EP2726273A1 - Method for laying up and consolidating during laying thermoplastic composite components containing fibrous reinforcements - Google Patents
Method for laying up and consolidating during laying thermoplastic composite components containing fibrous reinforcementsInfo
- Publication number
- EP2726273A1 EP2726273A1 EP12730984.7A EP12730984A EP2726273A1 EP 2726273 A1 EP2726273 A1 EP 2726273A1 EP 12730984 A EP12730984 A EP 12730984A EP 2726273 A1 EP2726273 A1 EP 2726273A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- semi
- thermoplastic polymer
- laying
- temperature
- polymer
- 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.)
- Withdrawn
Links
Classifications
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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
- 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
- B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
- B29C70/386—Automated tape laying [ATL]
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- 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
- B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
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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
- 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
- B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
- B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
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- 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
- B29K2071/00—Use of polyethers, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
-
- 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
- B29K2101/00—Use of unspecified macromolecular compounds as moulding material
- B29K2101/12—Thermoplastic materials
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- 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
- B29K2271/00—Use of polyethers, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as reinforcement
-
- 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
- B29K2301/00—Use of unspecified macromolecular compounds as reinforcement
- B29K2301/12—Thermoplastic materials
-
- 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
- B29K2307/00—Use of elements other than metals as reinforcement
- B29K2307/04—Carbon
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- 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
- B29K2707/00—Use of elements other than metals for preformed parts, e.g. for inserts
- B29K2707/04—Carbon
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- 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
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/10—Fibres of continuous length
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- 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
- B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
- B32B2309/02—Temperature
Definitions
- the invention relates to a method for draping and consolidating the deposition of a thermoplastic composite component with fibrous reinforcement.
- Automated draping by deposition of strips or placement of pre-impregnated fibers, is a method of manufacture widely used in the field of producing fibrous reinforcement composite parts in a thermosetting matrix. Indeed, the tackiness and fluidity of these resins make it possible to ensure a quality of room free of voids or porosities during the subsequent removal and cooking operations. In the case of so-called pre-impregnated strips of a thermoplastic polymer, said polymer does not exhibit tack at the lay-up temperature.
- Pre-impregnation is in practice carried out either by the calendering of a film consisting of said polymer on said fiber strips, or by a dusting of said fibers or by the insertion of polymer fibers co-mixed with the reinforcing fibers.
- pre-impregnation and "prepreg” when referring to fibers and a thermoplastic polymer must be understood according to the practical meaning set forth above.
- the successively deposited folds are bonded together by the melting of the polymer.
- the molten thermoplastic polymer is characterized by a very high viscosity, often several orders of magnitude compared to uncured thermosetting resins.
- thermoplastic polymer does not require firing to achieve its mechanical characteristics, it is however necessary to consolidate the lamination and draped to obtain a finished part meeting the requirements for structural applications of such a room.
- This consolidation consists in bringing the stratification obtained by draping at the melting temperature of the polymer, maintaining the thickness of the piece by means of pressurization, usually in an autoclave.
- pressurization usually in an autoclave.
- the re-melting of the polymer and the effect of the pressure make it possible to compact the assembly and to eliminate the voids and porosities of said stratification.
- the piece reaches its final thickness after the compaction operation subsequent to draping, and this operation requires the implementation of means, such as metal sheets. conformation, to obtain a uniform thickness of the part and the desired surface state on its faces. Since this compacting operation is carried out at the melting temperature of the thermoplastic polymer, this is generally much higher than the polymerization temperatures of the thermosetting resins.
- This operation involves the implementation of means such as autoclaves, tools and consumables, especially to achieve sealing, a high cost.
- the invention aims at solving the drawbacks of the prior art and proposes for this purpose a method of draping a fiber band comprising a thermoplastic polymer and consolidating the removal of a piece thus draped, said method comprising the steps consists in :
- the pre-consolidation makes it possible to obtain a fiber band free from defects such as porosities, by eliminating the air occluded in said fibers and at their junction, and regular impregnation of the fibers of this band, which also allows for to increase the polymer surface exposed to the weld during the draping operation.
- the process which is the subject of the invention does not require the melting of the entirety of the polymer included in the pre-consolidated strip and the polymer included in the previously deposited plies, but simply to bring the interface between the two to a temperature permitting welding at said interface, this temperature is of the order of the melting temperature of the material and is less restrictive in terms of viscosity than the temperature permitting the impregnation of the fibers during consolidation.
- solder is understood as the co-fusion of at least one surface layer on each of the elements (pre-deposited strip and ply) thus assembled.
- the invention can be implemented according to the advantageous embodiments described below, which can be considered individually or in any technically operative combination.
- step a) is carried out by the pultrusion of wicks pre-impregnated with a thermoplastic polymer, through a die.
- the pultrusion process allows rapid and dynamic pre-consolidation of the pre-impregnated fiber web and further allows a calibration in thickness and width of this band.
- the passage through the die thus makes it possible to crush the spindles of pre-impregnated locks and to obtain a regular distribution of the resin while expelling the air included in these locks.
- the pre-consolidation of step a) is carried out at a temperature T1 greater than the melting temperature of the thermoplastic polymer.
- T1 the melting temperature of the thermoplastic polymer.
