GB2503864A - Composite material for automated tape lay-up with fibre reinforced backing paper - Google Patents

Composite material for automated tape lay-up with fibre reinforced backing paper Download PDF

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Publication number
GB2503864A
GB2503864A GB1204084.6A GB201204084A GB2503864A GB 2503864 A GB2503864 A GB 2503864A GB 201204084 A GB201204084 A GB 201204084A GB 2503864 A GB2503864 A GB 2503864A
Authority
GB
United Kingdom
Prior art keywords
composite material
backing paper
sheet
structural layer
fibres
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
GB1204084.6A
Other versions
GB201204084D0 (en
GB2503864B (en
Inventor
John Ellis
Emilie Fisset
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.)
Hexcel Composites Ltd
Original Assignee
Hexcel Composites Ltd
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 Hexcel Composites Ltd filed Critical Hexcel Composites Ltd
Priority to GB201204084A priority Critical patent/GB2503864B/en
Publication of GB201204084D0 publication Critical patent/GB201204084D0/en
Priority to CN201380012889.9A priority patent/CN104428132B/en
Priority to PCT/EP2013/000701 priority patent/WO2013131657A1/en
Priority to RU2014140605A priority patent/RU2622122C2/en
Priority to JP2014560279A priority patent/JP6434809B2/en
Priority to BR112014018435A priority patent/BR112014018435A2/en
Priority to EP13716192.3A priority patent/EP2822758B1/en
Priority to ES13716192T priority patent/ES2706750T3/en
Priority to US14/381,565 priority patent/US20150111454A1/en
Publication of GB2503864A publication Critical patent/GB2503864A/en
Application granted granted Critical
Publication of GB2503864B publication Critical patent/GB2503864B/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
    • B29C70/386—Automated tape laying [ATL]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/28—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer impregnated with or embedded in a plastic substance
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/18—Manufacture of films or sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/0076—Curing, vulcanising, cross-linking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/02—2 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/04—4 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/103—Metal fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/12—Conjugate fibres, e.g. core/sheath or side-by-side
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/07—Parts immersed or impregnated in a matrix
    • B32B2305/076—Prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/08—Reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/748—Releasability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/12—Paper, e.g. cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00—Polyalkenes
    • B32B2323/04—Polyethylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2363/00—Epoxy resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2398/00—Unspecified macromolecular compounds
    • B32B2398/10—Thermosetting resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2405/00—Adhesive articles, e.g. adhesive tapes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/06—Interconnection of layers permitting easy separation
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3472—Woven fabric including an additional woven fabric layer
    • Y10T442/3602—Three or more distinct layers
    • Y10T442/3634—At least one layer comprises paper
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3927—Including a paper or wood pulp layer
    • Y10T442/3943—Plural paper or wood pulp layers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/643—Including parallel strand or fiber material within the nonwoven fabric

Abstract

The sheet-like composite material comprises a structural layer, curable thermosetting resin and fibre reinforced backing paper on an external surface. The preferred structural layer comprises expanded metal (for example, copper) foil or unidirectional (for example, glass, carbon, metallised or aramid) fibres. The preferred backing sheet contains woven fibres. The composite material (40, figure 5) is fed automatically from a roll (42, figure 5) to the substrate (50, figure 5), pressure is applied (47, figure 5) and then the backing paper (52, figure 5) is removed. Preferably, the laying apparatus includes a cutter (44, figure 5) which cuts through the structural layer and partially into the backing paper. Heat is preferably used to cure the resin. The application discloses a prepreg 32 (48, figure 5) comprising parallel fibres impregnated with epoxy resin, backing paper 34 reinforced with cotton yarns 37, super-calendared backing paper 38 having low compressibility and another backing paper 39.

