US20150290883A1 - Method of applying an intermediate material making it possible to ensure the cohesion thereof, method of forming a stack intended for the manufacture of composite components and intermediate material - Google Patents

Method of applying an intermediate material making it possible to ensure the cohesion thereof, method of forming a stack intended for the manufacture of composite components and intermediate material Download PDF

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Publication number
US20150290883A1
US20150290883A1 US14/441,192 US201314441192A US2015290883A1 US 20150290883 A1 US20150290883 A1 US 20150290883A1 US 201314441192 A US201314441192 A US 201314441192A US 2015290883 A1 US2015290883 A1 US 2015290883A1
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Prior art keywords
thermoplastic
intermediate material
layer
thermosetting
unidirectional
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US14/441,192
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English (en)
Inventor
Jean-Marc Beraud
Jacques Ducarre
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Hexcel Fabrics SA
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Hexcel Fabrics SA
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Assigned to HEXCEL REINFORCEMENTS reassignment HEXCEL REINFORCEMENTS ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BERAUD, JEAN-MARC, DUCARRE, JACQUES
Publication of US20150290883A1 publication Critical patent/US20150290883A1/en
Abandoned legal-status Critical Current

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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
    • B29C70/06—Fibrous reinforcements only
    • 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
    • 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
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • 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
    • B29C70/382—Automated fiber placement [AFP]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • 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
    • B29C70/06—Fibrous reinforcements only
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/543—Fixing the position or configuration of fibrous reinforcements before or during moulding
    • 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
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/545—Perforating, cutting or machining during or after moulding
    • 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
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/56—Tensioning reinforcements before or during shaping
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • 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
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    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • 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
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
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    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0872—Prepregs
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Definitions

  • the present invention relates to the technical field of reinforcing materials, suitable for the forming of composite parts. More precisely, it relates to methods and uses for improving the resistance to delamination of materials during their application.
  • the fabrication of composite parts or articles i.e. comprising, firstly, one or more reinforcements or fibrous sheets and, secondly, a matrix (which is, usually, mainly of thermosetting type and can include one or more thermoplastics) can, for example, be produced by a method called “direct” or “LCM” (Liquid Composite Molding) method.
  • a direct method is defined by the fact that one or more fibrous reinforcements are employed in the “dry” state (i.e.
  • the resin or matrix being implemented separately, for example by injection into the mold containing the fibrous reinforcements (the “RTM” method, for Resin Transfer Molding), by infusion through the thickness of the fibrous reinforcements (“LRI” method or Liquid Resin Infusion method, or “RFI” method or Resin Film Infusion method), or else by manual coating/impregnation with roller or brush, on each of the individual layers of fibrous reinforcement, applied successively to the form.
  • RTM Resin Transfer Molding
  • LRI Liquid Resin Infusion method
  • RFI Resin Film Infusion method
  • Composite parts used in the automotive, aeronautical or naval industries are particularly subject to very strict requirements, particularly in terms of mechanical properties.
  • the aeronautical industry has replaced many metallic materials by composite materials, which are lighter.
  • the resin which is subsequently added, particularly by injection or infusion, to the unidirectional reinforcing sheets during the production of the part can be a thermosetting resin, for example of epoxy type.
  • this resin is usually very fluid, for example with a viscosity in the order of 50 to 200 mPa ⁇ s. at the infusion/injection temperature.
  • the major drawback of this type of resin is its fragility after polymerization/reticulation, which causes the produced composite parts to have poor impact resistance.
  • the laying-up tension being generally considered to be constant, and the result is that the shear stress is higher in the first centimeters of lay-up and will decrease with the length of the laid-up tape.
  • the shear stress is distributed over the whole thickness of the tape and, if the laying-up tension is too high, a delamination of the tape in its central area, which is composed of dry reinforcing fibers, has been observed in some cases by the applicant in the first centimeters of lay-up.
  • This phenomenon can also be accentuated in the case of materials associated on each of their main faces to a layer of thermoplastic and/or thermosetting material, when a laying-up member, of the small or large roller type depending on the width of the material to be laid up, is used to lay up the material.
  • a laying-up member of the small or large roller type depending on the width of the material to be laid up
  • the face in contact with the roller tends to adhere to it, which can also promote the delamination of the material when its other face is then bonded to the surface on which it is laid and which can be a support or the preceding ply.
  • the objective of the invention is to remedy the delamination problems that can be observed in some cases, during the application of intermediate materials composed of a layer of reinforcing fibers associated on at least one its faces to a layer of thermoplastic or thermosetting material or a mixture of thermoplastic and thermosetting materials, such as for example with the veiled tapes described in the patent applications WO 2010/046609 and WO 2010/061114, which are implemented in the production of stacks in particular.
  • the present invention proposes a new deposition method implementing a prior step and making it possible to preserve the integrity of the intermediate materials used during deposition (laying-up).