- the semi-product is stored in step b) in the form of a roller that can be installed and unwound by a draping machine during step c).
- the polymer strip is sufficiently fine to lend itself to this conditioning mode, which exploits a natural tendency of the strip, particularly at the pultrusion outlet, to curl up on itself after the dynamic consolidation.
- PEEK polyetheretherketone
- T1 400 ° C
- T is equal to the crystalline melting temperature of the polymer.
- FIGS. 1A and 1B The invention is explained below according to its preferred embodiments, in no way limiting, and with reference to FIGS. 1A and 1B in which:
- FIG. 1A shows in profile and in a schematic diagram the pre-consolidation operation by pultrusion of a pre-impregnated fibrous web a thermoplastic polymer according to an exemplary embodiment of the method which is the subject of the invention
- FIG. 1 B shows a side view of a schematic diagram of the embodiment of a draping operation according to an exemplary embodiment of the invention.
- wicks (1 10) consisting of fibers, for example of carbon fiber, prepreged with a thermoplastic polymer, for example polyetheretherketone, or PEEK , are pre-consolidated during a dynamics process (120), for example pultrusion.
- a dynamics process 120
- Such a pultrusion process is known from the prior art and consists, according to an exemplary embodiment, not limiting, to wear said wicks (1 10) pre-impregnated by filming, dusting or co-blending polymer locks at a temperature close to the melting temperature of said polymer, for example, during the passage of said wicks in an infrared heating device (125).
- this first heating carries the said locks at a temperature between 300 ° C and the crystalline melting temperature of said polymer is about 360 ° C depending on the grade of PEEK used.
- the locks are then passed through a so-called hot first die (126), heated to a temperature sufficient for the fluidity of the molten polymer to impregnate the locks in a regular manner.
- this temperature T1 is typically between the crystalline melting temperature and 400 ° C, so that T1 is preferably fixed at 400 ° C.
- Said die has a variable air gap for progressively bringing the locks into the form of an impregnated sheet of defined thickness and width, which sheet is then introduced into a die (127) cooling and calibration.
- the consolidated web (1 15) at the outlet of the calibration die is thin (1 ply) and sufficiently flexible to be wound on a storage roller (130) of appropriate diameter.
- the web thus pre-consolidated is stable and can be stored indefinitely at room temperature in this form of semi-product.
- said semi-product (1 15) can be manufactured in very large series, according to continuous manufacturing processes in factories or dedicated production units, remote and independent of the draping units.
- Figure 1 B the manufacture of the composite part is performed by layering by placing the semi-finished product roll (130) in a draper machine. The draping is performed on a tool (150) sculpted to the shape of the part to obtain.
- Such draper machine capable of implementing said semi-product is known from the prior art and described in its dispensing principle by way of non-limiting example in the document FR-A-2 950 285.
- Such a machine drape adapted to the implementation of the method according to the invention comprises:
- - pressing means (160) adapted to apply a pressure (165) on the semi-product (1 15) during draping;
- the heating means (170) are dimensioned to bring this interface to a temperature T for welding the preconsolidated semi-product to the fold (1 17) already deposited, this fold being itself pre-consolidated.
- This temperature is close to the crystalline melting temperature of the thermoplastic polymer is about 360 ° C for PEEK depending on the grade used.
- the first pre-consolidated fold deposited on the tooling may, for example, be draped in the same manner, on a tear-off fabric, for example a glass fabric, which glass fabric can be held on the tooling by adhesives or a vacuum device.
- the folds are thus deposited by draping according to defined orientations until the desired lamination is obtained.
- the finished part can then be demolded and does not require further consolidation.
- the tooling (150) used does not require holding at high temperature nor the management of the differential expansions between this tool and the workpiece during said consolidation step.
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Robotics (AREA)
- Moulding By Coating Moulds (AREA)
- Reinforced Plastic Materials (AREA)
Abstract
The invention relates to a method for laying up a strip (110) of fibres containing a thermoplastic polymer and for consolidating during laying of a component thus laid up, said method involving the steps consisting in: a. pre-consolidating a strip (115) through the pultrusion (120) of rovings (110) that have been pre-impregnated with a thermoplastic polymer through a die; b. storing said pre-consolidated strip in the form of a semifinished product; c. laying up said semifinished product on a ply (117) of the same kind, previously laid on a form (150) while pressing (165) said semifinished product (115) onto said ply (117) and heating the interface between the semifinished product and the ply (117) already laid to a temperature T capable of causing the semifinished product (115) to weld to said ply (117).
Description
PROCÉDÉ POUR LE DRAP AGE ET LA CONSOLIDATION À LA DÉPOSE DE PIÈCES COMPOSITES THERMOPLASTIQUES À RENFORT FIBREUX PROCESS FOR SHEET AID AND CONSOLIDATION IN THE REMOVAL OF FIBROUS REINFORCED THERMOPLASTIC COMPOSITE PARTS
L'invention concerne un procédé pour le drapage et la consolidation à la dépose d'une pièce composite thermoplastique à renfort fibreux. The invention relates to a method for draping and consolidating the deposition of a thermoplastic composite component with fibrous reinforcement.
