当接头稳定时来确定的。
在本发明的一种实施方式中，接合两个热塑性交错材料区段的步骤包括以下步骤：将两个区段的末端交叠，使得它们通过搭接接头接合，优选其中重叠部分的长度为5mm至100mm，更优选为10mm至80mm，最优选为20mm至50mm。
在本发明的一种实施方式中，两个热塑性交错材料区段的末端在横跨两个热塑性交错材料区段的宽度的连续接合区域处接合，且优选交错层具有纵向轴，其中接合区域平行于垂直于纵向轴的横向轴延伸。
在本发明的一种实施方式中，两个热塑性交错材料区段的末端在在横跨两个热塑性交错材料区段的宽度上的多个离散的接合区域处接合，且优选地多个接合区域的每一个是细长的且平行于热塑性交织材料的纵向方向。
在本发明的一种实施方式中，接合区域通过与加热丝接触形成。
在本发明的一种实施方式中，通过接合热塑性交错材料区段形成的热塑性交错层比预浸料条带宽，使得其在一个末端或两个末端处悬于预浸料条带上。
在本发明的一种实施方式中，预浸料条带的长度、因此也是本发明中间材料的长度为至少3,000m，优选为3,000m至25,000m，更优选为5,000m至15,000m。
在本发明的一种实施方式中，主预浸料在裁切前的宽度为至少0.075m，优选为0.075m至3m，更优选为0.5至1.5m。
在本发明的一种实施方式中，在步骤b)中从主预浸料切割的多个纵向预浸料条带中的每一个的宽度为2mm至100mm，优选为3mm至55mm。
在本发明的一种实施方式中，在步骤b)中，将主预浸料切割成至少2个纵向预浸料条带，优选为至少5个条带，更优选为5至100个条带，最优选为25至50个条带。
在本发明方法的一种实施方式中，每一个预浸料条带的长度大于主预浸料的长度，且该方法包括以下的另外步骤：将至少一个另外长度的主预浸料切割成另外多个纵向预浸料条带，和将另外多个纵向预浸料条带的每一个接合于第一批多个纵向预浸料条带。在该实施方式中，在接合前，主预浸料的每一个长度为50m至2,000m长，优选为700m至1500m长。
在本发明方法的一种实施方式中，每一个热塑性交错材料区段的长度优选为100m至4,000m，更优选为500m至3,000m。
在本发明的一种实施方式中，步骤c)至i)在多个纵向预浸料条带中的至少两个上进行，优选在全部的多个预浸料条带上进行。在该实施方式中，优选地，基本上在同一时间加工其上要进行步骤c)至i)的预浸料条带的每一个。
在本发明的一种实施方式中，在步骤f)中施加热量的步骤包括使用手持式加热装置施加热量，优选地其中手持式加热装置是电池供电装置。
本申请的“手持式”装置表示下述，其通常为便携式的、且可单手轻松携带(因此其质量大于2kg)的装置。该装置可以是电池供电操作的，便于携带。优选地，装置具有被弹性偏置到打开位置的一对夹钳(例如，压机砧板布置)。来自用户手部的握持力可用于将夹钳放在一起，从而夹住并密封交错材料。
在一种实施方式中，该装置的两侧都(上文所提及的压机和砧板)可以包括加热元件，由此加热交错材料的两侧。
加热装置可以包括一根或多根加热丝或者可以带有具有不同形状或构造的加热“头部”，例如阴影线/交叉阴影线/多个“点”矩阵等。
手持式加热装置的使用特别适于用于本发明的方法中，特别是其中多个预浸料切割条带通过同时施用交错层来加工的实施方式，因为这样的装置可以与现有设备一起使用，即，无需增加固定的密封单元。同样，其中需要发生交错材料区段的接合的面积是严格受限的，特别是当很多预浸料条带是平行加工的时，可以将手持式装置相对快速和容易地移动到任何需要它们的地方。此外，当施加热量时，仅需要少量的力将区段接合(小于对于成人而言约500N的人类握持力)。再进一步，因为当将交错材料区段接合时可能需要完全停止该设备，使用手持式装置是有利的，因为其可以快速操纵到位，这限制了当停止设备时的“停机时间”。
以下将参照附图描述中间材料、交错层和制造方法的实例，其中：
图1A是用于在第一操作阶段中制造根据本发明的中间材料的设备和方法的示意性侧视图；