  • the present invention relates to a method for continuously applying on a deposition surface of an intermediate material composed of a unidirectional layer of reinforcing fibers associated on at least one of its faces to a layer of thermoplastic and/or thermosetting material, the layer(s) of thermoplastic and/or thermosetting material forming the intermediate material not representing more than 10% of the total weight of the intermediate material, and preferably representing 0.5 to 10%, and more preferably 2 to 6%, of the total weight of the intermediate material, wherein:
  • the intermediate material before the deposition operation the intermediate material undergoes an operation applying spot transverse forces, in such a way as to increase cohesion in the thickness of the intermediate material.
  • the integrity of the intermediate material is then better preserved during its deposition, in spite of the shear stresses it undergoes.
  • the invention also relates to a method for forming a stack by successive applications of intermediate materials composed of a unidirectional layer of reinforcing fibers associated on at least one its faces to a layer of thermoplastic and/or thermosetting material, wherein the intermediate materials are applied according to the continuous method of the invention.
  • the produced stack includes several unidirectional layers of reinforcing fibers, with at least two unidirectional layers of reinforcing fibers extending in different directions.
  • Another subject of the invention is the use, in a continuous application method according to the invention, of an intermediate material having previously undergone an operation applying spot transverse forces, to preserve the cohesion of the material during its deposition, and in particular in the first centimeters of deposition.
  • Another subject of the invention is a method for fabricating a composite part comprising a step of formation, according to the method defined in the context of the invention, of a stack by successive applications of intermediate materials, said intermediate materials being each composed of a layer of reinforcing fibers associated on at least one of its faces to a layer of thermoplastic or thermosetting material, followed by a step of diffusion, by infusion or injection, of a thermosetting resin, of a thermoplastic resin or of a mixture of such resins, inside the stack, followed by a step of consolidation of the desired part followed by a step of polymerization/reticulation according to a defined pressure-temperature cycle, and a cooling step.
  • the present invention also relates to intermediate materials composed of a unidirectional layer of reinforcing fibers associated on at least one of its faces to a thermoplastic and/or thermosetting material, the layer(s) of thermoplastic and/or thermosetting material forming the intermediate material not representing more than 10% of the total mass of the intermediate material and preferably representing from 0.5 to 10%, and more preferably from 2 to 6%, of the total mass of the intermediate material, having undergone an operation applying spot transverse forces, performed in such a way as to traverse the total thickness of the intermediate material and being accompanied by heating leading to the at least partial melting of the thermoplastic material or the partial or complete polymerization of the thermosetting material, at the application spots of transverse forces, and leading to the penetration of the thermoplastic and/or thermosetting material and creating bridges in the thickness of the unidirectional layer of reinforcing fibers, preferably extending from one main face of the unidirectional layer of reinforcing fibers to the other.
  • the operation applying spot transverse forces is carried out with a density of application points of 40000 to 250000 per m 2 , and preferably of 90000 to 110000 per m 2 and the obtained intermediate material has an opening factor of 0 to 2%, and preferably of 0 to 1% and more preferably of 0%.
  • such an intermediate material can have an opening factor of 0 to 2% and preferably of 0%, and have been obtained with a density of application points of 90000 to 110000 per m 2 .
  • FIGS. 1A and 1B are schematic views illustrating two modes of application of intermediate materials that can be used in the context of the invention.
  • FIG. 2 schematically represents the forces applied to an intermediate material at the start of its deposition.
  • FIG. 3 is a schematic view illustrating another mode of application of intermediate materials that can be used in the context of the invention.
  • FIGS. 4A to 4C are schematic views illustrating the successive application of intermediate materials appearing in tape form.
  • FIG. 5 is a schematic view of a series of application points where transverse forces, penetrations or perforations are exerted.
  • FIG. 6A is an overall photograph of a perforated intermediate material that can be used in the context of the invention.
  • FIG. 6B is a photograph corresponding to a microscopic view, giving a detailed view of the effect of a perforation of the material shown in FIG. 6A .
  • FIG. 6C is a photograph of another perforated intermediate material that can be used in the context of the invention, having different features (OF).
  • FIG. 6D is a photograph corresponding to a microscopic view, giving a detailed view of the effect of a perforation of the material shown in FIG. 6C .
  • FIG. 6E shows a microscope image of a cut in the thickness of a stratified material produced from the intermediate material shown in FIG. 6C with infusion of RTM 6 resin (from Hexcel Corporation®) at 60% fiber volume ratio.
  • FIG. 7 schematically represents a device for applying spot transverse forces.
  • FIG. 8 studies the resistance to delamination of an intermediate material used in the context of the invention, as a function of the tension applied to said intermediate material during a perforation operation.
  • FIG. 9 studies the resistance to delamination obtained as a function of the density of microperforations applied to the intermediate material, in different cases of grammage of the unidirectional sheets of carbon fibers.
  • FIG. 10 shows the resistance to delamination results obtained for various intermediate materials as a function of the veil and of the grammage of the unidirectional sheet of carbon fiber used.
  • FIG. 11 shows the resistance to delamination results obtained as a function of the basis weight of the veil.