Le drapage automatisé, par dépôt de bandes ou placement de fibres préimprégnées, est un mode de fabrication très répandu dans le domaine de la réalisation de pièces composites à renfort fibreux dans une matrice thermodurcissable. En effet, la pégosité et la fluidité de ces résines permettent d'assurer une qualité de pièce exempte de vides ou de porosités lors des opérations de dépose et de cuisson subséquentes. Dans le cas de bandes dites pré-imprégnées d'un polymère thermoplastique, ledit polymère ne présente pas de pégosité à la température de drapage. La « pré-imprégnation » est en pratique réalisée soit par le calandrage d'un film constitué dudit polymère sur lesdites bandes de fibres, soit par un poudrage desdites fibres soit encore par l'insertion de fibres polymères co-mêlées aux fibres de renfort. Sauf indication particulière les termes « pré-imprégnation » et « pré-imprégné » lorsqu'ils se rapportent à des fibres et un polymère thermoplastique doivent être compris selon le sens pratique exposé ci-avant. Les plis successivement déposés sont liés entre eux par la mise en fusion du polymère. Or, le polymère thermoplastique fondu se caractérise par une viscosité très élevée, souvent de plusieurs ordres de grandeur comparativement aux résines thermodurcissables non durcies. Ainsi, même en mettant en fusion la charge polymère contenue dans la bande fibreuse il est très difficile d'obtenir une imprégnation efficace de l'ensemble des plis déposés. De plus, si la viscosité du polymère fondu peut être réduite en augmentant la température, généralement au-delà de la température de fusion, celui-ci fait alors l'objet d'un foisonnement important difficile à contrôler dans un processus de dépose dynamique. En conséquence, des vides ou des porosités subsistent dans l'empilement et ce d'autant plus que la vitesse de dépose ou, plus précisément, le débit de matière déposée est élevé. Ainsi, bien que le polymère thermoplastique ne nécessite pas de cuisson pour atteindre ses caractéristiques mécaniques, il est cependant nécessaire de réaliser une consolidation de la stratification ainsi drapée pour obtenir une pièce finie répondant aux exigences requises pour des applications structurales d'une telle pièce. Cette consolidation consiste à porter la stratification obtenue par
drapage à la température de fusion du polymère, en maintenant l'épaisseur de la pièce par des moyens de pressurisation, généralement en autoclave. Ainsi, la remise en fusion du polymère et l'effet de la pression permettent de compacter l'ensemble et d'éliminer les vides et porosités de ladite stratification. Toujours du fait du foisonnement du polymère lors de sa mise en fusion, la pièce n'atteint son épaisseur définitive qu'après l'opération de compactage ultérieure au drapage, et cette opération nécessite la mise en œuvre de moyens, tels que des tôles de conformation, permettant d'obtenir une épaisseur uniforme de la pièce et l'état de surface désiré sur ses faces. Cette opération de compactage étant réalisée à la température de fusion du polymère thermoplastique, celle-ci est, d'une manière générale, nettement plus élevée que les températures de polymérisation des résines thermodurcissable. Cette opération entraîne la mise en œuvre de moyens tels que des autoclaves, des outillages et des consommables, notamment pour réaliser l'étanchéité, d'un coût élevé. Automated draping, by deposition of strips or placement of pre-impregnated fibers, is a method of manufacture widely used in the field of producing fibrous reinforcement composite parts in a thermosetting matrix. Indeed, the tackiness and fluidity of these resins make it possible to ensure a quality of room free of voids or porosities during the subsequent removal and cooking operations. In the case of so-called pre-impregnated strips of a thermoplastic polymer, said polymer does not exhibit tack at the lay-up temperature. "Pre-impregnation" is in practice carried out either by the calendering of a film consisting of said polymer on said fiber strips, or by a dusting of said fibers or by the insertion of polymer fibers co-mixed with the reinforcing fibers. Unless otherwise indicated, the terms "pre-impregnation" and "prepreg" when referring to fibers and a thermoplastic polymer must be understood according to the practical meaning set forth above. The successively deposited folds are bonded together by the melting of the polymer. However, the molten thermoplastic polymer is characterized by a very high viscosity, often several orders of magnitude compared to uncured thermosetting resins. Thus, even by melting the polymer filler contained in the fibrous web it is very difficult to obtain effective impregnation of all the deposited plies. In addition, if the viscosity of the molten polymer can be reduced by increasing the temperature, generally above the melting temperature, it is then subject to a large expansion difficult to control in a dynamic deposition process. As a result, voids or porosities remain in the stack and all the more so as the rate of deposition or, more specifically, the rate of deposited material is high. Thus, although the thermoplastic polymer does not require firing to achieve its mechanical characteristics, it is however necessary to consolidate the lamination and draped to obtain a finished part meeting the requirements for structural applications of such a room. This consolidation consists in bringing the stratification obtained by draping at the melting temperature of the polymer, maintaining the thickness of the piece by means of pressurization, usually in an autoclave. Thus, the re-melting of the polymer and the effect of the pressure make it possible to compact the assembly and to eliminate the voids and porosities of said stratification. Always due to the proliferation of the polymer during its melting, the piece reaches its final thickness after the compaction operation subsequent to draping, and this operation requires the implementation of means, such as metal sheets. conformation, to obtain a uniform thickness of the part and the desired surface state on its faces. Since this compacting operation is carried out at the melting temperature of the thermoplastic polymer, this is generally much higher than the polymerization temperatures of the thermosetting resins. This operation involves the implementation of means such as autoclaves, tools and consumables, especially to achieve sealing, a high cost.
