JP4510446B2 - Z軸繊維の頂部端部および底部端部を、複合積層体の頂部表面および底部表面それぞれに締め付ける方法 - Google Patents
Z軸繊維の頂部端部および底部端部を、複合積層体の頂部表面および底部表面それぞれに締め付ける方法 Download PDFInfo
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Description
本願は、2001年4月6日に出願された、仮特許出願60/281838および2001年5月29日に出願された、仮特許出願60/293939の優先権を主張する。本願はまた、2001年8月2日に出願された米国特許出願番号09/922,053の優先権も主張する。
本発明は、ポリマーマトリクス複合体の外表皮および発泡体、エンドグレインバルサ材、またはハニカムのいずれかである内部コアで形成されるサンドイッチ構造として公知である、複合積層構造体の分野における改良に関し、より具体的には、複合積層体を通してポリマーマトリクス複合表皮の平面に垂直な何らかのタイプのZ軸繊維強化をさらに有する、これらのサンドイッチ構造の分野に関する。
複合積層構造体の移送産業においては、その複合積層体の軽量かつ魅力的な性能に依存して、広範な用途が存在する。これらの産業としては、航空宇宙産業、海産、鉄道産業、および基地所属の運搬具が挙げられる。この複合積層構造体は、ポリマーマトリクス繊維複合体の表皮から主として作製され、ここで、このマトリクスは、熱硬化性樹脂または熱可塑性樹脂のいずれかであり、そして繊維は、ガラス、カーボン、アラミドなどの繊維フィラメントのグループから形成される。コアは、エンドグレインバルサ材、金属箔もしくはアラミド紙のハニカムなど、または広範な種々のウレタン、PNC、もしくはフェノール発泡体のハニカムから形成される。
改善された引出成形され締め付けられたZ軸繊維で強化された複合構造体の形成のための方法および装置は、原料繊維を供給する複数の上スプールおよび下スプールで開始し、これらの原料繊維は、それぞれ上表皮および下表皮に形成され、これらの表皮は、樹脂タンク内の一次ウェットアウトステーションに供給される。コア材料が、それぞれの上表皮と下表皮との間で、一次ウェットアウトステーションに供給され複合積層プレフォームを形成する。上表皮および下表皮ならびにコアは、ツーリングを通して自動的に引かれ、ここで、表皮材料が樹脂でウェットアウトされ、そして複合積層体全体が、ほぼその最終の厚さで予備形成される。この複合積層プレフォームは、自動三次元Z軸繊維配置機械に引き込まれ続け、この繊維配置機械は、「繊維フィラメントのグループ」を、複数の位置で、対向する積層構造体の面に対して垂直に配置し、そして個々のグループを切断し、その結果、各「繊維フィラメントのグループ」の延長部は、上表皮の上および下表皮の下に残る。
図1は、引抜成形され、そして締め付けられた、3−D Z軸繊維強化複合積層構造体を形成するための、方法および装置を示す。引抜成形の方向は、矢印によって示されるように、図1の左から右である。この装置の主要な構成要素は、以下の説明によって明らかになる。
Claims (20)
- Z軸を強化する繊維の頂部端部および底部端部を、複合積層体のそれぞれの頂部表面および底部表面に締め付ける方法であって、該方法は、以下:
少なくとも2つのスプール上に少なくとも2つの複合繊維材料のロールを提供する工程;
該複合繊維材料のロールを、頂部表面を有する頂部表皮、底部表面を有する底部表皮、X軸およびY軸を有する複合積層体プレフォームに組み立てる工程;
該複合積層体プレフォームを機械に供給し、それによってZ軸繊維束が、該X軸および該Y軸に沿った所定の位置で該複合積層体プレフォーム中に配置される工程であって、該Z軸繊維束は、それぞれ該頂部表皮の頂部表面上に所定の高さH1伸長する、頂部端部、および該底部表皮の底部表面より下に所定の高さH2伸長する、底部端部を有し、該複合積層体プレフォームは、改変された複合積層体プレフォームとして該機械から出る、工程;および
該改変された複合積層体プレフォームをリベット留め手段または折り曲げ手段に供給する工程であって、ここで、該Z軸繊維束の該頂部縁部および底部縁部は、該改変された複合積層体プレフォームの該頂部表皮の頂部表面および該底部表皮の底部表面に締め付けられる工程であって、該改変された複合積層体プレフォームは、組み立てられた複合積層体パネルとして該リベット留め手段または折り曲げ手段から出る、工程、
を包含する、方法。 - 前記複合繊維材料のロールを、該複合繊維材料のロールを前記複合積層体プレフォームに組み立てる前に、樹脂タンクに供給する工程をさらに包含し、該複合繊維材料のロールが、該樹脂タンクにおいて樹脂でコーティングされる、請求項1に記載の方法。
- 前記複合積層体プレフォームを、前記樹脂タンクから出る前に脱バルクする工程をさらに包含する、請求項2に記載の方法。
- 前記複合積層体プレフォームを、前記改変された複合積層体プレフォームが前記機械から出た後に樹脂タンクに供給する工程をさらに包含し、該改変された複合積層体が、該樹脂タンクにおいて樹脂でコーティングされる、請求項1に記載の方法。
- 少なくとも1つの前記複合繊維材料のロールが、連続的なストランドマットのロービングロール形態である、請求項4に記載の方法。
- 少なくとも1つの前記複合繊維材料のロールが、X−Y軸に縫われたファブリックの形態である、請求項4に記載の方法。
- 少なくとも1つの前記複合繊維材料のロールが、織られたロービングファブリックの形態である、請求項4に記載の方法。
- 少なくとも2つの前記複合繊維材料のロール間に、コア材料を、該ロールが前記複合積層体プレフォームに組み立てられる際に組み立てる工程をさらに包含する、請求項4に記載の方法。
- 前記コア材料がウレタンである、請求項8に記載の方法。
- 前記コア材料がPVC発泡体である、請求項8に記載の方法。
- 前記コア材料が2ポンド/立方フィート〜12ポンド/立方フィート(32kg/m3〜192kg/m3)の範囲の密度を有する発泡体である、請求項8に記載の方法。
- 前記コア材料がバルサ材である、請求項8に記載の方法。
- 前記バルサ材が4lb/立方フィート〜16lb/立方フィート(64kg/m3〜256kg/m3)の範囲の密度を有する、請求項12に記載の方法。