  • the invention uses the continuous application of an intermediate material, along a given movement trajectory, with simultaneous application on the intermediate material of a tension and a pressure in such a way as to apply it on the deposition surface, the laying-up being carried out by applying one face of the intermediate material in the process of being laid up corresponding to a layer of thermoplastic and/or thermosetting material on the deposition surface and/or by applying the intermediate material in the process of being laid up on the deposition surface carrying a thermoplastic and/or thermosetting material, and by activating, at the deposition area, the interface between the intermediate material and the deposition surface, in such a way as to ensure the bond between the laid-up intermediate material and the deposition surface.
  • FIG. 1A illustrates the application of an intermediate material 1 composed of a layer of unidirectional fibers 2 associated to a single one of its faces named 1 1 to a layer of thermoplastic and/or thermosetting material 3 .
  • the intermediate material is applied so that its face 1 2 , which corresponds to the layer of unidirectional fibers 2 , is applied against the deposition surface 4 .
  • the deposition surface 4 is itself composed of a layer of thermoplastic and/or thermosetting material 5 which is activated and which ensures the bond with the intermediate material. The activation is ensured by appropriate means that are not represented, as the intermediate material is laid up.
  • the intermediate material is continuously applied, along a given movement trajectory, with simultaneous application on the intermediate material of a tension and a pressure in such a way as to apply on the deposition surface a face of the intermediate material in the process of being laid up corresponding to a layer of thermoplastic and/or thermosetting material and by activating said layer of thermoplastic and/or thermosetting material during deposition, in such a way as to ensure the bond between the laid-up intermediate material and the deposition surface.
  • FIG. 1B One such possibility where the intermediate material is applied in such a way as to apply the layer of thermoplastic and/or thermosetting material 3 against the deposition surface 4 is shown in FIG. 1B .
  • the activation is done at or near the deposition area, in such a way as to render sticky the layer of thermoplastic and/or thermosetting material ensuring the bonding, before the contact between the intermediate material and the deposition surface is achieved.
  • each intermediate material comprises a layer of reinforcing fibers associated on at least one of its faces to a layer of thermoplastic or thermosetting material or of a mixture of thermoplastic or thermosetting materials.
  • each intermediate material is applied on a surface which can be, either a support element in the case of the application of the first layer of intermediate material(s) required to produce the stack, or a previously applied intermediate material.
  • each intermediate material is preferably performed in such a way that at least one layer of thermoplastic or thermosetting material or a mixture of thermoplastic and thermosetting materials is applied on the deposition surface and is activated during its deposition, in such a way as to ensure the bond with the surface on which the intermediate material is applied.
  • a deposition facilitates the application of the first ply, which can be applied on any type of gluing surface compatible with the chosen polymer material.
  • at least one layer of thermoplastic or thermosetting material or a mixture of thermoplastic and thermosetting materials thus exists at the interface of two intermediate materials applied one on top of the other and ensures their mutual bond.
  • the application of an intermediate material is performed continuously, with application of a pressure on the latter in such a way as to apply it on the deposition surface.
  • the force resulting from this pressure can, for example, be of 0.3 to 8 N per cm of width of the intermediate material.
  • the intermediate material is stretched during its deposition. To do this, it is stretched parallel to the direction of the unidirectional fibers. In particular, a tension of 2 to 50 g per cm of width of the intermediate material can, in particular, be applied to the intermediate material.
  • the intermediate material 1 undergoes a shear stress due to the fact that it is stretched in one direction due to its bonding to the deposition surface 4 and in the opposite direction due to the tension applied to the latter, as schematically represented in FIG. 2 .
  • the laying-up member is a rotating device of large roller, roller or small roller type, according to the width of the intermediate material applied.
  • This laying-up member is coupled to a device for moving and feeding the material during its deposition. The deposition of the intermediate material can thus be performed in an automated manner using a control device.
  • FIG. 3 illustrates another embodiment wherein the movement of the intermediate material 1 is ensured as it is laid up by exerting a pressure, preferably substantially perpendicular to the deposition surface 4 to which it is applied.
  • the laying-up member is composed of a roller 6 which exerts a pressure on the material 1 , in such a way as to apply it to the deposition surface 4 .
  • the intermediate material is composed of a unidirectional sheet 10 associated on each of its faces to a layer of thermoplastic and/or thermosetting material 20 and 30 . The handling of such symmetrical intermediate materials is easier, given that in all cases two layers of thermoplastic and/or thermosetting material exist at the interface, and the material can be applied to either one of its faces.
  • the layer of thermoplastic and/or thermosetting material located at the interface of the intermediate material in the process of being laid up and the surface on which it is applied is activated as the deposition is carried out, by any appropriate means, for example by a heating device, particularly an infrared light, a hot gas duct or a laser represented by the reference number 7 in FIG. 3 , oriented toward the deposition area of the intermediate material.
  • a heating device particularly an infrared light, a hot gas duct or a laser represented by the reference number 7 in FIG. 3
  • a laser diode of 500 W and of a wavelength between 965 nm and 980 nm offered the possibility of laying up the intermediate material at speeds of 1 m/second over 50 mm in width. A higher power makes it possible to further increase this speed or to lay up a greater width.
  • the activation makes it possible to soften the polymer layer to be activated by effecting an at least partial melting in the case of a thermoplastic material and the start of polymerization in the case of
  • the depositing trajectory of the intermediate material can be straight or curved.
