WO1993022128A1 - Materiau composite en polymere perfore resistant a des temperatures elevees et procede de fabrication - Google Patents

Materiau composite en polymere perfore resistant a des temperatures elevees et procede de fabrication Download PDF

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Publication number
WO1993022128A1
WO1993022128A1 PCT/US1993/004124 US9304124W WO9322128A1 WO 1993022128 A1 WO1993022128 A1 WO 1993022128A1 US 9304124 W US9304124 W US 9304124W WO 9322128 A1 WO9322128 A1 WO 9322128A1
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WO
WIPO (PCT)
Prior art keywords
perforated
composite material
sheet
semi
polymer composite
Prior art date
Application number
PCT/US1993/004124
Other languages
English (en)
Inventor
Kenneth Leslie Laubsch
Mark Gerard Coughlin
Robert Howard Hall
Kevin Allyn Mcafee
Original Assignee
Martin Marietta Corporation
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Martin Marietta Corporation filed Critical Martin Marietta Corporation
Priority to EP93913791A priority Critical patent/EP0640036A1/fr
Publication of WO1993022128A1 publication Critical patent/WO1993022128A1/fr

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Classifications

    • 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 form; Layered products 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 form; Layered products 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 form; Layered products 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
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
    • B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
    • B26F1/02—Perforating by punching, e.g. with relatively-reciprocating punch and bed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
    • B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
    • B26F1/16—Perforating by tool or tools of the drill type
    • 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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/0033—Moulds or cores; Details thereof or accessories therefor constructed for making articles provided with holes
    • 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
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • 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
    • 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 form; Layered products 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 form; Layered products 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 form; Layered products 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
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/04—Punching, slitting or perforating
    • 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
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0045—Perforating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2079/00—Use of polymers having nitrogen, with or without oxygen or carbon only, in the main chain, not provided for in groups B29K2061/00 - B29K2077/00, as moulding material
    • B29K2079/08—PI, i.e. polyimides or derivatives thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • 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
    • B29K2105/0809—Fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/24—Condition, form or state of moulded material or of the material to be shaped crosslinked or vulcanised
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/24—Condition, form or state of moulded material or of the material to be shaped crosslinked or vulcanised
    • B29K2105/243—Partially cured
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2307/00—Use of elements other than metals as reinforcement
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/04—Punching, slitting or perforating
    • B32B2038/047—Perforating
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/40—Weight reduction

Definitions

  • the present invention relates to methods for fabricating perforated composites and composite laminates, that are capable of being contoured and able to withstand high temperatures to be used for sound suppression 5 applications. Also disclosed are flexible and rigid pin mat apparatuses that may be ' utilized in fabricating perforated composites.
  • fiber reinforced polymer composite 0 material is generally utilized to describe a composite material that comprises a cured polymeric resin matrix that incorporates reinforcing fibers.
  • the reinforcing fibers are generally incorporated in the form of a woven fiber mat.
  • Perforated fiber reinforced polymer composites are 5 widely utilized as acoustic skins and sound suppression treatments.
  • perforated fiber reinforced polymer composites are used in the sound suppression systems of aircraft engine nacelles.
  • High temperature polymer composite materials are generally necessary for the inner 0 cowl bondment of a jet engine fan reverser, which is subjected to high temperatures during combustion.
  • the acoustic skins and sound suppression treatments require shaping or contouring the high temperature polymer composite material to fit the shape of the engine nacelle.
  • 5 Graphite fiber/bismaleimide preimpregnated fabric is a commercially available fiber reinforced polymer composite material that is able to withstand the high temperature environment of aircraft engine nacelles.
  • high temperature fiber reinforced polymer composite material is used to describe fiber reinforced composite materials that are able to withstand high temperatures, i.e. above approximately 176.6 ⁇ C (350 ⁇ F) , without suffering a degradation in performance characteristics.
  • the methods of the present invention may also be utilized in the formation of perforated fiber reinforced polymer composite materials and laminates that are not required to withstand high temperatures.
  • perforated is utilized to describe a material that has a plurality of holes.
  • a three step process is utilized to fabricate a perforated and contoured fiber reinforced polymer composite material or laminate having a high temperature capability.
  • resin rheology is utilized to precure or "stage” a flat laminate (or composite) using heat and pressure.
  • the precured, or staged, laminate is cured to a viscoelastic state, without inducing a complete cure, wherein the staged laminate may be handled and formed but still not experience excessive resin flow upon final cure.
