JP5453408B2 - 繊維強化熱可塑性複合材構造体の製造方法および装置 - Google Patents

繊維強化熱可塑性複合材構造体の製造方法および装置 Download PDF

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JP5453408B2
JP5453408B2 JP2011515608A JP2011515608A JP5453408B2 JP 5453408 B2 JP5453408 B2 JP 5453408B2 JP 2011515608 A JP2011515608 A JP 2011515608A JP 2011515608 A JP2011515608 A JP 2011515608A JP 5453408 B2 JP5453408 B2 JP 5453408B2
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fiber reinforced
thermoplastic material
reinforced thermoplastic
layer
local heating
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JP2011525441A (ja
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インストン,デイビッド
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エアバス オペレーションズ リミティド
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/0261Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using ultrasonic or sonic vibrations
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/0266Local curing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/081Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations having a component of vibration not perpendicular to the welding surface
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/10Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16Laser beams
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16Laser beams
    • B29C65/1629Laser beams characterised by the way of heating the interface
    • B29C65/1654Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
    • B29C65/1658Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined scanning once, e.g. contour laser welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/72Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by combined operations or combined techniques, e.g. welding and stitching
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/02Preparation of the material, in the area to be joined, prior to joining or welding
    • B29C66/024Thermal pre-treatments
    • B29C66/0242Heating, or preheating, e.g. drying
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112Single lapped joints
    • B29C66/1122Single lap to lap joints, i.e. overlap joints