  • the unidirectional fibers follow the depositing trajectory.
  • FIGS. 4A to 4C illustrate an embodiment wherein different strips 100 of intermediate materials are laid up one in front of the other along parallel deposition trajectories, in such a way as to form layers 200 1 to 200 n .
  • the device 300 for activating the thermoplastic and/or thermosetting material forms a single component with the laying-up member 400 so that they can move together.
  • the laying-up member 400 is moved for the depositing of the various strips 100 which are cut at the end of the trajectory using a cutting member (not represented).
  • a cutting member not represented
  • FIG. 4C represents the depositing of the second layer 200 2 .
  • the strips 100 of intermediate materials forming one and the same layer are laid up adjacently, without inter-strip spacing, and with a gluing over 100% of their surface area. It is thus possible to produce a said multi-axial material.
  • the depositing method illustrated in FIGS. 4A to 4C is particularly suitable for the application of intermediate materials of a width between 3 and 300 mm and with small width variation, typically having a standard deviation on the width of less than 0.25 mm.
  • the intermediate material is prepared, prior to its continuous application during which the latter undergoes a certain pressure and a certain tension giving rise to the application of shear stresses, in such a way as to guarantee a better cohesion of the intermediate material in spite of the shear forces exerted on the latter during the lay-up operation.
  • This preparation consists in performing on the intermediate material an operation applying spot transverse forces, in such a way as to traverse the total thickness of the intermediate material.
  • spot transverse forces is accompanied by heating, leading to the at least partial melting of the thermoplastic material or the partial or complete polymerization of the thermosetting material, at the application spots of transverse forces, and creates bonding bridges in the thickness of the unidirectional layer of reinforcing fibers.
  • these bonding bridges are established between the two main faces of the unidirectional layer of reinforcing fibers.
  • the invention is adapted to the application of intermediate materials wherein, over at least a part of the thickness of the unidirectional layer, the unidirectional reinforcing fibers are dry, i.e. not impregnated with thermoplastic and/or thermosetting material, and therefore more sensitive to delamination.
  • thermoplastic and/or thermosetting layer(s) associated with the unidirectional sheet can however have slightly penetrated into the latter upon attachment, generally carried out by thermocompression, but the central part, in the case of a material including two layers of thermoplastic and/or thermosetting material, or the part opposite the layer of thermoplastic and/or thermosetting material in the case of a material including only one layer of thermoplastic and/or thermosetting material, which generally corresponds to at least 50% of the thickness of the layer of unidirectional fibers, remains unimpregnated and is therefore classed as dry.
  • the penetration operation consists in traversing the total thickness of the intermediate material, while heating the thermoplastic or thermosetting material in such a way that the latter is softened and can be drawn into the layer of unidirectional fibers, at the application spots of transverse forces. Once cooled, the thermoplastic and/or thermosetting material creates bonding bridges in the thickness of the layer of unidirectional fibers, which reinforces its cohesion. After such an operation, with the exception of the areas bordering the application spots of transverse forces, over at least 50% of its thickness, the layer of unidirectional fibers is dry, i.e. unimpregnated with thermoplastic and/or thermosetting material.
  • the operation applying spot transverse forces corresponds to an operation of penetration at different application or penetration points.
  • the terms “operation of spot application of transverse forces” or “operation of penetration at different penetration points” will be used indiscriminately to describe such a step consisting in traversing an intermediate material, at least over a part of its thickness.
  • the operation of applying spot transverse forces is preferably performed using the penetration of a needle or a series of needles, which makes it possible to properly control the orientation of the transverse forces.
  • the operation of applying spot transverse forces performed on the intermediate material must be accompanied by heating, leading to the at least partial melting of the thermoplastic material and/or the softening of the thermosetting material at the application spots of transverse forces.
  • a penetrating member itself heated, will be used.
  • a hot gas jet heating the layer of thermoplastic and/or thermosetting material prior to the penetration operation could also be envisioned.
  • the operation applying spot transverse forces is performed by applying a tensile force to the intermediate material.
  • a sufficient tension particularly of 15 to 3000 g per cm of width will be applied to the intermediate material, usually as it is fed through, during the penetration operation, in such a way as to allow the introduction of the chosen penetrating means or member.
  • the tensile force on the intermediate material will be selected in such a way as to lead to the at least partial retightening of the unidirectional fibers after the operation of applying spot transverse forces.
  • an effort will be made to obtain the lowest opening factor possible, to avoid damaging the mechanical properties of the part subsequently obtained from such an application of intermediate material.
  • the penetration operation will be implemented by applying to the intermediate material a tension such that the opening created by the penetrating member or means can close up again after the withdrawal of the latter.
  • a tension 300 to 2000 g per cm of width will be applied to the intermediate material to obtain such a retightening.
  • the member or the means used for the penetration operation is withdrawn either after having traversed the intermediate material in question by making a sole outward journey or a return.
  • This withdrawal will therefore preferably be made before cooling of the thermoplastic and/or thermosetting material, in order to allow the retightening of the fibers.
  • the time to cool the thermoplastic and/or thermosetting material to its setting point will therefore be greater than the time required for the fibers to retighten, or even to completely realign, under the high tension that is applied to them.
