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
  • 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
  • B29C70/06—Fibrous reinforcements only
  • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
  • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
  • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
  • B29C70/202—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres arranged in parallel planes or structures of fibres crossing at substantial angles, e.g. cross-moulding compound [XMC]
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
  • Y10T156/10—Methods of surface bonding and/or assembly therefor
  • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
  • Y10T156/12—Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
  • Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
  • Y10T428/24074—Strand or strand-portions
  • Y10T428/24116—Oblique to direction of web

Definitions

• the present invention relates to a semifinished composite product and method for making this semi finished composite product.
• composite part or by composite material is meant a part or a material composed of a reinforcement generally of woven or non-woven fibers and a material (thermosetting or thermoplastic resin) which ensures the cohesion of the structure and the transmission of the forces towards the reinforcement.
• a material thermosetting or thermoplastic resin
• the method of implementing prepregs consists in positioning a set of webs composed of unidirectional fibers or woven webs.
• unidirectional webs or fabrics are stacked and are polymerized under pressure.
• the part can be indifferently unidirectional sheets pre-impregnated or woven fabrics pre-impregnated.
• a pre-impregnated fabric usually a 2/2 twill which can deform within certain limits.
• a draping of unidirectional layers can be envisaged; it is then necessary to have successively several layers of large amount of juxtaposed tablecloths of small width.
• This method is however not fully adapted to the production of complex parts since the base element is a flat sheet so unlikely to fit shapes of complex geometry.
• the manufacturing cycle times of this type of parts can be relatively long. This process is therefore poorly suited to the manufacture of parts at an industrial rate.
• the RTM (Resin Transfer Molding) process is a pressure molding process in which a dry fiber preform (glass, carbon, aramid) is placed in a mold and then a resin, optionally combined with filler pigments, is injected into the mold. mold. Once the resin has polymerized, the mold can be opened and the workpiece can be removed. This process has the advantage of producing parts that have two finished faces.
• This method provides for dry draping reinforcing folds of a mold and, after sealing with a sealed film, the resin is transferred into the reinforcing plies between a distribution network and one or more suction points.
• an object of the invention is to provide a process for producing composite semi-finished products that can be used in the manufacture of structural parts having complex geometries.
• the invention relates to a method of manufacturing a planar multi axial composite product, which comprises in particular the steps of:
• a first layer comprising layers juxtaposed with unidirectional reinforcing fibers pre-impregnated with resin, the plies of the first layer having a first angle with respect to the longitudinal direction of the mattress, drape on the first layer, at least one second layer comprising unidirectional layers of juxtaposed resin pre-impregnated reinforcing fibers, the plies of the second layer having a second angle with respect to the longitudinal direction of the mattress, (b) exert a compacting on at least two layers,
• the invention thus proposes to manufacture a composite product according to a process that can be largely automated; an essential point of the semi-finished product obtained by the process according to the invention is its capacity of deformability which results from its multi-layer structure inside which sliding between and inside the layers are possible. This capacity can be implemented for the production of complex shaped parts, for example having evolutionary curves and / or curves with double curvature. It is pointed out that the composite product according to the invention can be manufactured in an automated manner at a first place to then be transported to a second location possibly remote from the first to be implemented in a process in which the composite product is deformed.
• the step (a) of forming the mattress comprises the step of:
• a third layer comprising unidirectional layers of juxtaposed resin pre-impregnated reinforcing fibers, said layers having a third angle with respect to the longitudinal direction of the mattress.
• the semi finished product obtained is thus a tri-layer product.
• the implementation of the method according to the invention provides that the draping of the first layer is carried out with an angular orientation of between 10 ° and 90 ° with respect to the longitudinal direction of the mattress.
