EP3423620B1 - Facility and method for manufacturing a belt-shaped fibrous texture having a changing profile in cross-section - Google Patents

Facility and method for manufacturing a belt-shaped fibrous texture having a changing profile in cross-section Download PDF

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Publication number
EP3423620B1
EP3423620B1 EP17712211.6A EP17712211A EP3423620B1 EP 3423620 B1 EP3423620 B1 EP 3423620B1 EP 17712211 A EP17712211 A EP 17712211A EP 3423620 B1 EP3423620 B1 EP 3423620B1
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Prior art keywords
roller
take
sector
profile
thickness
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EP17712211.6A
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German (de)
French (fr)
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EP3423620A1 (en
Inventor
Jérémy Hellot
Hubert Jean Marie Fabre
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Safran Aircraft Engines SAS
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Safran Aircraft Engines SAS
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    • DTEXTILES; PAPER
    • D03WEAVING
    • D03DWOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D49/00Details or constructional features not specially adapted for looms of a particular type
    • D03D49/04Control of the tension in warp or cloth
    • D03D49/20Take-up motions; Cloth beams
    • DTEXTILES; PAPER
    • D03WEAVING
    • D03DWOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D41/00Looms not otherwise provided for, e.g. for weaving chenille yarn; Details peculiar to these looms
    • D03D41/004Looms for three-dimensional fabrics