  • the result or goal of this penetration operation is to minimize the risks of delamination, which could occur during the deposition of the intermediate material, in accordance with the deposition step previously described, and particularly during the first centimeters of deposition when it undergoes the main shear forces.
  • the penetration operation is performed in a direction transverse to the surface of the intermediate material that is traversed.
  • the penetration operation can leave or not leave perforations in the intermediate material that has been traversed.
  • the openings created by the penetration operation will usually have a circular or more or less elongated cross section in the form of an eye or a slot, in the plane of the intermediate material that has been traversed.
  • the resulting perforations are, for example, of a larger size, measured parallel to the surface that has been traversed, reaching up to 10 mm and of a width of up to 300 ⁇ m.
  • the operation of applying spot transverse forces leads to an opening factor greater than or equal to 0 and less than or equal to 5% and preferably of 0 to 2% and more preferably of 0 to 1%, in such a way as to have as little impact as possible on the mechanical properties of the composite parts subsequently obtained.
  • the opening factor can be defined as the ratio of the surface area unoccupied by the material to the total observed surface area, the observation of which can be achieved from the top of the material with lighting from underneath the latter. It can, for example, be measured using the method described in the patent application WO 2011/086266.
  • the opening factor can be zero and correspond to a material with greatly improved delamination.
  • Heating will be performed at the penetrating means or around the latter, in such a way as to allow the softening of the thermoplastic and/or thermosetting material initially present only at the surface of the intermediate material, and its penetration into the unidirectional fiber layers.
  • a heating resistor can, for example, be directly integrated into the penetration means, of needle type. The melting of the thermoplastic material, or the partial or complete polymerization in the case of a thermosetting material, thus takes place around the penetrating means, which, after cooling, leads to the creation of bonding bridges between the fibers of the unidirectional layer.
  • the heating means is directly integrated into the penetrating means, so that the penetrating means is itself heated.
  • FIG. 7 shows a heating/penetration device 600 equipped with an assembly of needles 700 aligned in accordance with the selected penetration lines and spacing increments.
  • the penetration points are, preferably, arranged in such a way as to form, for example a network of parallel lines, and will therefore be advantageously arranged in two series S 1 and S 2 of lines, so that:
  • FIG. 5 Such a configuration is illustrated in FIG. 5 .
  • the penetration of a member such as a needle can incur, not the formation of a hole, but rather a slot as shown in FIGS. 6A and 6C , due to the fact that the unidirectional fibers spread apart from one another at the penetration point, the slots are thus offset with respect to one another. This avoids the creation of an excessively large opening due to the meeting of two slots that are too close together.
  • FIG. 6A shows an intermediate material composed of a unidirectional sheet of 140 g/m 2 of IMA 12K carbon fibers from the Hexcel Corporation® with a 1R8D03 veil from Protechnic® (Cernay, France) thermocompressed on either face.
  • This intermediate material has a width of 6.35 mm and an opening factor of 1.6% (standard deviation 0.5%). It was produced by penetration with a series of hot needles with a tension of 315 g/cm.
  • FIG. 6B shows a magnification of a perforated area of the material shown in FIG. 6A .
  • FIG. 6C shows an intermediate material of 210 g/m 2 of IMA 12K fibers from Hexcel Corporation® with a 1R8D06 veil from Protechnic® (Cernay, France) thermocompressed on either face, of 6.35 mm in width having an opening factor of 0.5% (standard deviation 0.3%). It was produced by penetration with a series of hot needles with a tension of 315 g/cm.
  • FIG. 6D shows a magnification of a perforated area of the material shown in FIG. 6C .
  • FIG. 6E shows a microscope image of a cut into the thickness of a stratified material produced from the intermediate material shown in FIG. 6C with infusion of RTM 6 resin (from Hexcel Corporation®) at 60% fiber volume ratio.
  • RTM 6 resin from Hexcel Corporation®
  • the basis weight of the reinforcing threads and the veil have an effect on the opening factor obtained with one and the same tension of the threads during perforation.
  • the 210 g/m 2 sheet has a smaller opening factor than the 140 g/m 2 sheet, even though a veil of higher grammage was used.
  • the phenomenon of rearrangement of the filaments under tension occurs more easily with a thicker material.
  • the application WO 2010/046609 describes such intermediate materials having undergone a prior penetration/perforation operation, composed of a unidirectional sheet of carbon fibers, associated on each of its faces to a non-woven material of thermoplastic fibers. The reader may refer to this patent application for more details, given that it describes in detail the intermediate materials that can be used in the context of the invention.
  • the operation of applying spot transverse forces will be performed by an appropriate penetrating means, preferably automated, and in particular using a series of needles, pins or otherwise.
  • the needle diameter (in the regular part after the tip) will in particular be of 0.8 to 2.4 mm.
  • the application points will usually be spaced apart by 5 to 2 mm.
  • the penetration operation is performed on the intermediate materials which are then laid up, or even stacked to form a stack required for the production of a composite part. It is not necessary for the penetration points to then be superimposed during the stacking of the intermediate materials.
