FR2771332A1 - Molding large layered sections - Google Patents

Molding large layered sections Download PDF

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Publication number
FR2771332A1
FR2771332A1 FR9714862A FR9714862A FR2771332A1 FR 2771332 A1 FR2771332 A1 FR 2771332A1 FR 9714862 A FR9714862 A FR 9714862A FR 9714862 A FR9714862 A FR 9714862A FR 2771332 A1 FR2771332 A1 FR 2771332A1
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France
Prior art keywords
mold
semi
flexible
fabrics
core
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Granted
Application number
FR9714862A
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French (fr)
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FR2771332B1 (en
Inventor
Jean Marie Finot
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Individual
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Individual
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Publication date
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Priority to FR9714862A priority Critical patent/FR2771332B1/en
Priority to PCT/FR1998/002216 priority patent/WO1999026775A1/en
Priority to AU96326/98A priority patent/AU9632698A/en
Publication of FR2771332A1 publication Critical patent/FR2771332A1/en
Application granted granted Critical
Publication of FR2771332B1 publication Critical patent/FR2771332B1/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
    • B29D99/0014—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with ridges or ribs, e.g. joined ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/467—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements during mould closing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
    • 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
    • B29L2031/3067—Ships
    • B29L2031/307—Hulls

Abstract

To shape large layered sections, three molds are used as an outer rigid mold (1) of the best finish, a pliable core mold (2) and a rigid inner shaping mold (3), with holders to keep the core mold (2) in place. The inner shaping mold (3) is positioned upwards, and the pliable core (2) is placed on it. A coating of gel (4) and dry or impregnated fabrics for the structure (5) are placed on the core (2), and the channels (6) in the core (2) are filled. Outer fabrics (7) are placed on the structure, to be covered by the outer mold (1) treated with a gel coating (8). The assembly is evacuated, and a resin is fed in for polymerizing, or heat setting in an autoclave etc. for impregnated fabrics. A foam or inflatable sealed plug or bladder bodies are used to fill the core channels (6)

Description

La présente invention est relative à la fabrication de pièces de grandes dimensions, notamment de coques de bateaux, de portes d'écluse etc. en stratifié. The present invention relates to the manufacture of large parts, in particular boat hulls, lock doors, etc. in laminate.

A l'heure actuelle, pour fabriquer de telles pièces de grandes dimensions, on dispose essentiellement des trois procédés suivants:
Selon le premier, on commence par fabriquer une peau extérieure par exemple manuellement avec de la résine polymérisée in sitar ou en utilisant un pré-imprégné polymérisé sous vide, en étuve ou bien encore en mettant en oeuvre le procédé d'injection, infusion. Sur la peau ainsi obtenue, on réalise en un second stade, une structure devant tenir la pièce, en collant des nervures en mousse sur la peau et en stratifiant une nouvelle peau sur lesdites nervures.At present, in order to manufacture such large parts, the following three methods are essentially available:
According to the first, we begin by manufacturing an outer skin, for example manually with resin polymerized in sitar or by using a prepreg polymerized under vacuum, in an oven or else by implementing the injection, infusion process. On the skin thus obtained, a structure is produced in a second stage, which must hold the part, by sticking foam ribs on the skin and laminating a new skin on said ribs.

Selon le second procédé connu, on fabrique une peau nervurée, appelée contre moule, dans un moule spécialement adapté et cette peau nervurée est ultérieurement collée sur une peau extérieure. According to the second known method, a ribbed skin, called a counter mold, is produced in a specially adapted mold and this ribbed skin is subsequently bonded to an outer skin.

Enfin, la troisième solution connue consiste à positionner l'ensemble des tissus, secs ou pré-imprégnés à l'intérieur des moules et à infuser l'ensemble. Finally, the third known solution consists in positioning all of the fabrics, dry or prepreg inside the molds and infusing the whole.

L'un des inconvénients principaux de ces procédés connus réside dans la faible vitesse d'exécution qui a une influence négative sur les prix de revient des pièces réalisées. One of the main drawbacks of these known methods lies in the low speed of execution which has a negative influence on the cost prices of the parts produced.