Tous les dispositifs de l'art antérieur, et à titre d'exemple le dispositif et le procédé décrits dans le document EP-B-1 91 1 569, abordent le problème de la consolidation, dit in situ, c'est-à-dire lors de la dépose des bandes fibreuses pré-imprégnées d'un polymère thermoplastique, par la recherche d'un chauffage et d'une mise en pression les plus uniformes possibles de la bande en cours de dépose et des plis pré-déposés. Ainsi, l'obtention d'une qualité de pièce exempte de porosité repose sur des dispositifs complexes de chauffage et de mise en pression permettant de maintenir les couches déposées à une température et une pression suffisante pendant un temps suffisant pour assurer une imprégnation uniforme des plis. Les résultats sont ainsi obtenus au prix de la complexité des dispositifs et au détriment du rendement. Même au prix de cette complexité, de tels procédés sont en pratique limités dans les épaisseurs maximales qui peuvent être ainsi déposées et consolidées in situ et l'expérience industrielle de la demanderesse montre qu'il n'est pas possible, dans des conditions de production industrielles, de réaliser par ces procédés des stratifications comprenant plus de 8 plis superposés dans le respect des exigences relatives aux pièces structurales de classe 2F pour le domaine aéronautique. All the devices of the prior art, and for example the device and the method described in the document EP-B-1 91 1 569, address the problem of consolidation, called in situ, that is to say say when removing the fiber webs pre-impregnated with a thermoplastic polymer, by seeking the heating and pressure as uniform as possible of the strip being deposited and pre-deposited folds. Thus, obtaining a quality of porosity-free part is based on complex heating and pressurizing devices making it possible to maintain the deposited layers at a sufficient temperature and pressure for a time sufficient to ensure uniform impregnation of the plies. . The results are thus obtained at the cost of the complexity of the devices and to the detriment of the yield. Even at the expense of this complexity, such processes are in practice limited in the maximum thicknesses that can thus be deposited and consolidated in situ and the industrial experience of the applicant shows that it is not possible, under production conditions. by these processes, laminates comprising more than 8 superposed plies in compliance with the requirements for Class 2F structural parts for the aeronautical field.
Le document « Manufacturing processes for advanced composites » Chapitre 10, Elsevier Advanced Technology du 1 er janvier 2004, confirme que
ces procédés de consolidation in situ d'une stratification de plis pré-imprégnés d'un polymère thermoplastique, ne permettent pas d'atteindre, dans des conditions industrielles, des taux de consolidation supérieurs 90 % et qu'une étape de post-consolidation, notamment au moyen d'une tôle de compactage est nécessaire après le drapage. The "Manufacturing processes for advanced composites" document Chapter 10, Elsevier Advanced Technology of January 1, 2004, confirms that these processes of consolidation in situ of a stratification of plies pre-impregnated with a thermoplastic polymer, do not make it possible to reach, under industrial conditions, consolidation rates higher than 90% and a post-consolidation step, especially by means of a compacting plate is necessary after draping.
L'invention vise à résoudre les inconvénients de l'art antérieur et propose à cette fin un procédé de drapage d'une bande de fibres comprenant un polymère thermoplastique et de consolidation à la dépose d'une pièce ainsi drapée, ledit procédé comprenant les étapes consistant à : The invention aims at solving the drawbacks of the prior art and proposes for this purpose a method of draping a fiber band comprising a thermoplastic polymer and consolidating the removal of a piece thus draped, said method comprising the steps consists in :
a. pré-consolider une bande de fibres pré-imprégnée d'un polymère thermoplastique ; at. pre-consolidate a fiber web pre-impregnated with a thermoplastic polymer;
b. stocker ladite bande pré-consolidée sous forme de semi-produit ; c. draper ledit semi-produit sur un pli de même nature préalablement déposé sur une forme en pressant ledit semi-produit sur ledit pli et en chauffant l'interface entre le semi-produit et le pli préalablement déposé à une température, T, apte à obtenir la soudure du semi-produit sur ledit pli. b. storing said pre-consolidated strip as a semi-finished product; vs. drape said semi-product on a fold of the same nature previously deposited on a shape by pressing said semi-product on said fold and by heating the interface between the semi-product and the fold previously deposited at a temperature, T, able to obtain the welding of the semi-product on said fold.
