GB2245862A - Manufacture of a composite material - Google Patents

Manufacture of a composite material Download PDF

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Publication number
GB2245862A
GB2245862A GB9113766A GB9113766A GB2245862A GB 2245862 A GB2245862 A GB 2245862A GB 9113766 A GB9113766 A GB 9113766A GB 9113766 A GB9113766 A GB 9113766A GB 2245862 A GB2245862 A GB 2245862A
Authority
GB
United Kingdom
Prior art keywords
stack
blade
loop
layers
intermediate fabric
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB9113766A
Other versions
GB9113766D0 (en
GB2245862B (en
Inventor
Robert Samuel Wilson
Mark Anthony Braniff
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Short Brothers PLC
Original Assignee
Short Brothers PLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Short Brothers PLC filed Critical Short Brothers PLC
Publication of GB9113766D0 publication Critical patent/GB9113766D0/en
Publication of GB2245862A publication Critical patent/GB2245862A/en
Application granted granted Critical
Publication of GB2245862B publication Critical patent/GB2245862B/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C15/00—Making pile fabrics or articles having similar surface features by inserting loops into a base material
    • D05C15/04—Tufting
    • D05C15/08—Tufting machines
    • D05C15/16—Arrangements or devices for manipulating threads
    • D05C15/24—Loop cutters; Driving mechanisms therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
    • 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
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/543—Fixing the position or configuration of fibrous reinforcements before or during moulding

Abstract

Apparatus for fastening together layers of intermediate fabric material to form a stack (2) includes a first knife blade (4) having a forward cutting edge and a longitudinal slot. A second flat knife blade (10) is in sliding contact with the blade (4). The blade (10) is stationary, and its forward cutting edge is located at a pre-selected distance above the upper surface of the stack (2). The blade (4) is advanced to cut through the stack (2) until the slot (8) is clear of the lower face of the stack. A pre-selected length of a tow (18) is threaded through the slot (8), to extend equal distances each side of the blade (4), which is then withdrawn until the cutting edge (12) of the blade (10) cuts the tow loop to form two independent tow pieces (20, 22). These pieces (20, 22) are each folded back onto the upper and lower faces (13, 16) of the stack (2) which is then cured. <IMAGE>

