WO2009090221A1 - Method and device for moulding a part of a composite material - Google Patents

Method and device for moulding a part of a composite material Download PDF

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Publication number
WO2009090221A1
WO2009090221A1 PCT/EP2009/050435 EP2009050435W WO2009090221A1 WO 2009090221 A1 WO2009090221 A1 WO 2009090221A1 EP 2009050435 W EP2009050435 W EP 2009050435W WO 2009090221 A1 WO2009090221 A1 WO 2009090221A1
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WO
WIPO (PCT)
Prior art keywords
mold
preform
resin
projections
draining member
Prior art date
Application number
PCT/EP2009/050435
Other languages
French (fr)
Inventor
Patrice Lefebure
Original Assignee
European Aeronautic Defence And Space Company Eads France
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.)
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Publication date
Application filed by European Aeronautic Defence And Space Company Eads France filed Critical European Aeronautic Defence And Space Company Eads France
Publication of WO2009090221A1 publication Critical patent/WO2009090221A1/en

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Classifications

    • 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
    • B29C70/48—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 and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
    • 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
    • B29C70/541—Positioning reinforcements in a mould, e.g. using clamping means for the 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
    • B29C70/28—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
    • B29C70/546—Measures for feeding or distributing the matrix material in the reinforcing structure
    • B29C70/547—Measures for feeding or distributing the matrix material in the reinforcing structure using channels or porous distribution layers incorporated in or associated with the product

Definitions

  • the present invention relates to a method for manufacturing parts made of composite material and especially high-performance thermoplastic composite parts.
  • Composite material parts have excellent mechanical and chemical properties. They can thus combine a high resistance to mechanical and / or thermal stresses and a high rigidity for a minimum mass. They can also have complex shapes.
  • RTM resin transfer molding
  • the resins used in this RTM process must be thermosetting resins of low viscosities so as to ensure a good filling of the mold.
  • LRI liquid resin infusion molding process
  • the pressures generated are likely to strongly deform the folds of the preform not linked together since they are not powdered or sized.
  • thermoplastic resins HP
  • HP high performance thermoplastic resins
  • thermoplastic matrices have many advantages in particular because they are ductile and offer opportunities for reforming (i.e. folding) and recycling.
  • the object of the present invention is to provide a method and a device for molding a single composite material part in their design and in their operating mode, fast and economical, allowing maintenance of the fibrous preform during injection LCM type ("Liquid Composite Molding" - injection on fibrous reinforcements) of the very high viscosity liquid resin.
  • LCM type Liquid Composite Molding
  • Another object of the invention is to facilitate the complete impregnation of the preform regardless of the viscosity of the liquid resin introduced into the mold at the processing temperature and whatever the temperature of the mold.
  • the invention relates to a method of molding a composite material part by injecting a high-performance thermoplastic resin into a preform placed in a mold, this preform having folds not bonded to each other.
  • a draining member having a high permeability is placed directly in contact with the preform, and each element of this assembly thus obtained in the mold is placed and held in position,
  • the resin is injected in the viscous state into the mold in order to impregnate this assembly
  • draining member having a high permeability means that the draining member has a permeability typically greater than 10 "9 m 2 .
  • the present invention also relates to the following features which should be considered in isolation or in all their technically possible combinations:
  • the draining member is a rigid grid
  • this rigid grid is a polymer grid capable of withstanding the injection temperatures of the resin.
  • a polymer grid capable of withstanding the injection temperatures of the resin.
  • Teflon glass-based polymer By way of illustration, mention may be made of a Teflon glass-based polymer.
  • this draining body is covered with a release agent
  • This demolding agent is, for purely illustrative purposes, a high temperature release liquid or spray, a high temperature drying of which ensures good performance on the draining mesh.
  • each element of this draining member / fibrous preform assembly is held in position by its ends by means of pointed projections.
  • These projections are preferably chosen from the group comprising tip rods, spikes and combinations of these elements. These elements may be straight or curved, of varying diameter or section depending on the nature of the draining organ and the fibrous preform.
  • the internal volume of the mold is placed under vacuum.
  • the invention also relates to a device for implementing the molding method as described above, this device comprising a mold intended to receive a liquid resin for impregnating a preform placed in this mold, this preform comprising folds not related to each other.