Definitions

  • the present invention relates to the manufacture by three-dimensional weaving (3D) or multilayer fiber reinforcement structures of composite material parts.
  • the invention relates more particularly to fibrous structures intended to form reinforcements of composite parts of revolution having in radial section an evolutive profile (variation of shape and or thickness) such as for example an aeronautical engine fan casing.
  • the 3D or multilayer weaving of fibrous structures intended to constitute the fibrous reinforcement of a composite material part, such as an aircraft engine fan casing for example, is made in a Jacquard loom, the weaving consisting of insert weft threads, creating a pattern, between warp threads.
  • the warp yarns are organized at the loom harness into a plurality of layers and columns that are manipulated by the loom to allow the insertion of the weft yarns according to the weaving pattern or patterns programmed in the weaving loom. loom.
  • the weft threads are inserted between the warp threads per column.
  • one or more call rollers are used between the exit of the loom and a mandrel or storage drum on which the texture woven fiber is wound for subsequent formation of a fiber preform on an injection mold.
  • This or these call rollers placed downstream of the loom, have the role of calling the right length of warp son after the insertion of each weft column.
  • the outer surface of these rolls is covered with a material to which the weaving son adhere so as to exert a tensile force on the warp son.
  • the fibrous texture thus woven is intended to be wound on an injection mold formed of a mandrel comprising a winding surface having in radial section a raised profile corresponding to the profile of the part to be manufactured.
  • a weave-shaped, also called “contour weaving” is used, which consists in calling a different length of warp son according to their position on the width of the fibrous texture woven in the form band.
  • the call roll or rollers have, on their axial width, a variable radius defining an external surface with a raised profile making it possible to call different lengths of warp thread according to their position on the width of the fibrous texture.
  • a longer length of warp being called by the part or parts of a call roller having a greater radius than the rest of the roll.
  • the differential calls of the warp threads are made by the sum of the lengths of fibrous texture in contact with the call rollers. Differential calls made by the call rollers echo into the weaving cell of the loom by pulling the correct length of warp threads before inserting the next weft column.
  • the fibrous texture is wound on itself several times. At each winding turn, the ratio between the different radii defining the relief profile changes as a function of the fibrous texture layers already wound. These profile changes are all the greater as the shape and / or thickness ratios in the final piece are important.
  • the manufacturing method described above allows to weave a fibrous texture with a constant relief profile, that is to say, according to the rays whose ratio in cross section is fixed. When wound on the injection mold, the fibrous texture decays because of the differences between the woven profile, which is constant over the entire length of the woven texture, and the actual profile on which it is wound, resulting in voltage losses at certain axial positions in the texture.
  • An installation for the manufacture of a fibrous texture according to the preamble of claim 1 is known from FR2660673 A1 .
  • an installation for the manufacture of a fibrous texture in the form of a strip having at least in cross section an evolutive profile comprising a loom, one or more call rollers and a storage mandrel, each call roller and the storage mandrel having on their axial width a variable radius so as to define an external surface having a raised profile
  • at least one call roller comprises a plurality sectors removably affixed to the outer surface of said call roller, each sector extending over a fraction of the circumference of the call roller and over all or part of the axial width of said call roller, each sector having in addition, at least one thickness determined so as to locally modify the thickness of the raised profile of the outer surface of the call roller.
  • the installation of the invention makes it possible to manufacture band-shaped fibrous textures having an evolutive profile in cross-section in which the voltage losses or inhomogeneities are significantly reduced.
  • These effects are visible during the winding of the texture on the injection mold for its shaping. Indeed, during its winding on the injection mold, the fiber preform has few defects (waves, buckling and / or pinching of fibers, areas of undesired thickenings, non-specification fiber volume ratio, folds, misalignments, etc. .) with respect to a fibrous texture manufactured according to the prior art where the voltage imbalances are greater. This reduces the unexpected stops of the winding machine usually necessary to recover defects such as folds or collapses of portions of the texture that require in in addition to a return to the machine and an intervention of one or more technicians.
  • each sector has a variable thickness in the axial direction. It is thus possible to maintain or modify the variation of the radius of the call roller.
  • each sector has an inner surface having a shape corresponding to the portion of the external surface with raised profile of the call roller on which said sector is fixed.
  • the increase of the call of the warp threads in contact with the sectors is adjusted with respect to the call of the warp threads made at the same place on the call roll without sectors.
  • each sector has on its outer surface layer of gripping material so as to cause the son of the fibrous texture in contact with the sectors.
  • At least one sector of the plurality of sectors comprises a beveled edge so as not to put the preform in contact with a sharp edge of the edge of a first sector added to the roll call and gradually increase the call strength of the wires.
  • a fifth particular characteristic of the installation of the invention comprises a first call roller placed near the exit of the loom and at least a second call roller placed between the first roll of call and the storage chuck, the second caller roller comprising a plurality of sectors removably attached to the outer surface of said second call roller, each sector extending over a fraction of the circumference of the second call roller and all or part of the axial width of said second call roller, each sector further having a thickness determined so as to locally modify the thickness of the raised profile of the outer surface of the call roller.
  • Preference sectors are thus preferably used with the "inverse” or “reverse” call roll or rollers, which have greater variations in radius than on the so-called “shooter” roll or rollers. "Puller” and which realize, therefore, a string length call son more important than the call rollers called “shooter” or “puller” located upstream in the direction of winding.
  • the subject of the invention is also a method for manufacturing a band-shaped fibrous structure having in cross-section an evolutive profile by three-dimensional weaving or multilayer weaving between a plurality of layers of warp threads linked together by weft threads, the warp yarns being driven out of the loom by one or more call rollers, the fibrous texture being wound on a storage mandrel placed downstream of each call roller, each call roller and the mandrel.
  • each sector extending over a fraction of the circumference of the call roller and over all or part of the axial width of said call roller, each sector further having at least one thickness determined so as to locally modify the thickness of the raised profile of the outer surface of the call roller.
  • each sector extends over a fraction of the circumference of the call roller determined as a function of the circumferential contact portion between the fibrous texture and the external surface of said call roller.
  • each sector has a thickness that varies in the axial direction.
  • each sector has an outer surface having a shape corresponding to the portion of the raised profile outer surface of the call roller on which said sector is fixed.
  • the invention is generally applicable to the production of fibrous textures capable of constituting fibrous reinforcements, or preforms, for the manufacture of parts made of composite material of revolution presenting in radial section an evolutive profile and / or a variable thickness. in particular in radial section, the radial section corresponding to a plane defined by the axial direction and the radial direction of the mold on which the preform is shaped.
  • the pieces being obtained by winding a fibrous texture on a mold and injecting a matrix precursor into the shaped fibrous texture, the matrix typically being a resin.
  • the fibrous structure of the invention in the form of a strip having a cross-sectional evolutionary profile is obtained by three-dimensional weaving or by multilayer weaving.
  • 3D weaving By “three-dimensional weaving” or “3D weaving” is meant here a weaving mode whereby at least some of the weft yarns bind warp yarns on several chain layers or vice versa. 3D weaving can be interlock type as described in document WO 2006/136755 .
  • multilayer weave is meant here a 3D weave with several chain layers whose basic armor of each layer is equivalent to a conventional 2D fabric weave, such as a linen, satin or twill type armor, but with some points of the armor that bind the warp layers between them or vice versa.
  • the production of the fibrous structure by 3D or multilayer weaving makes it possible to obtain a bond between the layers, and thus to have good mechanical strength of the fibrous structure and of the composite material part obtained, in a single textile operation.
  • the fibrous structure may in particular be woven from carbon fiber threads, ceramic such as silicon carbide, glass, or aramid.
  • the figure 1 illustrates a loom 100 equipped with a Jacquard mechanism 101 supported by a superstructure not shown on the figure 1 .
  • the loom 100 also comprises a harness 110 consisting of a plow board 111 and control or smooth son 113, each lug 113 being connected at one end to a control hook 1010 of the Jacquard machine 101 and to the other end to one of the return springs 102 attached to the frame 103 of the loom 100.
  • Each loom 113 comprises an eyelet 114 traversed by a warp yarn 201.
  • the heddles 113 and their eyelet 114 associated extend in an area in which the smooth 113 and eyelets 114 are driven by a substantially vertical oscillation movement represented by the double arrow F.
  • the shafts 113 are subjected to tensile stresses respectively exerted by the control hooks 1010 and by the return springs 102.
  • the heddles 113 can lift certain warp son 201 according to a defined weaving program. By lifting some warp son 201, the heddles 113 thus create a crowd 104 allowing the introduction of weft yarns 202 for 3D weaving or multilayer of a fibrous structure 210 in the form of tape or ribbon.
  • the warp threads 201 are organized into a plurality of layers of warp threads C 1 to C n .
  • the warp yarns 201 are fed from bobbins arranged on a creel (not shown in FIG. figure 1 ) upstream of the Jacquard machine 101 of the loom 100.
  • the figure 2 represents an installation 10 for the manufacture of an evolutive shape fiber texture according to an embodiment of the invention.
  • the installation 10 comprises the loom 100 described above and three call rollers 300, 400 and 500 disposed downstream of the loom.
  • the frame 120 delimits the exit of the loom 100, that is to say the area from which the warp threads 201 are no longer woven with the weft threads 202 and which corresponds to the closure of the shed 104 .
  • the first call roller 300 which is located closest to the exit 120 of the loom 100 is a roller called "shooter” or "puller".
  • the call roller 300 is driven in a direction of rotation S 300 indicated on the figure 2 . It has on its axial width a variable radius so as to define an outer surface 301 having a raised profile corresponding to the weaving profile referred for the fibrous texture 210 so as to have an angle between the nearest warp and weft son 90 °.
  • the outer surface 301 is covered with a material, for example a tackifier, to which the weaving threads adhere so as to exert a tensile force on the warp threads.
  • the other two call rollers 400 and 500 located downstream of the first call roller 300 are so-called “reverse” or “reverse” rollers which are rotated respectively in directions of rotation S 400 and S 500 indicated on the figure 2 and which are opposed to the direction of rotation S 300 of the call roller 300.
  • the call rollers 400 and 500 also have on their axial width a variable radius so as to define respectively external surfaces 401 and 501 having a profile in relief .
  • the radius variations on the call rollers 400 and 500 are greater than on the call roller 300, the rollers 400 and 500 making a longer call for the length of the warp thread than the call roller 300.
  • external surfaces 401 and 501 are covered with a material, for example a tackifier, to which the weaving threads adhere so as to exert a tensile force on the warp threads.
  • the installation 10 further comprises a mandrel or storage drum 600, also called “take-up" mandrel, which is rotated in the direction of rotation S 600 and which also has a variable radius on its axial width so as to defining an outer surface 601 having a raised profile corresponding to the weaving pattern referred for the fibrous texture 210 to limit the deformation of the fibrous texture 210.
  • the fibrous texture 210 is wound on the storage mandrel 600 and is thus stored therein. the subsequent formation of a fibrous preform by winding the fibrous texture onto an injection mold.
  • At least one call roller is provided with a plurality of sectors removably fixed, for example by means of screw-nut or interlocking clamping members, on the outer surface of the roller. of call, each sector extending over a fraction of the circumference of the call roller and over all or part of the axial width of said call roller.
  • the call roller 400 which extends axially along an axis X 400 and whose radius R 400 varies along the axis X400 ( figure 6 ), includes 3 sectors 410, 420 and 430 as illustrated in the figures 3 and 4 .
  • the sectors 410, 420 and 430 have respective axial widths L 410 , L 420 and L 430 which are smaller than the axial width L 400 of the call roller 400, the axial widths being measured. in the direction of the roller axis as the X axis 400 for the follower roller 400.
  • the sectors 410, 420, 430 are intended to be placed on a portion 402 of the call roller 400, part of the roller 400 in which the radius R 400 varies over the axial width L 400 so as to define in radial section a relief profile ( figure 6 ).
  • the sectors 410, 420 and 430 respectively comprise an inner surface 411, 421 and 431 having a shape corresponding to the portion 402 of the external surface 401 with raised profile of the call roller 400 on which the sectors are intended to be fixed and an outer surface 412, 422 and 432 having a shape determined according to the voltage adjustment that is desired to achieve in portion of the fibrous texture in contact with the sectors.
  • the outer surfaces 412, 422 and 432 are covered with a layer of gripping material (not shown), for example a layer elastomer (rubber), to which the weaving son adhere so as to exert a tensile force on the warp son.
  • a layer of gripping material for example a layer elastomer (rubber), to which the weaving son adhere so as to exert a tensile force on the warp son.
  • Sectors 410, 420 and 430 here have respectively thicknesses which are variable on the axial widths L 410, L 420 and L 430 of the sectors 410, 420 and 430, as shown in figure 6 for the thicknesses E 410 and E 420 of the sectors 410 and 420.
  • the variation of the thicknesses of the sectors 410, 420 and 430 follows mainly the variation of the radius R 400 , and, consequently, the shape of the profile in relief on the part 402 so as to modify locally the thickness of the roll 400 while following the raised profile of the outer surface of the call roller in the part 402.
  • the sectors can also add an extra thickness which is independent of the shape of the embossed profile of the roll.
  • the roller 400 calls for a longer length of warp son at the warp threads in contact with the sectors.
  • FIGS 7 to 9 show how the sectors 410, 420 and 430 are mounted on the call roller 400 during the manufacture of the fibrous texture 210.
  • the sectors are fixed on the outer surface of the call roller for example by means of clamping members as screws that cooperate with a tapped hole in the roller (not shown in the figures).
  • a first sector, here sector 410 is mounted on the portion of the portion 402 of the roll 400 which is not in contact with the fibrous texture 210.
  • the sector 410 which is the first to come into contact with the texture 210, comprises a first edge 413 which preferably has a beveled edge oriented towards the outer surface of the roll so as not to bring the preform into contact with a sharp edge of the edge of the sector and gradually increase the appeal force of the wires. of chain.
  • the rotation of call roller 400 in direction S 400 is then continued until a new portion of part 402 of call roller 400 is released from the zone of contact with texture 210 enabling the second sector 430 to be mounted ( figure 8 ).
  • the edge 433 of the sector 430 is placed against the edge 414 of the sector 410 which is partially in contact with the texture 210.
  • the rotation of the call roller 400 in the direction S 400 is continued until the last free portion of the part 402 of the call roller 400 of the contact zone with the texture 210.
  • the third sector 420 is then mounted on the roller 400 ( figure 9 ).
  • the edge 424 of the sector 420 is placed against the beveled edge 413 of the sector 410, the edge 424 having a beveled shape complementary to that of the edge 413.
  • the edge 423 of the sector 420 is placed against the edge 434 of the sector 420.
  • Sectors 410, 420 and 430 are added during the manufacture of the fibrous texture 210 when a longer length of warp yarn is to be called, for example when the difference between the woven profile and the actual profile on which the texture is wound such that it can cause voltage losses at certain axial positions in the texture.
  • the sector 430 which is the last sector to be removed, comprises an edge 434 which preferably has a beveled edge oriented towards the outer surface of the roller so as not to bring the preform into contact with a sharp edge of the edge of the sector, the edge 423 of the sector 420 having a beveled shape complementary to that of the edge 434.
  • Each sector extends over a fraction of the circumference of the roll. It has an arc length, such as the arc length A 410 of the sector 410 shown in FIG. figure 7 which is defined as a function of the arc length of the portion of the call roller 400 which is not in contact with the fibrous texture 210. Therefore, if the fibrous texture is in contact with the roll of call on a small arc length, it is possible to use sectors having a large arc length and vice versa. The number of sectors necessary to cover the entire circumference of the call roller is therefore also determined according to the arc length of the portion of the call roller that is not in contact with the fiber texture.
  • Sectors can be used on a single call roller, as described above for the roller 400, or on several call rollers, as on the rollers 300, 400 and 500 described above so as to locally modify the the thickness of the profile in relief of the external surface of the call roller or rollers.
  • the sectors are, however, preferably used with the so-called “reverse” or “reverse” call roll or rollers which have greater variations of radius than on the so-called “shooter” or “puller” roll or rollers and which , therefore, realize a longer string wire length call than the call rollers called "shooter” or "puller”.
  • the sectors are made of a rigid material or having a good compressive strength such as metal or plastic.
  • the sectors can be made for example by molding, machining or 3D printing.
  • the installation and method of manufacture of the invention allow to manufacture fibrous textures in evolutionary form in which the losses or inhomogeneities of voltage are significantly reduced.
  • the effects of the invention on a fibrous texture manufactured with the installation and the method of the invention are visible during the winding of this texture on the injection mold for their shaping.
  • the formed fiber preform has few defects (waves, buckling and / or pinching of fibers, areas of undesired thickenings, volume ratio of fibers out of specification, folds, misalignments, etc.) with respect to a fibrous texture manufactured according to the prior art or the voltage imbalances are more important. This reduces the unexpected stops of the winding machine usually necessary to recover defects such as folds or collapse of portions of the texture that also require a backward movement of the machine and an intervention of one or more technicians.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Woven Fabrics (AREA)
  • Moulding By Coating Moulds (AREA)
  • Braiding, Manufacturing Of Bobbin-Net Or Lace, And Manufacturing Of Nets By Knotting (AREA)

Description

Arrière-plan de l'inventionBackground of the invention

La présente invention concerne la fabrication par tissage tridimensionnel (3D) ou multicouche de structures fibreuses de renfort de pièces en matériau composite.The present invention relates to the manufacture by three-dimensional weaving (3D) or multilayer fiber reinforcement structures of composite material parts.