Ainsi, la pré-consolidation permet d'obtenir une bande de fibres exempte de défauts tels que des porosités, en éliminant l'air occlus dans lesdites fibres et à leur jonction, et une imprégnation régulière des fibres de cette bande permettant en outre d'augmenter la surface de polymère exposée à la soudure lors de l'opération de drapage. Ainsi, le procédé objet de l'invention ne nécessite pas la mise en fusion de l'intégralité du polymère compris dans la bande pré-consolidée et du polymère compris dans les plis préalablement déposés, mais simplement de porter l'interface entre les deux à une température permettant la soudure à ladite interface, cette température est de l'ordre de la température de fusion du matériau et est moins contraignante en termes de viscosité que la température permettant l'imprégnation des fibres lors de la consolidation. Le terme soudure s'entend comme la co-fusion d'au moins une couche superficielle sur chacun des éléments (bande et pli pré-déposé) ainsi assemblés. Ces conditions, outre l'avantage de la consolidation in situ, permettent une dépose rapide avec des moyens simples, autorisant la réalisation de formes complexes et/ou l'utilisation de bandes de grande largeur pour obtenir des débits massiques de drapage comparable à ceux obtenus
avec des résines d'imprégnation thermodurcissables. En l'absence de consolidation à haute température à l'issue du drapage, les coûts d'outillage, d'installation et de consommables sont réduits. Thus, the pre-consolidation makes it possible to obtain a fiber band free from defects such as porosities, by eliminating the air occluded in said fibers and at their junction, and regular impregnation of the fibers of this band, which also allows for to increase the polymer surface exposed to the weld during the draping operation. Thus, the process which is the subject of the invention does not require the melting of the entirety of the polymer included in the pre-consolidated strip and the polymer included in the previously deposited plies, but simply to bring the interface between the two to a temperature permitting welding at said interface, this temperature is of the order of the melting temperature of the material and is less restrictive in terms of viscosity than the temperature permitting the impregnation of the fibers during consolidation. The term solder is understood as the co-fusion of at least one surface layer on each of the elements (pre-deposited strip and ply) thus assembled. These conditions, in addition to the advantage of consolidation in situ, allow rapid removal with simple means, allowing the realization of complex shapes and / or the use of wide strips to obtain draping mass flow rates comparable to those obtained with thermosetting impregnating resins. In the absence of consolidation at high temperature after draping, the costs of tools, installation and consumables are reduced.
L'invention peut être mise en œuvre selon les modes de réalisation avantageux exposés ci-après, lesquels peuvent être considérés individuellement ou selon toute combinaison techniquement opérante. The invention can be implemented according to the advantageous embodiments described below, which can be considered individually or in any technically operative combination.
Avantageusement, l'étape a) est réalisée par la pultrusion de mèches préimprégnées d'un polymère thermoplastique, à travers une filière. Ainsi le procédé de pultrusion permet une pré-consolidation dynamique et rapide de la bande de fibres pré-imprégnées et permet en outre un calibrage en épaisseur et en largeur de cette bande. Le passage dans la filière permet ainsi d'écraser les fuseaux de mèches pré-imprégnées et d'obtenir une distribution régulière de la résine tout en chassant l'air inclus dans ces mèches. Advantageously, step a) is carried out by the pultrusion of wicks pre-impregnated with a thermoplastic polymer, through a die. Thus the pultrusion process allows rapid and dynamic pre-consolidation of the pre-impregnated fiber web and further allows a calibration in thickness and width of this band. The passage through the die thus makes it possible to crush the spindles of pre-impregnated locks and to obtain a regular distribution of the resin while expelling the air included in these locks.
Avantageusement, la pré-consolidation de l'étape a) est réalisée à une température T1 supérieure à la température de fusion du polymère thermoplastique. Ainsi, la fluidité du polymère permet une imprégnation parfaite des fibres. Advantageously, the pre-consolidation of step a) is carried out at a temperature T1 greater than the melting temperature of the thermoplastic polymer. Thus, the fluidity of the polymer allows perfect impregnation of the fibers.
Avantageusement, le semi-produit est stocké à l'étape b) sous la forme d'un rouleau apte à être installé et dévidé par une machine de drapage au cours de l'étape c). La bande de polymère est suffisamment fine pour se prêter à ce mode de conditionnement, qui exploite une tendance naturelle de la bande, notamment en sortie de pultrusion, à s'enrouler sur elle-même à l'issue de la consolidation dynamique. Advantageously, the semi-product is stored in step b) in the form of a roller that can be installed and unwound by a draping machine during step c). The polymer strip is sufficiently fine to lend itself to this conditioning mode, which exploits a natural tendency of the strip, particularly at the pultrusion outlet, to curl up on itself after the dynamic consolidation.
Selon un mode de réalisation particulier, le polymère thermoplastique est un polyétheréthercétone (PEEK), T1 = 400 °C et T est égale à la température de fusion cristalline du polymère. Ainsi le procédé objet de l'invention permet de créer par drapage et consolidation in situ des pièces constituées d'un composite à renfort fibreux continu dans une telle matrice à haute performance sans nécessiter de moyens, tels qu'étuve ou autoclave, aptes à réaliser la consolidation de la pièce à haute température. According to a particular embodiment, the thermoplastic polymer is a polyetheretherketone (PEEK), T1 = 400 ° C and T is equal to the crystalline melting temperature of the polymer. Thus, the method which is the subject of the invention makes it possible to create, by draping and consolidation in situ, pieces consisting of a composite with continuous fiber reinforcement in such a high performance die without requiring means, such as an oven or autoclave, capable of producing the consolidation of the room at high temperature.
