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
  • B29C70/28—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]
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B15/00—Layered products comprising a layer of metal
  • B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
  • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
  • B32B3/14—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a face layer formed of separate pieces of material which are juxtaposed side-by-side
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
  • B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
  • B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
  • B32B7/04—Interconnection of layers
  • B32B7/05—Interconnection of layers the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
  • B32B7/04—Interconnection of layers
  • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
  • B32B7/14—Interconnection of layers using interposed adhesives or interposed materials with bonding properties applied in spaced arrangements, e.g. in stripes
• • 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
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
  • B29L2031/3055—Cars
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B15/00—Layered products comprising a layer of metal
  • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B15/06—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of natural rubber or synthetic rubber
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2250/00—Layers arrangement
  • B32B2250/02—2 layers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2255/00—Coating on the layer surface
  • B32B2255/06—Coating on the layer surface on metal layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2255/00—Coating on the layer surface
  • B32B2255/26—Polymeric coating
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
  • B32B2260/02—Composition of the impregnated, bonded or embedded layer
  • B32B2260/021—Fibrous or filamentary layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
  • B32B2260/04—Impregnation, embedding, or binder material
  • B32B2260/046—Synthetic resin
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/02—Synthetic macromolecular fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/10—Inorganic fibres
  • B32B2262/101—Glass fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/10—Inorganic fibres
  • B32B2262/106—Carbon fibres, e.g. graphite fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/732—Dimensional properties
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2605/00—Vehicles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
  • B32B7/04—Interconnection of layers
  • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties

Definitions

• the present invention relates to a method for producing a reinforced part, more particularly to a process for producing metal parts reinforced with continuous fibers.
• the metal part is conventionally obtained from a flat metal sheet, optionally embossed to the desired shape.
• Each reinforcement is formed of fibers and a polymer matrix, in particular thermoplastic.
• the reinforcement may be manufactured by applying to a mold pre-impregnated or non-resinous fibers, in the form of fabric or in the form of unidirectional layers or wicks. After application of the fibers, the preform obtained is subjected to a consolidation or hardening operation, with a possible prior infusion or polymer injection operation. After completion of the reinforcements to the desired shape, they are assembled on the metal part, for example by gluing or and / or riveting.
• the object of the present invention is to propose a solution to overcome the aforementioned drawbacks.
• the present invention proposes a method for producing a reinforced part, characterized in that it comprises the draping of unidirectional continuous fibers on a metal part provided with an adhesion layer comprising at least a first thermoplastic polymer said fibers being pre-impregnated with at least a second thermoplastic polymer, said draping being carried out by automatically placing the pre-impregnated fibers on the metal part, by means of a compacting roll and by heating the pre-impregnated continuous fibers to drape and the adhesion layer of the metal part, preferably just upstream of the roll, at a temperature at least greater than or equal to the melting temperature of the second polymer, for welding the pre-impregnated fibers to the metal part to obtain a reinforced part, said prepreg fibers being preferably draped in the direction or directions of the main stresses of the reinforced part to which said part will be subjected.
• the reinforced piece is obtained by draping directly by placing fibers of the continuous fibers on a metal part which has been previously covered with an adhesion layer formed from a thermoplastic polymer.
• the metal part has been subjected to a surface treatment by application of an adhesion layer, also called adhesion promoter layer or thermoplastic layer, this adhesion layer making it possible to ensure a satisfactory connection between the continuous fibers and metal part during draping, especially at high draping speeds.
• the invention uses the so-called fiber placement method, known per se, in which continuous fibers are deposited in contact on a tool to form one or more plies in defined orientations.
• This method of application to the contact is implemented by means of a fiber application head comprising a compacting roller intended to come into contact with the metal part to apply a strip formed of one or more fibers.
• the compaction roller presses the fiber web against the tooling to facilitate adhesion of the deposited strips to the metal part and adhesion of the strips deposited therebetween, as well as to progressively evacuate the air trapped between the metal part and the tapes deposited, then between the deposited tapes.
• the head is equipped with a heating system for heating the fiber web, as well as for heating the metal part, in particular the adhesion layer, or strips already applied, just before compacting the web.
• the unidirectional continuous fibers applied by fiber placement are, for example, carbon fibers, glass fibers or synthetic fibers. These unidirectional continuous fibers are preferably in the form of flat fibers or wicks, e.g. one-eighth of an inch, one-quarter inch or one-half inch (1/8 ", 1/4" or 1/2 ")
• the fibers continuous prepregs of a thermoplastic polymer have before draping a porosity less than or equal to 3%, preferably less than or equal to 2%, more preferably less than or equal to 1%.