L'invention concerne plus particulièrement les structures fibreuses destinées à former des renforts de pièces en matériau composite de révolution présentant en section radiale un profil évolutif (variation de forme et ou d'épaisseur) tel que par exemple un carter de soufflante de moteur aéronautique.The invention relates more particularly to fibrous structures intended to form reinforcements of composite parts of revolution having in radial section an evolutive profile (variation of shape and or thickness) such as for example an aeronautical engine fan casing.

Le tissage 3D ou multicouche de structures fibreuses destinées à constituer le renfort fibreux d'une pièce en matériau composite, telle qu'un carter de soufflante de moteur aéronautique par exemple, est réalisé dans un métier à tisser de type Jacquard, le tissage consistant à insérer des fils de trame, en créant un motif, entre des fils de chaîne. Les fils de chaîne sont organisés au niveau du harnais du métier à tisser en une pluralité de couches et de colonnes qui sont manipulées par le métier à tisser afin de permettre l'insertion des fils de trames suivant le ou les motifs de tissage programmés dans le métier à tisser. Les fils de trame sont insérés entre les fils de chaîne par colonne.The 3D or multilayer weaving of fibrous structures intended to constitute the fibrous reinforcement of a composite material part, such as an aircraft engine fan casing for example, is made in a Jacquard loom, the weaving consisting of insert weft threads, creating a pattern, between warp threads. The warp yarns are organized at the loom harness into a plurality of layers and columns that are manipulated by the loom to allow the insertion of the weft yarns according to the weaving pattern or patterns programmed in the weaving loom. loom. The weft threads are inserted between the warp threads per column.

Afin de permettre l'introduction de chaque colonne de fils de trame lors du tissage de la structure fibreuse, un ou plusieurs rouleaux d'appel sont utilisés entre la sortie du métier à tisser ainsi qu'un mandrin ou tambour de stockage sur lequel la texture fibreuse tissée est enroulée en vue de la formation ultérieure d'une préforme fibreuse sur un moule d'injection. Ce ou ces rouleaux d'appel, placés en aval du métier à tisser, ont pour rôle d'appeler la bonne longueur de fils de chaîne après l'insertion de chaque colonne de trame. La surface externe de ces rouleaux est recouverte d'une matière à laquelle les fils de tissage adhèrent de manière à exercer un effort de traction sur les fils de chaîne.In order to allow the introduction of each column of weft threads during weaving of the fibrous structure, one or more call rollers are used between the exit of the loom and a mandrel or storage drum on which the texture woven fiber is wound for subsequent formation of a fiber preform on an injection mold. This or these call rollers, placed downstream of the loom, have the role of calling the right length of warp son after the insertion of each weft column. The outer surface of these rolls is covered with a material to which the weaving son adhere so as to exert a tensile force on the warp son.

La texture fibreuse ainsi tissée est destinée à être enroulée sur un moule d'injection formé d'un mandrin comportant une surface d'enroulement ayant en section radiale un profil en relief correspondant au profil de la pièce à fabriquer. Afin de réaliser une texture fibreuse adaptée à la forme évolutive du moule d'injection, on utilise un tissage en forme, encore appelé « contour weaving », qui consiste à appeler une longueur différente de fils de chaîne en fonction de leur position sur la largeur de la texture fibreuse tissée sous forme de bande. A cet effet, le ou les rouleaux d'appel présentent sur leur largeur axiale un rayon variable définissant une surface externe à profil en relief permettant d'appeler des longueurs de fils de chaîne différentes en fonction de leur position sur la largeur de la texture fibreuse, une plus grande longueur de fil de chaîne étant appelée par la ou les parties d'un rouleau d'appel ayant un rayon plus important que le reste du rouleau. Les appels différentiels des fils de chaîne sont réalisés par la somme des longueurs de texture fibreuse en contact avec les rouleaux d'appel. Les appels différentiels réalisés par les rouleaux d'appel se répercutent jusque dans la cellule de tissage du métier à tisser en tirant la bonne longueur de fils de chaîne avant l'insertion de la colonne de fils de trame suivante.The fibrous texture thus woven is intended to be wound on an injection mold formed of a mandrel comprising a winding surface having in radial section a raised profile corresponding to the profile of the part to be manufactured. In order to achieve a suitable fiber texture in the evolutionary shape of the injection mold, a weave-shaped, also called "contour weaving" is used, which consists in calling a different length of warp son according to their position on the width of the fibrous texture woven in the form band. For this purpose, the call roll or rollers have, on their axial width, a variable radius defining an external surface with a raised profile making it possible to call different lengths of warp thread according to their position on the width of the fibrous texture. , a longer length of warp being called by the part or parts of a call roller having a greater radius than the rest of the roll. The differential calls of the warp threads are made by the sum of the lengths of fibrous texture in contact with the call rollers. Differential calls made by the call rollers echo into the weaving cell of the loom by pulling the correct length of warp threads before inserting the next weft column.

Cependant, lors de sa mise en forme sur un moule avant injection, la texture fibreuse est enroulée sur elle-même plusieurs fois. A chaque tour d'enroulement, le rapport entre les différents rayons définissant le profil en relief change en fonction des couches de texture fibreuse déjà enroulées. Ces changements de profil sont d'autant plus grands que les ratios de forme et/ou d'épaisseur dans la pièce finale sont importants. Or, le procédé de fabrication décrit ci-avant ne permet de tisser une texture fibreuse qu'avec un profil en relief constant, c'est-à-dire suivant des rayons dont le rapport en section transversale est fixe. Lors de son enroulement sur le moule d'injection, la texture fibreuse se décadre en raison des différences entre le profil tissé, qui est constant sur toute la longueur de la texture tissée, et le profil réel sur lequel elle est enroulée, ce qui entraîne des pertes de tension à certaines positions axiales dans la texture. Ces déséquilibres de tension dans la largeur de la pièce peuvent entraîner de nombreux défauts comme des vagues, des flambements de fibres, des pincements de fibres, des zones de surépaisseurs non désirées et des taux volumiques de fibres hors spécification. Ces déséquilibres de tension compliquent également la mise en forme par enroulement de la texture fibreuse en entraînant notamment la formation de plis ou de désalignements, ce qui augmente la pénibilité et le temps de la mise en forme de la texture fibreuse.However, during its forming on a mold before injection, the fibrous texture is wound on itself several times. At each winding turn, the ratio between the different radii defining the relief profile changes as a function of the fibrous texture layers already wound. These profile changes are all the greater as the shape and / or thickness ratios in the final piece are important. However, the manufacturing method described above allows to weave a fibrous texture with a constant relief profile, that is to say, according to the rays whose ratio in cross section is fixed. When wound on the injection mold, the fibrous texture decays because of the differences between the woven profile, which is constant over the entire length of the woven texture, and the actual profile on which it is wound, resulting in voltage losses at certain axial positions in the texture. These imbalances of tension in the width of the part can lead to numerous defects such as waves, fiber buckling, pinching of fibers, zones of undesired thicknesses and voluminal rates of fibers out of specification. These tension imbalances also complicate the winding of the fibrous texture resulting in particular the formation of folds or misalignments, which increases the hardness and time of shaping the fiber texture.

Une installation pour la fabrication d'une texture fibreuse selon le préambule de la revendication 1 est connue de FR2660673 A1 .An installation for the manufacture of a fibrous texture according to the preamble of claim 1 is known from FR2660673 A1 .