Description

MANUFACTURE OF A COMPOSITE MATERIAL The present invention relates to apparatus for and a method of manufacturing a composite material such as, for example, a composite material particularly suitable for forming the outer surface material of an aircraft.
The term "material" includes any suitable component or structure, such as for example a laminate joint, depending on the application of the invention.
A previously proposed composite material has been manufactured by embedding high strength fibres having a high modulus of elasticity within a homogeneous matrix.
In one example of such a material, the fibres are made of carbon, aramid or boron, and the matrix can be formed of material such as an epoxy, bismalemide or polyimide resin.
The fibres are supplied in a uni-directional, woven or fibrous mat format which is pre-impregnated with slightly cured resin to form an intermediate fabric material.
This intermediate fabric material is flexible and tacky, and the positions of the fibre filaments therein are not fixed. Layers of these intermediate fabric materials are assembled one upon the other in a mould, and then compressed and heated. The heating action accelerates the curing of the resin, and the combination of the heating and compression joins together the intermediate fabric materials to form the composite material.
In our co-pending patent application publication No.
GB2238977A there is disclosed a method of manufacturing a composite material comprising placing together face to face a plurality of layers of intermediate fabric material, each layer comprising high strength fibres have a high modulus of elasticity in a tacky homogeneous resin matrix, fastening together said layers at spaced locations thereon, and then compressing and heating the layer assembly to cure the resin.
The present invention is particularly concerned with apparatus for and a method of fastening together the layers of intermediate fabric material at spaced locations thereon.
According to one aspect of the invention there is provided apparatus for fastening together a plurality of layers of intermediate fabric material located in a stack, said apparatus comprising first means to make a passage through the stack, second means to draw a loop of prepared material through the passage to extend from both faces of the stack, third means to cut the loop at a preselected distance from one face of the stack to form two independent pieces of prepared material, and means to fold back the end portions of each piece onto the opposite faces of the stack to extend away from the other piece.
According to another aspect of the invention, there is provided a method of fastening together a plurality of layers of intermediate fabric material located in a stack, said method comprising making a passage through the stack, drawing a loop of prepared material through the passage to extend from both faces of the stack, cutting the loop at a preselected distance from one face of the stack to form two independent pieces of prepared material, and folding back the end portions of each piece onto the opposite faces of the stack to extend away from the other piece.
The stack of fastened layers of intermediate fabric material may then be compressed and heated to cure the resin.
In one embodiment of the invention a moveable flat, narrow blade having a longitudinal slot adjacent its forward cutting edge may constitute both the first and second means of the invention. In operation, the blade is advanced to make a passage through the stack. A loop of prepared material is then threaded through the longitudinal slot in the blade so that the blade is located at the mid-point of the loop, and the blade is withdrawn through the stack so that the loop is located in the passage with the mid portion and end portions of the loop extending from opposite faces of the stack. The third means may comprise a static blade to cut the loop when the mid-point of the loop has been positioned at a pre-selected distance from one face of the stack so as to form two independent pieces of prepared material.The length of the material forming the loop, and the position of the static blade are arranged so that the two pieces each project an equal distance from opposite faces of the stack.
An embodiment of the invention will now be described by way of example with reference to the accompanying illustrative drawings in which: Figures 1 to 7 are diagrammatic illustrations of seven stages in the fastening together of layers of intermediate fabric material previously referred to herein; Figures 8a and 8b are a top plan view and side view respectively of a tow of prepared material for fastening together the layers of intermediate fabric material; and Figures 9 and 10 are illustrations of a modified fastening technique.
Referring to Figures 1 to 7, a stack 2 of intermediate fabric material is supplied on a release film (not shown) which is removed before commencement of the fastening operation. The stack has been compacted or debulked under vacuum at room temperature. This compaction or debulking gives to the stack a degree of structural rigidity which aids assembly of the proposed composite material. The stack consists of a plurality of layers of the material placed together face to face. Each layer of intermediate fabric material is formed by embedding high strength fibres having a high modulus of elasticity in a homogeneous matrix which may be an epoxy, bismalemide or a polyimide resin. The fibres may be uni-directional, woven or in the form of a fibrous mat, and the fibres may be made of materials such as carbon, aramid or boron.
Each intermediate fabric material layer is supplied with the resin matrix slightly cured to ensure that the fabric layer is tacky and flexible, and at this stage the fibres are not in a fixed position in the matrix. The stack 2 is rectangular in shape, and is located in a horizontal position beneath a moveable knife blade 4 having a forward cutting edge 6. The blade has its minor dimension in the plane of the drawings, and its major dimension in the plane perpendicular to that of the drawings. The blade 4 is also flat, by which is meant that it lies completely in a plane perpendicular to the plane of the drawings. An elongate longitudinal slot 8 is located in the blade 4 adjacent to the blade cutting edge 6.