• the draping of the second layer is performed with an angular orientation equal to 90 ° with respect to the longitudinal direction of the mattress.
• the draping of the third layer is carried out with an angular orientation of between -10 ° and -90 ° with respect to the longitudinal direction of the mattress.
• the method can provide the steps of draping an even number of layers disposed on either side of a central plane separating the mattress in two, the two layers of the same rank with respect to said plane being oriented at opposite angles.
• opposite angles are meant angles whose absolute values are identical but whose orientations are opposite to the longitudinal direction of the mattress.
• a layer having an orientation of + 30 ° and a layer having an orientation of -30 ° in the sense of the present document means that the first layer forms an angle of + 30 ° with respect to the longitudinal direction of the mattress and that the second layer forms an angle of -30 ° or + 150 ° with respect to the longitudinal direction of the mattress.
• the method comprises the steps of draping an even number of layers distributed on either side of a central layer oriented at 90 ° with respect to the longitudinal direction of the mattress, the two layers of a same rank relative to the central layer being oriented at opposite angles.
• pre-impregnated unidirectional reinforcing fiber layers are draped over a support which moves continuously in the longitudinal direction of the mattress.
• the method can provide for the formation of a mattress whose width is of the order of 2000 mm.
• the invention relates to a device which comprises in particular a conveyor having a continuously moving bearing surface and at least two sheet supply equipment oriented relative to the conveyor respectively at the first angle and the second angle. .
• the device comprises a third third-angle-fed web supply equipment.
• the device has means for cutting the mattress into a multi-layer product.
• the invention relates to a multi-axial semi-finished composite product obtained by the method described above. comprising at least two superposed layers of preimpregnated unidirectional reinforcing fibers oriented respectively at angles of between 10 ° and 90 °.
• the product according to the invention is therefore devoid of plies oriented at 0 ° that is to say is devoid of plies oriented in its longitudinal direction. This provision is important for the ability of the product to deform because it is thus possible to deform to make him marry a left shape using the ability to slip between them sheets and unidirectional fibers and exerting deformation preferably in a direction perpendicular to the longitudinal direction of the product.
• the multi-axial multi-finished composite product according to the invention is devoid of fibers arranged in its longitudinal direction which could oppose its harmonious deformation when it is used in the manufacture of a complex part, in particular curvilinear or with double curves. . Thus after deformation, the fiber content remains large and homogeneous in all parts of the product.
• the multi-axial semi-finished composite product comprises an even number of layers disposed on either side of a plane separating the layers in two, the two layers of the same rank with respect to said plane being oriented according to opposite angles.
• the multi-axial semi-finished composite product comprises an even number of layers distributed on either side of a central layer oriented at 90 ° with respect to the longitudinal direction of the product, the two layers of the same rank relative to the central layer being oriented at opposite angles.
• the semi-finished composite product comprises a superposition of:
• a first layer comprising unidirectional layers of juxtaposed pre-impregnated reinforcing fiber fibers, said layers having a first angle with respect to the longitudinal direction of the product,
• a second layer comprising unidirectional layers of juxtaposed resin pre-impregnated reinforcing fibers, said layers having a second angle with respect to the longitudinal direction of the product,
• a third layer comprising unidirectional layers of juxtaposed pre-impregnated resin reinforcement fibers, said layers having a third angle with respect to the longitudinal direction of the mattress.
• the first layer is oriented at an angle of between 10 ° and 90 ° with respect to the longitudinal direction of the product, that the second layer is oriented at an angle equal to 90 ° to the direction longitudinally of the product, that the third layer is oriented at an angle opposite the angle of the first layer between -10 ° and -90 ° with respect to the longitudinal direction of the product.
• the unidirectional fibers that come into the composition of the product according to the invention are pre-impregnated carbon fibers in a thermosetting or thermoplastic resin, which allows the semi-finished product after a subsequent phase to be used as a piece of structure especially in aeronautical applications.
• Figure 1 is a schematic view showing an embodiment of the method
