JP5714674B2 - 高度複合材のテーラードブランクの高速かつ自動化された製造のためのシステムおよび方法 - Google Patents
高度複合材のテーラードブランクの高速かつ自動化された製造のためのシステムおよび方法 Download PDFInfo
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- JP5714674B2 JP5714674B2 JP2013183812A JP2013183812A JP5714674B2 JP 5714674 B2 JP5714674 B2 JP 5714674B2 JP 2013183812 A JP2013183812 A JP 2013183812A JP 2013183812 A JP2013183812 A JP 2013183812A JP 5714674 B2 JP5714674 B2 JP 5714674B2
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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
- B29C70/28—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]
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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
- B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D1/00—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor
- B26D1/01—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work
- B26D1/04—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member
- B26D1/045—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member for thin material, e.g. for sheets, strips or the like
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- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D7/00—Details of apparatus for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
- B26D7/0006—Means for guiding the cutter
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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- 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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- Life Sciences & Earth Sciences (AREA)
- Forests & Forestry (AREA)
- Robotics (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
- Reinforced Plastic Materials (AREA)
Description
本発明は、プリプレグ繊維、ポリマーテープおよび純ポリマーテープなどのテープ材料により高度複合材のプリフォームを製造するために使用することができる。高度複合材は、強化繊維、高分子樹脂を含み、場合によっては発泡体またはハニカムなどの芯材を含む。製品は、1以上の向きまたはプライ角で材料の層を積層することによって製造される。プライ角は、製品の負荷要件によって決定される。一般に、積層体に含まれる材料は、強化繊維と高分子樹脂を含むプリプレグテープである。しかし、用途の要件によって、無強化ポリマーテープ、芯材または金属膜などの他の材料が積層体に含まれてもよい。
本発明の特定の実施を図1〜16に示す。この例示的なシステムは、材料ディスペンスシステム1、テープ搬送レール2、配置ヘッド3、ブランク加工面として機能する真空テーブル4、3軸可動テーブル5、および構造ビーム6を備える。配置ヘッド3とテープ搬送レール2は、構造体のビームに取り付けられており、可動テーブル5と真空テーブル4の上に位置している。追加の支援システムも図示されており、これには、オペレータインタフェースコンピュータ7、電子制御キャビネット8、真空ポンプ9および周辺安全ガード10が含まれる。
Claims (39)
- テープ材料から複合材プリフォームを製造する方法であって、
テーブルが持つ加工面の上でテープ断片を浮かせるテープ断片ガイドに前記テープ断片を送り出すステップと、
前記テープ断片を前記加工面に対して所望の位置および向きに配置するために、前記テープ断片ガイドと前記加工面の少なくとも一方を移動させるステップと、
最初のテープ断片については加工面に、2つ目以降のテープ断片については前記加工面に先に置かれているテープ断片に向けて前記テープ断片を移動させるステップと、
2つ目以降のテープ断片については先に置かれている前記テープ断片に前記テープ断片を融着させるステップと、
を含んでおり、