  • the produced stack is exclusively composed of intermediate materials defined in the context of the invention, having undergone the penetration operation.
  • the stack by superimposition of intermediate materials composed of a reinforcing material based on unidirectional carbon fibers, associated on at least one of its faces to a layer of thermoplastic or thermosetting material or of a mixture of the two.
  • Such an intermediate material can be composed of a unidirectional sheet of carbon fibers, associated on a single one of its faces, or on each of its faces, to a layer of thermoplastic or thermosetting material or of a mixture of the two.
  • Such intermediate materials have a proper cohesion, the layer(s) of thermoplastic or thermosetting material or of a mixture of the two having been previously associated with the reinforcing material, preferably owing to the thermoplastic or thermosetting nature of the layer by thermocompression.
  • the stack produced in the context of the invention can comprise a large number of layers of intermediate materials, in general at least four and in certain cases over 100, or even over 200.
  • Each layer of intermediate material(s) can be composed either of a single width of intermediate material, or of side-by-side applications, produced jointly or not with the intermediate materials.
  • the stack will preferably be composed solely of the intermediate materials defined in the context of the invention and according to an advantageous embodiment, of intermediate materials that are all identical.
  • the reinforcing fibers forming the intermediate materials applied in the context of the invention and, therefore, used for the creation of the stacks are, for example, fiberglass, carbon, aramid, or ceramics, carbon fibers being particularly preferred.
  • the term “unidirectional sheet or layer of reinforcing fibers” is understood to mean a sheet composed exclusively or quasi-exclusively of reinforcing fibers applied along one and the same direction, in such a way as to extend substantially parallel to one another.
  • the unidirectional sheet does not include any weft yarn interlacing the reinforcing fibers, or even any sewing that might have the goal of giving cohesion to the unidirectional sheet before its association to a layer of thermoplastic or thermosetting material or of a mixture of the two. This makes it possible, in particular, to avoid any undulations in the unidirectional sheet.
  • the reinforcing yarns are preferably not associated with a polymer binder and are therefore designated as dry, i.e. they are neither impregnated, nor coated, nor associated with any polymer binder before their association to the layers of thermoplastic and/or thermosetting material.
  • the reinforcing fibers are, however, usually characterized by a standard sizing concentration by weight that can represent at most 2% of their weight. This is particularly suitable for the production of composite parts by resin diffusion, using direct methods well known to those skilled in the art.
  • the constituting fibers of the unidirectional sheets are preferably continuous.
  • the unidirectional layer or sheet present in the applied intermediate materials can be composed of one or more yarns.
  • a carbon yarn is composed of a set of filaments and generally contains 1000 to 80000 filaments, advantageously 12000 to 24000 filaments.
  • carbon yarns of 1 to 24K for example of 3K, 5K, 12K or 24K, and preferably of 12K and 24K are used.
  • the carbon yarns present within the unidirectional sheets have a count of 60 to 3800 tex, and preferably 400 to 900 tex.
  • the unidirectional sheet can be produced with any type of carbon yarn, for example High Resistance (HR) threads, the tensile modulus of which is between 220 and 241 GPa and the stress rupture in tension of which is between 3450 and 4830 MPa, Intermediate Modulus (IM) yarns, the tensile modulus of which is between 290 and 297 GPa and the tensile breaking stress of which is between 3450 and 6200 MPa and High Modulus (HM) yarns, the tensile modulus of which is between 345 and 448 GPa and the stress rupture in tension of which is between 3450 and 5520 MPa (according to the “ASM Handbook”, ISBN 0-87170-703-9, ASM International 2001).
  • HR High Resistance
  • IM Intermediate Modulus
  • HM High Modulus
  • the stack is preferably composed of several intermediate materials each comprising a layer of unidirectional reinforcing fibers, with at least two layers of unidirectional reinforcing fibers extending in different directions. All the layers of unidirectional reinforcing fibers can have different directions, or only some of them can. Otherwise, outside their differences in orientation, the layers of unidirectional reinforcing fibers will preferably have identical features.
  • the favored orientations are usually those forming an angle of 0°, +45° or ⁇ 45° (also equivalent to)+135°, and +90° with the main axis of the part to be produced.
  • the 0° corresponds to the axis of the machine for producing the stack, i.e. the axis that corresponds to the direction of feeding of the stack during its creation.
  • the main axis of the part which is the largest axis of the part, is generally merged with 0°. It is, for example, possible to produce quasi-isotropic, symmetrical or oriented stacks by choosing the orientation of the plies. Examples of quasi-isotropic stacks include the angles 45°/0°/135/°90°, or 90°/135°/0°/45°. Examples of symmetrical stacks include 0°/90°/0°, or 45°/135°/45°. In particular, stacks comprising more than 4 unidirectional sheets, for example of 10 to 300 unidirectional sheets, can be produced. These sheets can be oriented in 2, 3, 4, 5 or even more different directions.
  • the intermediate materials used include a unidirectional sheet of carbon fibers having a grammage of 100 to 280 g/m 2 .
  • the layer(s) of thermoplastic and/or thermosetting material present in the intermediate materials used is (are), preferably, a non-woven material made of thermoplastic fibers.