  • the staged laminate is subjected to an automated drilling process to create a perforated staged laminate with a high hole density.
  • the perforated staged laminate is contoured, if desired, and subjected to final curing while the perforations are kept open and free of blockage from any excess resin flow.
  • a perforated and contoured high temperature fiber reinforced polymer composite material, or laminate may be fabricated by the following steps. First, a preimpregnated fiber reinforced polymer composite material, capable upon final cure of withstanding high temperatures, is pressed over a pin mat to form a perforated preimpregnated fiber reinforced polymer composite material.
  • the mat and the pins (projections) are sufficiently rigid to withstand the pressures utilized to force the pins through the preimpregnated composite without deforming.
  • the pins may fabricated so that they end in a point to facilitate the pressing of the pins through the composite material. Further details relating to the mat are set forth below.
  • the mat/material structure is subsequently staged to a state of partial cure using heat and pressure.
  • the mat and material are then separated thereby leaving a partially cured perforated polymer composite material.
  • the staging of the structure is performed to a state wherein upon separation the material may be formed when heated but does not exhibit substantial flow of the resin during the subsequent completion of the cure. This state is similar, in feel, to a swatch of leather.
  • the separated perforated polymer composite material is formed, using a contoured mold, and the cure completed, under heat and pressure, on the contoured mold.
  • the result is a perforated and contoured high temperature fiber reinforced polymer composite material.
  • a high temperature fiber reinforced polymer composite material may be fabricated by the following series of steps.
  • resin rheology is utilized to precure or "stage” a flat laminate (composite) using heat and pressure.
  • the precured, or staged, laminate is cured to a viscoelastic state, without inducing a complete cure, wherein the staged laminate may be handled and formed but still not experience excessive resin flow upon final cure.
  • the staged laminate is subjected to an automated drilling process to create a perforated staged laminate with a high hole density. Alternatively, a die punching process may be utilized to create the perforated stage laminate.
  • the first, "male”, sheet includes an array of pin-like projections, also referred to as pins
  • the second, "female” sheet includes an array of orifices or holes corresponding to the pin-like projections of the male sheet such that the male and female sheets may be joined.
  • the pin-like projections and holes are located in a manner such that they correspond to the perforations in the perforated staged laminate so that the laminate may be sandwiched between the mats.
  • the outside dimensions of the mats will generally roughly correspond to, or exceed, the outside dimensions of the laminate.
  • the perforated laminate is sandwiched between the male and female sheets and the resulting structure is contoured into the desired shape. Using heat and pressure, the perforated laminate is cured to a final state in this sandwiched configuration. The sheets are then removed to produce a perforated and contoured high temperature fiber reinforced polymer composite material.
  • Each of the methods of the present invention is especially well suited for use in fabricating perforated and contoured fiber reinforced polymer composite materials from graphite/bismaleimide preimpregnated fabric.
  • This fabric is commercially available from a variety of sources including BASF-Narmco, Hexcel, and US Polymeric.
  • the methods of the present invention may also be utilized to fabricate perforated composite materials from polyimides, high temperature epoxy systems, reinforced thermoplastic systems such as polyether ether ketone, polyphenyl sulfide, polyether-imide, polyamides, polysulfones, polyamide-imide systems and from other starting material systems known to those of ordinary skill in the art.
  • the methods of the present invention include the formation of a partially cured fiber reinforced polymer composite materials. We have discovered that this step advantageously overcomes the deficiencies in heretofore known methods for forming perforated and contoured fiber reinforced polymer composite materials. We have also discovered an apparatus for use in a process for fabricating perforated fiber reinforced polymer composite materials.
  • the apparatus comprises a plurality of sheets wherein a first sheet has a plurality of pin-like projections (also referred to herein as pins ) , preferably arranged in an array like fashion, extending from a first surface of the sheet and a second sheet has a plurality of orifices or holes arranged in a similar manner to the pin ⁇ like projections on the first sheet such that the first and second sheets may be juxtaposed to align the orifices and pin-like projections and permit the two sheets to slide together.
  • the first sheet, containing the pins may be described as he "male" sheet and the second sheet with the corresponding holes, may be described as the "female" sheet. When fit together the male and female sheets fit together form a single unit.
  • the male and female sheets are fabricated from a flexible polymer material.
  • This embodiment is hereinafter referred to as the flexible pin mat apparatus.