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43Joining a relatively small portion of the surface of said articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721Fibre-reinforced materials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/80General aspects of machine operations or constructions and parts thereof
    • B29C66/83General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/836Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/90Measuring or controlling the joining process
    • B29C66/91Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91411Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/9141Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/91943Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to Tg, i.e. the glass transition temperature, of the material of one of the parts to be joined higher than said glass transition temperature
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    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
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    • B32B37/14Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
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    • YGENERAL 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
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    • YGENERAL 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
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  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
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  • Moulding By Coating Moulds (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
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Description

複合材は、種々の分野の試みの中で構造材料として、今日では一般的に用いられている。そのような領域の1つは、航空宇宙産業であり、その中では、構造複合材は、航空機構造の増大する割合を形成するように用いられている。この関連では、複合材は、繊維またはメッシュ、最も典型的には炭素繊維であるが、しかしながらあるいは他の材料の繊維もしくは金属製メッシュ、で強化されたポリマーマトリックスであると考えられる。この複合材は、材料の2つの主な分類、熱可塑性マトリックスを有するそれらの複合材、および熱硬化性マトリックスを有するもの、の内の1つの範囲内に入る傾向にある。熱硬化性複合材は硬化させる必要があり、その工程によって、通常は熱および所望による圧力の適用により、ポリマーマトリックスの化学構造は不可逆的に変化する。一旦硬化すると、この熱硬化性複合材は、その剛性、硬度および強度の最終的な特性を有し、そして非硬化の柔軟な状態には戻すことはできない。対照的に、熱可塑性複合材は、硬化の必要はなく、冷めている場合にはそれらの所望の構造特性を有しており、そして加熱された場合には柔軟になる。熱可塑性複合材は、繰り返して熱によって柔軟になり、そして冷却することによって硬くなる、何故ならば、加熱された場合には、それらは化学的変化ではなく、実質的に物理的な変化を受けるからである。