  • this mold comprises means for maintaining in position at least the folds of the preform in this mold during the injection of said liquid resin.
  • this device comprises a first mold part and a second mold part, these parts being intended to cooperate to seal the mold in a molding position.
  • the means for holding in position at least the folds of the preform comprise projections placed on the first mold part, each of these projections having a pointed end and one or more recesses placed on the second part and intended to receive these pointed ends when the first and second parts are in their molding position.
  • these projections are placed on at least a portion of the periphery of the central portion of the first mold part so as to maintain the periphery of the preform.
  • projections being placed on the periphery of the central part of the first part of the mold, it is thus possible to avoid damaging the central part of the preform.
  • projections are preferably selected from the group consisting of tipped rods, spikes and combinations of these elements. These elements can be straight or curved.
  • FIG. 1 is a partial view of a portion of a molding device according to a preferred embodiment of the invention
  • FIG. 2 shows schematically a set preform / draining member according to a preferred embodiment of the invention, the draining member being partially shown to show the preform;
  • FIG. 3 is a view of the polymerized assembly of FIG. 2, the draining member having been partially removed to reveal the composite part;
  • Figure 1 shows a partial view of a portion of a molding device according to a preferred embodiment of the invention.
  • This molding device comprises a mold comprising a first mold part 1 and a second mold part (not shown).
  • first 1 and second parts are intended to cooperate to seal the mold in a molding position in which the resin is injected into the mold to impregnate a preform comprising folds not bonded together.
  • This first portion has projections 2 each having a pointed end 3.
  • These projections 2 are here in the form of a bar of nails 2 made of a metallic material such as stainless steel.
  • the molding process consists in placing a draining member 4 having a high permeability directly in contact with a preform 5, the latter comprising folds not secured to each other.
  • This set preform / draining member is then placed in the mold by embedding this assembly in the nails 2 of sufficient length to protrude from the assembly in order to maintain this assembly in position during the injection of the resin in the viscous state into the mold.
  • the device comprises means for creating the vacuum in the mold (not shown), these means being in fluid communication with the mold.
  • thermoplastic resin in the viscous state is injected into the mold to impregnate the assembly.
  • the high permeability of the draining member 4 advantageously contributes to increasing the overall permeability of the preform 5 and to facilitate the impregnation thereof in the planar direction.
  • the pressures generated by the injection of the resin into the preform are also reduced by the presence of this draining member 4.
  • the thermoplastic resin is consolidated in the preform 5.
  • Figure 3 shows the draining member 4 partially removed to reveal the composite part 6 impregnated and consolidated.

Abstract

The invention relates to a device and a method for moulding a part made of a composite material that comprises injecting a high-performance thermoplastic resin into a preform (5) placed in a mould, said preform (5) including folds that are not connected together. According to the invention, the method comprises placing a draining member (4) having a high perviousness directly in contact with the preform (5), and placing and maintaining in position each member of the assembly thus formed in the mould using a specific device. The resin is injected in a viscous state into the mould for impregnating the assembly, and the resin is consolidated in the preform (5).

Description

PROCEDE ET DISPOSITIF DE MOULAGE D'UNE PIECE EN MATERIAU COMPOSITE METHOD AND DEVICE FOR MOLDING A PIECE OF COMPOSITE MATERIAL
La présente invention concerne un procédé de fabrication de pièces en matériau composite et notamment de pièces composites thermoplastiques à hautes performances.The present invention relates to a method for manufacturing parts made of composite material and especially high-performance thermoplastic composite parts.
Les pièces en matériau composite présentent des propriétés, notamment mécaniques et chimiques, excellentes. Elles peuvent ainsi combiner une résistance élevée aux contraintes mécaniques et/ou thermiques et une forte rigidité pour une masse minimale. Elles peuvent également présenter des formes complexes.Composite material parts have excellent mechanical and chemical properties. They can thus combine a high resistance to mechanical and / or thermal stresses and a high rigidity for a minimum mass. They can also have complex shapes.
Ces matériaux composites sont donc largement mis en œuvre dans l'industrie spatiale (satellites, sondes, lanceurs), dans l'industrie aéronautique (trappes, portes, bords d'attaque, ailerons, cloisons intérieures, ...) et dans l'industrie automobile ou ferroviaire.These composite materials are therefore widely used in the space industry (satellites, probes, launchers), in the aerospace industry (hatches, doors, leading edges, fins, interior partitions, ...) and in the automotive or railway industry.