• the metal part provided with an adhesion layer is for example obtained from a metal sheet, partially or completely covered on one side with an adhesion layer.
• the metal part is for example obtained from a flat sheet, possibly embossed to the desired final shape.
• the metal part provided with an adhesion layer is obtained by projection on the metal part, at least on the areas of the metal part on which the fibers will be draped, with a bonding agent formed the first thermoplastic polymer in powder form, said metal part being then subjected to heating by passage in an oven, to form the adhesion layer.
• the metal part provided with an adhesion layer is obtained by spraying the metal part, at least on the areas of the metal part on which the fibers will be draped, with a bonding agent formed of the first thermoplastic polymer in the solvent phase.
• the first thermoplastic polymer and the second thermoplastic polymer are for example selected from the group consisting of polyamides, polyesters such as polyethylene terephthalate, polyethersulfones, polyetheretherketones, phenylene polysulfides, polyurethanes, epoxides, polyolefins, polylactic acid, or a mixture of one or more of these polymers.
• the first polymer and the second polymer may be the same or different, polymers of the same family of thermoplastics or different families.
• said heating is carried out at a temperature greater than or equal to the melting temperature of the first polymer to ensure effective welding between the metal part and the continuous fibers.
• said heating is carried out at a temperature greater than or equal to the processability temperatures of the first polymer and the second polymer, to which said polymers are conventionally used.
• said draping comprises the automated placement of continuous pre-impregnated fibers on pre-draped continuous fibers, by means of a compacting roll and by heating the pre-impregnated fibers to be draped and fibers previously draped to a higher than the melting temperature of the second polymer, said draping being carried out in overlap in the same direction as the previously draped fibers, and / or in complementary directions.
• said heating during draping is performed to ensure in situ consolidation of the reinforcement, formed of continuous fibers and the second polymer, on the metal part, so that the reinforced part obtained after draping does not require additional heat treatment operation to achieve the desired mechanical characteristics, the reinforcement formed of the continuous fibers and its second polymer matrix having after draping a porosity less than or equal to 3%, preferably less than or equal to 2%, better still lower or
• the method comprises continuous heating during the lay-up of continuous fibers for continuously welding the fibers pre-impregnated to the metal part over their entire length.
• the method comprises discontinuous heating during lay-up of continuous fibers to weld the fibers to the metal part on fiber portions spaced apart from one another, the method may include draping fibers with batch heating and draping fibers with discontinuous heating.
• the heating is performed by a laser-type heating means.
• the method comprises draping overlapping fibers, in complementary directions, at one or more assembly areas of the reinforced part, in order to take up the forces transmitted by assembly means.
• the method comprises draping pre-impregnated fibers around one or more assembly areas of the reinforced part, in order to take up the forces transmitted by the assembly means.
• the fiber is draped around at least one assembly axis, in particular on a surface of the metal part substantially parallel to the assembly axis, and extends in a direction opposite to said assembly axis.
• axis for example substantially perpendicular to said axis.
• the metal part is provided with one or more flats at which the fibers are draped.
• specific planar zones such as flats, are provided in order to facilitate the lay-up of fibers by placement of fibers and thus allow fast draping of the fibers while guaranteeing a uniform effective compaction of the fibers on all their width.
• the fibers draped over the metal part follow geodesic trajectories.
• the reinforced piece constitutes a piece for a land or air vehicle, for example for a motor vehicle, such as a body post, a door frame or a seat frame.
• FIG. 1 is a schematic perspective view of a metal part for the production of a first reinforced part according to the invention
• FIG. 2 is a partial schematic side view of the metal part of FIG. 1 during an investment operation by means of a fiber placement head;
• FIG. 3 is a schematic view of the metal part after placement of first fibers
• FIG. 4 is a view similar to that of Figure 3 illustrating the reinforced part after placement of second fibers
• - Figure 5 is a view similar to that of Figure 4 illustrating an alternative embodiment for fiber placement operations
• FIGS. 6A and 6B are respectively a top view and an enlarged partial side view of a second reinforced part according to the invention.
• FIGS. 7A and 7B are respectively a top view and an enlarged partial side view of a third reinforced part according to the invention.
• FIG. 1 illustrates a metal part 1 for the production of an amount of the bodywork of a motor vehicle, disposed on each side of the vehicle between the rear door and the front door, conventionally called upright or central pillar, and designed to withstand in particular side shocks and compressive forces.