熱可塑性と熱硬化性複合材の両方とも、薄い可撓性のシートまたは繊維に形成することができる。このことは、複合材部品が、この複合材を成形型の中に、部品の厚さが並べられる複合材の層の数によって部分により変わっており、そしてまた1つもしくは2つ以上の層の方向が、形成された複合材部品の最終的な構造特性を制御するように調整可能であるように、並べることによって形成されることを可能にする。積重ねられたこれらの部品は、次いで「固結され(consolidated)」、この工程は、両方の場合において、熱硬化性または熱可塑性マトリックスが、単一の一体となったマトリックスを形成するのに十分な程度に柔軟化されるように複合材構造体を加熱すること、ならびにこの柔軟化されたマトリックスに、いずれの捕捉された空気もマトリックスから排出され、そしてまた強化繊維がこのマトリックス中に「定着する」ことを可能にするのに十分な圧力を加えること、を含んでいる。
最終的な構造特性の点からすると、熱可塑性複合材は、熱硬化性複合材の衝撃および損傷抵抗特性に対して、より優れた衝撃および損傷抵抗特性を有しており、そして一般的に化学的攻撃により強く、そしてより抵抗力があり、それらの全ては航空宇宙用途では好ましい特性である。更には、熱可塑性複合材は、繰り返して再加熱し、そして再成形することができるので、それらは本質的に再生利用可能であり、このことは益々重要な考慮すべき事項である。
積重ねられたスタックが固結される前に、繊維強化複合材の個々の層を「積み重ねる」操作は、人手によって行なうことができる。しかしながら、このことは非常に時間の掛かることであり、そして良好な結果を得るためには熟練した労働者を必要として、そして従って比較的に費用を要し、そして複合材構造体の大規模生産には好適ではない。この問題と取り組むために、自動テープ布設(ATL)および自動繊維配置(AFP)技術および装置が開発されており、その中では、複合材テープもしくは繊維は、材料の大きなロールから、テープもしくは繊維布設ヘッドへと連続的に供給され、それがこの複合材を所望の位置に自動的に配置する。このプロセスは自動化され、そして機械化されているので、速度と正確性は、人手によって複合材を並べるよりも非常に増大している。繊維強化熱硬化性複合材料を用いる場合の、この技術の更なる進歩においては、繊維もしくはテープが布設された直ぐ後に、この繊維もしくはテープの局所的加熱が、例えば赤外レーザーもしくは高温ガストーチを用いて行なわれ、この局所的加熱は、この複合材が布設されるに連れて、熱硬化性マトリックスの、全体的なもしくは部分的な、のいずれかの固結をもたらす。この部分的な固結が、局所的加熱によって既に為されているために、次の固結工程は、完全に排除されるか、または短縮された時間内で達成されるので、この技術は、熱硬化性複合材構造体の製造に必要とされる時間を更に低減させる。この技術の特別な改良においては、この局所的加熱は、超音波エネルギーを、超音波振動子を用いて、熱硬化性複合材マトリックスに投入することによって達成される。超音波エネルギーは、熱硬化性マトリックス材料を超音波振動数で振動させ、そしてこの振動自体が、熱硬化性材料内部の局所的加熱を引き起こし、そして所望の全体的なもしくは部分的な固結を達成させる。
しかしながら、この超音波テープ布設技術は、熱可塑性複合材を用いた場合には、上述したようには、効果的で、迅速な方法では、未だに達成されてはいない。従って、熱可塑性複合材で超音波テープ布設を行なうための、所望の速度と効率を達成させる方法および装置を提供することが望ましい。
本発明の第1の態様によれば、繊維強化熱可塑性材料の第1層を、繊維強化熱可塑性材料の第2層の上に配置すること、局所的加熱源を準備し、そして上および下層の一部を局所的に加熱すること、ならびに超音波振動子を準備し、そして超音波のエネルギー波を熱可塑性材料の加熱された部分に局所的に投入して、繊維強化熱可塑性材料の超音波固結が起こるようにすること、を含む繊維強化熱可塑性複合材構造体の製造方法が提供される。
相対運動が、好ましくは、一方の繊維強化熱可塑性材料の第1層と、他方の局所的加熱源および超音波振動子との間で発生する。
繊維強化熱可塑性材料の第1層は、好ましくは長尺物として与えられ、そして繊維強化熱可塑性材料の第2層の上に、連続的に配置される。好ましくは、この局所的加熱および超音波エネルギーの投入は、繊維強化熱可塑性材料の第1層が第2層の上に配置された点の近位の熱可塑性層の部分で起こる。
繊維強化熱可塑性材料層の一部は、好ましくは繊維強化熱可塑性材料のガラス転移相の範囲内の温度に加熱される。更に、繊維強化熱可塑性材料の一部は、ガラス転移温度から実質的に広がり、そして熱可塑性材料のタンデルタのピーク値に相当する温度の5℃上の温度にまで広がる範囲内の温度に、局所的に加熱することができる。最も好ましくは、繊維強化熱可塑性材料の一部は、熱可塑性材料のタンデルタのピーク値に相当する温度に実質的に等しい温度にまで局所的に加熱することができる。
この局所的加熱源は、赤外レーザーを含むことができる。
本発明の更なる態様によれば、本発明の第1の態様の方法によって製造された繊維強化熱可塑性複合材構造体が提供される。
本発明の第3の態様によれば、繊維強化熱可塑性層のスタックの一部を加熱するように配置された局所的加熱源、および繊維強化熱可塑性材料層の加熱された部分に、超音波のエネルギー波を局所的に投入するように配置され、これらの層の超音波固結が起こるようにした超音波振動子を含む、繊維強化熱可塑性複合材構造体の製造用の装置が提供される。
局所的加熱源、超音波振動子は、好ましくは繊維強化熱可塑性層のスタックに対して動くように準備される。
好ましい態様では、局所的加熱源は赤外レーザーを含む。
