JP2017159660A - 熱可塑性材料および金型の表面工学 - Google Patents
熱可塑性材料および金型の表面工学 Download PDFInfo
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- B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
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- 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
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- 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
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- B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
- B29C70/386—Automated tape laying [ATL]
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- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/56—Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
- B29C33/60—Releasing, lubricating or separating agents
- B29C33/62—Releasing, lubricating or separating agents based on polymers or oligomers
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- 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
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/56—Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
- B29C33/68—Release sheets
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- 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
- B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
- B29C37/0067—Using separating agents during or after moulding; Applying separating agents on preforms or articles, e.g. to prevent sticking to each other
- B29C37/0075—Using separating agents during or after moulding; Applying separating agents on preforms or articles, e.g. to prevent sticking to each other using release sheets
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- 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
- B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
- B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
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- 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
- B32B38/0008—Electrical discharge treatment, e.g. corona, plasma treatment; wave energy or particle radiation
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- 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
- B32B7/03—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 with respect to the orientation of features
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2071/00—Use of polyethers, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2079/00—Use of polymers having nitrogen, with or without oxygen or carbon only, in the main chain, not provided for in groups B29K2061/00 - B29K2077/00, as moulding material
- B29K2079/08—PI, i.e. polyimides or derivatives thereof
- B29K2079/085—Thermoplastic polyimides, e.g. polyesterimides, PEI, i.e. polyetherimides, or polyamideimides; Derivatives thereof
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2101/00—Use of unspecified macromolecular compounds as moulding material
- B29K2101/12—Thermoplastic materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/0872—Prepregs
- B29K2105/0881—Prepregs unidirectional
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- 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
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/26—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer which influences the bonding during the lamination process, e.g. release layers or pressure equalising layers
- B32B2037/268—Release layers
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- 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
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31855—Of addition polymer from unsaturated monomers
- Y10T428/31935—Ester, halide or nitrile of addition polymer
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- Moulding By Coating Moulds (AREA)
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- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
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Abstract
Description