L'invention est exposée ci-après selon ses modes de réalisation préférés, nullement limitatifs, et en référence aux figures 1 A et 1 B dans lesquelles : The invention is explained below according to its preferred embodiments, in no way limiting, and with reference to FIGS. 1A and 1B in which:
- la figure 1 A montre de profil et selon un schéma de principe l'opération de pré-consolidation par pultrusion d'une bande fibreuse pré-imprégnée
d'un polymère thermoplastique selon un exemple de réalisation d procédé objet de l'invention ; FIG. 1A shows in profile and in a schematic diagram the pre-consolidation operation by pultrusion of a pre-impregnated fibrous web a thermoplastic polymer according to an exemplary embodiment of the method which is the subject of the invention;
- la figure 1 B représente selon une vue de profil un schéma de principe de la réalisation d'une opération de drapage selon un exemple de réalisation de l'invention. - Figure 1 B shows a side view of a schematic diagram of the embodiment of a draping operation according to an exemplary embodiment of the invention.
Figure 1 A, au cours d'une première étape du procédé objet de l'invention, des mèches (1 10) constituée de fibres, par exemple de fibre de carbone, préimprégnées d'un polymère thermoplastique, par exemple du polyétheréthercétone, ou PEEK, sont pré-consolidées au cours d'un processus de dynamique (120) par exemple de pultrusion. Un tel processus de pultrusion est connu de l'art antérieur et consiste, selon un exemple de réalisation, non limitatif, à porter les dites mèches (1 10) pré-imprégnées par filmage, poudrage ou co-mêlage de mèches polymères à une température proche de la température de fusion dudit polymère, par exemple, au cours du passage desdites mèches dans un dispositif (125) de chauffage par infrarouge. Dans le cas où le polymère thermoplastique est constitué de PEEK, ce premier chauffage porte les dites mèches à une température comprise entre 300 °C et la température de fusion cristalline du dit polymère soit 360 °C environ selon le grade de PEEK utilisé. Les mèches sont alors passées dans une première filière (126) dite chaude, portée à une température suffisante pour que la fluidité du polymère fondu puisse imprégner de manière régulière les mèches. Pour le PEEK, cette température T1 est typiquement comprise entre la température de fusion cristalline et 400 °C, de sorte que T1 est préférentiellement fixée à 400 °C. Ladite filière présente un entrefer variable permettant d'amener progressivement les mèches vers la forme d'une nappe imprégnée d'épaisseur et de largeur définies, laquelle nappe est alors introduite dans une filière (127) de refroidissement et de calibrage. La nappe consolidée (1 15) en sortie de la filière de calibrage est de faible épaisseur (1 pli) et suffisamment flexible pour être enroulée sur un rouleau (130) de stockage de diamètre approprié. La nappe ainsi pré-consolidée est stable et peut être stockée indéfiniment à température ambiante sous cette forme de semi-produit. Ainsi, ledit semi- produit (1 15) peut être fabriqué en très grande série, selon des procédés de fabrication continue dans des usines ou des unités de production dédiées, éloignées et indépendantes des unités de drapage.
Figure 1 B, la fabrication de la pièce composite est réalisée par drapage en plaçant le rouleau de semi-produit (130) dans une machine à draper. Le drapage est réalisé sur un outillage (150) sculpté à la forme de la pièce à obtenir. Une telle machine à draper, apte à mettre en œuvre ledit semi-produit est connue de l'art antérieur et décrite dans son principe de dépose à titre d'exemple non limitatif dans le document FR-A-2 950 285. Une telle machine à draper adaptée à la mise en œuvre du procédé selon l'invention comprend : FIG. 1A, during a first step of the process which is the subject of the invention, wicks (1 10) consisting of fibers, for example of carbon fiber, prepreged with a thermoplastic polymer, for example polyetheretherketone, or PEEK , are pre-consolidated during a dynamics process (120), for example pultrusion. Such a pultrusion process is known from the prior art and consists, according to an exemplary embodiment, not limiting, to wear said wicks (1 10) pre-impregnated by filming, dusting or co-blending polymer locks at a temperature close to the melting temperature of said polymer, for example, during the passage of said wicks in an infrared heating device (125). In the case where the thermoplastic polymer consists of PEEK, this first heating carries the said locks at a temperature between 300 ° C and the crystalline melting temperature of said polymer is about 360 ° C depending on the grade of PEEK used. The locks are then passed through a so-called hot first die (126), heated to a temperature sufficient for the fluidity of the molten polymer to impregnate the locks in a regular manner. For PEEK, this temperature T1 is typically between the crystalline melting temperature and 400 ° C, so that T1 is preferably fixed at 400 ° C. Said die has a variable air gap for progressively bringing the locks into the form of an impregnated sheet of defined thickness and width, which sheet is then introduced into a die (127) cooling and calibration. The consolidated web (1 15) at the outlet of the calibration die is thin (1 ply) and sufficiently flexible to be wound on a storage roller (130) of appropriate diameter. The web thus pre-consolidated is stable and can be stored indefinitely at room temperature in this form of semi-product. Thus, said semi-product (1 15) can be manufactured in very large series, according to continuous manufacturing processes in factories or dedicated production units, remote and independent of the draping units. Figure 1 B, the manufacture of the composite part is performed by layering by placing the semi-finished product roll (130) in a draper machine. The draping is performed on a tool (150) sculpted to the shape of the part to obtain. Such draper machine capable of implementing said semi-product is known from the prior art and described in its dispensing principle by way of non-limiting example in the document FR-A-2 950 285. Such a machine drape adapted to the implementation of the method according to the invention comprises:
- des moyens pour accueillir et dévider le rouleau (130) de semi-produit (1 15) ; means for receiving and unwinding the roll (130) of semi-finished product (1 15);
- des moyens presseurs (160) apte à appliquer une pression (165) sur le semi-produit (1 15) au cours du drapage ; - pressing means (160) adapted to apply a pressure (165) on the semi-product (1 15) during draping;
- des moyens de chauffage (170) aptes à porter l'interface entre le semi- produit (1 15) en cours de dépose et le pli (1 17) préalablement déposé. - Heating means (170) capable of carrying the interface between the semi-product (1 15) being deposited and the fold (1 17) previously deposited.