Objet et résumé de l'inventionObject and summary of the invention

Il est donc souhaitable de pouvoir réaliser des structures fibreuses 3D ou multicouches avec un profil en relief qui varie au cours du tissage de la texture afin d'éviter des pertes ou des déséquilibres de tension dans la texture fibreuse.It is therefore desirable to be able to produce 3D or multilayer fibrous structures with a relief profile that varies during the weaving of the texture in order to avoid losses or tension imbalances in the fibrous texture.

A cet effet, selon l'invention, il est proposé une installation pour la fabrication d'une texture fibreuse en forme de bande présentant au moins en section transversale un profil évolutif comprenant un métier à tisser, un ou plusieurs rouleaux d'appel et un mandrin de stockage, chaque rouleau d'appel et le mandrin de stockage présentant sur leur largeur axiale un rayon variable de manière à définir une surface externe ayant un profil en relief, caractérisée en ce qu'au moins un rouleau d'appel comprend une pluralité de secteurs fixés de façon amovible sur la surface externe dudit rouleau d'appel, chaque secteur s'étendant sur une fraction de la circonférence du rouleau d'appel et sur tout ou partie de la largeur axiale dudit rouleau d'appel, chaque secteur présentant en outre au moins une épaisseur déterminée de manière à modifier localement l'épaisseur du profil en relief de la surface externe du rouleau d'appel.For this purpose, according to the invention, there is provided an installation for the manufacture of a fibrous texture in the form of a strip having at least in cross section an evolutive profile comprising a loom, one or more call rollers and a storage mandrel, each call roller and the storage mandrel having on their axial width a variable radius so as to define an external surface having a raised profile, characterized in that at least one call roller comprises a plurality sectors removably affixed to the outer surface of said call roller, each sector extending over a fraction of the circumference of the call roller and over all or part of the axial width of said call roller, each sector having in addition, at least one thickness determined so as to locally modify the thickness of the raised profile of the outer surface of the call roller.

Par l'utilisation de secteurs permettant de modifier localement l'épaisseur du profil en relief de la surface externe d'un ou plusieurs rouleaux d'appel lors de la fabrication d'une texture fibreuse à forme évolution, l'installation de l'invention permet de fabriquer des textures fibreuses en forme de bande présentant en section transversale un profil évolutif dans lesquelles les pertes ou inhomogénéités de tension sont significativement réduites. Ces effets sont visibles lors de l'enroulement de la texture sur le moule d'injection pour sa mise en forme. En effet, lors de son enroulement sur le moule d'injection, la préforme fibreuse présente peu de défauts (vagues, flambements et/ou pincements de fibres, zones de surépaisseurs non désirées, taux volumiques de fibres hors spécification, plis, désalignements, etc.) par rapport à une texture fibreuse fabriquée selon l'art antérieur où les déséquilibres de tension sont plus importants. On réduit ainsi les arrêts inopinés de la machine d'enroulement habituellement nécessaires pour reprendre les défauts tels que des plis ou effondrements de portions de la texture qui requièrent en outre un retour en arrière de la machine ainsi qu'une intervention d'un ou plusieurs techniciens.By the use of sectors making it possible locally to modify the thickness of the profile in relief of the external surface of one or more call rollers during the manufacture of an evolutionarily shaped fiber texture, the installation of the invention makes it possible to manufacture band-shaped fibrous textures having an evolutive profile in cross-section in which the voltage losses or inhomogeneities are significantly reduced. These effects are visible during the winding of the texture on the injection mold for its shaping. Indeed, during its winding on the injection mold, the fiber preform has few defects (waves, buckling and / or pinching of fibers, areas of undesired thickenings, non-specification fiber volume ratio, folds, misalignments, etc. .) with respect to a fibrous texture manufactured according to the prior art where the voltage imbalances are greater. This reduces the unexpected stops of the winding machine usually necessary to recover defects such as folds or collapses of portions of the texture that require in in addition to a return to the machine and an intervention of one or more technicians.

Selon une première caractéristique particulière de l'installation de l'invention, chaque secteur présente une épaisseur variable dans le sens axial. Il est ainsi possible de conserver ou de modifier la variation du rayon du rouleau d'appel.According to a first particular characteristic of the installation of the invention, each sector has a variable thickness in the axial direction. It is thus possible to maintain or modify the variation of the radius of the call roller.

Selon une deuxième caractéristique particulière de l'installation de l'invention, chaque secteur présente une surface interne ayant une forme correspondant à la partie de la surface externe à profil en relief du rouleau d'appel sur laquelle ledit secteur est fixé. Dans ce cas, on ajuste l'augmentation de l'appel des fils de chaîne en contact avec les secteurs par rapport à l'appel des fils de chaîne réalisé au même endroit sur le rouleau d'appel sans secteurs.According to a second particular feature of the installation of the invention, each sector has an inner surface having a shape corresponding to the portion of the external surface with raised profile of the call roller on which said sector is fixed. In this case, the increase of the call of the warp threads in contact with the sectors is adjusted with respect to the call of the warp threads made at the same place on the call roll without sectors.

Selon une troisième caractéristique particulière de l'installation de l'invention, chaque secteur comporte sur sa surface externe couche de matériau agrippant de manière à entraîner les fils de la texture fibreuse en contact avec les secteurs.According to a third particular feature of the installation of the invention, each sector has on its outer surface layer of gripping material so as to cause the son of the fibrous texture in contact with the sectors.

Selon une quatrième caractéristique particulière de l'installation de l'invention, au moins un secteur de la pluralité de secteurs comprend un bord biseauté afin de ne pas mettre la préforme en contact avec une arrête vive du bord d'un premier secteur ajouté sur le rouleau d'appel et d'augmenter progressivement la force d'appel des fils.According to a fourth particular characteristic of the installation of the invention, at least one sector of the plurality of sectors comprises a beveled edge so as not to put the preform in contact with a sharp edge of the edge of a first sector added to the roll call and gradually increase the call strength of the wires.

Selon une cinquième caractéristique particulière de l'installation de l'invention, celle-ci comprend un premier rouleau d'appel placé à proximité de la sortie du métier à tisser et au moins un deuxième rouleau d'appel placé entre le premier rouleau d'appel et le mandrin de stockage, le deuxième rouleau d'appel comprenant une pluralité de secteurs fixés de façon amovible sur la surface externe dudit deuxième rouleau d'appel, chaque secteur s'étendant sur une fraction de la circonférence du deuxième rouleau d'appel et sur tout ou partie de la largeur axiale dudit deuxième rouleau d'appel, chaque secteur présentant en outre une épaisseur déterminée de manière à modifier localement l'épaisseur du profil en relief de la surface externe du rouleau d'appel.According to a fifth particular characteristic of the installation of the invention, it comprises a first call roller placed near the exit of the loom and at least a second call roller placed between the first roll of call and the storage chuck, the second caller roller comprising a plurality of sectors removably attached to the outer surface of said second call roller, each sector extending over a fraction of the circumference of the second call roller and all or part of the axial width of said second call roller, each sector further having a thickness determined so as to locally modify the thickness of the raised profile of the outer surface of the call roller.

On utilise ainsi des secteurs de préférence avec le ou les rouleaux d'appel dits « inverses » ou « reverser » qui présentent des variations de rayon plus importantes que sur le ou les rouleaux d'appel dits « tireur » ou « puller » et qui réalisent, par conséquent, un appel de longueur de fils de chaîne plus important que les rouleaux d'appel dits « tireur » ou « puller » situés en amont selon le sens d'enroulement.Preference sectors are thus preferably used with the "inverse" or "reverse" call roll or rollers, which have greater variations in radius than on the so-called "shooter" roll or rollers. "Puller" and which realize, therefore, a string length call son more important than the call rollers called "shooter" or "puller" located upstream in the direction of winding.

L'invention a également pour objet un procédé de fabrication d'une structure fibreuse en forme de bande présentant en section transversale un profil évolutif par tissage tridimensionnel ou multicouche entre une pluralité de couches de fils de chaîne liées entre elles par des fils de trame, les fils de chaîne étant entraînés en sortie du métier à tisser par un ou plusieurs rouleaux d'appel, la texture fibreuse étant enroulée sur un mandrin de stockage placé en aval de chaque rouleau d'appel, chaque rouleau d'appel et le mandrin de stockage présentant sur leur largeur axiale un rayon variable de manière à définir une surface externe ayant un profil en relief, caractérisé en ce qu'il comprend, en cours de tissage, l'ajout d'une pluralité de secteurs sur la surface externe d'au moins un rouleau d'appel, chaque secteur s'étendant sur une fraction de la circonférence du rouleau d'appel et sur tout ou partie de la largeur axiale dudit rouleau d'appel, chaque secteur présentant en outre au moins une épaisseur déterminée de manière à modifier localement l'épaisseur du profil en relief de la surface externe du rouleau d'appel.The subject of the invention is also a method for manufacturing a band-shaped fibrous structure having in cross-section an evolutive profile by three-dimensional weaving or multilayer weaving between a plurality of layers of warp threads linked together by weft threads, the warp yarns being driven out of the loom by one or more call rollers, the fibrous texture being wound on a storage mandrel placed downstream of each call roller, each call roller and the mandrel. storage having on their axial width a variable radius so as to define an external surface having a profile in relief, characterized in that it comprises, during weaving, the addition of a plurality of sectors on the outer surface of at least one call roller, each sector extending over a fraction of the circumference of the call roller and over all or part of the axial width of said call roller, each sector further having at least one thickness determined so as to locally modify the thickness of the raised profile of the outer surface of the call roller.