A second flat, narrow blade 10, similar in form to the first blade 4, is located in sliding contact with the first blade 4. This blade 10 is static, and its forward cutting edge 12 is located a pre-selected distance "h" above the upper surface 13 of the stack 2.
In operation, the blade 4 is advanced from its rest position illustrated in Figure 1 to cut through the stack 2 thereby forming a slit-shaped passage 14 through the stack 2. The blade 4 is advanced until the slot 8 is clear of the lower face 16 of the stack 2. A pre-cut, pre-selected length of a tow 18 of a prepared material is threaded through the slot 8 so as to extend equal distances from each side of the blade 4. Referring to Figures 8a and 8b, it will be seen that the tow 18 is of substantially rectangular cross-section. This tow 18 is made from a plurality of layers of woven and/or undirectional material which may be in a pre-impregnated (prepreg) or a dry (without resin) condition. Each layer may be made of thermo-setting and/or thermo-plastic material, including a reinforcement made of Kevlar, carbon or boron. The term prepreg refers to a reinforcement impregnated with a B-staged resin system.
The term B-staged refers to a resin which has undergone limited curing in order to increase its viscosity and tack so as to improve the handling quality of prepreg fabrics. This is the condition in which thermoset prepregs, whether woven or undirectional, are supplied by the processors and is in no way unique to this particular invention. The layers of tow material (stack) are in a debulked condition which refers to a stack of material consolidated under vacuum at room temperature only.
The blade 4 is then withdrawn as shown in Figures 4 and 5, and when the lower edge of the slot 8 is withdrawn to a distance "h" above the upper face 13 of the stack 2, the cutting edge 12 of the static blade 10 cuts the loop of tow 18 to form two independent pieces of tow 20 and 22 as illustrated in Figure 5. The position of the static blade 10, and the length of the tow pieces 20 and 22 are arranged so that the pieces 20 and 22 are of equal length to one another, and each extend equal distances from the upper and lower faces 13 and 16 of the stack 2.
Referring to Figure 6, the tow pieces 20 and 22 are each folded back onto the upper and lower faces 13 and 16 of the stack 2 so that the end portions of each piece 20 and 22 extend away from one another.
The above-mentioned operation is repeated so as to locate a plurality of fastening tows 18 in the stack 2 at required spaced locations from one another, and the stack 2, and the located tow fasteners are then cured.
Referring to Figure 9, if desired, additional layers of intermediate fabric material may be placed over the folded back tow pieces 20 and 22. These additional layers may be dimensioned to cover only the tow pieces 20 and 22, or the entire upper and lower faces 13 and 16 of the stack 2.
Referring to Figure 10, the stack and the tow fasteners are then cured to encapsulate the tow fasteners.
One suitable apparatus and process for curing the stack 2 and tow fasteners is described in our co-pending patent application publication No. GB2238977A.
In a modified version of this embodiment, the single stack 2 can be replaced by two stacks of intermediate fabric material which are placed in over lapping relationship as disclosed in our co-pending patent application publication No. GB2238977A.
The described and illustrated embodiment of this invention possesses the following advantageous features: (a) Improved impact resistance, tensile, peel and shear strength together with an increased resilience to crack propagation.
(b) The structural elements of the tows can be positioned so as to align more accurately with the load applied to the fastened material then is the case with previously known mechanical fasteners.
(c) It can overcome the following principal problems associated with known mechanical joints: (1) An increase in the thickness of the stack is less than the increase caused by known mechanical fasteners.
This is because the cutting blade makes a clean cut through the material of the stack, and any increase in stack thickness is at least partially removed during the subsequent curing process.
(2) Typical problems associated with drilling, jigging, counter sinking and riveting used with the technique of mechanical fastenings are avoided.
(3) The joints are self sealing, and in consequence are ideal for use in a hostile environment. One example of such use is for containing fuel in the wing of an aircraft which is used in all weather conditions.
(4) The fasteners are lighter than mechanical fasteners.
(5) The completed joints are aerodynamically smooth on the outer surfaces of the stack, and consequently it is not necessary to carry out any filling, feathering, smoothing or counter-sinking operations.
(d) The joints can be used to provide local reinforcement for the stack, for example at the end of the stack to: (1) Act as anti-peel fasteners to prevent the intermediate fabric layers from peeling away.
(2) Secure accurately in position the intermediate fabric layers of the stack prior to and during the curing operation.
(e) The fastening operation is more labour efficient than the operation with mechanical fasteners because it can be completed in a single automated operation.
(f) There is a higher safety factor because the fasteners are non-metallic. For example, if the fasteners are used in fuel cell environment the risk of arcing is avoided.
(g) The fasteners can be located in regions where extra fastening is required, and where fasteners would not normally be used, such as for example with blades and stiffeners webs.
(h) The tow fasteners may be employed to increase the structural strength of advanced composite materials, i.e. to prevent delamination of the plies.
(i) Galvanic corrosion problems associated with metallic fasteners do not arise with the fasteners of this invention.
(j) High strength or high modulus materials may be selected for the tows in order to accommodate the loading requirements of the fastened material.