する前に提案したソリューションは、個別の両面接着テープを最初の層として、熱可塑性複合材テープの第1の層が次に接着される金型表面に適用することを含んでいた。同様に、接着剤を金型の表面に溶射することも提案された。提案された双方のソリューションは、熱可塑性複合材テープの最初の層を複雑形状の金型表面に連続して適用することを許容するとはいえ、それらは、敷設プロセスが完了したときに、構成要素は金型表面に効果的に結合しているために、次いで、形成された複合材構成要素を金型からどのようにして除去するかというそれ自身の問題を導入する。結果として、未だ現在のところ、熱可塑性複合材料によって提供される優れた物理的特性にもかかわらず、熱硬化性複合材料を用いることが望ましい。
熱硬化性材料を用いるとき、敷設ヘッドでTgを超えるポリマーは、この力を提供する。マトリックス樹脂が高性能の熱意可塑性物質であるとき、温度Tgは、室温よりも実質的にしかもかなり高い。金型を加熱すること、真空源を提供すること、より低い温度のフィルムを使用すること、または規制力を提供するために溶媒和熱可塑性ポリマーを用いることはすべて、現在用いられている方法である。これらの方法の各々が、経費、金型の複雑さ、部分の寸法に対する変更という点で制限を有するまたは実施のための厄介な危険な溶媒を必要とする。
を適切に固結させるために一般的に必要とされた時間の長さのため、最小時間で最良の固結を達成することが望まれ得る。その上、より低い固結の圧力もしくは温度ならびにより短い固結時間は、結果として、成形および他の製造上の恩典によって、一個当たりの低下したエネルギー消費によりより安価の生産プロセスとなる。
れる複合材部分に転移する。火、腐食、または摩耗に対する保護などのこのような望ましい特徴は、表面層ポリマーコーティングに対する多機能性添加物のせいであり得る。
、同一または異なる組成物を有し得る。
する。
るPAEKおよび、これに限られないが、ジフェニルスルフォン等とのブレンドを含む。熱可塑性表面層ポリマーがPEKKを含むとき、PEKKのT:I比は、表面層ポリマーの遅速結晶加速度を維持するために、約0:100〜約70:30の範囲である。特定の実施形態では、熱可塑性表面層ポリマーのT:I比は、約0:100〜約70:30のT:I比を有するCYPEK(登録商標)DSを用いる。本発明で用いることが可能な適切なPEKKポリマーは、これに限られないが、CYPEK(登録商標)DS−EまたはCYPEK(登録商標)DS−MおよびCYPEK(登録商標)HTなどの、Cytec Industries Inc.Woodland Park NJから市販されているものを含む。
コーティング(50)に損傷を与えることなく離型させて除去するのが困難となりかねない表面層ポリマーコーティング(50)をもたらしかねない。
ス繊維、アラミド繊維、およびこれらの混合物などの市販の構造繊維のうちの任意のものを含む。好ましい実施形態では、繊維状構造強化繊維は、ポリアクリロニトリル(PAN)ベースの炭素繊維である。
明が係る当業者には周知であり理解されるからである。
例1―金型に適用される溶媒ベースのPEIポリマー溶射された溶液
例2―金型に手動適用された水ベースのスラリー
例3―成形型にプラズマ溶射されたPEKポリマー
例4―成形型のシボ仕上げ成形面上へプラズマ溶射されたPEKポリマー
るため、8プライの疑似等方性パネルが、APC PEKK/AS−4の単一テープ材料を用いて作製された。パネルは、720°F(382℃)のオートクレーブ温度およびN2の100psiで、羊膜プレートで処理された。
例5―プレプレグ上へのプラズマPEKポリマー溶射されたコーティング
例6
例7
Claims (11)
- 成形型内での熱可塑性繊維強化複合材料の自動化テープ敷設の方法であって、
(a)成形面を有する非多孔性成形型を提供する段階と、
(b)前記成形型の前記成形面に離型フィルムを適用する段階と、
(c)複数の熱可塑性表面層ポリマー粒子をプラズマ溶射ガンに導入する段階と、
(d)前記成形型上に熱可塑性表面層ポリマーコーティングを形成するために,プラズマ溶射ガンを用いて前記熱可塑性表面層ポリマー粒子を前記離型フィルム上にプラズマ溶射する段階と、
(e)第1の熱可塑性繊維強化複合材料の層を自動的に熱可塑性表面層ポリマーコーティングに敷設し、ここで、熱可塑性繊維強化複合材料は熱可塑性ポリマーに含浸された熱可塑性繊維を有する、段階と
(f)第1の熱可塑性繊維強化複合材料層の露出された表面上に、熱可塑性表面層ポリマー粒子をプラズマ溶射して、熱可塑性ポリマー層間層を形成する段階と、
(g)熱可塑性ポリマー層間層の上に後続の熱可塑性繊維強化複合材料の層を自動的に敷設する段階と、
(h)所望の数の熱可塑性繊維強化複合材料層と熱可塑性ポリマー層間層が適用されることにより、熱可塑性ポリマー層間層が2つの熱可塑性繊維強化複合材料層の間に存在するまで段階(f)と段階(g)を繰り返す段階、
を含む方法。 - 前記成形型の前記成形面が、シボを有する、請求項1に記載の方法。
- 前記成形型の前記成形面の前記シボが、砂吹きによって作製される、請求項2に記載の方法。
- 前記成形型の前記成形面の前記シボが、0.07μm以上のプロファイル要素の平均間隔および5.0以上の最大プロファイル高さを有する、請求項2に記載の方法。
- 熱可塑性表面層ポリマーコーティングが、PEK、PEKK、PEEK、またはこれらのブレンドを含む、請求項1に記載の方法。
- 前記熱可塑性表面層ポリマーコーティングが、1つ以上の多機能性剤をさらに含む、請求項1に記載の方法。
- 前記熱可塑性表面層ポリマーコーティングが、前記離型フィルムに離型可能に接着した不連続の複数の良好に融着した熱可塑性粒子である、請求項1に記載の方法。
- 前記熱可塑性表面層ポリマーコーティングが、前記離型フィルムに離型可能に接着した良好に融着した熱可塑性粒子である不連続の複数のビーズである、請求項1に記載の方法。
- 前記熱可塑性表面層ポリマー粒子が、プラズマ溶射前には、90〜180μmの直径D90サイズを有する、請求項1に記載の方法。
- 前記プラズマ溶射ガンに導入された前記熱可塑性表面層ポリマー粒子が、プラズマ溶射前には、90〜180μmの直径D90サイズを有するPEKK粒子である、請求項1に記載の方法。
- 前記熱可塑性表面層ポリマーコーティング形成後、熱可塑性表面層ポリマーを焼きなま
すまたは結晶化するために前記成形型に熱を適用することをさらに含む、請求項1に記載の方法。
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US61/715,438 | 2012-10-18 |
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JP2017081914A Active JP6387142B2 (ja) | 2012-10-18 | 2017-04-18 | 熱可塑性繊維強化複合材料の自動化テープ敷設の方法 |
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CN (1) | CN104736328B (ja) |
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JP6639009B1 (ja) * | 2019-03-04 | 2020-02-05 | 日本飛行機株式会社 | 治具台 |
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JP2015534913A (ja) | 2015-12-07 |
EP2909011A1 (en) | 2015-08-26 |
US20140110633A1 (en) | 2014-04-24 |
TWI596010B (zh) | 2017-08-21 |
MX2015004899A (es) | 2015-10-29 |
EP2909011B1 (en) | 2021-01-20 |
TW201422435A (zh) | 2014-06-16 |
BR112015008752B1 (pt) | 2021-02-23 |
WO2014062900A1 (en) | 2014-04-24 |
CA2888615A1 (en) | 2014-04-24 |
BR112015008752A2 (pt) | 2017-07-04 |
AU2013331261B2 (en) | 2017-10-19 |
CN104736328B (zh) | 2017-06-13 |
US20160221223A1 (en) | 2016-08-04 |
AU2013331261A1 (en) | 2015-04-30 |
ES2859507T3 (es) | 2021-10-04 |
RU2015118348A (ru) | 2016-12-10 |
KR102085024B1 (ko) | 2020-03-05 |
JP6387142B2 (ja) | 2018-09-05 |
CA2888615C (en) | 2020-03-31 |
CN104736328A (zh) | 2015-06-24 |
RU2622306C2 (ru) | 2017-06-14 |
KR20150074056A (ko) | 2015-07-01 |
MY183181A (en) | 2021-02-18 |
US11214019B2 (en) | 2022-01-04 |
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