JP6968519B2 - 付加製造のための複合原料ストリップ、及びそれを形成する方法 - Google Patents
付加製造のための複合原料ストリップ、及びそれを形成する方法 Download PDFInfo
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- JP6968519B2 JP6968519B2 JP2016156169A JP2016156169A JP6968519B2 JP 6968519 B2 JP6968519 B2 JP 6968519B2 JP 2016156169 A JP2016156169 A JP 2016156169A JP 2016156169 A JP2016156169 A JP 2016156169A JP 6968519 B2 JP6968519 B2 JP 6968519B2
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Description
航空宇宙応用のような多数の応用は、複雑な形状寸法を有するが生産数量が少ない部品を要する。多大な生産数量に適する成型などの多数の技法が時の経過と共に開発されてきたが、これらの技法は、膨大な費用がかかる上、多くの場合、必要とされる特性を有する部品を生み出さない。付加製造は、近年、この欠点を埋め合わせるための試みにおいて人気を博している。しかし、多くの構造要件(製造された構成要素の強度等)は、現行の付加製造技法では、容易には満たすことができない。例えば、付加製造原料に繊維又は粒子のような構造支持体を組み入れることは、大きな課題であり続けてきた。たとえ小さな繊維及び粒子であっても、小型の断面形状を有する原料の直接形成を試みる時に、押出ノズルを詰まらせる傾向がある。けれども、複雑な形状寸法、厳しい寸法公差、及び/又は滑らかな表面仕上げを伴う部品を製造するために、小型形状は不可欠である。
図1Aは、いくつかの実施形態による、付加製造のための複合原料ストリップを形成する方法100に対応するプロセスフロー図である。方法100は、工程102におけるレイアップの形成で始まってよく、工程110におけるレイアップの積層がそれに続く。積層されたシートが、工程110において形成され、その後工程120において、スリット加工されて複合原料ストリップになる。いくつかの実施形態では、複合原料ストリップの断面形は、オプション工程130において変更される。この工程130は、オプション工程132における複合原料ストリップの加熱、及び/又は、オプション工程134における材料の再分配を伴いうる。材料を再分配することは、複合原料ストリップ内の繊維の相対配向に影響を与えることなく実行されうる。いくつかの実施形態では、方法100は、オプション工程140のおける付加製造の実行を伴いうる。複合原料ストリップは、この工程において消費されて複合部品を形成しうる。これらの工程の各々について、方法100の様々な段階における構成要素、説明される工程を実行するために使用される器材、及び試験サンプルを示している様々な図を参照して、これからより詳細に説明する。
例示された実施形態は、連続繊維が連続して単方向に配向されており、かつ、これらの連続繊維がストリップの断面全体を通じて適切に分布している、複合原料ストリップを形成する新規な製造方法を提供する。更に、これらの方法は、ストリップの種々の断面形状及び/又は寸法を提供する。これらの方法において使用される連続処理は、処理スループットを増大させるだけでなく、複合原料ストリップの様々な特性の高水準な制御も提供する。実施形態は、例えば航空宇宙産業におけるものを含む多種多様な潜在的応用での、適用可能な使用法を見い出す。開示されている方法は、理想的には、ブラケット、クリップ支持体、リンクレバー、又はより一般的には、現在は金属で形成されている任意の不定形断面構造物(例えばラグ、端末取付具)のような複雑な形状寸法を有する部品の付加製造に適する。それらの部品は概して、ビームのような単純な(例えば線形の)形状寸法(変動しない断面など)を有する部品とは区別されるべきである。開示されている方法は、付加製造を使用して製造される可能性がある、一点ものの、カスタマイズされた、又は、変動しない断面を伴う非常に限定された部品にも適する。
本書で開示されている装置(複数可)及び方法(複数可)の種々の例は、多種多様な構成要素、特徴及び機能を含む。本書で開示されている装置(複数可)及び方法(複数可)の様々な例は、本書で開示されている装置(複数可)及び方法(複数可)のその他の例のうちの任意のものの、任意の構成要素、特徴及び機能を、任意の組み合わせにおいて含む可能性があり、かかる可能性は全て、本開示の本質及び範囲に含まれると意図されていることを、理解すべきである。
シートをスリット加工して、複合原料ストリップにすることであって、
シートは、第1樹脂と、シートの中で互いに平行に延びる繊維とを含み、
スリット加工は、シートの中の全ての繊維に平行な方向に沿って実行される、スリット加工することと、