Claims (13)

1. Apparatus for fastening together a plurality of layers of intermediate fabric material located in stack, said apparatus comprising first means to make a passage through the stack, second means to draw a loop of prepared material through the passage to extend from both faces of the stack, third means to cut the loop at a preselected distance from one face of the stack to form two independent pieces of prepared material, and means to fold back the end portions of each piece onto the opposite faces of the stack to extend away from the other piece.
2. Apparatus as claimed in claim 1, wherein said first means is a first knife blade.
3. Apparatus as claimed in claim 2 in which said second means is said first knife blade.
4. Apparatus as claimed in claim 3 wherein said first knife blade has an aperture therethrough to receive said loop.
5. Apparatus as claimed in any preceding claim wherein said third means is a second knife blade having its cutting edge located at said preselected distance from said one face of the stack.
6. Apparatus as claimed in claim 5 wherein said blades are in sliding contact with one another.
7. A method of fastening together a plurality of layers of intermediate fabric material located in a stack, said method comprising making a passage through the stack, drawing a loop of prepared material through the passage to extend from both faces of the stack, cutting the loop at a preselected distance from one face of the stack to form two independent pieces of prepared material, and folding back the end portions of each piece onto the opposite faces of the stack to extend away from the other piece.
8. A method as claimed in claim 7 wherein the length of the loop and the said preselected distance are arranged so that the two independent pieces each project an equal distance from opposite faces of the stack.
9. A method as claimed in claim 7 or claim 8, further including placing at least one additional layer of intermediate fabric material over the folded back end portions on each face of the stack.
10. A method as claimed in any one of claims 7 to 9 further including repeating said operations at required spaced locations from one another.
11. A method as claimed in any one of claims 7 to 10 further including curing the fastened layers.
12. Apparatus as claimed in claim 1 substantially as herein described and shown the in the accompanying drawings.
13. A method as claimed in claim 7 substantially as herein described with reference to the accompanying drawings.
GB9113766A 1990-07-03 1991-06-26 Manufacture of a composite material Expired - Fee Related GB2245862B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB909014770A GB9014770D0 (en) 1990-07-03 1990-07-03 Manufacture of a composite material

Publications (3)

Publication Number Publication Date
GB9113766D0 GB9113766D0 (en) 1991-08-14
GB2245862A true GB2245862A (en) 1992-01-15
GB2245862B GB2245862B (en) 1994-01-26

Family

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Family Applications (2)

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GB909014770A Pending GB9014770D0 (en) 1990-07-03 1990-07-03 Manufacture of a composite material
GB9113766A Expired - Fee Related GB2245862B (en) 1990-07-03 1991-06-26 Manufacture of a composite material

Family Applications Before (1)

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GB909014770A Pending GB9014770D0 (en) 1990-07-03 1990-07-03 Manufacture of a composite material

Country Status (9)

Country Link
EP (1) EP0648159A1 (en)
JP (1) JPH05508362A (en)
AU (1) AU8006791A (en)
BR (1) BR9106615A (en)
CA (1) CA2085253A1 (en)
FI (1) FI925805A (en)
GB (2) GB9014770D0 (en)
IL (1) IL98585A0 (en)
WO (1) WO1992000845A1 (en)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2003011577A1 (en) * 2001-08-02 2003-02-13 Ebert Composites Corporation Method of clinching top and bottom ends of z-axis fibers into the respective top and bottom surfaces of a composite laminate
US7105071B2 (en) * 2001-04-06 2006-09-12 Ebert Composites Corporation Method of inserting z-axis reinforcing fibers into a composite laminate
WO2006125561A1 (en) * 2005-05-27 2006-11-30 Airbus Deutschland Gmbh Reinforcement of cellular materials
WO2007012353A1 (en) * 2005-07-27 2007-02-01 Evonik Röhm Gmbh Method for producing a core material reinforcement for sandwich structures and said sandwich structures
US7217453B2 (en) 2001-04-06 2007-05-15 Ebert Compoistes Corporation Composite laminate structure
DE102007055684A1 (en) * 2007-11-21 2009-06-10 Airbus Deutschland Gmbh Device for producing a reinforced foam material
EP2228199A1 (en) * 2009-02-24 2010-09-15 Bayerische Motoren Werke Aktiengesellschaft Method for producing a fibre reinforced plastic component

Families Citing this family (9)

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Publication number Priority date Publication date Assignee Title
DE19628388A1 (en) * 1996-07-13 1998-01-15 Inst Polymerforschung Dresden Multi-axial, multi-layer, fiber preform with adequate force flow with at least partial Z-axis reinforcement and a process for its production
US7785693B2 (en) 2001-04-06 2010-08-31 Ebert Composites Corporation Composite laminate structure
US7731046B2 (en) 2001-04-06 2010-06-08 Ebert Composites Corporation Composite sandwich panel and method of making same
US6645333B2 (en) * 2001-04-06 2003-11-11 Ebert Composites Corporation Method of inserting z-axis reinforcing fibers into a composite laminate
DE102007033869A1 (en) * 2007-07-20 2009-01-29 Eads Deutschland Gmbh Apparatus and method for providing cut-to-length rovings and machine for reinforcing a textile semifinished product
WO2016180420A1 (en) * 2015-05-12 2016-11-17 Vestas Wind Systems A/S Improvements relating to the production of wind turbine components
EP3498448B1 (en) * 2016-08-09 2021-11-24 Nissan Motor Co., Ltd. Molding method for composite material and intermediate member for composite material
EP3470214B1 (en) * 2017-10-10 2021-06-16 Groz-Beckert KG Device and method for the preparation of a carrier having multiple fibre bundles
FR3098444B1 (en) * 2019-07-08 2021-10-01 Soc Internationale Pour Le Commerce Et Lindustrie A method of reinforcing a panel and a method of manufacturing a composite panel implementing such a method