On connaît de nombreux procédés permettant l'imprégnation d'une préforme avec une résine liquide pour la fabrication d'une pièce composite. Certains de ces procédés tels que le procédé de moulage par transfert de résine (RTM), impliquent l'injection de résine liquide dans un système clos pour imprégner la préforme, ce qui permet d'éliminer la plupart des éléments volatils dégagés par la résine. Cette injection étant réalisée sous vide, on évite ainsi le piégeage de bulles d'air et on assure la diffusion de cette résine même dans les zones peu accessibles.Numerous methods are known for permitting the impregnation of a preform with a liquid resin for the manufacture of a composite part. Some of these methods, such as the resin transfer molding (RTM) process, involve the injection of liquid resin into a closed system to impregnate the preform, thereby eliminating most of the volatile elements released by the resin. This injection is carried out under vacuum, thus avoiding entrapment of air bubbles and ensures the diffusion of this resin even in inaccessible areas.
Bien que ce procédé RTM permette l'obtention de pièces présentant un bon état de surface, la migration de la résine se fait perpendiculairement à la section de la préforme. Le temps d'imprégnation d'une pièce de grande dimension telle qu'un panneau ou longeron est donc long et coûteux.Although this RTM process makes it possible to obtain parts having a good surface state, the migration of the resin is perpendicular to the section of the preform. The impregnation time of a large piece such as a panel or spar is therefore long and expensive.
De plus, les résines mises en œuvre dans ce procédé RTM doivent être des résines thermodurcissables de basses viscosités de manière à assurer un bon remplissage du moule.In addition, the resins used in this RTM process must be thermosetting resins of low viscosities so as to ensure a good filling of the mold.
Les résines présentant des viscosités plus importantes n'autorisent pas une imprégnation totale à basses pressions de la préforme sèche. Il peut en résulter un excès de résine accumulée dans des zones non désirées de la préforme. Le procédé de moulage par infusion de résine liquide (LRI) se différencie du procédé RTM par le mode d'injection de la résine liquide. Cette résine est en effet injectée dans un diffuseur interposé entre la préforme et le moule. La résine étant répartie sur une plus grande surface, sa migration s'effectue alors dans le sens de l'épaisseur de la préforme. On peut ainsi réaliser des pièces de plus grandes dimensions et introduire des résines présentant des viscosités plus importantes.Resins with higher viscosities do not allow complete impregnation at low pressures of the dry preform. This can result in an excess of resin accumulated in undesired areas of the preform. The liquid resin infusion molding process (LRI) differs from the RTM process by the injection mode of the liquid resin. This resin is in fact injected into a diffuser interposed between the preform and the mold. The resin being distributed over a larger area, its migration then takes place in the direction of the thickness of the preform. It is thus possible to make larger pieces and introduce resins with higher viscosities.
Toutefois, il n'est pas possible avec ces procédés d'injecter une préforme fibreuse constituée de différents plis de tissus structuraux non ensimés et non poudrés avec une résine thermoplastique de très haute viscosité à la température de mise en oeuvre.However, it is not possible with these methods to inject a fibrous preform consisting of different plies of non-sized and unpowdered structural fabrics with a thermoplastic resin of very high viscosity at the processing temperature.
En effet, les pressions engendrées sont susceptibles de déformer fortement les plis de la préforme non liés entre eux puisque non poudrés ou ensimés.Indeed, the pressures generated are likely to strongly deform the folds of the preform not linked together since they are not powdered or sized.
Il est donc typiquement nécessaire de solidariser les plis de la préforme par poudrage, ensimage ou encore par couture préalablement à l'imprégnation de la préforme ainsi obtenue avec la résine liquide.It is therefore typically necessary to secure the folds of the preform by dusting, sizing or sewing prior to impregnation of the preform thus obtained with the liquid resin.
Cependant, ces étapes d'assemblage supplémentaires augmentent de manière significative la complexité et le coût de la pièce à réaliser.However, these additional assembly steps significantly increase the complexity and cost of the part to be made.