  • the male and female sheets are fabricated from a substantially rigid polymer, metal, or alloy material. This embodiment is hereinafter referred to as the rigid pin mat apparatus.
  • Other embodiments of the apparatus of the present invention, not described in detail herein, will be apparent to those of ordinary skill in the art from the following description.
  • the flexible mat apparatus of the present invention may advantageously be utilized in the fabrication of perforated and contoured high temperature fiber reinforced polymer composite materials.
  • the design of the sheets allows a perforated composite material to be sandwiched between the male and female sheets and contoured and/or cured.
  • the sheets of the flexible mat apparatus of the present invention may be fabricated from any material capable of withstanding the curing temperatures of the resins utilized in the composite materials without degrading. Generally a high durometer, high temperature elastomer is utilized. Preferably the sheets are fabricated from an elastomer or other polymeric material. More preferably the sheets are fabricated from a polymeric material that will not contaminate the fiber reinforced polymer composite material and provide flexibility and dimensional stability at high temperatures. The sheets may be fabricated from a polymer material that allows the sheets to be contoured while joined together.
  • Suitable flexible polymer materials include, but are not limited to, Silastic ® J RTV silicone rubber, manufactured and sold by Dow Corning, Midland, MI; Dapco ® 10 high temperature RTV silicone, manufactured and sold by D Aircraft Corporation, Los Angeles, CA; Dapco ® 60 high temperature RTV silicone, manufactured and sold by D Aircraft Corporation, Los Angeles, CA; 5887 RTV silicone rubber, manufactured and sold by Emerson and Cumming, St. Louis, MO; KE 1604 high strength RTV silicone rubber, manufactured and sold by Shin-Etsu, Chino, CA; TPE-4211-60 advanced thermoplastic elastomer, manufactured and sold by Monsanto Corporation, St.
  • the male sheet of the flexible mat apparatus of the present invention may be formed in manners known to the art, such as by casting and curing the polymer on a drilled aluminum plate with a mirror image of the desired pin/hole pattern.
  • the female sheet of the flexible mat apparatus of the present invention may be formed in manners known to the art such as by casting and curing the polymer on an aluminum sheet with pins corresponding to the pins on the male sheet, or by punching or drilling a preformed solid polymer sheet.
  • the number of pins and the corresponding hole density of the female sheet may be varied depending on the desired hole density of the perforated composite material to be formed utilizing the sheets.
  • the diameter of the pins is between 0.0889 and 0.254 cm (0.035 and 0.100 inch), with a tolerance of plus or minus 0.0058 to 0.0127 cm (0.002 to 0.005 inch), and the pins are spaced apart at a center to center distance of 0.1905 to 0.381 cm (0.075 to 0.150 inch), with a tolerance of plus or minus 0.00508 to 0.0127 cm (0.002 to 0.005 inch).
  • the height of the pins is generally between 0.1905 to 0.381 cm (0.075 and 0.150 inch).
  • the rigid pin mat apparatus of the present invention is similar to the flexible mat apparatus of the present invention except the pins on the male sheet of the rigid pin mat apparatus are sufficiently rigid to withstand the pressures generated in forcing the pins through the composite material being fabricated.
  • the male sheet of the rigid pin mat apparatus should be fabricated from a polymeric material that is substantially rigid when cured.
  • the male sheet of the rigid pin mat apparatus may be fabricated from a metal or alloy.
  • the male and female sheets of the rigid pin mat apparatus of the present invention are fabricated from a material capable of withstanding the curing temperatures of the resins utilized in the composite materials without degrading.
  • the sheets are fabricated from a material that will not contaminate the fiber reinforced polymer composite material and provide toughness abrasion resistance and dimensional stability.
  • Suitable materials for use in fabricating the male sheet of the rigid pin mat apparatus of the present invention include, but are not limited to: polyetherimide, commercially available from GE Plastics Lowell, MA; polypropylene; Nylon 6/6, manufactured and sold by the DuPont Corporation, Wilmington, DE; Polysulfone, manufactured and sold by Phillips, Burtlesville, OR.
  • the male sheet of the rigid pin mat apparatus of the present invention may be fabricated from steel, aluminum, or an alloy.
  • the female sheet of the rigid pin mat apparatus may be fabricated from any of these materials or may be fabricated from the materials described above for fabricating the male and female sheet of the flexible pin mat apparatus.