图1B是图1A的设备和方法的示意性平面图；
图1C是图1A的设备和方法在第二操作阶段的示意性侧视图；
图2A是交错层的第二制造方法中的第一阶段的平面图；
图2B是图2A的交错层的制造方法中的第二阶段的平面图；
图3是图2A的交错层的制造方法中的第三阶段的平面图；
图4是图2A的交错层的制造方法中的可替换的第三阶段的平面图；和
图5是用于实施图4的阶段的设备的侧视图。
参照图1A和图1B，显示了执行根据本发明的制造方法的设备100。设备100包括主卷筒102，切割组件104，张紧组件106，交错材料卷筒108和线轴卷绕器110。
主卷筒102具有卷绕在其上的未固化的(或部分固化的)主预浸渍的(“预浸料”)材料112。主预浸料材料112具有在横向方向T(垂直于纵向方向L)上的宽度W。在该实施方式中宽度为1m，但是本领域技术人员可以理解其它宽度也是可以的。储存在主卷筒上的主预浸料材料112的长度Lp在该实施方式中为1000m，但是通常为700至1,500米。在该方法过程中，预浸料材料在纵向方向L上移动。
切割组件104包括在横向方向T上间隔开的多组N个切割刀片114。每个切割刀片配置为当预浸料材料在纵向方向上移动时切割穿过预浸料材料的厚度。切割刀片114等距间隔开，使得制得N+1个具有宽度w的预浸料材料的条带或带材116，其中w＝W/(N+1)。
尽管为简单起见未显示于图1，一旦已将主卷筒102上的全部材料112裁切，布置基本上等同于第一主卷筒102的新的主卷筒，以使用切割组件104进行裁切，产生基本上等同于第一批多个带材116的另外多个带材，将另外多个带材的每一个接合于第一批多个带材116之一，使得独立带材116的每一个的长度大于主卷筒102上的预浸料112的长度。裁切带材可以按任何便利的方式接合，且方法优选为连续的，使得只要新裁切带材一形成(即，在另外带材的剩余部分通过从主带材裁切形成之前)，新裁切带材的第一末端就接合于原裁切带材116的第二末端。必要时，很多预浸料的主卷筒102可以按该方式接合以产生所需长度的卷绕的中间材料132。例如，9个各自为1,000m长的主卷筒102可以接合以制得约9,000m的中间材料132。
图1B和图1C则显示在N+1个带材116之一上发生的过程，但是应该知道在典型的方法中，但是按该方式同时处理全部的N+1个带材。
带材116穿过张紧组件106，所述张紧组件106包括一系列辊118。
提供第一长度的交错材料120a，其卷绕在第一交错材料卷筒108a上。交错材料通常比预浸料带材116宽3至12mm，但是关键地通常以下述长度提供，该长度比中间材料132的所需长度短。
将交错材料120a从卷筒108a展开并在辊122上通过通往装配辊124。在该点，交错材料120a的第一末端开始接触预浸料带材116，且当预浸料带材116和第一交错材料区段120a通过装配辊124之上时，它们从第一交错材料区段120a的第一末端开始逐渐形成平面接触。
交错材料120通常为热塑性聚合物材料，在该情况中为LDPE(低密度聚乙烯)。这样的材料通常以数百米且至多约2,500m的数量级提供。通常，因此交错材料的可用长度Li将小于用于方法的预浸料条带材料的总长度Lp，即，通过将从多个主卷筒裁切的预浸料的长度接合或通过裁切具有极长长度的主预浸料制成的预浸料带材的长度。更典型地，Li<2xLp。Li比Lp小一个数量级的情况并不少见，例如Li可以为数百米且至多约2,500m的数量级，其中Lp的数量级为数千米，例如9,000m或更长。
为了提供适于将根据本发明的预浸料带材116的长度的显著长度(如果不是全部长度)堆层的交错材料120的长度，将多个长度的交错材料120a，120b等作为方法的一部分接合，如下文所述。
在卷筒108a耗尽(即，交错材料120a已经用光)之前，提供交错材料120b的第二卷筒108b。第二长度的交错材料120b在接合区126处接合于第一长度120a。典型的接合区126显示在图1C中的区域A。在本申请的实施方式中，停止设备100以有助于接合。下文给出第一长度的交错材料120a如何接合于第二长度的交错材料120b的进一步详情。