Selon une première caractéristique particulière du procédé de l'invention, chaque secteur s'étend sur une fraction de la circonférence du rouleau d'appel déterminée en fonction de la portion de contact circonférentielle entre la texture fibreuse et la surface externe dudit rouleau d'appel.According to a first particular characteristic of the method of the invention, each sector extends over a fraction of the circumference of the call roller determined as a function of the circumferential contact portion between the fibrous texture and the external surface of said call roller. .

Selon une deuxième caractéristique particulière du procédé de l'invention, chaque secteur présente une épaisseur variable dans le sens axial.According to a second particular feature of the method of the invention, each sector has a thickness that varies in the axial direction.

Selon une troisième première caractéristique particulière du procédé de l'invention, chaque secteur présente une surface externe ayant une forme correspondant à la partie de la surface externe à profil en relief du rouleau d'appel sur laquelle ledit secteur est fixé.According to a third particular characteristic of the method of the invention, each sector has an outer surface having a shape corresponding to the portion of the raised profile outer surface of the call roller on which said sector is fixed.

Brève description des dessinsBrief description of the drawings

D'autres caractéristiques et avantages de l'invention ressortiront de la description suivante de modes particuliers de réalisation de l'invention, donnés à titre d'exemples non limitatifs, en référence aux dessins annexés, sur lesquels :

  • la figure 1 est une vue schématique en perspective d'un métier à tisser de type Jacquard,
  • la figure 2 est une vue schématique d'une installation pour la fabrication d'une texture fibreuse à forme évolutive conformément à un mode de réalisation de l'invention,
  • la figure 3 est une vue schématique en perspective d'un rouleau d'appel de l'installation de la figure 2,
  • la figure 4 est une vue schématique en perspective éclatée du rouleau d'appel de la figure 3,
  • la figure 5 est une vue schématique en coupe radiale du rouleau d'appel selon le plan V de la figure 3,
  • la figure 6 est une vue schématique en coupe axiale du rouleau d'appel selon le plan VI de la figure 5,
  • les figures 7 à 9 montrent une séquence de montage de secteurs sur un rouleau d'appel de l'installation de la figure 2, et
  • les figures 10 à 13 montrent une séquence de démontage de secteurs sur un rouleau d'appel de l'installation de la figure 2.
Other features and advantages of the invention will emerge from the following description of particular embodiments of the invention, given as non-limiting examples, with reference to the appended drawings, in which:
  • the figure 1 is a schematic perspective view of a Jacquard loom,
  • the figure 2 is a schematic view of an installation for the manufacture of a scalable fiber texture according to an embodiment of the invention,
  • the figure 3 is a schematic perspective view of a call roller from the installation of the figure 2 ,
  • the figure 4 is a schematic exploded perspective view of the call roller of the figure 3 ,
  • the figure 5 is a schematic view in radial section of the call roller according to the plane V of the figure 3 ,
  • the figure 6 is a schematic view in axial section of the call roller according to the plane VI of the figure 5 ,
  • the Figures 7 to 9 show a sector mounting sequence on a call roller of the installation of the figure 2 , and
  • the Figures 10 to 13 show a sector disassembly sequence on a call roller of the installation of the figure 2 .

Description détaillée de modes de réalisationDetailed description of embodiments

L'invention s'applique d'une manière générale à la réalisation de textures fibreuses aptes à constituer des renforts fibreux, ou préformes, pour la fabrication de pièces en matériau composite de révolution présentant en coupe radiale un profil évolutif et/ou une épaisseur variable notamment en section radiale, la section radiale correspondant à un plan défini par la direction axiale et la direction radiale du moule sur lequel la préforme est mise en forme. Les pièces étant obtenues par enroulement d'une texture fibreuse sur un moule et injection d'un précurseur de matrice dans la texture fibreuse mise en forme, la matrice étant typiquement une résine.The invention is generally applicable to the production of fibrous textures capable of constituting fibrous reinforcements, or preforms, for the manufacture of parts made of composite material of revolution presenting in radial section an evolutive profile and / or a variable thickness. in particular in radial section, the radial section corresponding to a plane defined by the axial direction and the radial direction of the mold on which the preform is shaped. The pieces being obtained by winding a fibrous texture on a mold and injecting a matrix precursor into the shaped fibrous texture, the matrix typically being a resin.

La structure fibreuse de l'invention en forme de bande présentant en section transversale un profil évolutif est obtenu par tissage tridimensionnel ou par tissage multicouche.The fibrous structure of the invention in the form of a strip having a cross-sectional evolutionary profile is obtained by three-dimensional weaving or by multilayer weaving.

Par "tissage tridimensionnel" ou "tissage 3D", on entend ici un mode de tissage par lequel certains au moins des fils de trame lient des fils de chaîne sur plusieurs couches de chaîne ou inversement. Le tissage 3D peut être de type interlock comme décrit dans le document WO 2006/136755 .By "three-dimensional weaving" or "3D weaving" is meant here a weaving mode whereby at least some of the weft yarns bind warp yarns on several chain layers or vice versa. 3D weaving can be interlock type as described in document WO 2006/136755 .

Par "tissage multicouche", on désigne ici un tissage 3D avec plusieurs couches de chaîne dont l'armure de base de chaque couche est équivalente à une armure de tissu 2D classique, tel qu'une armure de type toile, satin ou sergé, mais avec certains points de l'armure qui lient les couches de chaîne entre elles ou inversement.By "multilayer weave" is meant here a 3D weave with several chain layers whose basic armor of each layer is equivalent to a conventional 2D fabric weave, such as a linen, satin or twill type armor, but with some points of the armor that bind the warp layers between them or vice versa.

La réalisation de la structure fibreuse par tissage 3D ou multicouche permet d'obtenir une liaison entre les couches, donc d'avoir une bonne tenue mécanique de la structure fibreuse et de la pièce en matériau composite obtenue, en une seule opération textile.The production of the fibrous structure by 3D or multilayer weaving makes it possible to obtain a bond between the layers, and thus to have good mechanical strength of the fibrous structure and of the composite material part obtained, in a single textile operation.

La structure fibreuse peut être notamment tissée à partir de fils de fibres de carbone, de céramique telle que du carbure de silicium, de verre, ou encore d'aramide.The fibrous structure may in particular be woven from carbon fiber threads, ceramic such as silicon carbide, glass, or aramid.

La figure 1 illustre un métier à tisser 100 équipé d'une mécanique Jacquard 101 supportée par une superstructure non représentée sur la figure 1. Le métier 100 comprend également un harnais 110 constitué d'une planche d'empoutage 111 et des fils de commande ou lisses 113, chaque lisse 113 étant reliée à une extrémité à un crochet de commande 1010 de la mécanique Jacquard 101 et à l'autre extrémité à un des ressorts de rappel 102 fixés au bâti 103 du métier à tisser 100. Chaque lisse 113 comprend un œillet 114 traversé par un fil de chaîne 201. Les lisses 113 et leur œillet 114 associés s'étendent dans une zone dans laquelle les lisses 113 et les œillets 114 sont animés d'un mouvement d'oscillation sensiblement vertical représenté par la double flèche F. Les lisses 113 sont soumises à des efforts de traction respectivement exercés par les crochets de commande 1010 et par les ressorts de rappel 102. Les lisses 113 permettent de soulever certains fils de chaîne 201 suivant un programme de tissage défini. En soulevant certains fils de chaîne 201, les lisses 113 créent ainsi une foule 104 permettant l'introduction de fils de trame 202 pour le tissage 3D ou multicouche d'une structure fibreuse 210 sous forme de bande ou de ruban. Les fils de chaîne 201 sont organisés en une pluralité de couches de fils de chaîne C1 à Cn.The figure 1 illustrates a loom 100 equipped with a Jacquard mechanism 101 supported by a superstructure not shown on the figure 1 . The loom 100 also comprises a harness 110 consisting of a plow board 111 and control or smooth son 113, each lug 113 being connected at one end to a control hook 1010 of the Jacquard machine 101 and to the other end to one of the return springs 102 attached to the frame 103 of the loom 100. Each loom 113 comprises an eyelet 114 traversed by a warp yarn 201. The heddles 113 and their eyelet 114 associated extend in an area in which the smooth 113 and eyelets 114 are driven by a substantially vertical oscillation movement represented by the double arrow F. The shafts 113 are subjected to tensile stresses respectively exerted by the control hooks 1010 and by the return springs 102. The heddles 113 can lift certain warp son 201 according to a defined weaving program. By lifting some warp son 201, the heddles 113 thus create a crowd 104 allowing the introduction of weft yarns 202 for 3D weaving or multilayer of a fibrous structure 210 in the form of tape or ribbon. The warp threads 201 are organized into a plurality of layers of warp threads C 1 to C n .

