JP6689342B2 - 誘導加熱・締固めシステムおよび締固めの方法 - Google Patents
誘導加熱・締固めシステムおよび締固めの方法 Download PDFInfo
- Publication number
- JP6689342B2 JP6689342B2 JP2018182129A JP2018182129A JP6689342B2 JP 6689342 B2 JP6689342 B2 JP 6689342B2 JP 2018182129 A JP2018182129 A JP 2018182129A JP 2018182129 A JP2018182129 A JP 2018182129A JP 6689342 B2 JP6689342 B2 JP 6689342B2
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- Prior art keywords
- compaction
- composite material
- induction heating
- ply layer
- compaction foot
- 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.)
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- 238000010438 heat treatment Methods 0.000 title claims description 89
- 230000006698 induction Effects 0.000 title claims description 78
- 238000000034 method Methods 0.000 title claims description 23
- 239000000463 material Substances 0.000 claims description 71
- 239000002131 composite material Substances 0.000 claims description 45
- 238000001816 cooling Methods 0.000 claims description 44
- 239000011159 matrix material Substances 0.000 claims description 21
- 239000000835 fiber Substances 0.000 claims description 17
- 230000005672 electromagnetic field Effects 0.000 claims description 14
- 238000009718 spray deposition Methods 0.000 claims description 9
- 238000005137 deposition process Methods 0.000 claims description 7
- 230000001939 inductive effect Effects 0.000 claims description 5
- 238000011065 in-situ storage Methods 0.000 claims description 3
- 230000000694 effects Effects 0.000 claims 2
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- 238000010586 diagram Methods 0.000 description 5
- 125000006850 spacer group Chemical group 0.000 description 4
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- 229920000049 Carbon (fiber) Polymers 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 239000004917 carbon fiber Substances 0.000 description 2
- 239000002826 coolant Substances 0.000 description 2
- 230000010354 integration Effects 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 238000004806 packaging method and process Methods 0.000 description 2
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- 229920002994 synthetic fiber Polymers 0.000 description 2
- 230000037303 wrinkles Effects 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 239000002134 carbon nanofiber Substances 0.000 description 1
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- 238000007596 consolidation process Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 238000013461 design Methods 0.000 description 1
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- 238000003475 lamination Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