De plus, l'emploi de résines thermoplastiques à hautes performances (HP) nécessite une injection à hautes températures, qui dégrade les polymères d'ensimage et poudres de compactage des préformes RTM usuelles.In addition, the use of high performance thermoplastic resins (HP) requires a high temperature injection, which degrades the sizing polymers and compacting powders of conventional RTM preforms.
En outre, on peut observer des mouvements parasites des plis ainsi liés dans le moule lorsque les pressions engendrées par l'injection de la résine liquide restent élevées comme, à titre illustratif, dans le cas d'une résine thermoplastique de très haute viscosité à la température de mise en œuvre.In addition, parasitic movements of the folds thus bonded in the mold can be observed when the pressures generated by the injection of the liquid resin remain high, for example, in the case of a thermoplastic resin of very high viscosity at the implementation temperature.
Or, les matrices thermoplastiques présentent de nombreux avantages notamment parce qu'elles sont ductiles et offrent des possibilités de reformage (i.e. pliage) et de recyclage.However, thermoplastic matrices have many advantages in particular because they are ductile and offer opportunities for reforming (i.e. folding) and recycling.
Il serait donc intéressant de disposer d'un procédé et d'un moule pour la fabrication de pièces en matériau composite permettant d'empêcher tout mouvement parasite des plis lors de l'introduction de résine liquide dans le moule. L'objectif de la présente invention est de proposer un procédé et un dispositif pour le moulage d'une pièce en matériau composite simple dans leur conception et dans leur mode opératoire, rapide et économique, permettant un maintien de la préforme fibreuse pendant l'injection de type LCM ("Liquid Composite Molding" - injection sur renforts fibreux) de la résine liquide de très haute viscosité.It would therefore be advantageous to have a method and a mold for the manufacture of composite material parts to prevent parasitic movement of the folds during the introduction of liquid resin into the mold. The object of the present invention is to provide a method and a device for molding a single composite material part in their design and in their operating mode, fast and economical, allowing maintenance of the fibrous preform during injection LCM type ("Liquid Composite Molding" - injection on fibrous reinforcements) of the very high viscosity liquid resin.
Avantageusement, il n'est pas nécessaire avec le procédé de l'invention de solidariser entre eux les plis de la préforme. On évite ainsi des étapes préalables onéreuses de couture ou de poudrage.Advantageously, it is not necessary with the method of the invention to join together the folds of the preform. This avoids expensive preliminary sewing or dusting steps.
Un autre objectif de l'invention est de faciliter l'entière imprégnation de la préforme quelque soit la viscosité de la résine liquide introduite dans le moule à la température de mise en œuvre et quelque soit la température du moule.Another object of the invention is to facilitate the complete impregnation of the preform regardless of the viscosity of the liquid resin introduced into the mold at the processing temperature and whatever the temperature of the mold.
A cet effet, l'invention concerne un procédé de moulage d'une pièce en matériau composite par l'injection d'une résine thermoplastique à hautes performances dans une préforme placée dans un moule, cette préforme comportant des plis non liés entre eux.To this end, the invention relates to a method of molding a composite material part by injecting a high-performance thermoplastic resin into a preform placed in a mold, this preform having folds not bonded to each other.
Selon l'invention, on réalise les étapes suivantes :According to the invention, the following steps are carried out:
- on place un organe drainant ayant une haute perméabilité directement en contact avec la préforme, - on place et on maintient en position chaque élément de cet ensemble ainsi obtenu dans le moule,a draining member having a high permeability is placed directly in contact with the preform, and each element of this assembly thus obtained in the mold is placed and held in position,
- on injecte la résine à l'état visqueux dans le moule pour imprégner cet ensemble,the resin is injected in the viscous state into the mold in order to impregnate this assembly,
- on consolide la résine dans la préforme. On entend par « organe drainant ayant une haute perméabilité » que l'organe drainant a une perméabilité supérieure typiquement à 10"9 m2.the resin is consolidated in the preform. The term "draining member having a high permeability" means that the draining member has a permeability typically greater than 10 "9 m 2 .