• the upright 1 comprises a vertical central portion 11 connected at the end to a lower portion 12 and an upper portion 13 for the assembly of the upright respectively to the rocker, and the roof.
• the central portion has a generally U-shaped variable section with a central base or wall 1a and two branches or side walls 1b, the section expands at the end with curved sidewalls for the joining of the central portion to the parts.
• the upper portion 13 has a U-shaped section and is connected by one of its side walls 13b to the central wall 11a of the central portion.
• the lower portion 12 has a U-shaped section, with two curved side walls 12b disposed in the extension of the side walls 11b of the central portion, and a horizontal central wall 12a disposed in the extension of the central wall 1a of the central portion.
• the metal part has an outer main face la, and an inner main face lb.
• this metal part 1 is provided on its outer face with an adhesion layer comprising at least a first thermoplastic polymer.
• This metal part is then reinforced by draping continuous fibers pre-impregnated with a second thermoplastic polymer on the outer face, this draping being effected by means of a fiber placement head to stiffen the metal part with respect to the forces to which she must be able to resist.
• a fiber placement head to stiffen the metal part with respect to the forces to which she must be able to resist.
• only the or the areas of the outer face on which fibers will be applied are covered with a layer of adhesion.
• FIG. 2 schematically illustrates a fiber placement head 2, known per se, for automatic draping in contact with fiber.
• the head comprises a compacting roller 21 for applying the fiber to the contact on the metal part.
• the head further comprises cutting means 22 for cutting the fiber at the end of the trajectory, locking means 23 arranged upstream of the cutting means with respect to the direction of advancement of the fiber to block the newly-formed fiber. cut, and rerouting means 24 arranged upstream of the cutting means, to drive the fiber, this in order to be able to stop and resume the application of the fiber at any time.
• the head is further equipped with a heating system 25 for heating, during draping, the fiber to be draped and the metallic piece adhesion layer, just upstream of the roll with respect to the direction of the head, and thus to weld the fiber to the metal piece.
• the heating system here is of the laser type and comprises an optical 25a mounted on the head.
• the beam emitted by a source (not shown) offset from the head is conveyed via an optical fiber 25b to the optics 25a to form a laser beam in the direction of the nip between the roll and the metal part.
• the draping is achieved by relative movement of the head relative to the metal part. To do this, the head and / or the metal part are assembled to a displacement system.
• first fibers 31, 32 prepreg are draped longitudinally on the central wall l ia of the central portion, the outer side thereof. These first fibers extend on the side wall 13b of the upper part, and on the central wall 12a of the lower part. These first fibers are here three in number, with a central fiber 31, and two lateral fibers 32 which end follow the curvature of the side walls 1 lb, 12b.
• the first fibers 31, 32 are draped one by one, starting for example from the upper part.
• the reinforced piece 4 according to the invention is obtained after draping second fibers 33, 34. These second fibers are draped over the lower and upper portions in overlap of the first fibers 31, 32. A second fiber 33 is draped on the wall lateral 13b of the upper part. Second fibers 34, three in number, are draped over the central wall 12a of the lower part in overlap of the first fibers.
• the heating is defined to continuously weld the fibers 31-34 to the metal part, and so ensure in situ consolidation of the fibers and obtain a reinforced part that does not require an additional heat treatment step.
• the applied fibers are 1/4 inch (1.35 mm) wide wicking carbon fibers pre-impregnated with a polyamide.
• the metal part is covered with a layer of polyamide.
• the preimpregnated continuous fiber and the metal part are heated to a higher temperature, for example 10 to 30 ° C, at the melting temperatures of the two polyamides used.
• the polyamide layer is, for example, produced by electrostatically spraying the metal part with a powder-form adhesion promoter, then passing the metal part through an oven to melt the adhesion agent and form the coating layer. adhesion.
• the adhesion promoter is in the solvent phase and is applied by spraying in the manner of a paint or a lacquer.
• the draping operation is performed by means of a fiber placement head for drapering a strip formed of one or more fibers arranged parallel to each other, for example substantially edge to edge.
• a fiber placement head for drapering a strip formed of one or more fibers arranged parallel to each other, for example substantially edge to edge.
• first fibers may be draped side by side or superimposed. Fibers may also be draped to form local reinforcements at attachment areas provided for attachment of the upright to the sill and flag. These local reinforcements may be formed by superposing fibers in different orientations.