好ましくは、この装置は、局所的加熱源と組み合わせて、超音波テープ布設装置を含んでいる。
本発明の態様が、ここで以下に、添付した図面を参照して、例示のためだけの例によって説明される。
図1は、従来技術による超音波テープ布設を概略的に例示している。 図2は、繊維強化マトリックス複合材についての、温度に対する、動的弾性率の大きさおよびタンデルタの一般化されたプロットを概略的に示している。 図3は本発明の1つの態様による、超音波テープ布設を概略的に示している。
図1を参照すると、熱硬化性複合材の超音波テープ布設を行なう典型的な配置が、概略的に図示されている。熱硬化性テープの上層10は、存在している熱硬化性複合材の下層12の上に配置される。下層12は、熱硬化性テープ材料の単一の層でもよく、または予め堆積された多重の層のスタックであってもよい。超音波振動子14が、図1中に示されている丸く囲んだ部分16の内側の、熱硬化性複合材の上および下層に、超音波エネルギーを投入するように与えられる。熱硬化性複合材の上および下層は、超音波振動子14に対して、図1中に示した方向に動いて、超音波振動子からの超音波エネルギーを受ける上および下層の部分が、熱硬化性複合材の上層10が、材料の下層12の上に配置された点の近位にあるようにする。
熱硬化性複合材の超音波固結が発生することの基礎となる機構およびその機構に関連する材料の重要な特性は、図2を参照して説明することができ、この図には、超音波エネルギーを加えられる材料の特定の特性の変化が、温度とともに概略的に示されている。図2中に示された実線の図形20は、粘弾性材料の弾性率の温度に対する変化を概略的に示しており、熱硬化性および熱可塑性樹脂の両方が、このような粘弾性材料の例である。材料の弾性率は、振動性の力が加えられた場合の、その材料の変形に対する応力の比率の指標である。熱硬化性および熱可塑性ポリマーのような粘弾性材料は、典型的には2つの異なる状態で存在している。より低い温度では、それらは「ガラス」相で存在しており、その中では、この材料は通常は硬く、そして「ガラス状」であり、そして高弾性率値を示す。この相は、縦軸と鎖線Aによって示される点との間の部分として、図2中の図形中に示される。よりずっと高い温度では、粘弾性材料は、弾性相で存在しており、その中では、それらは弾性材料の特性を示し、そして低弾性率値を有している。この相は、図2中に示された図形の中の、鎖線Bの右手側の領域によって示される。これらの2つの相の間では、粘弾性材料は、図2中で鎖線AとBとの間の領域として示される転移相を通過し、その間は、それらの弾性率は、それらのガラス層の上側の値と、それらの弾性相の下側の値の間で変化する。この転移相が開始する温度は、図2中の点Aに相当しており、通常はガラス転移温度(Tg)と称される。
図2中の破線図形22によって示される第2の値は、タンデルタ(tanθ)値である。この値は、加えられた振動性の力と実際の粘弾性材料中に誘導された振動との間の位相遅れの指標であり、そしてこの材料によって吸収された機械的エネルギーの指標と解釈することができる。図2中に示されているように、タンデルタの最大値は、ガラス転移相の中央に対応している。理解されるであろうように、タンデルタの値が高ければ高いほど、粘弾性材料によって吸収されたエネルギーは大きく、それは局所的加熱としてそれ自体現れ、それによりそのポリマー樹脂材料が柔軟化され、そして流動(固結)し、一方で同時に、超音波振動が、適切な操作条件を与えられたならば、その材料内部の強化繊維が、所望の厚さに、定着、または「収まる(nest)」ようにさせる。
繊維強化複合材構造体を作るのに典型的に用いられる熱硬化性材料では、ガラス転移は、一般的には周囲温度または室温と一致する。従って、タンデルタの値は、室温もしくは周囲温度で、そのピークであるか、またはその近傍であり、そして従って超音波振動子によって加えられるエネルギーの最大量が、熱硬化性ポリマー材料によって吸収され、上記の局所的加熱および固結をもたらす。このことが、熱硬化性複合材テープの超音波固結がそのように効果的であることの主な理由である。
対照的に、熱可塑性複合材テープのガラス転移温度Tgは、有意により高い。例えば、PEEKのTgは約145℃である。従って、室温または周囲温度では、熱可塑性材料は、初期のガラス相の範囲に留まっており、そこではタンデルタは比較的に低く、そして従って超音波振動子からは、非常に少しのエネルギーしか熱可塑性材料によって吸収されず、そうして局所的加熱はほんの少ししか、または全く発生しない。
本発明の態様では、この問題を克服する方法および装置が提供され、そして1つの態様が、図3中に概略的に示されている。図1中に示された配置と同様な様式で、熱可塑性複合材の上層10が、存在している、下層12の上に、好ましくは自動テープ布設技術および装置を用いて配置される。超音波振動子14が、上層10が下層12の上に配置されている点の近位の点で、上の熱可塑性層の部分16に超音波エネルギーを投入するように与えられている。好ましい態様では、赤外レーザーである局所的加熱源18が、それが図3中に示されているように、超音波振動子14が超音波エネルギーを注入するのと同じ、熱可塑性材料の上層の部分16を局所的に加熱するか、あるいは、固結されるべき熱可塑性材料の上層10の部分に、超音波エネルギーが注入される直前もしくはそれと同時のいずれかに、局所的加熱が達成されるように、熱可塑性材料の上層の部分を局所的に加熱するように、超音波振動子14および局所的加熱源18を通過する上および下の熱可塑性材料層の相対運動に対して、超音波振動子の直前に更に与えられ、そして配置されている。