Description

Composite material for automated lay-up
Technical field
S The present invention relates to composite materials suitable for application in an automatic tape lay-up apparatus.
Background
Composite materials have well-documented advantages over traditional construction matenals, particularly in providing excellent mechanical properties at very low material densities. As a result, the use of such materials is becoming increasingly widespread and their fields of application range from "industrial" and "sports and leisure" to high performance aerospace components.
Such composite materials comprise a structural element, such as a fibre layer, impregnated with a composition comprising a resin, such as a thermosetting or thermoplastic resin.
Prepregs, comprising a fibre arrangement impregnated with curable thermosetting resin are now widely used in the preparation of such composite materials. These allow careful control of the fibre and resin quantities and provide flexibility in the shapes they can adopt.
Typically, a number of plies of such prepregs are "laid-up" as desired and the resulting laminate is cured, typically by exposure to elevated temperature, to produce a cured composite laminate.
Historically, such prepregs or similar materials, were laid-up by the hand of a skilled operator. 1-lowever, modern methods of lay-up involve a significant contribution from an automated lay-up method, such as the so-called automatic tape lay-up apparatus, or NFL.
I
A typical ATL machine requires a roll of material which is loaded onto a mandrel and fed via a system of rollers to the ATL head. Typica'ly the route includes a cutting stage and an optional heating stage. The cutting stage ensures that the dimensions of the material are exactly as required, as any deviation can result in an unacceptable S finish. At the head of the ATL there is normally two application methods, the "shoe" of the ATL or the "compaction roller" of the ATL head. Whichever method is employed the material is brought down into contact with the surface and pressure is applied onto an uppermost backing sheet of release paper. The tacky loweimost surface adheres under pressure and the backing sheet is removed automatically.
During this process the material is exposed to very high tensions of between 50 and 300 N over a typical product width of 300 mm.
In order for a prepreg or similar material to be laid down by an automated machine it needs to be prepared to an exacting specification. For convenience, such material is typically provided on a roll, ready to feed the material to the ATL apparatus.
As the composite material is generally tacky, it is necessary for the composite material to have a rdeasable backing sheet to prevent adhesion of adjacent layers on the roll. Such backing sheets are typically made of paper.
The backing sheet also allows the ATL apparatus to apply force to the composite material, to induce adhesion during lay-up. without the head of the apparatus adhering to the composite material.
The backing sheet is therefore typically removed only after the ATL apparatus had laid the composite material down.
In a refinement of this method, incisions can be made in the composite material by blades fornñng part of the ATL apparatus. Such blades are very precise and can cut through the backing paper and penetrate a short distance (i.e. a fraction of a millimetre) into the composite material. This has the effect that shapes and contours can be introduced, giving flexibility to the range of lay-up designs the ATL apparatus can cope with.
In a typical method, when an incision is made through the backing sheet, the "shoe" of the ATL apparatus is lifted upwards at the "compaction roller" moves into place to ensure that the portions of the composite material to one side of the incisions are not S laid down and are instead carried off remaining attached to their backing sheet as waste.
Once the portion containing the incisions has been laid down, the ATL lifts the compaction roller and lowers the shoe simultaneously, to resume normal operation of laying down the whole composite material.
However, such transitions often involve spikes of tensional force on the composite material. Such forces are also magnified during periods where incisions are made through the backing paper. Problematically, it is precisely when the composite material has been cut and weakened when the tensional spikes tend to accumulate.
e.g. as the shoe and compaction rollers change over.
The resuli of this is a tendency for the backing sheet to tear and fail which requires the automated process to be shut down while the failed material is removed. This increases cost and reduces the efficiency of the process.
Thus, any way in which this proNem cou'd be addressed wou'd be highly desirable.
Summary of Invention
In a first aspect, the invention relates to a sheet-like composite material comprising a structural layer and curable thermosetting resin, and comprising a fibre-reinforced backing paper on one of its external faces.
It has been found that by including a fibre reinforcement in the backing paper then the burst strength and resistance to tear is greatly improved, thus improving the efficiency of the ATL process, when such a material is laid down.
Although this approach solves a significant problem, it has been found that the introduction of reinforcing fibres into the backing paper can result in the transfer of a pattern of the fibres into the resin of the composite material. For some applications this is undesirable, and a pattern-free material is required.
S
It has been further found that such pattern transfer can be significantly reduced or eliminated entirely, by the introduction of a second backing paper between the fibre-reinforced backing paper and the rest of the composite material. The second backing paper does not contain a fibre reinforcement, and protects the rest of the composite JO material from the fibre reinforcement pressing into the resin.
It has been found that pattern transfer can be further reduced or eliminated if the second backing paper is relatively incompressible.