• the adhesion agent used to form the adhesion layer is also applied to the pre-impregnated fibers, in particular on the face of the fibers intended to come into contact with the metal part.
• the fibers previously provided with adhesion promoter, for example in the form of a powder, are then draped over the metal part provided with its adhesion layer.
• FIG. 5 illustrates an alternative embodiment in which each fiber of the reinforced part 104 is soldered discontinuously during its layup.
• Each draped fiber 131, 132, 133, 134 comprises an alternation of welded portions 130a and non-welded portions 130b obtained by activation or not of the heating during draping, with a welded portion at the beginning and at the end of the trajectory, the first fibers and the second fibers overlapping at welded portions.
• Such partial welding of the fibers reduces the draping time and can be achieved when it does not reduce the mechanical properties of the reinforced part.
• FIGS. 6A and 6B show a second reinforced part 204 according to the invention made from a metal part 201 provided with an adhesion layer comprising a first thermoplastic polymer, on which fibers have been draped, continuous fibers pre-impregnated with a second thermoplastic polymer.
• the reinforced part 204 here constitutes a reinforcing beam intended for example to be assembled on a structural part.
• the metal part 201 is in the form of a plate 210 of longitudinal axis A, provided on its outer face with a longitudinal boss 211, said boss forming a recess on the opposite inner face.
• the boss has a flat upper wall 212 connected by longitudinal inclined walls 213 and transverse inclined walls 214 respectively to the flat side walls 215 and the end walls 216 planes.
• This type of beam is intended to be assembled by each of its end walls 216 at an assembly zone shown schematically under the reference 218 in FIG. 6B.
• the assembly is conventionally performed by drilling one or more holes in the reinforced part and placing an insert, for example a thermoplastic insert along an assembly axis B.
• the metal part 201 is provided on its outer face 201a of an adhesion layer.
• the metal part is for example made from a flat sheet which is subsequently stamped to the desired final shape of the reinforced part.
• An adhesion agent for example a polyamide, is applied before or after stamping, for example by electrostatic spraying of powder, then passage in an oven.
• First fibers 231, impregnated for example with polyamide, are draped longitudinally parallel to the axis A by placing fibers, from one end wall 216 to the other of the metal part.
• Second continuous fibers 233 are then draped at the end walls 216 in an orientation complementary to that of the first fibers, in order to take up the forces transmitted by the first fibers and the forces transmitted by the assembly insert.
• the second fibers 232 are draped at 90 ° of the first fibers 231.
• a first ply of second fibers is draped at 45 ° from the first fibers, then a second ply of second fibers is draped over the first fibers. fold at -45 °.
• first fibers are draped, for example 5 to 10 superimposed folds
• second fibers are draped, for example 5 to 10 superimposed folds.
• the draping on contact is carried out by heating at the contact line of the roll and the metal part at a temperature slightly higher than the melting temperature of the two polyamides.
• FIGS. 7A and 7B illustrate a third reinforced part 304 according to the invention formed from a metal part 301 which differs from the previous one mainly in that it does not comprise plane lateral parts, the part comprising a boss 311 extending by two end walls 316, these end walls having a flange 317 with two straight portions 317a interconnected by a curved portion 317b.
• This rim has a substantially flat outer surface, substantially perpendicular to the upper wall, substantially parallel to the assembly axis B.
• first continuous fibers 312 are draped longitudinally parallel to the axis A 'by placing fibers from one end wall 316 to the other of the metal part, via the transverse inclined walls 314.
• a second fiber 332 is draped over the flanges 317 of the two end walls 316 over the longitudinal inclined walls 313 and on the upper wall 312 of the boss 311, on either side of the first fibers 331.
• the draping of this fiber begins for example on the upper wall 312, a first side of the first fibers 331, and ends in coming cover the beginning of fiber.
• this second fiber is at least twice around the metal part, the second tower overlapping substantially in the first round.
• This second fiber makes it possible to take up the forces transmitted by B-axis assembly inserts which will be arranged at the assembly areas 318 of the end walls, substantially parallel to the flanges.
• Third fibers may also be draped over the end walls at these assembly areas, for example at 90 ° of the first fibers.

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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)

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• 2015
  • 2015-09-25 FR FR1501992A patent/FR3041660B1/fr not_active Expired - Fee Related
• 2016
  • 2016-09-16 WO PCT/FR2016/000139 patent/WO2017051081A1/fr active Application Filing
  • 2016-09-16 EP EP16784222.8A patent/EP3352977A1/de not_active Withdrawn

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