L'invention s'est fixé pour objectif d'apporter un procédé de fabrication de pièces de grandes dimensions en stratifié, se caractérisant notamment par une grande vitesse d'exécution et qui permet d'obtenir des pièces de bonne finition intérieurement et extérieurement et dans lesquelles les liaisons entre les différentes peaux et les structures présentent les caractéristiques de base du stratifié. The invention has set itself the objective of providing a process for manufacturing large-sized parts in laminate, characterized in particular by a high speed of execution and which makes it possible to obtain parts of good finish internally and externally and in which the connections between the different skins and the structures have the basic characteristics of the laminate.

Le procédé objet de la présente invention est caractérisé en ce qu'il met en oeuvre un jeu de trois moules : un moule extérieur rigide présentant la meilleure finition, un moule nervuré de l'intérieur, semi-souple et un moule intérieur conformateur, rigide, conçu de manière à maintenir en place le moule semi souple nervuré et en ce qu'il comporte les étapes successives suivantes:
a) mise en place du moule conformateur dirigé vers le haut;
b) positionnement du moule semi-souple nervuré sur le moule conformateur;
c) mise en place sur ledit moule semi-souple nervuré:
- du gel coat, si celui-ci est nécessaire,
- de tissus secs ou pré-imprégnés pour la réalisation de la structure;
d) remplissage des nervures du moule semi-souple nervuré par de la mousse, des boudins gonflables ou des vessies gonflables et étanches
e) pose des tissus extérieurs sur la structure ainsi obtenue;
f) positionnement du moule extérieur , ayant éventuellement reçu préalablement un gel-coat, sur la structure réalisée;
g) plaquage, par le vide, de l'ensemble des tissus et des moules conformateur et semi-souple dans le moule extérieur, et
h) introduction de la résine dans la structure stratifiée suivie de la polymérisation de l'ensemble, ou d'une cuisson en étuve ou en autoclave dans le cas de tissus préimprégnés.The process which is the subject of the present invention is characterized in that it implements a set of three molds: a rigid external mold having the best finish, a mold ribbed from the inside, semi-flexible and an internal mold conforming, rigid , designed to hold the semi-flexible ribbed mold in place and in that it comprises the following successive steps:
a) placing the shaping mold directed upwards;
b) positioning of the semi-flexible ribbed mold on the shaping mold;
c) placing on said semi-flexible ribbed mold:
- gel coat, if necessary,
- dry or pre-impregnated fabrics for the realization of the structure;
d) filling the ribs of the semi-flexible ribbed mold with foam, inflatable tubes or inflatable and waterproof bladders
e) placing external fabrics on the structure thus obtained;
f) positioning of the external mold, possibly having previously received a gel-coat, on the structure produced;
g) plating, by vacuum, of all of the conforming and semi-flexible fabrics and molds in the external mold, and
h) introduction of the resin into the laminated structure followed by polymerization of the assembly, or baking in an oven or in an autoclave in the case of prepreg fabrics.

D'autres caractéristiques et avantages de cette invention ressortiront de la description faite ci-après en référence au dessin annexé dont la figure unique est une coupe transversale verticale d'une coque de bateau en cours de réalisation par le procédé objet de l'invention. Other characteristics and advantages of this invention will emerge from the description given below with reference to the attached drawing, the single figure of which is a vertical cross section of a boat hull being produced by the process which is the subject of the invention.

Ainsi qu'on l'a expliqué ci-dessus, le procédé selon cette invention utilise un jeu de trois moules:
- un moule extérieur rigide 1 qui doit présenter la meilleure finition car c'est ce moule extérieur, ainsi qu'on le verra ci-après, qui confère à la pièce obtenue son aspect de surface extérieure;
- un moule semi-souple 2, nervuré de l'intérieur, réalisé par exemple en silicone ou en néoprène,
- un moule intérieur rigide, dit conformateur, 3, conçu de façon à maintenir en place le moule semi souple 2 ainsi qu'on le décrira ci-après.As explained above, the method according to this invention uses a set of three molds:
- A rigid external mold 1 which must have the best finish because it is this external mold, as will be seen below, which gives the part obtained its appearance of external surface;
a semi-flexible mold 2, ribbed from the inside, made for example of silicone or of neoprene,
- A rigid interior mold, said shaping, 3, designed to hold in place the semi flexible mold 2 as will be described below.