第2樹脂を含む材料で複合原料ストリップの外表面をコーティングし、それによって、複合原料ストリップを覆うように配置されたコーティング層を備えるコーティング済複合原料ストリップを形成することとを含む、方法。
第1樹脂、及び、シートの中で互いに平行に延びている繊維を含む、複合原料ストリップと、
第2樹脂を含み、複合原料ストリップの外表面上に配置され、かつ、複合原料ストリップの周囲に外殻を形成する、コーティング層とを備える、コーティング済複合原料ストリップ。
一又は複数の繊維含有プライ及び一又は複数の樹脂プライを備えるレイアップであって、
そのレイアップを形成する一又は複数の繊維含有プライ全てにおける全ての連続繊維が互いに平行である、レイアップを形成することと、
レイアップを積層し、それによって、積層されたシートを形成することと、
積層されたシートをスリット加工して、複合原料ストリップにすることとを含み、
スリット加工は、積層されたシートの中の全ての連続繊維に平行な方向に沿って実行される、方法。
樹脂と、
互いに平行であり、かつ、複合原料ストリップの主軸に沿って延びている連続繊維であって、
その体積分率は複合原料ストリップの主軸に垂直な少なくとも1つの方向に沿って変わる、連続繊維とを備える、複合原料ストリップ。
Claims (13)
- 付加製造のための複合原料ストリップを形成する方法であって、
シートをスリット加工して、複合原料ストリップにすることであって、前記シートは、第1樹脂と、シートの中で互いに平行に延びている繊維とを含み、スリット加工は、前記シートの中の全ての前記繊維に平行な方向に沿って実行される、スリット加工することと、
第2樹脂を含む材料で前記複合原料ストリップの外表面をコーティングし、それによって、前記複合原料ストリップを覆うように配置されたコーティング層を備える複合原料ストリップを形成することと、を含む、方法。 - 前記シートの中で互いに平行に延びている前記繊維は連続繊維である、請求項1に記載の方法。
- 前記複合原料ストリップの断面全体を通じての前記繊維の分布は均一である、請求項1に記載の方法。
- 前記複合原料ストリップの断面全体を通じての前記繊維の濃度は、少なくとも40体積%である、請求項1に記載の方法。
- 前記材料で前記複合原料ストリップの前記外表面をコーティングしている間、前記複合原料ストリップの断面は同じままである、請求項1に記載の方法。
- 前記複合原料ストリップの前記外表面上の前記コーティング層の厚みは均一である、請求項1に記載の方法。
- 前記複合原料ストリップのコーティング前の断面形状は、長方形、正方形、及び台形から成る群から選択され、前記複合原料ストリップのコーティング後の断面形状は、楕円形、円形、長方形、正方形、角が丸くなっている長方形、及び角が丸くなっている正方形から成る群から選択される、請求項1に記載の方法。
- 前記シートをスリット加工する前に、繊維含有プライを備えるレイアップを形成することと、前記レイアップを積層し、それによって前記シートを形成することとを更に含む、請求項1に記載の方法。
- 前記シートをスリット加工する前に、一又は複数の繊維含有プライ及び一又は複数の樹脂プライを備えるレイアップを形成することと、前記レイアップを積層し、それによって前記シートを形成することとを更に含む、請求項1に記載の方法。
- 複合原料ストリップであって、
第1樹脂、及び、前記複合原料ストリップの中で互いに平行に延びている繊維を含み、前記複合原料ストリップ内の前記繊維の体積分率は前記複合原料ストリップの厚み全体を通じて変わり、該厚さは前記繊維に垂直であり、互いに平行に延びている前記繊維は連続繊維であり、前記複合原料ストリップの断面全体を通じて平行に延びている前記繊維の濃度は、少なくとも40体積%である、複合原料ストリップと、
第2樹脂を含み、前記複合原料ストリップの外表面上に配置され、かつ、複合原料ストリップの周囲に外殻を形成する、コーティング層とを備える、複合原料ストリップ。 - 前記コーティング層は、繊維、粒子、及び薄片から成る群から選択された添加材を更に含む、請求項10に記載の複合原料ストリップ。
- 前記複合原料ストリップの断面形状は、長方形、正方形、及び台形から成る群から選択され、前記複合原料ストリップの断面形状は、楕円形、円形、長方形、正方形、角が丸くなっている長方形、及び角が丸くなっている正方形から成る群から選択される、請求項10に記載の複合原料ストリップ。
- 前記第1樹脂と前記第2樹脂の一方は、ポリエーテルスルホン(PES)、ポリフェニレンスルフィド(PPS)、ポリエーテルエーテルケトン(PEEK)、ポリエーテルケトンケトン(PEKK)、ポリエーテルイミド(PEI)、及び熱可塑性ポリイミド(TPI)から成る群から選択された、一又は複数の材料を含む、請求項10に記載の複合原料ストリップ。
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CA2932827C (en) | 2020-10-20 |
US20200016845A1 (en) | 2020-01-16 |
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