  • the male sheet of the rigid pin mat apparatus is fabricated from a polymeric material
  • the sheet may be formed in the, manners described above for fabricating the male sheet of the flexible pin mat apparatus of the present invention.
  • the male sheet is fabricated from a metal, it may be fabricated in any manner known to the art for fabricating a metal pin mat. Preferably, in either case, the tips of the pins are pointed to facilitate the puncturing of the composite material being fabricated.
  • the number of pins on the male sheet and the corresponding hole density of the female sheet may be varied depending on the desired hole density of the perforated composite material to be formed utilizing the sheets.
  • the cross-sectional diameter of the pins is between 0.0889 and 0.1524 cm (0.035 and 0.060 inch), with a tolerance of plus or minus 0.00508 to 0.0127 cm (0.002 to 0.005 inch), and the pins are spaced apart at a center to center distance of 0.1905 to 0.381 cm (0.075 to 0.150 inch), with a tolerance of plus or minus 0.00508 to 0.0127 cm (0.002 to 0.005 inch).
  • the height of the pins is between 0.1905 and 0.381 cm (0.075 and 0.150 inch) .
  • An advantage of the methods of the present invention is that the methods may be utilized to produce mechanically strong perforated and contoured fiber reinforced polymer composite materials having high temperature resistance and good acoustic properties.
  • Another advantage of the methods of the present invention is that the methods may be utilized ⁇ to fabricate high temperature fiber reinforced polymer composite material without extensive fiber damage, gross porosity, and matrix cracking which cause a loss in mechanical and acoustic performance.
  • a further advantage of the methods of the present invention is that the methods offer a cost efficient way to produce high temperature perforated fiber reinforced polymer composite materials and laminates.
  • An advantage of the apparatus of the present invention is that the apparatus may be utilized in the methods of the present invention.
  • Another advantage of the apparatus of the present invention is that the apparatus provides a controllable and uniform molded perforation hole size in the high temperature perforated fiber reinforced polymer composite materials and laminates produced using a method of the present invention.
  • the uniform perforation hole size imparts predictable, reliable acoustic performance.
  • a further advantage of the apparatus of the present invention is that the female sheet constrains the pins on the male sheet from moving and changing dimension during the thermal cycle of curing the composite material in the methods of the present invention, thereby easing the removal of the composite material from the sheets.
  • a still further advantage of the apparatus of the present invention is that the sheets help to control resin flow from the composite material sandwiched between the sheets according to a method of the present invention. Additionally, the pins on the male sheet act as physical barriers to prevent the flow of resin into the perforations in the composite material. This allows consolidation pressures during final cure up to 85 pounds per square inch. Pressures in this range form perforated fiber reinforced polymer composites that are free of voids.
  • a still further advantage of the apparatus of the present invention is that the sheets may be fabricated from a material that allows them to be contoured thereby allowing the fabrication of contoured composite materials according to a method of the present invention.
  • An advantage of the apparatus and the methods of the present invention is that the apparatus may be easily and economically fabricated to produce perforated composites of different sizes, and different perforation hole densities and perforation hole arrangements according to a method of the present invention.
  • Figure 1 depicts a male sheet of an embodiment of the apparatus of the present invention.
  • Figure la is a blow-up of a section of Figure 1.
  • Figure 2 depicts a female sheet of an embodiment of the apparatus of the present invention.
  • Figure 2a is a blow-up of a section of Figure 2.
  • Figure 3 depicts a perforated fiber reinforced polymer composite material sandwiched between a male and a female sheet of the apparatus of the present invention prior to final curing of the composite material.
  • Figure 4 depicts a high temperature perforated fiber reinforced polymer composite material manufactured according to a method of the present invention.
  • FIGS. 1 and 2 depict an embodiment of the apparatus of the present invention.
  • both the flexible pin mat apparatus and the rigid pin mat apparatus of the present invention comprise a first male sheet 10, having a plurality of pins 20.
  • the pins 20 are depicted in Figure 1 arranged in a variable 16 x 16 or greater array wherein each pin-like projection is equally spaced from adjacent pins.
  • the outside dimensions of the array are smaller than the dimensions of first sheet 10, however the present invention should not be considered limited to this configuration.
  • Figure 1 depicts a symmetric array of substantially circular pins, the pins the sheet may include any number and arrangement of pins.
  • the pins may be substantially circular in cross section or may be of any other shape, such as a polygonal shape or an elliptical shape.