Selon la procédé objet de l'invention, on commence par mettre en place le moule conformateur 3 en l'orientant vers le haut comme illustré par la figure. Sur ce moule conformateur 3 on pose le moule semi souple 2, le moule conformateur 3 maintenant ainsi en place le moule semi souple 2. According to the process which is the subject of the invention, one begins by putting the shaping mold 3 in place, orienting it upwards as illustrated in the figure. The semi-flexible mold 2 is placed on this shaping mold 3, the shaping mold 3 thus holding the semi-flexible mold 2 in place.

Ensuite, sur le moule semi souple 2, maintenu par le moule conformateur intérieur 3, on réalise la stratification des parties structurelles de la coque en mettant successivement en place:
- le gel-coat 4 s'il y a lieu
- les tissus secs ou pré-imprégnés, suivant le cas pour réaliser la structure 5 de la pièce puis on réalise le remplissage des nervures 6 par de la mousse ou par des boudins gonflables ou des vessies gonflables et étanches.Then, on the semi-flexible mold 2, held by the internal shaping mold 3, the structural parts of the shell are laminated by successively installing:
- gel-coat 4 if necessary
- dry or pre-impregnated fabrics, as appropriate to produce the structure 5 of the part, then the ribs 6 are filled with foam or with inflatable tubes or inflatable and waterproof bladders.

Enfin, sur cette structure, on pose les tissus extérieurs 7. Finally, on this structure, the outer fabrics 7 are placed.

Afin de compacter les différentes couches ainsi posées on peut faire le vide périodiquement par l'intermédiaire d'une peau. In order to compact the different layers thus laid, a vacuum can be created periodically via a skin.

Sur la structure stratifiée ainsi obtenue, on applique le moule extérieur 1 ayant éventuellement reçu au préalable un gel-coat 8. Puis on plaque, par le vide, I'ensemble des tissus de la stratification et des moules semi-souple 2 et conformateur intérieur 3 dans le moule extérieur 1. On the laminated structure thus obtained, the outer mold 1 is applied, having possibly received a gel coat 8 beforehand. Then, all of the laminating fabrics and semi-flexible molds 2 and inner conformator are plated by vacuum. 3 in the outer mold 1.

Enfin l'on introduit la résine dans la structure stratifiée, par exemple par injection puis l'on effectue la polymérisation, ou la cuisson, dans le cas de tissus pré-imprégnés, par toute technique connue, par exemple en étuve ou en autoclave. Finally, the resin is introduced into the laminated structure, for example by injection and then polymerization or baking is carried out, in the case of prepreg fabrics, by any known technique, for example in an oven or in an autoclave.

On comprend de la lecture de la description qui précède que le procédé objet de cette invention permet d'obtenir une pièce finie intérieurement et extérieurement dans laquelle les liaisons entre les différentes peaux et les structures présentent les caractéristiques de base du stratifié. It will be understood from reading the above description that the process which is the subject of this invention makes it possible to obtain a finished part internally and externally in which the connections between the various skins and the structures have the basic characteristics of the laminate.

Le procédé permet de gagner:
- en vitesse d'exécution,
- en poids,
- en qualité mécanique de la pièce réalisée.The process allows to gain:
- in execution speed,
- in weight,
- in mechanical quality of the part produced.