2つ目以降のテープ断片を前記加工面に先に置かれているテープ断片に向けて移動させるステップの少なくとも一つでは、追加のテープ断片を、先に置かれている前記テープ断片に対して、実質的に平行に、且つそれに含まれる繊維の方向が先に置かれている前記テープ断片に含まれる繊維の方向とは異なるように配置し、
先に置かれている前記テープ断片に前記テープ断片を融着させるステップでは、先に置かれた前記テープ断片が存在する部分でのみ融着を行うとともに、先に置かれた前記テープ断片が存在しない部分では融着を行わないようにする、
方法。 - 前記テープ断片は、熱可塑性または熱硬化性の高分子樹脂をプリプレグした複数の連続するまたはほぼ連続する強化繊維、熱可塑性または熱硬化性の高分子樹脂をプリプレグした複数の不連続な強化繊維、実質的に熱可塑性または熱硬化性の高分子樹脂、および金属膜の少なくとも1つを含む材料から形成される請求項1に記載の方法。
- 芯材に前記テープ断片を融着させるステップを更に有する請求項1に記載の方法。
- 前記プリフォームは部分的に金属層を含む請求項1に記載の方法。
- 前記テープ断片ガイドに前記テープ断片を送り出す前記ステップは、
テープ供給元から、前記加工面の上で前記テープ材料を浮かせる前記テープ断片ガイドにテープ材料を搬送するステップと、
前記テープ断片を提供するために前記テープ材料を所定の長さに切断するステップと、
を有する請求項1に記載の方法。 - 前記テープ供給元は、巻き出され、テープ断片を形成するために所定の長さに切断される1つ以上のテープ材料のスプールを有する請求項5に記載の方法。
- 前記テープ材料のスプールは1つ以上のテープ材料を含む請求項6に記載の方法。
- 1つのテープ材料のスプールは別のテープ材料のスプールと幅が異なる請求項6に記載の方法。
- 前記テープ材料が送り出される際の前記テープ材料の逆張力を低減させるためにスプールの端に弛みを維持するステップを更に有する請求項6に記載の方法。
- 前記テープ材料を搬送するステップは、1つ以上のピンチローラを使用して、前記テープ断片ガイドに前記テープ材料を送り出すステップを有する請求項5に記載の方法。
- 前記テープ断片を提供するために前記テープ材料を切断するステップはインライン(in line)の切断方法を有する請求項5に記載の方法。
- 前記テープ断片ガイドと前記加工面の少なくとも一方を移動させるステップは、前記テープ断片ガイドの下で、前記加工面を回転させ、前記加工面を2軸移動で水平に移動させるステップを有する請求項1に記載の方法。
- 先に置かれている前記テープ断片に向けて前記テープ断片を移動させるステップは、前記加工面に向けて前記テープ断片ガイドを移動させるステップを有する請求項1に記載の方法。
- 先に置かれている前記テープ断片を前記加工面を介した吸引によって前記加工面に固定するステップを更に有する請求項1に記載の方法。
- 前記テープ断片を融着させるステップは、熱融着工程を含む請求項1に記載の方法。
- 前記熱融着工程は、超音波スポット溶着を含む請求項15に記載の方法。
- 前記熱融着工程では、先に置かれている前記テープ断片に前記テープ断片を融着させるために、連続的またはほぼ連続的な超音波溶着を使用する請求項15に記載の方法。
- 先に置かれている前記テープ断片に前記テープ断片を融着させた後に、前記テープ断片が、前記テープ断片ガイドから引き出されるように、前記加工面から前記テープ断片ガイドを遠ざけるステップを更に有する請求項1に記載の方法。
- 前記テープ断片を送り出すステップは、前記テープ断片が、湾曲した形状に保持されるように、前記テープ断片ガイド内で前記テープ断片を締め付けるステップを有する請求項1に記載の方法。
- 前記テープ断片ガイドは、2本の離間されたレールを有し、
前記テープ断片は、前記レールの間に長手方向に浮かされ、
前記テープ断片を融着させるステップは、
前記離間されたレールの間の前記テープ断片を押圧するステップと、
先に置かれている前記テープ断片に前記テープ断片を融着させるステップと、
前記テープ断片が、前記離間されたレールから解放されるように、前記離間されたレールを前記加工面から遠ざける際に前記テープ断片の押圧を維持するステップと、
を有する請求項1に記載の方法。 - 先に置かれている前記テープ断片に向けて前記テープ断片を移動させるステップは、前記テープ断片が先に置かれている前記テープ断片の近くに載置されるまで、前記テープ断片ガイドを移動させるステップを有し、
前記テープ断片を融着させるステップは、
前記テープ断片が、先に置かれている前記テープ断片に接するように、前記テープ断片の、前記テープ断片ガイドによって支持されていない部分を押圧するステップと、
前記支持されていない部分を先に置かれている前記テープ断片に融着させるステップと、
を有する請求項1に記載の方法。 - 前記テープ断片ガイドは、対向する溝が設けられている実質的に平行なガイドレールを有し、
前記方法は、前記溝に前記テープ断片の長手縁を保持するステップを更に有する請求項20に記載の方法。 - 前記テープ材料を切断するステップは、前記テープ材料の長手方向に対して切断ブレードの角度を調整するステップを有し、
前記方法は、前記角度の調整前後で前記テープ断片ガイドと前記切断ブレード間の距離を実質的に一定に維持するステップを更に有する請求項5に記載の方法。 - 複合材テープから複合材プリフォームを製造するための装置であって、
テープ材料を配給するテープ供給ユニットと、
前記テープ供給ユニットからテープを受け取るテープフィードユニットと、
前記テープフィードユニットから送り出されたテープを切断するカッターユニットと、
前記テープフィードユニットから送り出され、前記カッターユニットによって切断されたテープ断片を受け取るテープ断片ガイドと、
テーブルが持つ加工面と、
前記テープ断片を他の同様のテープ断片に融着させるように構成されたテープ融着器と、
を有し、
前記テープ断片ガイドは、前記加工面の上で前記テープ断片を浮かせるように構成され、