  • the cross sectional shape chosen for the pins depends on the shape chosen for the perforations ip. the composite material fabricated utilizing the apparatus according to a method of the present invention. Additionally, the pins of the rigid pin mat apparatus of the present invention may be fabricated with pointed ends to facilitate the puncturing of the composite material.
  • Figure la depicts a portion of the sheet depicted in Figure 1.
  • Figure 2 depicts a second sheet 30, having orifices 40 corresponding to the pins 20 shown in Figure 1.
  • Figure 2a depicts a portion of the sheet depicted in Figure 2.
  • orifices 40 are arranged in a similar configuration to the pins of the first sheet in order that the first and second sheets may be juxtaposed and pins 20 slid into orifices 40.
  • Figure 3 depicts an elevation view of such an arrangement with a perforated fiber reinforced polymer " composite material, 50, sandwiched between the sheets 10 and 30, prior to final curing of the composite material.
  • composite material, 50 sandwiched between the sheets 10 and 30, prior to final curing of the composite material.
  • the male sheet of the flexible and rigid pin mat apparatuses may be fabricated by casting a high durometer, high temperature elastomer, such as the ones listed above, on a drilled aluminum plate having the desired hole pattern.
  • the hole pattern of the aluminum sheet should correspond to the desired hole pattern of the perforations in the composite material being fabricated.
  • the female sheet may be fabricated by casting off the male sheet, curing and separating the two sheets. Once cured the male and female sheets should be capable of being heated to a temperature higher than the temperature necessary to final cure the composite material being fabricated without losing their dimensional tolerance or stability.
  • the male ,sheet of the rigid pin mat apparatus may also be fabricated from steel or another metal or metal alloy in manners generally known for fabricating metal pin mats.
  • the female sheet of the rigid pin mat apparatus may be fabricated from a high temperature, high durometer elastomer casted off the male sheet.
  • the methods of the present invention are described below in sequential fashion following the order set forth above.
  • the methods of the present invention comprise partially curing a polymer composite material to a viscoelastic state without inducing complete cure.
  • the polymer composite material is formable when further heated, but does not experience excessive resin flow during final curing.
  • the polymer composite material may be perforated in the partially cured state, or prior to the partially cured state.
  • the rigid pin mat apparatus of the present invention may advantageously be utilized to perforate the composite material.
  • the polymer composite material may be contoured utilizing the flexible mat pin apparatus of the present invention, or may be contoured utilizing forming tools generally known to the art.
  • curing of the polymer composite material is completed to yield a perforated polymer composite material.
  • This method may advantageously be utilized with fiber- reinforced polymer composite starting materials, such as graphite/bismaleimide preimpregnated fabric to produce perforated and contoured fiber reinforced polymer composite materials.
  • a three step process is utilized to fabricate a perforated and contoured high temperature fiber reinforced polymer composite material or laminate.
  • resin rheology is utilized to precure or "stage" a flat laminate (or composite) using heat and pressure.
  • the starting material is generally a preimpregnated fabric such as graphite fiber/bismale ⁇ mide preimpregnated fabric.
  • One or more plies may be laminated and processed in manners known in the art. Additionally, surfacing plies such as adhesives, acoustic screens and core isolators may be readily integrated into the laminate and processed.
  • the material combination to be perforated is consolidated in an identical manner to either traditional autoclave or compression mold processing.
  • the assembly of plies, in the case of a laminate, or the starting material in the case of a preimpregnated fabric without additional layers is heated under sufficient pressure and temperature, and for a sufficient time to advance the resin to a semi-cured point in the resin's rheological profile wherein the laminate is formable when further heated, but does not experience excessive resin flow upon further curing.
  • Such resin flow would block the acoustic flow path by partially or completely blocking the perforations, and thereby severely limit the acoustic performance of the laminate.
  • the pressure utilized ranges from 344.75 KPa to 586.075 KPa (50 psi to 85psi) and the material is heated to a temperature of from 93.3°C to 148.8°C (200 ⁇ F to 300°F).
  • the time to reach the semi-cured state ranges from 15 mins to 1 hour.
  • the material is perforated by boring or drilling.
  • a multiaxis horizontal boring machine with automatic tool changer may be utilized to machine multiple holes in the semi-cured material. Drilling with both diamond and carbide tools, as well as end mills, is also possible.