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- Engineering & Computer Science (AREA)
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- Physics & Mathematics (AREA)
- Health & Medical Sciences (AREA)
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- Toxicology (AREA)
- Oral & Maxillofacial Surgery (AREA)
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- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Heating, Cooling, Or Curing Plastics Or The Like In General (AREA)
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- General Induction Heating (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Description
のプライ層をコンパクトな構成となるように固めるためにプリプレグ材料から熱を抽出するように構成および配置される。
的である場合、制御装置102は、一実施形態では、冷却源109に接続され、この冷却源109がさらに冷却部材111内での冷却レベルを管理する。例示の冷却システムを後で説明する。図2が別の誘導加熱・締固めシステム200を示す。このシステム200は図1に関連して説明したシステム100に類似する。しかし、図2の実施形態では、加熱部材122が締固め部材120の中ではなく締固め部材120の近傍に配置される。この実施形態はまた、締固め部材120の中ではなく締固め部材120の近傍に配置され得る第2の冷却部材121の使用を示す。複数の実施形態では、制御装置102が、冷却部材111および121のための冷却媒体を供給するために冷却源109を起動させる。複数の実施形態では、冷却部材111および121ならびに/または加熱部材112および122が、加熱部材112および122によって発生される熱の量ならびに冷却部材111および121に対してなされる冷却量を少なくとも部分的に制御するために制御装置102によって使用される1つまたは複数の温度センサを有する。
は、保持ブラケット428は、第1の保持アーム428aと、離間される第2の保持アーム428bとを有する。締固めローラ450のローラアクスル(axel)462が、保持ブラケット428の第1の保持アーム428aと第2の保持アーム428bとの間に結合される。図4Aが、形成ツール404の上にレイアップされているプリプレグ材料のプライに係合されている締固めローラ450をさらに示す。具体的には、図4Aは、形成ツール404の上にレイアップされている1つまたは複数のプライ層406の上で1つまたは複数のプライ層406aを締固めする(in−situ)ことを示している。図4Bに示される側面図を参照すると、誘導加熱および熱伝達の説明が提示されている。具体的には、図4Bは、図6Cに関連して後でさらに説明されるように、締固めローラ450内に収容される誘導加熱部材によって作られる誘導磁場440を示している。誘導磁場440が1つまたは複数のプライ層406aを加熱する。締固めローラ450がプライ層406に係合されるとき、プライ層406からの熱447が締固めローラ450に戻るように抽出され、プライ層がコンパクトな状態で固められる。この実施形態の締固めローラ450は、締固めローラ450を低温状態に維持するのを補助する冷却通路451を有する。図4Bは、材料406aの温度を調べて感知するようにおよび制御装置102にフィードバックを提供するように配置される温度センサ429をさらに示す。第2の誘導温度センサ(induction temperature sensor)(図示せず)が、締固めローラカバー452の温度を測定して制御装置102にフィードバックを提供するのに使用され得る。また、図4Aおよび4Bには、ローラ450に対して1つまたは複数のプライ層406aを分配して配置するように設計される材料分配部材425が示される。材料分配部材425は、通常、積層材内で必要に応じて材料を切断し、かつ再開させる能力を有する。
ル(axel)462を有する。第1の端部分462bおよび第2の端部分462cは中間部分462aより小さい直径を有する。別の実施形態では、一対のスタブシャフトがローラアクスル(axel)462の代わりに使用される。一対のスタブは、ローラアクスル(axel)462の第1の端部分462bおよび第2の端部分462cのように機能する。この実施形態では、円筒形遮蔽物453がローラアクスル(axel)462の中間部分462a上で受けられる。遮蔽物453が、誘導加熱部材458によって発生される電磁波からローラアクスル(axel)462の少なくとも一部分を遮蔽する。一実施形態では、遮蔽物453は電磁波遮蔽材料で作られる。例えば、遮蔽材料は、プロセスで使用される周波数に合わせて調整される、銅および/もしくはアルミニウムの薄いシートまたはニッケル含有量が高いフォイルから作られてよい。例えば、周波数が高い場合、より薄いシートが使用される。当業者には既知の別の種類の電磁波遮蔽材料が使用されもてよい。次いで、誘導加熱部材458が遮蔽物450の上でさらに受けられる。また、電源から誘導加熱部材458にエネルギーを供給する一対のリードワイヤ457aおよび457bが図6Cに示される。第1の軸受456がローラアクスル(axel)462の第1の端部分462b上で受けられる。第1の軸受456が、ローラアクスル(axel)462の第1の端部分462bと中間部分462aとの間に形成されるショルダ462dに係合される。第2の軸受464がローラアクスル(axel)462の第2の端部分462c上で受けられる。