- 前記リベット留め手段または折り曲げ手段が、引抜成形ダイを備える、請求項4に記載の方法であって、該引抜成形ダイは、前記組み立てられた複合積層体パネルを形成する操作の間、前記Z軸繊維束の頂部端部を、前記頂部表皮の前記頂部表面に押し付け、また該Z軸繊維束の前記底部端部を前記底部表皮の前記底部表面に押し付ける、方法。
- 前記引出成形ダイが、前記改変された複合積層体プレフォームが組み立てられた複合積層体パネルになるように、該改変された複合積層体プレフォームの触媒を引き起こすのに十分な温度まで該改変された複合積層体プレフォームを加熱するための手段を有する、請求項14に記載の方法。
- 前記リベット留め手段または折り曲げ手段の下流に配置されるフライス削り手段をさらに備え、該フライス削り手段は、ボルト穴の形成、端部のルータ加工、フライス削りおよび切断をし得る、請求項4に記載の方法。
- 前記組み立てられた複合積層体パネルを、前記リベット留め手段または折り曲げ手段から前記フライス削り手段に移動させるためのグリッパー手段をさらに備える、請求項16に記載の方法。
- 前記フライス削り手段が、多軸CNCフライス削り機械である、請求項17に記載の方法。
- 前記複合繊維材料のロールを、前記複合積層体プレフォームに組み立てることで始まり、そして該組み立てられた複合積層体パネルが、フライス削り手段から出続ける操作全体が、完全に自動化される、請求項17に記載の方法。
- Z軸を強化する繊維の頂部端部および底部端部を、複合積層体のそれぞれの頂部表面および底部表面に締め付ける方法であって、該方法は、以下:
少なくとも2つのスプール上に少なくとも2つの複合繊維材料のロールを提供する工程;
該少なくとも2つの複合繊維材料のロールの間にコア材料を提供する、工程;
該複合繊維材料のロールおよびコア材料を、複合積層体プレフォームに組み立てる工程であって、該複合積層体プレフォームは、頂部表面を有する頂部表皮、中心コア、底部表面を有する底部表皮、X軸およびY軸を有する、工程;
該複合積層体プレフォームを機械に供給し、それによってZ軸繊維束が、該X軸および該Y軸に沿った所定の位置で該複合積層体プレフォーム中に配置される工程であって、該Z軸繊維束は、それぞれ該頂部表皮の頂部表面上に所定の高さH1伸長する、頂部端部および該底部表皮の底部表面より下に所定の高さH2伸長する、底部端部を有し、該複合積層体プレフォームは、改変された複合積層体プレフォームとして該機械から出る、工程;
必要な場合、該Z軸繊維束の配置後、該プレフォームに樹脂を添加する工程;
グリッピング手段によって該改変された複合積層体をグリッピングし、該改変された複合積層体プレフォームをリベット留め手段または折り曲げ手段に供給する工程であって、該リベット留め手段または折り曲げ手段において、該Z軸繊維束の頂部端部および底部端部それぞれは、該改変された複合積層体プレフォームの該頂部表皮の頂部表面および該底部表皮の底部表面それぞれに締め付けられ、該改変された複合積層体プレフォームは、組み立てられた複合積層体パネルとして該リベット留め手段または折り曲げ手段から出る、工程;
該改変されたプレフォームを、該改変された複合積層体プレフォームが組み立てられた複合積層体パネルになるように、該改変された複合積層体プレフォームの触媒を引き起こすのに十分な温度まで加熱する工程;
該グリッパー手段によって該組み立てられた複合積層体パネルを、ボルト穴形成、端部ルーティング、フライス削りおよび切断をし得るフライス削り手段に下流へと移動させる工程;
多軸CNCフライス削り機械を用いて、該組み立てられた複合積層体パネルに所定の構造をフライス削りする工程;および
自動化を提供する工程であって、それによって該複合繊維材料のロールおよび該コア材料を該複合積層体プレフォームに組み立てる工程で始まり、該組み立てられた複合積層体パネルが該フライス削り手段から出続ける操作全体が完全に自動化される、工程、
を包含する、方法。
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US09/922,053 US6645333B2 (en) | 2001-04-06 | 2001-08-02 | Method of inserting z-axis reinforcing fibers into a composite laminate |
US10/059,956 US6676785B2 (en) | 2001-04-06 | 2001-11-19 | Method of clinching the top and bottom ends of Z-axis fibers into the respective top and bottom surfaces of a composite laminate |
PCT/US2002/024642 WO2003011577A1 (en) | 2001-08-02 | 2002-08-02 | Method of clinching top and bottom ends of z-axis fibers into the respective top and bottom surfaces of a composite laminate |
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JP2006057025A Division JP4266990B2 (ja) | 2001-08-02 | 2006-03-02 | Z軸繊維の頂部端部および底部端部を、複合積層体の頂部表面および底部表面それぞれに締め付ける方法 |
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JP2006057025A Expired - Fee Related JP4266990B2 (ja) | 2001-08-02 | 2006-03-02 | Z軸繊維の頂部端部および底部端部を、複合積層体の頂部表面および底部表面それぞれに締め付ける方法 |
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JP (2) | JP4510446B2 (ja) |
AT (1) | ATE509755T1 (ja) |