II demeure bien entendu que la présente invention n'est pas limitée aux exemples de réalisation décrits et/ou représentés mais qu'elle en englobe toutes les variantes qui entrent dans le cadre de la portée des revendications annexées  It remains to be understood that the present invention is not limited to the embodiments described and / or shown but that it encompasses all variants thereof which come within the scope of the appended claims

Claims (4)

REVENDICATIONS 1 - Procédé de réalisation de pièces de grandes dimensions, notamment de coques de bateaux, en stratifié caractérisé en ce qu'il met en oeuvre un jeu de trois moules : un moule extérieur (1), rigide, présentant la meilleure finition ; un moule nervuré de l'intérieur (2), semi-souple et un moule intérieur rigide (3), conformateur, conçu de façon à maintenir en place le moule semi-souple (2) et en ce qu'il comporte les étapes suivantes. 1 - Method for producing large parts, in particular boat hulls, in laminate characterized in that it implements a set of three molds: an outer mold (1), rigid, having the best finish; an interior ribbed mold (2), semi-flexible and a rigid interior mold (3), conforming, designed so as to hold the semi-flexible mold (2) in place and in that it comprises the following steps . a) mise en place du moule intérieur conformateur (3) dirigé vers le haut; a) positioning of the interior shaping mold (3) directed upwards; b) positionnement du moule semi-souple nervuré (2) sur ledit moule conformateur (3); b) positioning of the semi-flexible ribbed mold (2) on said shaping mold (3); c) mise en place sur ledit moule semi souple nervuré (2) du gel-coat éventuel (4) et des tissus secs ou pré-imprégnés pour réaliser la structure (5); c) placing on said semi-flexible ribbed mold (2) any gel-coat (4) and dry or prepreg fabrics to produce the structure (5); d) remplissage des nervures (6) du moule semi-souple (2); d) filling the ribs (6) of the semi-flexible mold (2); e) pose des tissus extérieurs (7) sur la structure ainsi obtenue  e) placing external fabrics (7) on the structure thus obtained f) positionnement du moule extérieur (1), ayant éventuellement reçu préalablement un gel coat (8), sur la structure réalisée; f) positioning of the external mold (1), possibly having previously received a gel coat (8), on the structure produced; g) plaquage, par le vide, de l'ensemble des tissus et des moules conformateur (3) et semi-soupie (2) dans le moule extérieur (1) et, g) plating, by vacuum, all the fabrics and the molds (3) and semi-soupie (2) in the external mold (1) and, h) introduction de la résine dans la structure stratifiée suivie de la polymérisation de l'ensemble, ou d'une cuisson, notamment en étuve ou en autoclave, dans le cas de tissus préimprégnés. h) introduction of the resin into the laminated structure followed by polymerization of the assembly, or by baking, in particular in an oven or in an autoclave, in the case of prepreg fabrics. 2 - Procédé selon la revendication 1 caractérisé en ce que le remplissage des nervures (6) du moule semi-souple (2) durant l'étape d) est effectué à l'aide de mousse. 2 - Method according to claim 1 characterized in that the filling of the ribs (6) of the semi-flexible mold (2) during step d) is carried out using foam. 3 - Procédé selon la revendication 1 caractérisé en ce que le remplissage des nervures (6) du moule semi-souple (2) durant l'étape d) est réalisé à l'aide de boudins gonflables. 3 - Method according to claim 1 characterized in that the filling of the ribs (6) of the semi-flexible mold (2) during step d) is carried out using inflatable tubes. 4 - Procédé selon la revendication 1 caractérisé en ce que le remplissage des nervures (6) du moule semi-souple (2) lors de l'étape d) est effectué au moyen de vessies gonflables et étanches.  4 - Method according to claim 1 characterized in that the filling of the ribs (6) of the semi-flexible mold (2) during step d) is carried out by means of inflatable and waterproof bladders.
FR9714862A 1997-11-26 1997-11-26 PROCESS FOR THE PRODUCTION OF LARGE-SIZED PARTS, ESPECIALLY LAMINATE BOAT HULLS Expired - Fee Related FR2771332B1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
FR9714862A FR2771332B1 (en) 1997-11-26 1997-11-26 PROCESS FOR THE PRODUCTION OF LARGE-SIZED PARTS, ESPECIALLY LAMINATE BOAT HULLS
PCT/FR1998/002216 WO1999026775A1 (en) 1997-11-26 1998-10-15 Method for producing pieces of large dimensions in skin material, in particular boat hulls
AU96326/98A AU9632698A (en) 1997-11-26 1998-10-15 Method for producing pieces of large dimensions in skin material, in particular boat hulls