A suitable measure of compressibility is the ratio of the thickness of the paper to its material density, called the compressibility ratio. It has been found that a compressibility of less than 0.001 kg1m2 is particularly effective at preventing pattern transfer.
However, introducing a second backing paper also introduces the risk that other problems may be introduced such as wrinkles and curl. Such problems occur because of relative expansions, particulady during storage and in a valying humidity environment. Relative expansion between the two layers can result in a curling action or wrinkling of the papers, which are both highly undesirable.
Thus it may be preferaNe to include a third backing paper to prevent such curhng or wrinkling. Preferably third backing paper will be of the same composition as the second backing paper. It is also preferably that the third backing paper be located on the exterior of the composite material. This has the effect that the reinforced backing paper is effectively sandwiched between the second and third backing papers.
The structural layer of the composite material can be any solid material capable of being impregnated with the thermosetting resin.
The structural layer could include a porous metal sheet such as an expanded foil, or it could include a structural layer of fibres.
Suitable metals for use as an expanded foil include any electrically conductive metal, such as bronze, aluminium, copper, silver, gold, nickel, zinc and tungsten. Copper is preferred due to its excellent electncal conductivity. Any fibres in the structural fibre layers may be unidirectional, fabric form, random or multi-axial. In one prefelTed embodiment, the fibres are unidirectional. Following lay-up their orientation will typically valy throughout the composite material, e.g. prepreg or semipreg, for example by alTanging for the fibres in neighbouring layers to be orthogonal to each other in a so-called 0/90 arrangement, signifying the angles between neighbouring fibre layers. Other alTangements such as 01+451-45190 are of course possible among many other arrangements.
The structural fibres may comprise cracked (i.e. stretch-broken), selectively discontinuous or continuous fibres.
The structural fibres may be made from a wide variety of materials such as glass, carbon, graphite, metallised polymers aramid and mixtures thereof. The composite material typically comprises from 30 to 70 wt % structural fibres.
As discussed above, the composite materials of the present invention comprise a curable thermosetting resin. The curable resin may be present as a discrete layer or may be fully or partially impregnated into a layer of structural fibres. The composite material typically comprises from 15 to 50 wt % curable resin.
The curable resin may be selected from those conventionally known in the art, such as resins of phenol-formaldehyde, urea-formaldehyde, 1,3,5-triazine-2,4,6-triarnine (nielamine), bismaleimide, epoxy resins, vinyl ester resins, benzoxazine resins, polyesters, unsaturated polyesters, cyanate ester resins, or mixtures thereof.
Particularly preferred are epoxy resins, for example monofunctional, difunctional or trifuncti onal or tetrafunctional epoxy resins.
The epoxy resin may comprise monofunctional, difunctional. trifunctional and/or S tetrafunctional epoxy resins.
Suitable difunctional epoxy resins, by way of example, include those based on; diglycidyl ether of Bisphenol F, Bisphenol A (optionally brominated), phenol and cresol epoxy novolacs, glycidyl ethers of phenol-aldelyde adducts, glycidyl ethers of aliphatic diols, diglycidyl ether, diethylene glycol diglycidyl ether, aromatic epoxy resins, aliphatic polyglycidyl ethers, epoxidised olefins, brominated resins, aromatic glycidyl amines, heterocyclic glycidyl imidines and amides, glycidyl ethers, fluorinated epoxy resins, or any combination thereof.
Difunctional epoxy resins may be preferably selected from diglycidyl ether of Bisphenol F, diglycidyl ether of Bisphenol A, diglycidyl dihydroxy naphthalene, or any combination thereof.
Suitable tnfunctional epoxy resins, by way of example, may include those based upon phenol and cresol epoxy novolacs, glycidyl ethers of phenol-aldehyde adducts, aromatic epoxy resins, aliphatic triglycidyl ethers, dialiphatic triglycidyl ethers, aliphatic polyglycidyl ethers, epoxidised &efins, brominated resins, triglycidyl aminophenyls, aromatic glycidyl amines, heterocyclic glycidyl imidines and amides, glycidyl ethers, fluorinated epoxy resins, or any combination thereof.
Suitable tetrafunctional epoxy resins include N,N,N,N -tetraglycidyLm-xylenedianilne (available commercially from Mitsubishi Gas Chemical Company under the name Tetrad-X, and as Erisys GA-240 from CVC Chemicals), and N,N,N,N -tetraglycidylmethylenedianiline (e.g. MY72 I from Huntsman Advanced Materials).
The thermosetting resin may also comprise one or more curing agent. Suitable curing agents include anhydrides, particularly poly carboxylic anhydrides; arnines.
particularly aromatic amines e.g. 1,3-diaminobenzene, 4,4' -diaminodiphenylmethane, and particularly the sulphones, e.g. 4,4'-diaminodiphenyl sulphone (4,4' DDS), and 3,3' -diaminodiphenyl sulphone (3,3' DDS), and the phenol-formaldehyde resins.
PrefelTed curing agents are the amino sulphoncs, particularly 4,4' DDS and 3,3' DDS.
Further examples of the type and design of the resin and fibres can be found in The fibre reinforcement in the backing sheet can take a wide variety of forms, for example they can be woven, knitted, random or spunlaced. Preferably the fibres are woven as this provides good strength without excessive protrusions being introduced to the backing paper.
The composite material of the present invention may include additional materials as desired, such as peiformance enhancers or modifying agents. Such materials may be selected from flexibilisers, toughening agents/particles, additional accelerators, core shell rubbers, flame retardants, melting agents, pigments/dyes, plasticisers, UV absorbers, anti-fungal components, fillers, viscosity modifiers/flow control agents, stabilisers and inhibitors.
However, preferably the composite material has a thickness of from 0.5 to 5.0mm.
more preferably 0.5 to 4.0mm, most preferably from 1.0 to 3.0mm, so that it can be conveniently handled by the ATL apparatus.