第2の軸受464が、ローラアクスル(axel)462の第2の端部分462cと中間部分462aとの間に形成される第2のショルダ462eに係合される。主ローラ支持体(main roller support)454がローラアクスル(axel)462上で受けられる。主ローラ支持体454が第1の軸受456および第2の軸受464に係合され、その結果、主ローラ支持体454がローラアクスル(axel)462に回転可能に結合される。主ローラ支持体454は、この実施形態では、図6Bで最も良好に見られるように、複数の冷却通路451を有する。さらにこの実施形態では、冷却デバイス466がローラアクスル(axel)462の第2の端部分462c上に設置される。この実施形態の冷却デバイス466は、主ローラ支持体454内の複数の冷却通路451を通る流体またはガスの流れを供給する。別の実施形態では、受動的な冷却が利用されてよく、冷却デバイス466が必要とならなくてよい。ローラカバー452が主ローラ支持体454上で受けられる。ローラカバー452はプリプレグ材料のプライ層を締固めするように設計される。ローラカバー452は、固体、または、統合される形状に従う適合性を有する材料(compliant material)であってよい。さらに、一部の実施形態では、ローラカバー452は交換されるように設計される。
で受けられる。図7Bにはまた、電源から誘導加熱部材506に電力を供給するリードワイヤ519aおよび519bが示される。この実施形態の締固めフット502はシールド部材504をさらに有する。シールド部材504は、シールド頂部カバー504aと、シールド頂部カバー504aから延在するシールド側方延在部分504bとを有し、それにより、誘導加熱部材506を中で受けるための内部チャンバが形成される。シールド側方延在部分504bはさらにスタンプ部材508の内部チャンバ509内で受けられる。シールド頂部カバー504aがスタンプ部材508の内部チャンバ509を覆う。シールドのデザインは、誘導磁場を望まないようなエリアを保護する目的に応じて変化してよく、誘導磁場が集中するような材料をコンパクトにすることを可能にする。したがって、シールド504は、誘導加熱部材506によって発生される電磁場から別の構成要素を遮蔽するために電磁波遮蔽材料から作られる。別の実施形態では、締固めフット502が互いに独立して移動することができるセクションで形成され、それにより、締固めフット502がin−situ締固め・堆積プロセスでプリプレグ材料を横切って動き回ることができるようになる。さらに、別の実施形態では、2つ以上の締固めシュー502がin−situ締固めビルドアッププロセスで使用される。また、示される締固めシュー502の形状は長方形であるが、締固めシュー502は、プリプレグ層を形成される複合構造の所望される形状に従わせるような任意の形状を有してよい。同じことが上で考察した締固めローラ450にも当てはまる。
Claims (15)
- 誘導加熱・締固めシステムであって、前記システムが、形成ツールの表面上にレイアップおよび位置決めされている複合材料を締固めしながら、in−situで前記複合材料から熱を抽出するように構成および配置される締固めフットを備えており、前記締固めフットが、
スタンプ部材であって、該スタンプ部材が、少なくとも1つのベース部分と、前記少なくとも1つのベース部分の両端部から延在する反対側にある第1の端壁および第2の端壁と、前記ベース部分の両側部から延在する反対側にある第1の側壁および第2の側壁とを有し、前記第1の端壁および第2の端壁、第1の側壁および第2の側壁、並びに前記ベース部分が、前記スタンプ部材の内部チャンバを少なくとも部分的に画定する、前記スタンプ部材と、
前記スタンプ部材の前記ベース部分の底部に結合される係合部材であって、前記複合材料を締固めするように構成および配置される、係合部材と、
前記締固めフットの前記スタンプ部材の内部チャンバ内で受けられる誘導加熱部材であって、前記誘導加熱部材が、選択される周波数の電磁場を発生させるように構成され、前記選択される周波数が、前記複合材料内の繊維およびマトリックスのうちの少なくとも1つを加熱するためのものであり、前記締固めフットが、前記誘導加熱部材によって発生される前記電磁場の前記選択される周波数に対して透過性である材料を備える少なくとも一部分を有し、前記誘導磁場が、前記締固めフットの前記少なくとも一部分を隔離しながら、前記締固めフットの前記少なくとも一部分を通して、統合される前記複合材料に当てられることが可能になる、誘導加熱部材と、
in−situ締固め・堆積プロセス中に前記複合材料のプライ層をコンパクトな構成で提供するように前記複合材料から熱エネルギーを抽出するように構成および配置される冷却組立体とを備える、誘導加熱・締固めシステム。 - 前記締固めフットが、前記複合材料に直接係合しそれを締固めるように設計される係合部材をさらに備える、請求項1に記載のシステム。
- 前記冷却組立体が前記締固めフット内に含有される、請求項1に記載のシステム。
- 前記誘導加熱部材によって発生される前記電磁場に対して透過性ではない前記締固めフットの少なくとも1つの反応性部分を、前記誘導磁場の加熱効果から遮蔽するように位置決めされる少なくとも1つの遮蔽部材をさらに備える、請求項3に記載のシステム。
- 前記冷却組立体が、前記締固めフット内で複数の冷却通路を通してガスまたは液体のうちの少なくとも1つのための流れを供給するように構成および配置される冷却デバイスを備える、請求項1に記載のシステム。
- 前記第1および第2の側壁が複数の冷却通路を有し、シールド部材をさらに備え、前記シールド部材が、シールド頂部カバーと、前記シールド頂部カバーから延在するシールド側方部分とを有し、前記シールド側方部分が、前記スタンプ部材の前記内部チャンバ内で受けられ、前記シールド頂部カバーが前記スタンプ部材の前記内部チャンバを覆うように構成および配置される、請求項1に記載のシステム。
- 前記締固めフットを所望されるロケーションに位置決めするように構成および配置される位置決め組立体をさらに備える、請求項1に記載のシステム。