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
FR9714862A FR2771332B1 (en) 1997-11-26 1997-11-26 PROCESS FOR THE PRODUCTION OF LARGE-SIZED PARTS, ESPECIALLY LAMINATE BOAT HULLS

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FR2771332A1 true FR2771332A1 (en) 1999-05-28
FR2771332B1 FR2771332B1 (en) 2000-01-07

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WO (1) WO1999026775A1 (en)

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EP1972428A2 (en) 2004-09-29 2008-09-24 The Boeing Company Caul for manufacturing composite parts
US7622066B2 (en) 2004-07-26 2009-11-24 The Boeing Company Methods and systems for manufacturing composite parts with female tools
US7655168B2 (en) 2006-01-31 2010-02-02 The Boeing Company Tools for manufacturing composite parts and methods for using such tools
US8465613B2 (en) 2011-08-24 2013-06-18 The Boeing Company Method and apparatus for fabricating variable gauge, contoured composite stiffeners
US8557165B2 (en) 2008-10-25 2013-10-15 The Boeing Company Forming highly contoured composite parts
US8601694B2 (en) 2008-06-13 2013-12-10 The Boeing Company Method for forming and installing stringers
US9254619B2 (en) 2008-05-28 2016-02-09 The Boeing Company Method and apparatus for fabricating variable gauge, contoured composite stiffeners
US9387628B2 (en) 2011-08-24 2016-07-12 The Boeing Company Method and apparatus for fabricating composite stringers
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US7622066B2 (en) 2004-07-26 2009-11-24 The Boeing Company Methods and systems for manufacturing composite parts with female tools
US8974212B2 (en) 2004-07-26 2015-03-10 The Boeing Company Systems for manufacturing composite parts with female tools
EP1972428A2 (en) 2004-09-29 2008-09-24 The Boeing Company Caul for manufacturing composite parts
EP1972428A3 (en) * 2004-09-29 2008-10-08 The Boeing Company Caul for manufacturing composite parts
US7951318B2 (en) 2004-09-29 2011-05-31 The Boeing Company Apparatuses, systems, and methods for manufacturing composite parts
US9561602B2 (en) 2005-04-13 2017-02-07 The Boeing Company Forming highly contoured composite parts
US9162380B2 (en) 2005-04-13 2015-10-20 The Boeing Company Forming highly contoured composite parts
US8632330B2 (en) 2006-01-31 2014-01-21 The Boeing Company Tools for manufacturing composite parts and methods for using such tools
US7655168B2 (en) 2006-01-31 2010-02-02 The Boeing Company Tools for manufacturing composite parts and methods for using such tools
US9254619B2 (en) 2008-05-28 2016-02-09 The Boeing Company Method and apparatus for fabricating variable gauge, contoured composite stiffeners
US8601694B2 (en) 2008-06-13 2013-12-10 The Boeing Company Method for forming and installing stringers
US9387627B2 (en) 2008-06-13 2016-07-12 The Boeing Company Apparatus for forming and installing stringers
US8557165B2 (en) 2008-10-25 2013-10-15 The Boeing Company Forming highly contoured composite parts
US8465613B2 (en) 2011-08-24 2013-06-18 The Boeing Company Method and apparatus for fabricating variable gauge, contoured composite stiffeners
US9387628B2 (en) 2011-08-24 2016-07-12 The Boeing Company Method and apparatus for fabricating composite stringers
US10369740B2 (en) 2015-07-09 2019-08-06 The Boeing Company Method of forming a contoured hat stiffener
US11370159B2 (en) 2015-07-09 2022-06-28 The Boeing Company Apparatus for forming a contoured hat stiffener

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AU9632698A (en) 1999-06-15
WO1999026775A1 (en) 1999-06-03
FR2771332B1 (en) 2000-01-07

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