Les fils de chaîne 201 sont amenés depuis des bobines disposées sur un cantre (non représenté sur la figure 1) en amont de la mécanique Jacquard 101 du métier à tisser 100.The warp yarns 201 are fed from bobbins arranged on a creel (not shown in FIG. figure 1 ) upstream of the Jacquard machine 101 of the loom 100.

La figure 2 représente une installation 10 pour la fabrication d'une texture fibreuse à forme évolutive conformément à un mode de réalisation de l'invention. L'installation 10 comprend le métier à tisser 100 décrit ci-avant et trois rouleaux d'appels 300, 400 et 500 disposés en aval du métier à tisser. Le cadre 120 délimite la sortie du métier à tisser 100, c'est-à-dire la zone à partir de laquelle les fils de chaîne 201 ne sont plus tissés avec les fils de trame 202 et qui correspond à la fermeture de la foule 104.The figure 2 represents an installation 10 for the manufacture of an evolutive shape fiber texture according to an embodiment of the invention. The installation 10 comprises the loom 100 described above and three call rollers 300, 400 and 500 disposed downstream of the loom. The frame 120 delimits the exit of the loom 100, that is to say the area from which the warp threads 201 are no longer woven with the weft threads 202 and which corresponds to the closure of the shed 104 .

Le premier rouleau d'appel 300 qui est situé au plus proche de la sortie 120 du métier à tisser 100 est un rouleau dit « tireur » ou « puller ». Le rouleau d'appel 300 est entraîné suivant un sens de rotation S300 indiqué sur la figure 2. Il présente sur sa largeur axiale un rayon variable de manière à définir une surface externe 301 ayant un profil en relief correspondant au profil de tissage visé pour la texture fibreuse 210 de manière à avoir un angle entre les fils de chaîne et de trame le plus proche de 90°. La surface externe 301 est recouverte d'une matière, par exemple un agent tackifiant, à laquelle les fils de tissage adhèrent de manière à exercer un effort de traction sur les fils de chaîne.The first call roller 300 which is located closest to the exit 120 of the loom 100 is a roller called "shooter" or "puller". The call roller 300 is driven in a direction of rotation S 300 indicated on the figure 2 . It has on its axial width a variable radius so as to define an outer surface 301 having a raised profile corresponding to the weaving profile referred for the fibrous texture 210 so as to have an angle between the nearest warp and weft son 90 °. The outer surface 301 is covered with a material, for example a tackifier, to which the weaving threads adhere so as to exert a tensile force on the warp threads.

Les deux autres rouleaux d'appel 400 et 500 situés en aval du premier rouleau d'appel 300 sont des rouleaux dits « inverses » ou « reverser » qui sont entraînés en rotation suivant respectivement des sens de rotation S400 et S500 indiqués sur la figure 2 et qui sont opposés au sens de rotation S300 du rouleau d'appel 300. Les rouleaux d'appel 400 et 500 présentent également sur leur largeur axiale un rayon variable de manière à définir respectivement des surfaces externes 401 et 501 ayant un profil en relief. Les variations de rayon sur les rouleaux d'appel 400 et 500 sont plus importantes que sur le rouleau d'appel 300, les rouleaux 400 et 500 réalisant un appel de longueur de fils de chaîne plus important que le rouleau d'appel 300. Les surfaces externes 401 et 501 sont recouvertes d'une matière, par exemple un agent tackifiant, à laquelle les fils de tissage adhèrent de manière à exercer un effort de traction sur les fils de chaîne.The other two call rollers 400 and 500 located downstream of the first call roller 300 are so-called "reverse" or "reverse" rollers which are rotated respectively in directions of rotation S 400 and S 500 indicated on the figure 2 and which are opposed to the direction of rotation S 300 of the call roller 300. The call rollers 400 and 500 also have on their axial width a variable radius so as to define respectively external surfaces 401 and 501 having a profile in relief . The radius variations on the call rollers 400 and 500 are greater than on the call roller 300, the rollers 400 and 500 making a longer call for the length of the warp thread than the call roller 300. external surfaces 401 and 501 are covered with a material, for example a tackifier, to which the weaving threads adhere so as to exert a tensile force on the warp threads.

L'installation 10 comprend en outre un mandrin ou tambour de stockage 600, encore appelé mandrin « take-up », qui est entraîné en rotation suivant le sens de rotation S600 et qui présente également sur sa largeur axiale un rayon variable de manière à définir une surface externe 601 ayant un profil en relief correspondant au profil de tissage visé pour la texture fibreuse 210 afin de limiter la déformation de la texture fibreuse 210. La texture fibreuse 210 est enroulée sur le mandrin de stockage 600 et y est ainsi stockée jusqu'à la formation ultérieure d'une préforme fibreuse par enroulement de la texture fibreuse sur un moule d'injection.The installation 10 further comprises a mandrel or storage drum 600, also called "take-up" mandrel, which is rotated in the direction of rotation S 600 and which also has a variable radius on its axial width so as to defining an outer surface 601 having a raised profile corresponding to the weaving pattern referred for the fibrous texture 210 to limit the deformation of the fibrous texture 210. The fibrous texture 210 is wound on the storage mandrel 600 and is thus stored therein. the subsequent formation of a fibrous preform by winding the fibrous texture onto an injection mold.

Conformément à l'invention, au moins un rouleau d'appel est muni d'une pluralité de secteurs fixés de façon amovible, par exemple au moyen d'organes de serrage de type vis-écrou ou par emboitement, sur la surface externe du rouleau d'appel, chaque secteur s'étendant sur une fraction de la circonférence du rouleau d'appel et sur tout ou partie de la largeur axiale dudit rouleau d'appel. Dans l'exemple décrit ici et tel qu'illustré sur les figures 3 à 6, le rouleau d'appel 400, qui s'étend axialement suivant un axe X400 et dont le rayon R400 varie le long de l'axe X400 (figure 6), comprend 3 secteurs 410, 420 et 430 comme illustré sur les figures 3 et 4. Toujours dans l'exemple décrit ici, les secteurs 410, 420 et 430 présentent respectivement des largeurs axiales L410, L420 et L430 équivalentes qui sont inférieures à la largeur axiale L400 du rouleau d'appel 400, les largeurs axiales étant mesurées dans la direction de l'axe du rouleau comme l'axe X400 pour le rouleau suiveur 400. Les secteurs 410, 420, 430 sont destinés à être placés sur une partie 402 du rouleau d'appel 400, partie du rouleau 400 dans laquelle le rayon R400 varie sur la largeur axiale L400 de manière à définir en section radiale un profil en relief (figure 6). A cet effet, les secteurs 410, 420 et 430 comportent respectivement une surface interne 411, 421 et 431 ayant une forme correspondant à la partie 402 de la surface externe 401 à profil en relief du rouleau d'appel 400 sur laquelle les secteurs sont destinés à être fixés et une surface externe 412, 422 et 432 ayant une forme déterminée en fonction de l'ajustement de tension que l'on souhaite réaliser dans portion de la texture fibreuse en contact avec les secteurs.According to the invention, at least one call roller is provided with a plurality of sectors removably fixed, for example by means of screw-nut or interlocking clamping members, on the outer surface of the roller. of call, each sector extending over a fraction of the circumference of the call roller and over all or part of the axial width of said call roller. In the example described here and as illustrated on the Figures 3 to 6 , the call roller 400, which extends axially along an axis X 400 and whose radius R 400 varies along the axis X400 ( figure 6 ), includes 3 sectors 410, 420 and 430 as illustrated in the figures 3 and 4 . Still in the example described here, the sectors 410, 420 and 430 have respective axial widths L 410 , L 420 and L 430 which are smaller than the axial width L 400 of the call roller 400, the axial widths being measured. in the direction of the roller axis as the X axis 400 for the follower roller 400. The sectors 410, 420, 430 are intended to be placed on a portion 402 of the call roller 400, part of the roller 400 in which the radius R 400 varies over the axial width L 400 so as to define in radial section a relief profile ( figure 6 ). For this purpose, the sectors 410, 420 and 430 respectively comprise an inner surface 411, 421 and 431 having a shape corresponding to the portion 402 of the external surface 401 with raised profile of the call roller 400 on which the sectors are intended to be fixed and an outer surface 412, 422 and 432 having a shape determined according to the voltage adjustment that is desired to achieve in portion of the fibrous texture in contact with the sectors.