  • the semi-cured material may be drilled without lubricants to prevent contamination of the composite material laminate. Additionally, multiple semi- cured laminates or composite materials may be drilled or bored simultaneously by stacking the individual laminates or composite materials and utilizing a fixture to apply even compacting pressure to the stack.
  • Hole diameter initial (semi-cured) 0.26416 cm (0.104 inch)
  • Hole diameter final (final cure) 0.23876 cm (0.094 inch)
  • Center to Center hole distance 0.3683 cm (0.145 inch)
  • Array Type plain square (equal number of rows and columns) .
  • the semi-cured composite material or laminate After drilling the semi-cured composite material or laminate is placed in a tool and if a contour is desired in the final product, the semi-cured composite material or laminate is formed using pressure and heat if required. Methods of forming and contouring are known to those of ordinary skill in the art and include vacuum assisted or pressure forming. The composite material or laminate is final cured to the desired configuration using pressure and heat to produce the composite part. As set forth above, if the proper semi-cured state is achieved there will be no significant resin flow during final cure and therefore the perforations drilled into the composite material or laminate will remain clear.
  • the flexible pin mat apparatus of the present invention is utilized during contouring and final curing of the composite material or laminate.
  • a fiber reinforced polymer composite material is produced as follows.
  • the starting material generally a preimpregnated fabric such as graphite fiber/bismaleimide preimpregnated fabric, is perforated.
  • a preimpregnated fabric such as graphite fiber/bismaleimide preimpregnated fabric
  • One or more plies of the starting material may be laminated and processed in manners known in the art. Additionally, surfacing plies such as adhesives, acoustic screens and core isolators may be readily integrated into the laminate and processed. Alternatively, individual plies may be perforated and then laminated in a subsequent operation.
  • the starting material or laminate may be perforated in a variety of ways that are within the skill of one having ordinary skill in the art.
  • the material or laminate is perforated by feeding the fiber-reinforced composite material, with a separator on both sides, through two sets of feeder rolls and a punch.
  • One feeder roll is located upstream of the punch and the other is located downstream on the exit side of the punch.
  • the rolls serve to feed the material automatically through the punch that can be made of either single or multiple rows of pin punches which have a matching die set.
  • the starting material or laminate may be semi-cured and then perforated by drilling with a multiaxis horizontal boring machine with automatic tool changer in the manners described in the preceding paragraphs. For good acoustical performance the perforations may be configured as set forth above.
  • the flexible pin mat utilized has an array of pins having a center to center distance equal to the center to center hole distance in the perforated composite material or laminate to allow the composite material of laminate to slide onto the male sheet.
  • the array type on the male sheet should be similar to the array type of the perforations.
  • the array on the male sheet could contain additional columns and/or rows and therefore be larger.
  • FIG. 3 depicts this configuration with composite material or laminate 50, sandwiched between male sheet 10 and female sheet 30.
  • the male sheet is placed on a flat tool with the pins facing upward.
  • the punched or drilled composite material or laminate is then placed by hand over the pin array and pressed to the bottom of the male sheet.
  • the female sheet is placed over the composite material and pressed downward to sandwich the composite material or laminate between the sheets of the flexible pin apparatus.
  • the entire sandwich assembly may then be placed in a tool and formed to contour using pressure and heat if required.
  • the composite material or laminate is final cured under pressure.
  • the male and female sheets are removed leaving the perforated and contoured fiber reinforced polymer composite material or laminate.
  • the pins of the flexible pin mat apparatus prevent residual resin, or fiber, from blocking the perforations during final cure. Additionally, use of the flexible pin mat apparatus allows consolidation pressures as high as 85 pounds per square inch to be utilized during final cure. Pressures in this range form acoustic laminates that are well consolidated and free of voids, even when the composite material or laminate is contoured.
  • both the perforating (punching) and drilling processes are very controllable and can readily be altered without the long tooling changes and lead times required by existing methods of fabricating perforated fiber reinforced polymer composite materials or laminates.
  • the drilling or punching process may remove a portion of the fiber reinforcement
  • the method of the present invention yields composite materials or laminates with superior mechanical performance to other perforation methods. While not wishing to be bound by any particular theory, it is believed this improvement is attributable, in part, to drilling the composite material or laminate in a semi-cured viscoelastic state, rather than the final cured state, thus causing reduced microstructural damage to the laminates.
  • a starting material or laminate such as the ones described in the preceding paragraphs, is perforated utilizing the rigid pin mat apparatus of the present invention.
  • a restraining tool such as those known to the art, is utilized to hold the starting material.