较宽的交错材料120在两侧都悬于预浸料带材116上。因为预浸料发粘，组装的预浸料带材116和交错材料120形成中间材料132。将中间材料132卷绕在线轴卷绕器110上，使得在卷绕时交错材料120在径向上在预浸料带材116的内侧。这防止发粘预浸料粘住其自身。
然后可以使包括堆层的交错材料和预浸料的中间材料132的所得卷筒110通到自动纤维放置装备，以进行沉积。应该理解，在展开之后，AFP装备将在沉积预浸料之前分离交错材料。
图2A和图2B显示其中可以形成接合区126的第一种方式。两个区段120a，120b交叠以形成重叠部分128，施加热量和压力以形成接合区126(图2B)作为搭接接头。重叠部分在纵向方向上通常为20mm至50mm。
图3显示其中可以将热量和压力施加于重叠部分128的第一种方式。在该实例中，在整个重叠部分128上施加同等的热量和压力以使区段120a，120b熔融。热量和压力可以由手持式装置施加，该装置优选为电池供电的手持式装置，该装置具有的加热头的宽度等于接合区128在纵向方向上的宽度以及长度等于两个交错材料区段120a，120b的宽度。
图4显示其中可以将热量和压力施加于重叠部分128的第二种方式。在该实例中，将同等的热量和压力施加于重叠部分128的三个独立的纵向延伸区域130a，130b，130c以使区段120a，120b熔融。在该实施方式中，热量和压力可以由在纵向方向上延伸的小的加热元件例如加热丝施加，如下文讨论。
在图3和图4的实施方式的每一种中，应注意到重叠部分128的侧向边缘(和因此的区段120a，120b)是密封的。这是有利的，因为这确保了发生钩住和可由松散末端/边缘引起的其它此类问题的可能性较小。
在图1A、图1B、图1C、图2A、图2B、图3和图4中所示的实施方式中，形成接合区的加热优选使用手持式装置、最优选为电池供电的手持式装置进行。
参照图5，显示用于接合两个区段120a，120b的设备200。该设备包括砧板202和压机204。压机包括单个加热丝206。压机204可以朝砧板202前进以将来自加热丝206的热量和压力同时施加在重叠部分128上。这产生了第一接合区域130a。设备200然后在横向方向上移动以形成第二接合区域130b，然后再次移动以形成第三接合区域130c(但是应该理解三个接合区域可以按任何顺序形成，或者如果需要可以形成更多的接合区域)。在一种实施方式中，装置200的两侧(压机204和砧板202)都可以包括加热元件，由此加热交错材料的两侧。当不使用加热丝时，接合设备200可以配有具有不同形状和构造的加热“头部”，例如阴影线、交叉阴影线、或多个“点”矩阵等。该装置优选为手持式装置，最优选为电池供电的手持式装置。
将热量施用于热塑性交织材料可使该材料部分熔融和增粘，由此该材料接合于相对的区段。
当在本发明的方法中使用设备200时，优选在密封之后缓慢释放压力(在这些实施方式中其耗时约2秒)。释放速度取决于众多因素，但是释放压力的时间和速度是通过当接头稳定时来确定的。这可以通过使接头充分冷却以形成来实现，或者通过停止加热同时使压机仍然闭合来进行，或者通过缓慢释放压机由此在压机和砧板完全分离之前接头冷却来进行。
一旦冷却，交错材料将不会展现出另外的粘性。