As the composite material is intended to be provided in the form of a roll, preferably it is sufficienfly flexibk so as to be able to form a roll with a diameter of less than 20cm, preferably less than i0cm.
The composite material according to the invenfion can be prepared by any known method in the art. Such methods typically inv&ve bringing together the structural layer and thermosetting resin and impregnating the structural layer with the resin.
Once prepared the composite material is typically rolled up ready for deposition by an ATL apparatus.
Thus, in a second aspect, the invention relates to a process of aying down onto a substrate, a composite material as described herein, which is fed automatically from a roll to the substrate such that the backing paper is uppermost. and the composite material adhering to the substrate by application of pressure onto the backing paper by a tool, followed by removal of the backing paper, leaving the composite material in place on the substrate without its backing paper.
In a preferred embodiment the process involves cutting through the structural layer and partially into the backing paper layer prior to laying down the composite material.
In this case it is important that the cutters do not cut so deep into the backing paper that the reinforcing yarns are aLo cut, otherwise the tear properties of the backing paper will be greatly reduced.
This process is typically followed by the subsequent placement of additional composite material, such as prepregs. to generate a stack of composite material.
Once the composite material has been laid down, the arrangement is cured by exposure to elevated temperature, and optionally elevated pressure, to produce a cured composite material.
The invention will now be illustrated, by way of example only, and with reference to the following figures, in which: Figure 1 is a schematic representation of reinforced backing paper for use in the present invention.
Figure 2 is a schematic representation of another reinforced backing paper for use in the present invention.
Figure 3 is a sectional view through a composite material according to the present invention.
Figure 4 is a sectional view through another composite material according to the invention.
S Figure 5 is a side view of an ATL apparatus for use in the process according to the present invention.
Figure 6 is schematic representation of a backing paper according to the present invention which has failed by tearing following cutting during lay-up.
Figure 7 is a sectional view of the composite material dunng cutting prior to the tearing shown in figure 6.
Figure 8 is a sectional view of composite material during cutting which did not result in the tearing as shown in figure 6.
Turning to the figures, Figure 1 shows a sheet 10 of backing paper reinforced with woven cotton yarns 1 2. The cotton yarns are woven in a regubr weave and the warp and weft are aligned in the 0° and 90° directions respectively.
Figure 2 shows another sheet 14 of backing paper reinforced with woven yarns which have a different pattern.
Figure 3 shows a composite material 20 according to the present invendon. The composite material 20 comprises a layer of prepreg 22 comprising a structural layer of unidirectional fibres (not shown) impregnated with a thermally curable epoxy resin.
Attached to this is a two-layer backing paper comprising a backing paper 24 reinforced with woven cotton yarns 26 and a second backing paper 28 free of woven yarns and being super-calendared so that it has a very low compressibility.
Figure 4 shows another composite material 30 according to the present invention. The composite material 30 comprises a layer of prepreg 32 compnsing a structural layer of unidirectional fibres (not shown) impregnated with a thermally curable epoxy resin.
Attached to this is a three-layer backing paper comprising a backing paper 34 reinforced with woven cotton yarns 37, a second backing paper 38 free of woven yarns and being super-calendared so that it has a very low compressibility, and a third backing paper 39.
S
Figure 5 shows a side view of an ATL apparatus laying down a composite material according to the present invention. The composite material 40 is fed from a roll of matenal with a central core 42, past a cutting station 44 to the ATL head 46.
Following lay-up the prepreg 48 adheres preferentially to the substrate 50 and the backing paper 52 is removed onto talce-up roller 54.
In normal operation no cutting of the prepreg occurs and lay-up is carried out by the head 46 pressing down onto the composite material.
When cuts are desired then head 46 lifts up and compaction roller 47 moves down to come into contact with the already laid-down prepreg 48. This has the effect that the part of the prepreg cut away is not laid down but remains attached to the backing paper and is taken up by take-up roller 54. The change-over of head and roller introduces tension peaks in the composite material, which can tngger tearing of the backing paper.
Once cutting ceases the compaction roller 47 is lifted away from contact with the prepreg 48 and head 46 moves down once again to continue lay-up by applying pressure onto the backing paper 52.
The cutting station 44 comprises two ulirasonic cutting devices 56, 58 which can be programmed to cut through the prepreg 48 and partially into the backing paper 52.
The cutters 56, 58 are programmed to penetrate 10% of the thiclcness of the backing paper, so as to ensure that the prepreg is entirely cut through without weakening the backing paper too much. Additionally, care must be taken not to cut through the reinforcing yarns, as this will remove any tear strength they would have provided.
Figure 6 shows a reinforced paper backing sheet 60 for use according to the present invention. However, as shown in figure 7, cutter 56 has been set to cut too deeply through the backing paper and has cut through the reinforcing yarns 26. This has resulted in a tear 62. resdting in the lay-up process being shut down while the material is reconfigured.
Figure 8 shows the correct setting for the cutter 58, wherein the cutter 58 does not cut through yarns 26. This backing paper does not fail when used in the ATL process, even during periods of cutting.