  • the starting material or laminate is stacked on top of the rubber pressure pad that lines the bottom of the restraining tool.
  • the individual plies may be stacked in the restraining tool.
  • the male sheet of the rigid pin mat apparatus is then placed on top of the plies of starting material or laminate with the rigid pins projecting towards the material.
  • a rigid lid generally fabricated from metal, that fits inside the restraining tool is then placed on the top of the rigid pin mat, on the side opposite the pin side, and the entire assembly is loaded into a press. Pressure is then applied to the lid and assembly forcing the rigid pins through the starting material or laminate.
  • the male sheet of the rigid pin mat apparatus with the material that now surrounds the pins is removed from the assembly and the female sheet of apparatus is placed over the material to sandwich the material between the male and female sheets.
  • This sandwich assembly is then heated under specific heat and pressure conditions to semi-cure the starting material. If the starting material has not already been completely laminated the heat and pressure will also serve to laminate the plies of the starting materials. As set forth above, the resulting semi-cured material is still formable when heated but does not exhibit substantial flow of the resin during subsequent completion of the cure. At this point the viscoelastic properties of the semi-cured material or laminate are similar to leather.
  • the resulting semi-cured perforated composite material is separated from the male and female sheets of the rigid pin apparatus and formed in manners known to the art, using heat if required. Subsequently, the composite material is cured, on a contoured tool if desired, to yield a perforated fiber reinforced polymer composite material.
  • This method is particularly well suited for use with starting materials, or laminates, requiring cure temperatures that would degrade the flexible pin mat apparatus of the present invention. Additionally, since the composite material is removed from the rigid pin mat in the semi-cured state, the rigid pin mat may be fabricated from polymers that would be degraded by the temperature/pressure conditions necessary to final cure the starting material.
  • Figure 4 depicts one such high temperature perforated fiber reinforced polymer composite material fabricated according to the present invention.

Abstract

Procédé servant à fabriquer un matériau composite en polymère renforcé par fibres et résistant à des températures élevées; ledit procédé comprend le durcissement partiel d'un matériau composite polymère jusqu'à un état viscoélastique sans introduire un durcissement total. Le matériau composite polymère peut se façonner quand il est réchauffé davantage mais ne subit pas d'écoulement de résine excessif pendant le durcissement final. D'après les procédés décrits par l'invention, le matériau composite polymère peut être perforé en l'état partiellement durci ou avant d'atteindre son état partiellement durci. On peut utiliser de façon avantageuse un dispositif décrit par l'invention et constitué par une plaque rigide à aiguilles, afin de perforer le matériau composite. Après son durcissement partiel, le matériau composite polymère peut être profilé au moyen d'un dispositif décrit par l'invention et constitué par une plaque souple à aiguilles ou bien au moyen d'outils de façonnage connus dans l'état actuel de la technique. On peut utiliser le procédé de façon avantageuse avec des matériaux de départ composites en polymère renforcé par fibres, tels qu'un tissu imprégné au graphite/bismaléimide, de façon à produire des matériaux composites en polymère renforcés par fibres et résistant à des températures élevées, perforés et profilés, servant à l'insonorisation.