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US7056576B2 (en) * | 2001-04-06 | 2006-06-06 | Ebert Composites, Inc. | 3D fiber elements with high moment of inertia characteristics in composite sandwich laminates |
US7785693B2 (en) * | 2001-04-06 | 2010-08-31 | Ebert Composites Corporation | Composite laminate structure |
EP1663625B1 (de) * | 2003-09-08 | 2009-08-26 | Evonik Röhm GmbH | Krafteinleitungsstelle in kernverbunden und verfahren zu ihrer herstellung mit in dickenrichtung des kernverbundes durchsetzenden armierungselementen |
DE20314187U1 (de) * | 2003-09-08 | 2003-12-18 | Roth, Matthias Alexander, Dipl.-Ing. | Krafteinleitungsstelle in Kernverbunden mit in Dickenrichtung des Kernverbundes durchsetzenden Armierungselementen |
US9511571B2 (en) * | 2007-01-23 | 2016-12-06 | The Boeing Company | Composite laminate having a damping interlayer and method of making the same |
EP2329939B1 (en) * | 2009-12-07 | 2013-03-20 | Groep Stevens International | Sandwich panel and method for its manufacture |
US20130330496A1 (en) * | 2012-06-06 | 2013-12-12 | General Electric Company | Composite structure with low density core and composite stitching reinforcement |
FR3029834B1 (fr) * | 2014-12-10 | 2019-06-07 | Doyen Entreprises | Procede pour l'insertion et la mise en place de fils individuels au travers d'un panneau |
JP6808946B2 (ja) * | 2016-02-23 | 2021-01-06 | 三菱ケミカル株式会社 | 繊維強化複合材料成形品の製造方法 |
DE102016209140A1 (de) * | 2016-05-25 | 2017-11-30 | Airbus Operations Gmbh | Reparaturkonzept mit präimprägniertem gepinntem Schaumkern für Sandwich-Strukturkomponenten |
DE102018216535A1 (de) * | 2018-09-27 | 2020-04-02 | AUNDE Achter & Ebels GmbH | Verfahren zur Herstellung eines Sitzbezugs für einen Fahrzeugsitz gebildet aus einem Formstrickteil |
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US2762739A (en) * | 1953-11-19 | 1956-09-11 | Alexander C H Weiss | Fiber-reinforced structural panel and method of making same |
US2954001A (en) * | 1957-05-03 | 1960-09-27 | Luxenburg Julius | Automatic eyelet attachment |
FR1359354A (fr) * | 1963-03-15 | 1964-04-24 | Rhodiaceta | Appareil pour la couture d'éléments plats à base de fils thermoplastiques |
US3647606A (en) * | 1969-11-21 | 1972-03-07 | Union Carbide Corp | Semirigid multilayer thermal insulation and method of making same |
JPH01110944A (ja) * | 1987-10-26 | 1989-04-27 | Toyota Motor Corp | Frp構造体 |
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JPH05138743A (ja) * | 1991-11-25 | 1993-06-08 | Sekisui Chem Co Ltd | 軽量構造体及びその接続部の構造 |
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MXPA04000950A (es) | 2005-02-17 |
ATE509755T1 (de) | 2011-06-15 |
EP1642702A2 (en) | 2006-04-05 |
EP1412164A1 (en) | 2004-04-28 |
CA2456017C (en) | 2009-12-08 |
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