- 前記位置決め組立体を制御するように結合される制御装置をさらに備え、前記制御装置が、連続締固めプロセスで前記システムを前記材料の上を通過させるときに前記複合材料を固まった状態にするために加熱、締固め、および冷却を制御するようにさらに構成される、請求項7に記載のシステム。
- 誘導加熱・締固めシステムであって、前記システムが、
複合材料のプライ層を、前記プライ層に直接接触することによって締固めするように構成および配置される締固めフットであって、該締固めフットが、前記スタンプ部材の内部チャンバを画定するベース部分及び壁を有するスタンプ部材と、前記スタンプ部材のベース部分の底部に結合され、前記複合材料を締固めるように構成および配置される係合部材とを有する、前記締固めフットと、
前記締固めフットの前記スタンプ部材の内部チャンバ内で受けられる誘導加熱部材であって、前記誘導加熱部材が、選択される周波数の電磁場を発生させるように構成され、前記選択される周波数の電磁場が、前記係合部材を通る前記複合材料内の繊維およびマトリックスのうちの少なくとも1つに熱エネルギーを与えるように構成される、誘導加熱部材と、
前記誘導加熱部材によって発生される前記電磁場の前記選択される周波数に対して透過性である材料から作られる少なくとも一部分を有する前記締固めフットであって、前記締固めフットが、前記締固めフットを通る前記誘導磁場を、前記締固めフットを温度上昇させずに前記締固めフットの一部分を通して、統合される前記複合材料に当てるように構成される、前記締固めフットと、
前記締固めフット内に受けられる冷却組立体であって、前記冷却組立体が、in−situ締固め・堆積プロセス中に前記複合材料の前記プライ層をコンパクトな構成となるように固めるために前記複合材料から熱エネルギーを抽出するように構成および配置される、冷却組立体と
を備える、誘導加熱・締固めシステム。 - 複合材料のプライ層を統合する方法であって、前記方法が、
締固めフットを提供するステップであって、前記締固めフットが、スタンプ部材の内部チャンバを少なくとも部分的に画定するベース部分と壁とを有するスタンプ部材と、前記スタンプ部材のベース部分の底部に結合され、前記複合材料を締め固めるように構成および配置される係合部材とを有する、締固めフットを提供するステップと、
締固めフットの前記スタンプ部材の内側チャンバ内に位置決めされる誘導加熱部材を用いて加熱されるエリア内のマトリックスを軟化させるために、形成ツールの表面上にレイアップされた少なくとも1つの第1の複合材料のプライ層内の繊維およびマトリックスのうちの少なくとも1つの繊維およびマトリックスのエリアを誘導加熱するステップであって、前記誘導加熱が前記締固めフットの前記スタンプ部材の係合部材を少なくとも部分的に通って向けられる、前記誘導加熱するステップと、
前記少なくとも1つの第1の複合材料のプライ層を第2の複合材料のプライ層の上にレイアップするときに、前記少なくとも1つの第1の複合材料のプライ層に締固めフットを直接係合させることによって、前記締固めフットを用いて前記少なくとも1つの第1の複合材料のプライ層の前記加熱されるエリアを締固めするステップと、
前記少なくとも1つの第1の複合材料の層および前記第2の複合材料のプライ層をコンパクトな状態に固めるために前記加熱されるエリアを前記締固めフットで締固めしながら、前記締固めフットの冷却組立体を用いて、前記少なくとも1つの第1の複合材料のプライ層および前記第2の複合材料の層から熱エネルギーを抽出するステップと
を含む、方法。 - 前記第1の複合材料のプライ層の少なくとも一部分を前記少なくとも1つの第2の複合材料のプライ層の上に自動でレイアップするステップと、
前記第1の複合材料のプライ層の前記少なくとも一部分内のマトリックスを軟化させるために、前記第1の複合材料のプライ層の前記少なくとも一部分内の繊維およびマトリックスの少なくとも1つを誘導加熱するステップと、
前記少なくとも1つの第2の複合材料のプライ層の上で前記第1の複合材料のプライ層の前記少なくとも一部分を締固めするステップと、
前記プライ層をコンパクトな状態に固めるために締固めするときに、前記第1の複合材料の層の前記少なくとも一部分および前記少なくとも1つの第2の複合材料のプライ層から熱エネルギーを抽出するステップと
をさらに含む、請求項10に記載の方法。 - 前記締固めフット内に収容される誘導加熱器を用いて、前記少なくとも1つの第1の複合材料のプライ層内の前記繊維およびマトリックスのうちの少なくとも1つに熱エネルギーを与える所与の周波数の誘導熱エネルギーを発生させるステップをさらに含む、請求項10に記載の方法。
- 前記誘導熱エネルギーを、前記締固めフットを通して、前記少なくとも1つの第1の複合材料のプライ層に当てるステップをさらに含む、請求項12に記載の方法。
- 前記誘導加熱部材の加熱効果から前記締固めフットの少なくとも一部の要素を遮蔽するステップをさらに含む、請求項10に記載の方法。
- 前記少なくとも1つの第1の複合材料のプライ層および前記第2の複合材料のプライ層から前記熱エネルギーを抽出するために、前記加熱されるエリアを締固めする前記締固めフットを冷却するステップをさらに含む、請求項10に記載の方法。
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CN104995014B (zh) | 2018-06-05 |
CA2897194A1 (en) | 2014-07-10 |
CN104995014A (zh) | 2015-10-21 |
CA2897194C (en) | 2018-09-25 |
EP2941343B1 (en) | 2020-07-22 |
KR102001406B1 (ko) | 2019-07-18 |
US9527237B2 (en) | 2016-12-27 |
WO2014107555A1 (en) | 2014-07-10 |
JP2019024012A (ja) | 2019-02-14 |
KR20150103263A (ko) | 2015-09-09 |
US20170080647A1 (en) | 2017-03-23 |
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