在接合根据本发明的交错材料的长度的一个实例中，将两个9mm宽和50μm厚的LDPE条带(PE Hoods Blue，购自Plasthill B.V.)的相应末端交叠以得到25mm的重叠部分，并通过使用电池供电的手持式装置(Bheema Mini Portable Handy Plastic Bag SealerSealing Machine，购自Amazon，UK)施加热量和压力将其接合在一起。该装置较小(约110mmⅹ45mmⅹ25mm)且轻质(约58g)，并且不需要连接于单独的电源，因此可特别便利地用在用于制造具有交错材料层的窄预浸料带材的生产线上可用的受限空间中。LDPE的全熔点为约124℃，但是当将其加热到40℃至110℃时其会软化并变得柔韧。因此，虽然用于在LDPE的条带之间形成接头的最佳温度为70℃至110℃，但是为了完全形成接头，也必须施加压力。使用手动挤压装置可方便实现的范围内的压力(即，30N至400N)，可以在2秒(使用接近该范围上限的温度)至8秒(使用接近该范围下限的温度)内形成接头。
当使用密封器装置时，释放压力的行为使电路断开，装置中电线的电阻加热由此停止，引起其温度下降，使得LDPE聚合物片材相对快速冷却，使接头固结并使材料易于处理。所得接合区具有的拉伸强度在由供应商报告的非接合的LDPE的范围内，在这种情况中在机器方向上拉伸强度的大于21MPa。
变型落入本发明的范围内。

Claims (33)

1.用于制造复合部件的中间材料，所述中间材料包括：
平坦且细长的预浸料层；和
与所述预浸料层的至少一侧接触的交错层，所述交错层包括至少两个热塑性交错材料区段，热塑性交错材料区段的每一个通过热量与至少一个其它热塑性材料区段接合以形成连续长度的交错材料；
其中将所述中间材料卷绕，使得所述交错层减少或消除所述预浸料层的自接触。
2.根据权利要求1所述的中间材料，其中所述热塑性交错材料区段中的至少两个通过部分熔融接合，所述部分熔融通过施加热量引起。
3.根据权利要求1或2所述的中间材料，其中所述热塑性交错材料区段中的至少两个通过搭接接头接合。
4.根据权利要求3所述的中间材料，其中所述两个热塑性交错材料区段的形成所述搭接接头的重叠部分的长度为5mm至100mm，优选为10mm至80mm，更优选为20mm至50mm。
5.根据前述权利要求任一项所述的中间材料，其中所述交错层比所述预浸料层宽，使得所述交错层在一个边缘或两个边缘悬于所述预浸料层上。
6.根据前述权利要求任一项所述的中间材料，其中所述热塑性交错材料区段中的至少两个在横跨所述两个热塑性交错材料区段的宽度上的连续接合区域处接合。
7.根据权利要求6所述的中间材料，其中所述交错层具有纵向轴，其中所述接合区域平行于垂直于所述纵向轴的横向轴延伸。
8.根据前述权利要求任一项所述的中间材料，其中所述热塑性交错材料区段中的至少两个在横跨所述两个热塑性交错材料区段的宽度上的多个离散的接合区域处接合。
9.根据权利要求8所述的中间材料，其中所述多个接合区域的每一个是细长的且平行于所述热塑性交错材料的纵向方向。
10.根据前述权利要求任一项所述的中间材料，其中所述预浸料层的宽度为2mm至100mm，优选为3mm至55mm。
11.根据前述权利要求任一项所述的中间材料，其具有的长度为至少3,000m，优选为3,000m至25,000，更优选为5,000m至15,000m。
12.制造中间材料的方法，其包括以下步骤：
a)提供一定长度的具有第一宽度的主预浸料；
b)将所述主预浸料切割成多个纵向预浸料条带，所述条带的每一个具有的宽度小于所述主预浸料的宽度；
c)提供第一热塑性交错材料区段，所述第一热塑性交错材料区段具有的长度小于每一个所述预浸料条带的长度；
d)将所述第一热塑性交错材料区段的第一末端放置为与所述预浸料条带之一的第一末端接触，所述第一热塑性交错材料层区段具有的宽度等同于或大于所述预浸料条带的宽度；
e)使所述第一热塑性交错材料区段的长度逐渐与所述预浸料条带的长度接触；
f)在所述第一热塑性交错材料区段的第二末端接触所述预浸料条带之前，提供具有的宽度等同于或大于所述预浸料条带的宽度的第二热塑性交错材料区段，和通过施加热量将所述第一热塑性交错材料区段的第二末端接合于所述第二热塑性交错材料区段的第一末端，以形成连续长度的热塑性交错材料；
g)一旦所述第一热塑性交错材料区段的第二末端接触所述预浸料条带，则使所述第二热塑性交错材料区段的长度逐渐接触所述预浸料条带的长度；