前記テープ断片ガイドと前記加工面の少なくとも一方は、前記加工面に対して平行とされた前記テープ断片を所望の位置におよびそれに含まれる繊維の方向を所望の角度とするようにして配置するために移動するように構成され、
前記テープ断片ガイドは、前記テープ断片を前記加工面に向けて移動させるように構成され、
前記テープ融着器は、前記テープ断片を押圧し、前記テープ断片を別の同様のテープ断片に融着させるように構成されているとともに、先に置かれた前記テープ断片が存在する部分でのみ融着を行うとともに、先に置かれた前記テープ断片が存在しない部分では融着を行わないようにするようになっている、装置。 - 前記テープ供給ユニットは、前記テープフィードユニットとテープのスプール間のテープの張力が最小限に低減されるように能動的に巻き出されるテープ材料のスプールを格納する1つ以上のクリールボックスを有する請求項24に記載の装置。
- ピンチローラが、クリールボックス内で、スプールからテープを送り出して、テープの弛んだ巻きを形成し、前記ピンチローラは、1つ以上の弛みループ位置センサからのフィードバックを使用して、前記弛みループのサイズを所定の範囲内に維持するように構成されている請求項25に記載の装置。
- 前記テープフィードユニットは、テープの位置合せを維持するピンチローラとフィードガイドとを有する請求項24に記載の装置。
- 前記カッターユニットは、前記テープフィードユニットがその間に前記テープを送り出すブレードおよびアンビルを有しており、前記ブレードが前記アンビルとの間で挟み込むことにより前記テープを前記テープ断片に切断するように、前記ブレードおよび前記アンビルの移動が制御されるようになっている請求項24に記載の装置。
- 前記カッターユニットは、前記テープの長手方向に対して複数の角度に前記テープを切断するようになっている請求項24に記載の装置。
- 前記テープ断片ガイドは、前記カッターユニットが切断角を変更する前後で、前記テープ断片ガイドと前記カッターユニット間に実質的に一定の距離を維持するように構成されている請求項29に記載の装置。
- 前記カッターユニットは、その幅にわたる湾曲した軌跡で前記テープを切断するようになっている請求項28に記載の装置。
- 前記テープ断片ガイドは、キャリッジに接続され、互いに対して配置されている2本以上の実質的に平行な溝付きレールを備えており、前記テープが前記溝に送り出されると、前記テープの対向する長手縁を保持するようになっている請求項28に記載の装置。
- 前記キャリッジは、前記テープ断片ガイドに保持されているテープ断片を、前記テープが送り出されて切断される第1の位置から、前記加工面の近くの第2の位置に移動させる請求項32に記載の装置。
- 前記加工面は、前記テープ断片を所望の位置および相対角度に配置するために、回転と、水平方向の互いに直行する2つの軸に沿う移動とを行えるようになっている、請求項28に記載の装置。
- 前記加工面は、実質的に平坦な多孔板であり、前記加工面と接しているテープ断片を固定するための十分な吸引を生じさせるために前記多孔板から空気を吸引するようになっている請求項28に記載の装置。
- 前記テープ融着器は、前記テープ断片を押圧し、先に置かれているテープ断片に前記テープ断片を取り付ける1以上の超音波タック溶着ヘッドの配列を有している請求項28に記載の装置。
- 前記テープ断片を前記加工面に対して実質的に移動させることなく、前記テープ断片が前記テープ断片ガイドから解放されるように、前記テープ断片ガイドが前記加工面から後退する間に、前記テープ断片の、前記テープ断片ガイドによって支持されていない部分を押圧する押圧フィートを更に有する請求項28に記載の装置。
- 1以上の超音波ウェルダーヘッドが前記押圧フィートを有する請求項37に記載の装置。
- 前記テープ断片ガイドは、幅の異なるテープ断片に対応するようにその幅を自動的に調整する請求項24に記載の装置。
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- 2008-09-26 CN CN2008801087927A patent/CN101883671B/zh not_active Expired - Fee Related
- 2008-09-26 WO PCT/US2008/011231 patent/WO2009042225A2/en active Application Filing
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CN102348773B (zh) * | 2009-03-10 | 2015-05-20 | 格拉贝特股份公司 | 紧固件 |
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JP2010540282A (ja) | 2010-12-24 |
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US8168029B2 (en) | 2012-05-01 |
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WO2009042225A2 (en) | 2009-04-02 |
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KR101436386B1 (ko) | 2014-09-01 |
EP2193016A2 (en) | 2010-06-09 |
WO2009042225A3 (en) | 2009-05-22 |
US20090101277A1 (en) | 2009-04-23 |
US8992715B2 (en) | 2015-03-31 |
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