Les moyens de chauffage (170) sont dimensionnés pour porter cette interface à une température T permettant le soudage du semi-produit préconsolidé sur le pli (1 17) déjà déposé, ce pli étant lui-même pré-consolidé. Cette température est proche de la température de fusion cristalline du polymère thermoplastique soit environ 360 °C pour le PEEK selon le grade utilisé. The heating means (170) are dimensioned to bring this interface to a temperature T for welding the preconsolidated semi-product to the fold (1 17) already deposited, this fold being itself pre-consolidated. This temperature is close to the crystalline melting temperature of the thermoplastic polymer is about 360 ° C for PEEK depending on the grade used.
Le premier pli pré-consolidé déposé sur l'outillage, peut, à titre d'exemple, être drapé de la même manière, sur un tissu arrachable, par exemple un tissu de verre, lequel tissu de verre peut être maintenu sur l'outillage par des adhésifs ou encore un dispositif à dépression. Les plis sont ainsi déposés par drapage selon des orientations définies jusqu'à obtenir la stratification désirée. La pièce finie peut alors être démoulée et ne nécessite pas de consolidation ultérieure. Ainsi, l'outillage (150) utilisé ne nécessite pas de tenue à haute température pas plus que la gestion des dilatations différentielles entre cet outillage et la pièce lors de ladite étape de consolidation. The first pre-consolidated fold deposited on the tooling may, for example, be draped in the same manner, on a tear-off fabric, for example a glass fabric, which glass fabric can be held on the tooling by adhesives or a vacuum device. The folds are thus deposited by draping according to defined orientations until the desired lamination is obtained. The finished part can then be demolded and does not require further consolidation. Thus, the tooling (150) used does not require holding at high temperature nor the management of the differential expansions between this tool and the workpiece during said consolidation step.
La description et les exemples de réalisation précédents montrent que l'invention atteint les objectifs visés, en particulier elle permet la réalisation d'une pièce finie comprenant un renfort fibreux continu dans une matrice thermoplastique directement par drapage.
The description and the previous examples of embodiment show that the invention achieves the intended objectives, in particular it allows the production of a finished part comprising a continuous fiber reinforcement in a thermoplastic matrix directly by draping.
Claims
REVENDICATIONS
Procédé pour le drapage d'une bande (1 10) de fibres comprenant un polymère thermoplastique et la consolidation à la dépose d'une pièce ainsi drapée, caractérisé en ce qu'il comprend les étapes consistant à : a. pré-consolider une bande (1 10) de fibres pré-imprégnée d'un polymère thermoplastique par la pultrusion (120) de mèches (1 10) pré-imprégnées d'un polymère thermoplastique, à travers une filière (126, 127). ; A method for draping a strip (1 10) of fibers comprising a thermoplastic polymer and consolidating the deposition of a piece thus draped, characterized in that it comprises the steps of: a. pre-consolidating a strip (1 10) of fibers pre-impregnated with a thermoplastic polymer by pultrusion (120) of wicks (1 10) pre-impregnated with a thermoplastic polymer, through a die (126, 127). ;
b. stocker ladite bande pré-consolidée sous forme de semi-produit b. storing said pre-consolidated strip as a semi-finished product
(1 15) ; (1 15);
c. draper ledit semi-produit (1 15) sur un pli (1 17) de même nature, préalablement déposé sur une forme (150) en pressant (165) ledit semi-produit (1 15) sur ledit pli (1 17) et en chauffant l'interface entre le semi-produit et le pli (1 17) préalablement déposé à une température, T, apte à obtenir la soudure du semi-produit (1 15) sur ledit pli (1 17). vs. coating said semi-product (1 15) on a fold (1 17) of the same nature, previously deposited on a form (150) by pressing (165) said semi-finished product (1 15) on said fold (1 17) and heating the interface between the semi-product and the fold (1 17) previously deposited at a temperature, T, capable of obtaining the welding of the semi-product (1 15) on said fold (1 17).
Procédé selon la revendication 1 , caractérisée en ce que la préconsolidation de l'étape a) est réalisée à une température T1 supérieure à la température de fusion du polymère thermoplastique. Process according to claim 1, characterized in that the preconsolidation of step a) is carried out at a temperature T1 greater than the melting temperature of the thermoplastic polymer.
Procédé selon la revendication 1 , caractérisé en ce que le semi-produit (1 15) est stocké à l'étape b) sous la forme d'un rouleau (130) apte à être installé et dévidé par une machine à draper au cours de l'étape c). Process according to Claim 1, characterized in that the semi-finished product (1 15) is stored in step b) in the form of a roll (130) which can be installed and unwound by a draper during step c).