  • layers of thermoplastic and/or thermosetting material or of a mixture of the two or a fabric, porous film, mesh, knitted fabric or powder deposition could be used.
  • layer of thermoplastic and/or thermosetting material means that said layer can be composed of a single thermoplastic or thermosetting material, of a mixture of thermoplastic materials, of a mixture of thermosetting materials or of a mixture of thermoplastic and thermosetting materials.
  • non-woven material which can also be known as a “veil”, is also conventionally understood to refer to an assembly of continuous or short fibers arranged randomly.
  • These non-woven materials or veils can for example be produced by dry methods (drylaid), wet methods (wetlaid), melting methods (spunlaid), for example by extrusion (spunbond), blown extrusion (meltblown), or by spinning with solvent (electrospinning, flashspinning) well known to those skilled in the art.
  • the fibers forming the non-woven material can have average diameters in the range from 0.5 to 70 ⁇ m, and preferably from 0.5 to 20 ⁇ m.
  • Non-woven materials can be composed of short fibers or, preferably, of continuous fibers. In the case of a non-woven material of short fibers, the fibers can have, for example, a length between 1 and 100 mm.
  • Non-woven materials offer random and preferably isotropic coverage.
  • each of the non-woven materials present in the intermediate materials used has a basis weight in the range from 0.2 to 20 g/m 2 .
  • each of the non-woven materials present in the intermediate materials used has a thickness of 0.5 to 50 microns, preferably of 3 to 35 microns. The features of these non-woven materials can be determined using the methods described in the application WO 2010/046609.
  • the layer(s) of thermoplastic or thermosetting material present in the intermediate materials used, and particularly the non-woven materials is (are) preferably made of a thermoplastic material chosen from among the polyamides, the copolyamides, the ether or ester block polyamides, the polyphthalamides, the polyesters, the copolyesters, the thermoplastic polyurethanes, the polyacetals, the C2-C8 polyolefins, the polyethersulfones, the polysulfones, the polyphenylene sulfones, the polyetheretherKetones, the polyetherKetoneKetones, the phenylene polysulphides, the polyetherimides, the thermoplastic polyimides, the liquid crystal polymers, the phenoxys, the block copolymers such as styrene-butadiene-methylmethacrylate copolymers, the methylmethacrylate-acrylate of butyl-methylmethacrylate-copolymers and mixtures thereof.
  • the manufacture of the composite part implements, as its final steps, a step of diffusion by infusion or injection of a thermosetting resin, a thermoplastic resin or a mixture of such resins, inside the stack, followed by a step of hardening of the desired part with a step of polymerization/reticulation in a defined pressure-temperature cycle, and a cooling step.
  • the steps of diffusion, hardening and cooling are implemented in an open mold.
  • a resin diffused inside the stack will be a thermoplastic resin as previously listed for the layer of thermoplastic material forming the stack, or preferably a thermosetting resin chosen from among the epoxides, the unsaturated polyesters, the vinyl esters, the phenol resins, the polyimides, the bismaleimides, the phenol-formaldehyde resins, the urea-formaldehydes, the 1,3,5-triazine-2,4,5-triamines, the benzoxazines, the cyanate esters, and mixtures thereof.
  • a resin can also comprise one or more setting agents well known to those skilled in the art, to be used with the selected thermosetting polymers.
  • thermosetting resin a thermoplastic resin or a mixture of such resins
  • the produced stack, before the addition of this external resin does not contain more than 10% of thermoplastic or thermosetting material.
  • the layer(s) of thermoplastic or thermosetting material or of a mixture of the two represent 0.5 to 10% of the total weight of the stack, and preferably 2 to 6% of the total weight of the stack, before the addition of this external resin.
  • the invention is particularly suitable for the direct implementation of the method, it is also applicable to indirect methods implementing materials of prepreg type.
  • the stack is made in an automated manner.
  • the invention will preferably use an infusion inside the stack, under reduced pressure, particularly under pressure below atmospheric pressure, particularly of less than 1 bar and preferably between 0.1 and 1 bar, of the thermoplastic or thermosetting resin or a mixture of such resins for the production of the composite part.
  • the infusion will preferably be performed in an open mold, for example by vacuum bag infusion.
  • the composite part is finally obtained after a thermal processing step.
  • the composite part is generally obtained by a conventional cycle of hardening of the polymers in question, by carrying out the thermal processing recommended by the suppliers of these polymers, and known to those skilled in the art.
  • This step of hardening of the desired part is performed by polymerization/reticulation according to a defined pressure-temperature cycle, followed by cooling.
  • thermosetting resin there is usually a step of gelation of the resin before its hardening.
  • the pressure applied during the processing cycle is low in the case of reduced-pressure infusion and higher in the case of injection into an RTM mold.
  • the composite part obtained has a fiber volume ratio of 55 to 70%, particularly of 57 to 63%, which leads to satisfactory properties for the field of aeronautics.