局所的加熱源18の動作は、他の態様においては、高温ガストーチまたは加熱ローラーを含んでおり、好ましくは、熱可塑性材料の選択された部分16が、この熱可塑性材料のガラス転移相の範囲内の温度に局所的に加熱されるのに十分なような、加熱源および与えられる熱エネルギーの選択を通して、用意される。超音波振動子14による超音波エネルギーの注入の直前の、ガラス転移相の範囲内への熱可塑性複合材の一部の予熱によって、超音波エネルギーのより大きな割合が熱可塑性材料によって吸収されることを可能とし、そして超音波振動が熱可塑性材料が流動および固結することを可能にし、また一方で、熱可塑性マトリックス内部の強化繊維が、熱硬化性複合材テープへの室温での超音波固結と類似した方法で、所望の厚さに「収まる」ことを可能にする。好ましくは、この予熱操作は、複合材の温度がガラス転移温度Tgを超えて、タンデルタのピーク値と一致する温度まで上昇するように段取りされ、そうして超音波エネルギーの最大量が、続いて吸収されることが可能となる。しかしながら、複合材を、タンデルタピークを含む温度範囲内、例えばガラス転移温度Tgからタンデルタピーク温度の約5℃上にまで予熱することは、複合材によって吸収される超音波エネルギーの量の向上をもたらし、そして効率的な超音波固結を可能にする。
本発明の上記の態様を、超音波テープもしくは繊維布設、すなわち、熱可塑性テープの連続的な布設およびテープを布設するのに連れての超音波固結の実施、との関連で説明してきたが、本発明の原理は、熱可塑性テープが人手で適用される、または大きなシートで人手で適用される他の態様や、また組合された熱および超音波固結が、続いて起こる、別個のプロセス工程として実施される他の態様にも適合する。また、炭素強化複合材は暗色であり、そして従って赤外エネルギーを非常によく吸収するために、赤外レーザー加熱はが、熱可塑性複合材テープに局所加熱を起こすのに特に好適であるが、所望の局所的加熱を、使用のための所望の速度で実行することができる他のいずれの局所的加熱技術も、用いることができ、そして本発明の態様の範囲に入ることが理解されるであろう。

Claims (11)

  1. 繊維強化熱可塑性材料の第1層を、繊維強化熱可塑性材料の第2層の上に配置すること、局所的加熱源を準備し、そして熱可塑性複合材の少なくとも上層の一部を局所的に加熱すること、ならびに超音波振動子を準備し、そして超音波のエネルギー波を熱可塑性材料の加熱された部分に局所的に投入して、該繊維強化熱可塑性材料の超音波固結が起こるようにすること、を含む繊維強化熱可塑性複合材構造体の製造方法であって、前記繊維強化熱可塑性材料の一部を、ガラス転移温度から実質的に広がり、そして該熱可塑性材料のタンデルタのピーク値に相当する温度の5℃上の温度にまで広がる範囲内の温度に、局所的に加熱する、方法。
  2. 相対運動が、一方の前記繊維強化熱可塑性材料の第1層と、他方の前記局所的加熱源および前記超音波振動子との間で発生する、請求項1記載の方法。
  3. 前記繊維強化熱可塑性材料の第1層が、長尺物として与えられ、そして前記繊維強化熱可塑性材料の第2層の上に、連続的に配置される、請求項1または2記載の方法。
  4. 前記局所的加熱および超音波エネルギーの投入が、前記繊維強化熱可塑性材料の第1層が第2層の上に配置された点の近位の部分で起こる、請求項3記載の方法。
  5. 前記繊維強化熱可塑性材料の一部が、前記熱可塑性材料のタンデルタのピーク値に相当する温度に実質的に等しい温度にまで局所的に加熱される、請求項1〜4のいずれか1項記載の方法。
  6. 前記局所的加熱源が、赤外レーザーを含む、請求項1〜5のいずれか1項記載の方法。
  7. 請求項1〜6のいずれか1項記載の方法によって作られた繊維強化熱可塑性複合材構造体。
  8. 繊維強化熱可塑性材料層のスタックの一部を加熱するように配置された局所的加熱源(18)、および該繊維強化熱可塑性材料層の加熱された部分に、超音波のエネルギー波を局所的に投入するように配置された超音波振動子(14)を含み、それによってこれらの層の超音波固結を起こさしめる、繊維強化熱可塑性複合材構造体の製造用の装置であって、前記加熱源が、前記スタックの一部を、ガラス転移温度から実質的に広がり、そして該熱可塑性材料のタンデルタのピーク値に相当する温度の5℃上の温度にまで広がる範囲内の温度に、加熱するように配置されている、装置。
  9. 前記局所的加熱源および前記超音波振動子が、前期繊維強化熱可塑性層のスタックに対して動くように準備される、請求項8記載の装置。
  10. 前記局所的加熱源が赤外レーザーを含む、請求項8または9記載の装置。
  11. 前記局所的加熱源と組み合わせて超音波型のテープ布設装置を含む、請求項8記載の装置。
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