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Publication number Priority date Publication date Assignee Title
GB600177A (en) * 1945-09-29 1948-04-01 Francis Colin Curtis A tufting needle embodying a cutter, wool-feeding action, and length of stitch adjuster
US3142276A (en) * 1962-06-25 1964-07-28 Roger H Mullen Inc Device for forming cut pile fabrics and the like
AU3984772A (en) * 1971-05-05 1973-09-13 Rheem Australia Limited Reinforced plastic mechanical fasteners and method and means for forming them
DE3246803A1 (en) * 1982-12-17 1984-06-20 Messerschmitt-Bölkow-Blohm GmbH, 8000 München METHOD FOR PRODUCING COMPONENTS FROM LAYERS OF FIBER REINFORCED PLASTIC
FR2565262B1 (en) * 1984-05-29 1986-09-26 Europ Propulsion METHOD FOR MANUFACTURING A MULTI-DIRECTIONAL FIBROUS TEXTURE AND DEVICE FOR CARRYING OUT THIS METHOD

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7217453B2 (en) 2001-04-06 2007-05-15 Ebert Compoistes Corporation Composite laminate structure
US7105071B2 (en) * 2001-04-06 2006-09-12 Ebert Composites Corporation Method of inserting z-axis reinforcing fibers into a composite laminate
WO2003011577A1 (en) * 2001-08-02 2003-02-13 Ebert Composites Corporation Method of clinching top and bottom ends of z-axis fibers into the respective top and bottom surfaces of a composite laminate
EP1642702A3 (en) * 2001-08-02 2010-06-09 Ebert Composites Corporation Method of clinching top and bottom ends of Z-axis fibers into the respective top and bottom surfaces of a composite laminate
CN101184606B (en) * 2005-05-27 2012-07-04 空中客车德国运营有限责任公司 Reinforcement of cellular materials
WO2006125561A1 (en) * 2005-05-27 2006-11-30 Airbus Deutschland Gmbh Reinforcement of cellular materials
US9289927B2 (en) 2005-05-27 2016-03-22 Airbus Operations Gmbh Reinforcement of cellular materials
WO2007012353A1 (en) * 2005-07-27 2007-02-01 Evonik Röhm Gmbh Method for producing a core material reinforcement for sandwich structures and said sandwich structures
CN101198459B (en) * 2005-07-27 2012-02-22 赢创罗姆有限责任公司 Method for producing a core material for sandwich structures reinforcement
DE102007055684A1 (en) * 2007-11-21 2009-06-10 Airbus Deutschland Gmbh Device for producing a reinforced foam material
RU2479427C2 (en) * 2007-11-21 2013-04-20 Эвоник Рем ГмбХ Device for making reinforced foam material
US8915201B2 (en) 2007-11-21 2014-12-23 Airbus Operations Gmbh Device and method for producing a reinforced foam material
EP2228199A1 (en) * 2009-02-24 2010-09-15 Bayerische Motoren Werke Aktiengesellschaft Method for producing a fibre reinforced plastic component

Also Published As

Publication number Publication date
WO1992000845A1 (en) 1992-01-23
GB9014770D0 (en) 1990-08-22
FI925805A0 (en) 1992-12-21
GB9113766D0 (en) 1991-08-14
EP0648159A1 (en) 1995-04-19
CA2085253A1 (en) 1992-01-04
FI925805A (en) 1992-12-21
JPH05508362A (en) 1993-11-25
BR9106615A (en) 1993-06-01
IL98585A0 (en) 1992-07-15
GB2245862B (en) 1994-01-26
AU8006791A (en) 1992-02-04

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Effective date: 20030626