Claims (16)

  1. Claims 1. A sheet-like composite material comprising a structural layer and curable thermosetting resin, and comprising a fibre-reinforced backing paper on one of its external faces.
  2. 2. A sheet-like composite material according to claim 1, which comprises a second backing paper between the fibre-reinforced backing paper and the rest of the composite material.
  3. 3. A sheet-like composite material according to claim 2, wherein the second backing paper has a compressibility of less than 0.001 lcg'm2,
  4. 4. A sheet-like composite material according to any one of the preceding claims, wherein the structural layer comprises a metal expanded foil.
  5. 5. A sheet-like composite material according to any one of the preceding claims, wherein the structural layer comprises a structural layer of fibres.
  6. 6. A sheet-like composite material according to claim 5, wherein the fibres are unidirectional.
  7. 7. A sheet-like composite material according to claim 5 or claim 6, which comprises from 30 to 70 wt % structural fibres.
  8. 8. A sheet-like composite material according to any one of the preceding claims, wherein fibre reinforcement in the backing sheet are woven.
  9. 9. A sheet-like composite material according to any one of the preceding claims having a thickness of from 0.5 to 5,0mm, preferably 0.5 to 4.0mm, more preferably from 1.0 to 3.0mm.
  10. 10. A sheet-like composite material according to any one of the preceding claims which is sufficiently flexible so as to be able to form a roll with a diameter of less than 20cm, preferably less than 10cm.
  11. 11. A process of laying down a composite material according to any one of the preceding claims onto a substrate, which is fed automatically from a roll to the substrate such that the backing paper is uppermost, and the composite material adheres to the substrate by application of pressure onto the backing paper by a tool, followed by removal of the backing paper, leaving the composite material in place on the substrate without its backing paper.
  12. 12. A process according to claim Ii, which comprises the step of cutting through the structural layer and partially into the backing paper layer prior to laying down the composite material.
  13. 13. A process according to claim 12, wherein the cutting is does not cut through the reinforcing yarns in the backing paper.
  14. 14. A process according to any one of claims II to 13, which is followed by the subsequent placement of additional composite material to generate a stack of composite material.
  15. 15. A process according to any one of claims 11 to 14, which is followed by curing by exposure to elevated temperature, and optionally elevated pressure, to produce a cured composite material.
  16. 16. A cured composite material obtainable by the process according to claim 15.
GB201204084A 2012-03-08 2012-03-08 Composite material for automated lay-up Expired - Fee Related GB2503864B (en)