Procédé selon la revendication 2, caractérisé en ce que le polymère thermoplastique est un polyétheréthercétone (PEEK) et que T1 = 400 °C et T est égale à la température de fusion cristalline du polymère.
Process according to claim 2, characterized in that the thermoplastic polymer is a polyetheretherketone (PEEK) and that T1 = 400 ° C and T is equal to the crystalline melting temperature of the polymer.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
FR1155982A FR2977187B1 (en) | 2011-07-01 | 2011-07-01 | METHOD FOR DRAPING AND CONSOLIDATING THE REMOVAL OF THERMOPLASTIC COMPOSITE PARTS WITH FIBROUS REINFORCEMENT |
PCT/EP2012/062862 WO2013004672A1 (en) | 2011-07-01 | 2012-07-02 | Method for laying up and consolidating during laying thermoplastic composite components containing fibrous reinforcements |
Publications (1)
Publication Number | Publication Date |
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EP2726273A1 true EP2726273A1 (en) | 2014-05-07 |
Family
ID=46420212
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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EP12730984.7A Withdrawn EP2726273A1 (en) | 2011-07-01 | 2012-07-02 | Method for laying up and consolidating during laying thermoplastic composite components containing fibrous reinforcements |
Country Status (7)
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US (1) | US20140246145A1 (en) |
EP (1) | EP2726273A1 (en) |
BR (1) | BR112014000040B1 (en) |
CA (1) | CA2838915C (en) |
FR (1) | FR2977187B1 (en) |
WO (1) | WO2013004672A1 (en) |
ZA (1) | ZA201309465B (en) |
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EP3459719A4 (en) * | 2016-07-14 | 2019-07-24 | Mitsubishi Heavy Industries, Ltd. | Method and device for producing pultruded article |
CN108604345B (en) * | 2017-01-25 | 2020-09-25 | 华为技术有限公司 | Method and device for adding bank card |
Family Cites Families (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE3375488D1 (en) * | 1982-07-28 | 1988-03-03 | Ici Plc | Method of producing fibre-reinforced composition |
US4714509A (en) * | 1984-07-02 | 1987-12-22 | E. I. Dupont De Nemours And Company | Method and apparatus for laying down tapes |
US4900499A (en) * | 1988-01-14 | 1990-02-13 | Phillips Petroleum Company | Molding process for forming a tape of long reinforcement |
US5078821A (en) * | 1990-08-13 | 1992-01-07 | The United States Of America As Represented By The United States Department Of Energy | Method and apparatus for producing composites of materials exhibiting thermoplastic properties |
US5205898A (en) * | 1990-11-15 | 1993-04-27 | The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration | Continuous fiber thermoplastic prepreg |
US5700347A (en) * | 1996-01-11 | 1997-12-23 | The Boeing Company | Thermoplastic multi-tape application head |
US5843355A (en) * | 1996-01-24 | 1998-12-01 | The Boeing Company | Method for molding a thermoplastic composite sine wave spar structure |
JP2005329593A (en) * | 2004-05-19 | 2005-12-02 | Fuji Heavy Ind Ltd | Automatic lamination apparatus |
US7404868B2 (en) | 2006-10-10 | 2008-07-29 | Accudyne Systems, Inc. | Tape placement head for applying thermoplastic tape to an object |
ES2728665T3 (en) * | 2008-09-18 | 2019-10-28 | Fraunhofer Ges Forschung | Procedure and device for the production of composite construction elements as well as pressure unit |
DE102009009186B4 (en) * | 2009-02-16 | 2011-04-21 | Airbus Operations Gmbh | Pressing device for pressing fiber-reinforced thermoplastic materials and fiber arranging device |
FR2950285A1 (en) | 2009-09-21 | 2011-03-25 | Airbus Operations Sas | AUTOMATED DRAPING DEVICE |
-
2011
- 2011-07-01 FR FR1155982A patent/FR2977187B1/en not_active Expired - Fee Related
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2012
- 2012-07-02 CA CA2838915A patent/CA2838915C/en not_active Expired - Fee Related
- 2012-07-02 WO PCT/EP2012/062862 patent/WO2013004672A1/en active Application Filing
- 2012-07-02 EP EP12730984.7A patent/EP2726273A1/en not_active Withdrawn
- 2012-07-02 US US14/130,041 patent/US20140246145A1/en not_active Abandoned
- 2012-07-02 BR BR112014000040-9A patent/BR112014000040B1/en not_active IP Right Cessation
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2013
- 2013-12-13 ZA ZA2013/09465A patent/ZA201309465B/en unknown
Non-Patent Citations (1)
Title |
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See references of WO2013004672A1 * |
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BR112014000040A2 (en) | 2017-02-07 |
ZA201309465B (en) | 2014-08-27 |
WO2013004672A1 (en) | 2013-01-10 |
US20140246145A1 (en) | 2014-09-04 |
BR112014000040B1 (en) | 2021-05-18 |
CA2838915A1 (en) | 2013-01-10 |
FR2977187A1 (en) | 2013-01-04 |
FR2977187B1 (en) | 2017-06-09 |
CA2838915C (en) | 2020-12-01 |
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