Les surfaces externes 412, 422 et 432 sont recouvertes d'une couche de matériau agrippant (non représentée), par exemple une couche d'élastomère (caoutchouc), à laquelle les fils de tissage adhèrent de manière à exercer un effort de traction sur les fils de chaîne.The outer surfaces 412, 422 and 432 are covered with a layer of gripping material (not shown), for example a layer elastomer (rubber), to which the weaving son adhere so as to exert a tensile force on the warp son.

Les secteurs 410, 420 et 430 présentent ici respectivement des épaisseurs qui sont variables sur les largeurs axiales L410, L420 et L430 des secteurs 410, 420 et 430, comme montrées sur la figure 6 pour les épaisseurs E410 et E420 des secteurs 410 et 420. Dans l'exemple décrit ici, la variation des épaisseurs des secteurs 410, 420 et 430 suit principalement la variation du rayon R400, et, par conséquent, la forme du profil en relief sur la partie 402 de manière à modifier localement l'épaisseur du rouleau 400 tout en suivant le profil en relief de la surface externe du rouleau d'appel dans la partie 402. Les secteurs peuvent également ajouter une surépaisseur qui est indépendante de la forme du profil en relief du rouleau.Sectors 410, 420 and 430 here have respectively thicknesses which are variable on the axial widths L 410, L 420 and L 430 of the sectors 410, 420 and 430, as shown in figure 6 for the thicknesses E 410 and E 420 of the sectors 410 and 420. In the example described here, the variation of the thicknesses of the sectors 410, 420 and 430 follows mainly the variation of the radius R 400 , and, consequently, the shape of the profile in relief on the part 402 so as to modify locally the thickness of the roll 400 while following the raised profile of the outer surface of the call roller in the part 402. The sectors can also add an extra thickness which is independent of the shape of the embossed profile of the roll.

Une fois muni des secteurs 410, 420 et 430, le rouleau 400 appelle une longueur de fils de chaîne plus importante au niveau des fils de chaîne en contact avec les secteurs.Once equipped with sectors 410, 420 and 430, the roller 400 calls for a longer length of warp son at the warp threads in contact with the sectors.

Les figures 7 à 9 montrent comment les secteurs 410, 420 et 430 sont montés sur le rouleau d'appel 400 lors de la fabrication de la texture fibreuse 210. Les secteurs sont fixés sur la surface externe du rouleau d'appel par exemple au moyen d'organes de serrage comme des vis qui coopèrent avec un taraudage ménagé dans le rouleau (non représentés sur les figures). Comme illustrée sur la figure 7, un premier secteur, ici le secteur 410, est monté sur la portion de la partie 402 du rouleau 400 qui n'est pas en contact avec la texture fibreuse 210. Le secteur 410, qui est le premier à entrer en contact avec la texture 210, comprend un premier bord 413 qui présente de préférence un bord biseauté orienté vers la surface externe du rouleau afin de ne pas mettre la préforme en contact avec une arrête vive du bord du secteur et d'augmenter progressivement la force d'appel des fils de chaîne. On poursuit alors la rotation du rouleau d'appel 400 dans le sens S400 jusqu'à dégager une nouvelle portion de la partie 402 du rouleau d'appel 400 de la zone de contact avec la texture 210 permettant le montage du deuxième secteur 430 (figure 8). Le bord 433 du secteur 430 est placé contre le bord 414 du secteur 410 qui est partiellement en contact avec la texture 210. La rotation du rouleau d'appel 400 dans le sens S400 est poursuivie jusqu'à dégager la dernière portion libre de la partie 402 du rouleau d'appel 400 de la zone de contact avec la texture 210. Le troisième secteur 420 est alors monté sur le rouleau 400 (figure 9). Le bord 424 du secteur 420 est placé contre le bord biseauté 413 du secteur 410, le bord 424 présentant une forme biseauté complémentaire de celle du bord 413. Le bord 423 du secteur 420 est placé contre le bord 434 du secteur 420.The Figures 7 to 9 show how the sectors 410, 420 and 430 are mounted on the call roller 400 during the manufacture of the fibrous texture 210. The sectors are fixed on the outer surface of the call roller for example by means of clamping members as screws that cooperate with a tapped hole in the roller (not shown in the figures). As illustrated on the figure 7 a first sector, here sector 410, is mounted on the portion of the portion 402 of the roll 400 which is not in contact with the fibrous texture 210. The sector 410, which is the first to come into contact with the texture 210, comprises a first edge 413 which preferably has a beveled edge oriented towards the outer surface of the roll so as not to bring the preform into contact with a sharp edge of the edge of the sector and gradually increase the appeal force of the wires. of chain. The rotation of call roller 400 in direction S 400 is then continued until a new portion of part 402 of call roller 400 is released from the zone of contact with texture 210 enabling the second sector 430 to be mounted ( figure 8 ). The edge 433 of the sector 430 is placed against the edge 414 of the sector 410 which is partially in contact with the texture 210. The rotation of the call roller 400 in the direction S 400 is continued until the last free portion of the part 402 of the call roller 400 of the contact zone with the texture 210. The third sector 420 is then mounted on the roller 400 ( figure 9 ). The edge 424 of the sector 420 is placed against the beveled edge 413 of the sector 410, the edge 424 having a beveled shape complementary to that of the edge 413. The edge 423 of the sector 420 is placed against the edge 434 of the sector 420.

Les secteurs 410, 420 et 430 sont ajoutés au cours de la fabrication de la texture fibreuse 210 lorsqu'une longueur de fil de chaîne plus importante doit être appelée, par exemple lorsque la différence entre le profil tissé et le profil réel sur lequel la texture est enroulée est telle qu'elle peut entraîner des pertes de tension à certaines positions axiales dans la texture.Sectors 410, 420 and 430 are added during the manufacture of the fibrous texture 210 when a longer length of warp yarn is to be called, for example when the difference between the woven profile and the actual profile on which the texture is wound such that it can cause voltage losses at certain axial positions in the texture.

Le retrait des secteurs 410, 420 et 430 s'opère de la même façon comme illustré sur les figures 10 à 13. Au cours de fabrication de la texture fibreuse 210, le premier secteur qui n'est pas en contact avec la texture fibreuse, correspondant ici sur la figure 10 au secteur 420, est retiré. Les deux autres secteurs 410 et 430 sont ensuite retirés l'un après l'autre comme illustrés sur les figures 11 à 13 de manière à réduire l'épaisseur ou le rayon de la partie 402 du rouleau d'appel 400. Le secteur 430, qui est le dernier secteur à être retiré comprend un bord 434 qui présente de préférence un bord biseauté orienté vers la surface externe du rouleau afin de ne pas mettre la préforme en contact avec une arrête vive du bord du secteur, le bord 423 du secteur 420 présentant une forme biseautée complémentaire de celle du bord 434.The withdrawal of sectors 410, 420 and 430 operates in the same way as illustrated in Figures 10 to 13 . During manufacture of the fibrous texture 210, the first sector that is not in contact with the fibrous texture, corresponding here on the figure 10 at sector 420, is removed. The other two sectors 410 and 430 are then removed one after the other as illustrated on the Figures 11 to 13 in order to reduce the thickness or radius of the portion 402 of the call roller 400. The sector 430, which is the last sector to be removed, comprises an edge 434 which preferably has a beveled edge oriented towards the outer surface of the roller so as not to bring the preform into contact with a sharp edge of the edge of the sector, the edge 423 of the sector 420 having a beveled shape complementary to that of the edge 434.

Chaque secteur s'étend sur une fraction de la circonférence du rouleau. Il présente une longueur d'arc de cercle, comme la longueur d'arc de cercle A410 du secteur 410 représenté sur la figure 7, qui est définie en fonction de la longueur d'arc de cercle de la portion du rouleau d'appel 400 qui n'est pas en contact avec la texture fibreuse 210. Par conséquent, si la texture fibreuse est en contact avec le rouleau d'appel sur une longueur d'arc de cercle peu importante, il est possible d'utiliser des secteurs ayant une longueur d'arc de cercle importante et inversement. Le nombre de secteurs nécessaires pour couvrir toute la circonférence du rouleau d'appel est donc également déterminé en fonction de la longueur d'arc de cercle de la portion du rouleau d'appel qui n'est pas en contact avec la texture fibreuse.Each sector extends over a fraction of the circumference of the roll. It has an arc length, such as the arc length A 410 of the sector 410 shown in FIG. figure 7 which is defined as a function of the arc length of the portion of the call roller 400 which is not in contact with the fibrous texture 210. Therefore, if the fibrous texture is in contact with the roll of call on a small arc length, it is possible to use sectors having a large arc length and vice versa. The number of sectors necessary to cover the entire circumference of the call roller is therefore also determined according to the arc length of the portion of the call roller that is not in contact with the fiber texture.