  • the volume fiber ratio (FVR) of a composite part is calculated from the measurement of the thickness of a composite part, knowing the basis weight of the unidirectional carbon sheet and the properties of the carbon fiber, from the following equation:
  • FVR ⁇ ( % ) n plies ⁇ Basis ⁇ ⁇ Weight ⁇ ⁇ UD carbon ⁇ carbon ⁇ ⁇ fire ⁇ e board ⁇ 10 - 1 ( 1 )
  • Were e board is the thickness of the plate in mm
  • ⁇ carbon fiber is the density of the carbon fiber in g/cm 3 .
  • the basis weight UD carbon is in g/m 2 .
  • Copolyamide veil of a thickness of 118 ⁇ m and of 6 g/m 2 , commercially available under the reference number 1R8D06 by Protechnic® (Cernay, France)
  • Copolyamide veil of a thickness of 59 ⁇ m and of 3 g/m 2 , commercially available under the reference number 1R8D03 by Protechnic® (Cernay, France),
  • Unidirectional tape made with IMA 12K and 446 tex yarns from Hexcel®, so as to obtain a basis weight of 140, 210 or 280 g/m 2 .
  • An intermediate material of a width of 6.35 mm corresponding to a combination of polyamide veil/unidirectional carbon fiber sheet/polyamide veil is produced and thermally bonded in accordance with the method described in pages 27 to 30 of the application WO 2010/046609.
  • a device as illustrated in FIG. 7 is used to carry out a penetration operation on the material, with an arrangement of the penetration points as shown in FIG. 5 .
  • the needles were heated to a temperature of 220° C.
  • the needles used are made of treated steel with titanium carbonitride. They have a tip of a length of 5.25 mm which has a diameter that increases up to a diameter of 1.6 mm, to finish with a regular part of constant diameter equal to 1.6 mm over a length of 14 mm.
  • the specimens are made from a yarn of a length of 200 mm, laminated to an adhesive tape of 50 mm on its two opposite faces.
  • the stress is exerted by a traction machine by way of the adhesive tapes.
  • a tractive force in a direction parallel to the length of the specimen and of opposite direction is applied to each of the faces of the specimen.
  • the total stressed length is therefore applicable to the whole sample, i.e. 200 mm.
  • the test is performed at constant speed until total debonding of the specimen, and the value of the highest tensile strength obtained is retrieved.
  • the tension is controlled using a portable tensiometer of DTBX 500-10 and 5000-20 type upstream of the microperforation machine composed of a needle roller.
  • the density was divided by two. The tests were performed for the two grammages 210 and 280 g/m 2 for one type of veil (1R8D06 of 6 g/m 2 ).
  • microperforations improve the resistance to delamination and that this improvement increases with the perforation density.
  • the set of resistance to delamination results obtained as a function of the grammage of the unidirectional material and of the veil used are shown in FIG. 10 .
  • the proportion of veil is expressed in % by weight, with respect to the weight of carbon fibers present in the intermediate material.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Textile Engineering (AREA)
  • Robotics (AREA)
  • Laminated Bodies (AREA)
  • Moulding By Coating Moulds (AREA)
  • Reinforced Plastic Materials (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
US14/441,192 2012-11-19 2013-11-18 Method of applying an intermediate material making it possible to ensure the cohesion thereof, method of forming a stack intended for the manufacture of composite components and intermediate material Abandoned US20150290883A1 (en)

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FR1260966 2012-11-19
PCT/FR2013/052760 WO2014076433A1 (fr) 2012-11-19 2013-11-18 Procédé de dépôt d'un matériau intermédiaire permettant d'assurer la cohésion de ce dernier, procédé de constitution d'un empilement destiné a la fabrication de pièces composites et matériau intermédiaire

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US20170361781A1 (en) * 2014-12-05 2017-12-21 Compagnie Plastic Omnium Process for manufacturing a motor vehicle part
US20200139642A1 (en) * 2014-12-17 2020-05-07 E.I. Dupont De Nemours And Company Glass and carbon fiber composites and uses thereof
US20160185030A1 (en) * 2014-12-19 2016-06-30 Airbus Operations Limited Method of Forming Laminar Composite Charge
US20180161538A1 (en) * 2016-12-13 2018-06-14 St. Jude Medical Puerto Rico Llc Thermoplastic strike layer for bonding materials
CN107322953A (zh) * 2017-07-31 2017-11-07 江苏恒神股份有限公司 提高真空导入复合材料制品纤维体积含量的方法
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CN104797406A (zh) 2015-07-22
FR2998209A1 (fr) 2014-05-23
JP6457944B2 (ja) 2019-01-23
US20180186104A1 (en) 2018-07-05
JP2015536261A (ja) 2015-12-21
RU2618066C2 (ru) 2017-05-02
ES2811151T3 (es) 2021-03-10
BR112015011249A2 (pt) 2017-07-11
EP2919969B1 (de) 2020-07-01
AU2013346634A1 (en) 2015-05-21
CA2889303A1 (en) 2014-05-22
WO2014076433A1 (fr) 2014-05-22
FR2998209B1 (fr) 2015-05-22
AU2013346634B2 (en) 2017-11-02
RU2015123699A (ru) 2017-01-10
US10576697B2 (en) 2020-03-03
EP2919969A1 (de) 2015-09-23

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