Priority Applications (9)

Application Number Priority Date Filing Date Title
GB201204084A GB2503864B (en) 2012-03-08 2012-03-08 Composite material for automated lay-up
EP13716192.3A EP2822758B1 (en) 2012-03-08 2013-03-08 Composite material for automated lay-up
PCT/EP2013/000701 WO2013131657A1 (en) 2012-03-08 2013-03-08 Composite material for automated lay-up
RU2014140605A RU2622122C2 (en) 2012-03-08 2013-03-08 Composite material for automated laying of layers
JP2014560279A JP6434809B2 (en) 2012-03-08 2013-03-08 Composite materials for automatic layup
BR112014018435A BR112014018435A2 (en) 2012-03-08 2013-03-08 COMPOSITE MATERIAL FOR AUTOMATIC LAMINATION
CN201380012889.9A CN104428132B (en) 2012-03-08 2013-03-08 For the composite of automatic placement
ES13716192T ES2706750T3 (en) 2012-03-08 2013-03-08 Composite material for automatic stratification
US14/381,565 US20150111454A1 (en) 2012-03-08 2013-03-08 Composite material for automated lay-up

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RU2622122C2 (en) 2017-06-13
ES2706750T3 (en) 2019-04-01
EP2822758B1 (en) 2018-10-17
RU2014140605A (en) 2016-04-27
US20150111454A1 (en) 2015-04-23
GB201204084D0 (en) 2012-04-18
BR112014018435A2 (en) 2017-08-22
GB2503864B (en) 2014-09-03
CN104428132B (en) 2017-06-09
CN104428132A (en) 2015-03-18
JP2015520683A (en) 2015-07-23
EP2822758A1 (en) 2015-01-14
WO2013131657A1 (en) 2013-09-12

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