Dans différents modes de réalisation de ce procédé de moulage, la présente invention concerne également les caractéristiques suivantes qui devront être considérées isolément ou selon toutes leurs combinaisons techniquement possibles :In different embodiments of this molding method, the present invention also relates to the following features which should be considered in isolation or in all their technically possible combinations:
- l'organe drainant est un grillage rigide,the draining member is a rigid grid,
De préférence, ce grillage rigide est un grillage polymère apte à résister aux températures d'injection de la résine. A titre illustratif, on pourra citer un polymère à base verre téflonné.Preferably, this rigid grid is a polymer grid capable of withstanding the injection temperatures of the resin. By way of illustration, mention may be made of a Teflon glass-based polymer.
- préalablement à l'étape de mise en place de l'ensemble préforme/organe drainant dans le moule, on recouvre cet organe drainant d'un agent démoulant,before the step of placing the preform / draining organ assembly in the mold, this draining body is covered with a release agent,
Le traitement préalable à l'installation de la préforme et de l'organe drainant dans le moule, de cet organe avec un agent démoulant compatible avec les températures d'injection permet de faciliter le démoulage de l'organe drainant de la pièce injectée après consolidation.The pre-treatment prior to the installation of the preform and the draining member in the mold, of this member with a release agent compatible with the injection temperatures makes it possible to facilitate the demolding of the draining member of the injected part after consolidation. .
Cet agent démoulant est, à titre purement illustratif, un liquide ou spray démoulant hautes températures, dont un séchage à hautes températures assure la bonne tenue sur le grillage drainant.This demolding agent is, for purely illustrative purposes, a high temperature release liquid or spray, a high temperature drying of which ensures good performance on the draining mesh.
- on maintient en position chaque élément de cet ensemble organe drainant/préforme fibreuse par ses extrémités au moyen de saillies pointues, Ces saillies sont choisies de préférence dans le groupe comprenant des tiges à pointe, des picots et des combinaisons de ces éléments. Ces éléments peuvent être droits ou incurvés, de diamètre ou section variable suivant la nature de l'organe drainant et de la préforme fibreuse.each element of this draining member / fibrous preform assembly is held in position by its ends by means of pointed projections. These projections are preferably chosen from the group comprising tip rods, spikes and combinations of these elements. These elements may be straight or curved, of varying diameter or section depending on the nature of the draining organ and the fibrous preform.
- on place le volume intérieur du moule sous vide.the internal volume of the mold is placed under vacuum.
L'invention concerne également un dispositif pour la mise en œuvre du procédé de moulage tel que décrit précédemment, ce dispositif comportant un moule destiné à recevoir une résine liquide pour l'imprégnation d'une préforme placée dans ce moule, cette préforme comportant des plis non liés entre eux.The invention also relates to a device for implementing the molding method as described above, this device comprising a mold intended to receive a liquid resin for impregnating a preform placed in this mold, this preform comprising folds not related to each other.
Selon l'invention, ce moule comporte des moyens pour maintenir en position au moins les plis de la préforme dans ce moule lors de l'injection de ladite résine liquide. De préférence, ce dispositif comprend une première partie de moule et une deuxième partie de moule, ces parties étant destinées à coopérer pour assurer l'étanchéité du moule dans une position de moulage. Les moyens pour maintenir en position au moins les plis de la préforme comprennent des saillies placées sur la première partie de moule, chacune de ces saillies comportant une extrémité pointue et un ou plusieurs creux placés sur la deuxième partie et destinés à recevoir ces extrémités pointues lorsque les première et deuxième parties sont dans leur position de moulage.According to the invention, this mold comprises means for maintaining in position at least the folds of the preform in this mold during the injection of said liquid resin. Preferably, this device comprises a first mold part and a second mold part, these parts being intended to cooperate to seal the mold in a molding position. The means for holding in position at least the folds of the preform comprise projections placed on the first mold part, each of these projections having a pointed end and one or more recesses placed on the second part and intended to receive these pointed ends when the first and second parts are in their molding position.
Avantageusement, ces saillies sont placées sur au moins une partie du pourtour de la partie centrale de la première partie de moule de manière à maintenir la périphérie de la préforme.Advantageously, these projections are placed on at least a portion of the periphery of the central portion of the first mold part so as to maintain the periphery of the preform.