PCT/US1993/004124 1992-05-01 1993-04-26 Materiau composite en polymere perfore resistant a des temperatures elevees et procede de fabrication WO1993022128A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP93913791A EP0640036A1 (fr) 1992-05-01 1993-04-26 Materiau composite en polymere perfore resistant a des temperatures elevees et procede de fabrication

Applications Claiming Priority (2)

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US87693292A 1992-05-01 1992-05-01
US07/876,932 1992-05-01

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EP (1) EP0640036A1 (fr)
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EP0688647A3 (fr) * 1994-06-22 1996-03-27 Mitsubishi Heavy Ind Ltd Procédé de fabrication d'une plaque à plusieurs trous en matière composite et préforme non durcie en matière composite utilisée pour ce procédé
WO2000024553A1 (fr) * 1998-10-22 2000-05-04 Bae Systems Plc Decoupe d'un stratifie composite
WO2000046021A1 (fr) * 1999-02-03 2000-08-10 Aztex, Inc. Procede de fabrication d'un stratifie perfore
EP1500497A3 (fr) * 2003-07-22 2009-12-30 The Boeing Company Matériaux sans oxydes et poreux de manière sélective
US20100112283A1 (en) * 2008-10-31 2010-05-06 Howarth Graham F Perforated composite structures and methods therefore
WO2010077595A2 (fr) 2008-12-30 2010-07-08 Mra Systems, Inc. Procédé et appareil pour produire des structures composites
CN103640228A (zh) * 2013-11-28 2014-03-19 陕西飞机工业（集团）有限公司 一种耐高温玻璃钢模具的制作方法
WO2016071676A1 (fr) * 2014-11-03 2016-05-12 Short Brothers Plc Procédés et précurseurs pour la fabrication d'une pièce composite perforée
US11001017B2 (en) * 2017-07-11 2021-05-11 Faurecia Automotive Industrie Manufacturing method of a component of automotive vehicle equipment and associated component of equipment
CN114585500A (zh) * 2019-11-14 2022-06-03 美国圣戈班性能塑料公司 用于长纤维材料所制成的组件的预成型件、工具以及工艺设计

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Publication number Priority date Publication date Assignee Title
EP0688647A3 (fr) * 1994-06-22 1996-03-27 Mitsubishi Heavy Ind Ltd Procédé de fabrication d'une plaque à plusieurs trous en matière composite et préforme non durcie en matière composite utilisée pour ce procédé
US5637272A (en) * 1994-06-22 1997-06-10 Mitsubishi Jukogyo Kabushiki Kaisha Method of manufacturing a multi-holed surface plate made of a composite material and a raw forming element of the composite material therefor
US6190602B1 (en) * 1998-03-13 2001-02-20 Aztex, Inc. Method of manufacturing a perforated laminate
WO2000024553A1 (fr) * 1998-10-22 2000-05-04 Bae Systems Plc Decoupe d'un stratifie composite
JP2002528278A (ja) * 1998-10-22 2002-09-03 ビ−エイイ− システムズ パブリック リミテッド カンパニ− 複合ラミネート切断
WO2000046021A1 (fr) * 1999-02-03 2000-08-10 Aztex, Inc. Procede de fabrication d'un stratifie perfore
EP1500497A3 (fr) * 2003-07-22 2009-12-30 The Boeing Company Matériaux sans oxydes et poreux de manière sélective
EP3326814A1 (fr) * 2003-07-22 2018-05-30 The Boeing Company Structure laminee a haute resistance
EP2762311A3 (fr) * 2003-07-22 2015-05-06 The Boeing Company Matériaux poreux sélectivement non-oxydes
US20100112283A1 (en) * 2008-10-31 2010-05-06 Howarth Graham F Perforated composite structures and methods therefore
US8128775B2 (en) 2008-12-30 2012-03-06 Mra Systems, Inc. Process and apparatus for producing composite structures
US8567467B2 (en) 2008-12-30 2013-10-29 Mra Systems, Inc. Process and apparatus for producing composite structures
WO2010077595A3 (fr) * 2008-12-30 2010-10-21 Mra Systems, Inc. Procédé et appareil pour produire des structures composites
WO2010077595A2 (fr) 2008-12-30 2010-07-08 Mra Systems, Inc. Procédé et appareil pour produire des structures composites
CN103640228A (zh) * 2013-11-28 2014-03-19 陕西飞机工业（集团）有限公司 一种耐高温玻璃钢模具的制作方法
CN103640228B (zh) * 2013-11-28 2016-02-24 陕西飞机工业（集团）有限公司 一种耐高温玻璃钢模具的制作方法
WO2016071676A1 (fr) * 2014-11-03 2016-05-12 Short Brothers Plc Procédés et précurseurs pour la fabrication d'une pièce composite perforée
US10279548B2 (en) 2014-11-03 2019-05-07 Short Brothers Plc Methods and precursors for manufacturing a perforated composite part
US10946596B2 (en) 2014-11-03 2021-03-16 Short Brothers Plc Methods and precursors for manufacturing a perforated composite part
EP4116070A1 (fr) * 2014-11-03 2023-01-11 Short Brothers Plc Procédés et précurseurs pour la fabrication d'une pièce composite perforée
US11001017B2 (en) * 2017-07-11 2021-05-11 Faurecia Automotive Industrie Manufacturing method of a component of automotive vehicle equipment and associated component of equipment
CN114585500A (zh) * 2019-11-14 2022-06-03 美国圣戈班性能塑料公司 用于长纤维材料所制成的组件的预成型件、工具以及工艺设计

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EP0640036A1 (fr) 1995-03-01

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