h)如果必要，重复步骤f)和g)，直到所述预浸料条带的全部长度均与热塑性交错材料的连续长度接触；和
i)将与热塑性交错材料的连续层接触的所述预浸料条带卷绕，使得所述交错材料减少或消除所述预浸料层的自接触。
13.根据权利要求12所述的方法，其中在步骤f)中施加热量引起所述两个热塑性交错材料区段的接合末端中的至少一个、和优选为两个的部分熔融。
14.根据权利要求12或权利要求13所述的方法，其中在步骤f)中施加热量的步骤也包括施加压力。
15.根据权利要求12至14任一项所述的方法，其中在步骤f)中将所述两个热塑性交错材料区段接合的步骤包括以下步骤：将所述两个区段的末端交叠，使得它们通过搭接接头接合。
16.根据权利要求15所述的方法，其中重叠部分的长度为5mm至100mm，优选为10mm至80mm，更优选为20mm至50mm。
17.根据权利要求12至16任一项所述的方法，其中在步骤f)中，所述两个热塑性交错材料区段的末端在横跨所述两个热塑性交错材料区段的宽度上的连续接合区域处接合。
18.根据权利要求17所述的方法，其中所述交错层具有纵向轴，其中所述接合区域平行于垂直于所述纵向轴的横向轴延伸。
19.根据权利要求12至16任一项所述的方法，其中在步骤f)中，所述两个热塑性交错材料区段的末端在横跨所述两个热塑性交错材料区段的宽度上的多个离散的接合区域处接合。
20.根据权利要求19所述的方法，其中所述多个接合区域的每一个是细长的且平行于所述热塑性交错材料的纵向方向。
21.根据权利要求19或20所述的方法，其中所述接合区域通过与加热丝接触形成。
22.根据权利要求12至21任一项所述的方法，其中热塑性交错层的连续长度比所述预浸料条带宽，使得其在一个边缘或两个边缘悬于所述预浸料条带上。
23.根据权利要求12至22任一项所述的方法，其中所述预浸料条带的每一个的长度为至少3,000m，优选为3,000至25,000m，更优选为5,000至15,000m。
24.根据权利要求12至23任一项所述的方法，其中所述预浸料条带的每一个的长度大于所述主预浸料的长度，且所述方法包括另外的步骤：将至少一个另外长度的主预浸料切割成另外多个纵向预浸料条带，和将所述另外多个纵向预浸料条带的每一个与第一批多个纵向预浸料条带接合。
25.根据权利要求24所述的方法，其中主预浸料的每一个长度为50m至2,000m长，优选为700m至1500m长。
26.根据权利要求12至25任一项所述的方法，其中所述主预浸料的宽度为至少0.075m，优选为0.075m至3m，更优选为0.5至1.5m。
27.根据权利要求12至26任一项所述的方法，其中在步骤b)中从所述主预浸料切割的所述多个纵向预浸料条带的每一个的宽度为2至100mm，优选为3至55mm。
28.根据权利要求12至27任一项所述的方法，其中在步骤b)中，将所述主预浸料切割成至少2个纵向预浸料条带，优选为至少5个条带，更优选为5至100个条带。
29.根据权利要求12至28任一项所述的方法，其中所述热塑性交错材料区段的每一个的长度为100m至4,000m，优选为500m至3,000m。
30.根据权利要求12至29任一项所述的方法，其中步骤c)至i)在所述多个纵向预浸料条带中的至少两个之上、优选在所述多个预浸料条带的全部之上进行。
31.根据权利要求30所述的方法，其中基本上在同一时间加工其上要进行步骤c)至i)的所述预浸料条带的每一个。
32.根据权利要求12至31任一项所述的方法，其中在步骤f)中施加热量的步骤包括使用手持式加热装置施加热量。
33.根据权利要求32所述的方法，其中所述手持式加热装置是电池供电装置。
CN201880075528.1A 2017-11-23 2018-11-21 中间材料和制造此类材料的方法 Pending CN111372769A (zh)

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