Des secteurs peuvent être utilisés sur un seul rouleau d'appel, comme décrit ci-avant pour le rouleau 400, ou sur plusieurs rouleaux d'appel, comme sur les rouleaux 300, 400 et 500 décrits ci-avant de manière à modifier localement l'épaisseur du profil en relief de la surface externe du ou des rouleaux d'appel. Les secteurs sont toutefois de préférence utilisés avec le ou les rouleaux d'appel dits « inverses » ou « reverser » qui présentent des variations de rayon plus importantes que sur le ou les rouleaux d'appel dits « tireur » ou « puller » et qui, réalisent, par conséquent, un appel de longueur de fils de chaîne plus important que les rouleaux d'appel dits « tireur » ou « puller ». Les rouleaux d'appel dits « inverses » ou « reverser » sont placés entre le ou les rouleaux d'appel dits « tireur » ou « puller » et le mandrin de stockage dans l'installation pour la fabrication d'une texture fibreuse en forme de bande présentant en section transversale un profil évolutif.Sectors can be used on a single call roller, as described above for the roller 400, or on several call rollers, as on the rollers 300, 400 and 500 described above so as to locally modify the the thickness of the profile in relief of the external surface of the call roller or rollers. The sectors are, however, preferably used with the so-called "reverse" or "reverse" call roll or rollers which have greater variations of radius than on the so-called "shooter" or "puller" roll or rollers and which , therefore, realize a longer string wire length call than the call rollers called "shooter" or "puller". The so-called "reverse" or "reverse" call rollers are placed between the so-called "puller" or "puller" call roller (s) and the storage mandrel in the plant for the manufacture of a shaped fibrous texture. of band having in cross section an evolutive profile.

Il est également possible dans le cadre de l'invention de monter plusieurs secteurs les uns sur les autres de manière à augmenter ou réduire progressivement l'épaisseur du profil en relief de la surface externe du ou des rouleaux d'appel.It is also possible in the context of the invention to mount several sectors on each other so as to gradually increase or reduce the thickness of the raised profile of the outer surface of the call roller or rollers.

Les secteurs sont réalisés en un matériau rigide ou présentant une bonne résistance à la compression comme du métal ou du plastique. Les secteurs peuvent être réalisés par exemple par moulage, par usinage ou par impression 3D.The sectors are made of a rigid material or having a good compressive strength such as metal or plastic. The sectors can be made for example by molding, machining or 3D printing.

Par l'utilisation de secteurs permettant de modifier localement l'épaisseur du profil en relief de la surface externe d'un ou plusieurs rouleaux d'appel lors de la fabrication d'une texture fibreuse à forme évolutive, l'installation et le procédé de fabrication de l'invention permettent de fabriquer des textures fibreuses à forme évolutive dans lesquelles les pertes ou inhomogénéités de tension sont significativement réduites. Les effets de l'invention sur une texture fibreuse fabriquée avec l'installation et le procédé de l'invention sont visibles lors de l'enroulement de cette texture sur le moule d'injection pour leur mise en forme. En effet, lors de son enroulement sur le moule d'injection, la préforme fibreuse formée présente peu de défauts (vagues, flambements et/ou pincements de fibres, zones de surépaisseurs non désirées, taux volumiques de fibres hors spécification, plis, désalignements, etc.) par rapport à une texture fibreuse fabriquée selon l'art antérieur ou les déséquilibres de tension sont plus importants. On réduit ainsi les arrêts inopinés de la machine d'enroulement habituellement nécessaires pour reprendre les défauts tels que des plis ou effondrement de portions de la texture qui requièrent en outre un retour en arrière de la machine ainsi qu'une intervention d'un ou plusieurs techniciens.By using sectors for locally modifying the thickness of the embossed profile of the outer surface of one or more call rollers during the manufacture of an evolving shape fiber texture, the installation and method of manufacture of the invention allow to manufacture fibrous textures in evolutionary form in which the losses or inhomogeneities of voltage are significantly reduced. The effects of the invention on a fibrous texture manufactured with the installation and the method of the invention are visible during the winding of this texture on the injection mold for their shaping. Indeed, during its winding on the injection mold, the formed fiber preform has few defects (waves, buckling and / or pinching of fibers, areas of undesired thickenings, volume ratio of fibers out of specification, folds, misalignments, etc.) with respect to a fibrous texture manufactured according to the prior art or the voltage imbalances are more important. This reduces the unexpected stops of the winding machine usually necessary to recover defects such as folds or collapse of portions of the texture that also require a backward movement of the machine and an intervention of one or more technicians.

Claims (10)

  1. An installation for fabricating a fiber texture (210) in the form of a strip presenting a profile that varies at least in cross-section, the installation comprising a loom (100), one or more take-up rollers (300, 400, 500), and a storage mandrel (600), each take-up roller and the storage mandrel presenting a radius that varies across its axial width so as to define an outer surface having a profile in relief; the installation being characterized in that at least one take-up roller (400) includes a plurality of sectors (410, 420, 430) releasably fastened on the outer surface (401) of said take-up roller, each sector extending over a fraction of the circumference of the take-up roller and over all or part of the axial width of the take-up roller (400), each sector (410; 420; 430) also presenting at least one thickness that is determined in such a manner as to modify locally the thickness of the profile in relief of the outer surface of the take-up roller (400).
  2. An installation according to claim 1, wherein each sector (410; 420; 430) presents a thickness that varies in the axial direction.
  3. An installation according to claim 1 or claim 2, wherein each sector (410; 420; 430) presents an inner surface (411; 421; 431) having a shape corresponding to the portion (402) of the outer surface (401) of profile in relief of the take-up roller (400) on which said sector is fastened.
  4. An installation according to claim 1 or claim 2, wherein each sector (410; 420; 430) includes a layer of grip material on its outer surface (412; 422; 432).
  5. An installation according to any one of claims 1 to 3, wherein at least one sector (410) of the plurality of sectors has an edge (413) that is chamfered so as to avoid putting the preform into contact with a sharp edge on a sector that has been added to the take-up roller.
  6. An installation according to any one of claims 1 to 5, comprising a first take-up roller (300) placed in the proximity of the outlet from the loom, and at least one second take-up roller (400) placed between the first take-up roller (300) and the storage mandrel (600), the second take-up roller (400) including a plurality of sectors (410, 420, 430) releasably fastened on the outer surface (401) of said second take-up roller, each sector extending over a fraction of the circumference of the second take-up roller and over all or part of the axial width of said second take-up roller (400), each sector (410; 420; 430) also presenting a thickness that is determined in such a manner as to modify locally the thickness of the profile in relief of the outer surface of the take-up roller (400).
  7. A method of fabricating a fiber structure (210) in the form of a strip presenting a varying profile in cross-section by three-dimensional or multilayer weaving between a plurality of layers of warp yarns (201) interlinked by weft yarns (202), the warp yarns being driven at the outlet from the loom by one or more take-up rollers (300, 400, 500), the fiber texture (210) being wound onto a storage mandrel (600) placed downstream from the take-up rollers, each take-up roller (300, 400, 500) and the storage mandrel (600) presenting across its axial width a radius that varies so as to define an outer surface having a profile in relief; the method being characterized in that, during weaving, it comprises adding a plurality of sectors (420, 430, 401) on the outer surface (401) of at least one take-up roller (400), each sector extending over a fraction of the circumference of the take-up roller and over all or part of the axial width of said take-up roller (400), each sector (410; 420; 430) also presenting at least one thickness that is determined in such a manner as to modify locally the thickness of the profile in relief of the outer surface of the take-up roller (400).
  8. A method according to claim 7, wherein each sector (410; 420; 430) extends over a fraction of the circumference of the take-up roller (400), which fraction is determined as a function of the circumferential fraction of contact between the fiber texture and the outer surface (401) of said take-up roller.
  9. A method according to claim 7 or claim 8, wherein each sector (410; 420; 430) presents a thickness that varies in the axial direction.
  10. A method according to any one of claims 7 to 9, wherein each sector (410; 420; 430) presents an outer surface (412; 422; 432) having a shape corresponding to the portion (402) of the outer surface (401) of profile in relief of the take-up roller (400) on which said sector is fastened.
EP17712211.6A 2016-03-02 2017-03-02 Facility and method for manufacturing a belt-shaped fibrous texture having a changing profile in cross-section Active EP3423620B1 (en)

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FR1651741A FR3048435B1 (en) 2016-03-02 2016-03-02 INSTALLATION AND METHOD FOR MANUFACTURING FIBROUS BAND-SHAPED TEXTURE HAVING IN THE CROSS-SECTIONAL SECTION AN EVOLVING PROFILE
PCT/FR2017/050470 WO2017149252A1 (en) 2016-03-02 2017-03-02 Facility and method for manufacturing a belt-shaped fibrous texture having a changing profile in cross-section

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FR3048435A1 (en) 2017-09-08
US10309043B2 (en) 2019-06-04
CN108779590A (en) 2018-11-09
US20190062962A1 (en) 2019-02-28
EP3423620A1 (en) 2019-01-09
CN108779590B (en) 2020-10-13
WO2017149252A1 (en) 2017-09-08
FR3048435B1 (en) 2018-04-06

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