• Figure 2 is a plan view of the composite product during manufacture
• Figure 3 is a schematic view showing a second embodiment of the method.
• Figure 1 shows schematically a device for implementing the method according to the invention.
• This device comprises, therefore, a belt conveyor 2 and three equipment 3, 4, 5 for unrolling webs 7, 8, 9 of unidirectional fibers reinforcement prepreg.
• This equipment 3, 4, 5 allowing the unfolding of the plies 7, 8, 9 of unidirectional reinforcing fibers are oriented precisely with respect to the conveyor 2.
• these unwinding equipment 3, 4, 5 are in number of three and are respectively oriented by + 30 °, 90 °, and -30 ° with respect to the direction of movement of the conveyor 2.
• the equipment 3, 4, 5 unwinding may be reels or other systems for delivering a band.
• the equipment 3, 4, 5 unwinding can include servo electric motors for the unwinding of a given length of webs.
• a first layer 10 of unidirectional layers of reinforcement fibers pre-impregnated with resin is deposited on the conveyor 2.
• this first layer 10 is oriented at an angle of 30 °. relative to the direction of travel of the conveyor.
• the direction of movement of the conveyor will constitute the longitudinal direction of a mattress 13 which will be obtained by stacking successive layers of unidirectional layers of preimpregnated reinforcing fibers.
• plies of the first layer 10 are juxtaposed at an angle of 30 ° relative to the direction of movement of the conveyor 2.
• Each ply 7, 8, 9 of pre-impregnated unidirectional reinforcing fibers is cut to the width of the conveyor which will form the width of the mattress 13 obtained by the method according to the invention.
• webs 8 of unidirectional reinforcing fibers are juxtaposed to form the second layer 11 of the mattress. These plies 8 are cut to the width of the conveyor.
• a third station unidirectional plies of preimpregnated reinforcing fibers which is located downstream of the previous station, is oriented at an angle of -30 ° relative to the direction of movement of the conveyor.
• a third layer 12 of plies 9 of preimpregnated unidirectional fibers is formed by juxtaposition of unidirectional layers of fibers.
• a compacting step of the mattress formed of the three layers thus defined is provided downstream of the unwinding stations.
• This compaction step may be performed by passing the mat between two rolls with possibly heating thereof.
• the compaction step can also be performed by evacuating the table with optionally a passage in an oven at a temperature between 20 0 C and 70 0 C.
• the mattress 13 formed of these three layers is then, according to the invention, cut into products 1 units of width may be equal to 150 millimeters and length may be equal to the length of the table that is to say up to at 10 m.
• the elements thus formed are thus three-layer elements incorporating triaxially oriented fibers.
• This composite planar multi axial element can then be used and be deformed into left-handed shapes to be implemented in elements of U, Z, C, omega reinforcement type which, moreover, have a non-rectilinear curve.
• FIG. 3 illustrates this implementation of the invention in which two layers of layers are superimposed; in the example illustrated, the pre-impregnated unidirectional fiber plies of the first layer form an angle of 30 ° with the longitudinal direction of the product while the unidirectional fiber plies pre-impregnated with the second layer form an angle of -30 ° with the longitudinal direction of the product.
• the invention can be implemented with a number of layers equal to 2, 4, 6, 8 etc. arranged on each side of a central layer oriented at 90 ° with respect to the longitudinal direction of the mat thus formed (in the case of a mat comprising an odd number of layers) or arranged on either side of a plane of symmetry (in the case of a mattress comprising an even number of layers without a central layer), knowing that inside a pair of layers of the same rank with respect to the central layer or with respect to the plane of symmetry, the layers of these layers are oriented at opposite angles. It is also conceivable that one or more layers other than the central layer is itself oriented 90 ° with respect to the longitudinal direction of the product.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Composite Materials (AREA)
• Mechanical Engineering (AREA)
• Moulding By Coating Moulds (AREA)
• Reinforced Plastic Materials (AREA)

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Publications (1)

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• 2008
  • 2008-03-07 FR FR0801278A patent/FR2928293B1/fr not_active Expired - Fee Related
• 2009
  • 2009-03-05 WO PCT/FR2009/050360 patent/WO2009115737A2/fr active Application Filing
  • 2009-03-05 US US12/920,887 patent/US20110111168A1/en not_active Abandoned
  • 2009-03-05 EP EP09723074A patent/EP2262635A2/de not_active Withdrawn
  • 2009-03-05 CN CN2009801133296A patent/CN102006985A/zh active Pending

Non-Patent Citations (1)

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