Ces saillies étant placées sur le pourtour de la partie centrale de la première partie du moule, on évite ainsi d'endommager la partie centrale de la préforme. Ces saillies sont choisies de préférence dans le groupe comprenant des tiges à pointe, des picots et des combinaisons de ces éléments. Ces éléments peuvent être droits ou incurvés.These projections being placed on the periphery of the central part of the first part of the mold, it is thus possible to avoid damaging the central part of the preform. These projections are preferably selected from the group consisting of tipped rods, spikes and combinations of these elements. These elements can be straight or curved.
Dans différents modes de réalisation possibles, l'invention sera décrite plus en détail en référence aux dessins annexés dans lesquels : - la figure 1 est une vue partielle d'une partie d'un dispositif de moulage selon un mode de réalisation préféré de l'invention;In various possible embodiments, the invention will be described in more detail with reference to the accompanying drawings in which: - Figure 1 is a partial view of a portion of a molding device according to a preferred embodiment of the invention;
- la figure 2 représente schématiquement un ensemble préforme/organe drainant selon un mode de réalisation préféré de l'invention, l'organe drainant étant montré partiellement pour faire apparaître la préforme; - la figure 3 est une vue de l'ensemble polymérisé de la Figure 2, l'organe drainant ayant été partiellement retiré pour faire apparaître la pièce composite;- Figure 2 shows schematically a set preform / draining member according to a preferred embodiment of the invention, the draining member being partially shown to show the preform; FIG. 3 is a view of the polymerized assembly of FIG. 2, the draining member having been partially removed to reveal the composite part;
La Figure 1 montre une vue partielle d'une partie d'un dispositif de moulage selon un mode de réalisation préféré de l'invention. Ce dispositif de moulage comporte un moule comprenant une première partie de moule 1 et une deuxième partie de moule (non représentée).Figure 1 shows a partial view of a portion of a molding device according to a preferred embodiment of the invention. This molding device comprises a mold comprising a first mold part 1 and a second mold part (not shown).
Ces première 1 et deuxième parties sont destinées à coopérer pour assurer l'étanchéité du moule dans une position de moulage dans laquelle la résine est injectée dans le moule pour imprégner une préforme comprenant des plis non liés entre eux.These first 1 and second parts are intended to cooperate to seal the mold in a molding position in which the resin is injected into the mold to impregnate a preform comprising folds not bonded together.
Cette première partie comporte des saillies 2 comportant chacune une extrémité pointue 3. Ces saillies 2 se présentent ici sous la forme d'une barrette de clous 2 réalisés en matériau métallique tel que de l'acier inoxydable.This first portion has projections 2 each having a pointed end 3. These projections 2 are here in the form of a bar of nails 2 made of a metallic material such as stainless steel.
Leur extrémité pointue 3 sont chacune destinée à être reçue dans une cavité correspondante de la deuxième partie de moule dans la position de moulage. Typiquement, le procédé de moulage consiste à placer un organe drainant 4 ayant une haute perméabilité directement en contact avec une préforme 5, cette dernière comportant des plis non solidarisés entre eux.Their pointed end 3 are each intended to be received in a corresponding cavity of the second mold part in the molding position. Typically, the molding process consists in placing a draining member 4 having a high permeability directly in contact with a preform 5, the latter comprising folds not secured to each other.
On place ensuite cet ensemble préforme/organe drainant dans le moule en encastrant cet ensemble dans les clous 2 de longueur suffisante pour dépasser de l'ensemble afin de maintenir en position cet ensemble lors de l'injection de la résine à l'état visqueux dans le moule.This set preform / draining member is then placed in the mold by embedding this assembly in the nails 2 of sufficient length to protrude from the assembly in order to maintain this assembly in position during the injection of the resin in the viscous state into the mold.
Ces clous 2 sont placés dans la première partie 1 de moule de sorte à percer les extrémités de la préforme 5 à injecter et de ne pas endommager la partie centrale de celle-ci. Ces saillies 2 sont de préférence placées au niveau des ports d'entrée et de sortie de la résine dans le moule, c'est-à-dire au niveau des baignoires d'entrée et de sortie de la résine. On limite alors fortement les mouvements des plis sous l'effet des fortes pressions d'injection de la résine thermoplastique à hautes performances. Avantageusement, le dispositif comporte des moyens pour créer le vide dans le moule (non représentés), ces moyens étant en communication de fluide avec le moule.These nails 2 are placed in the first mold part 1 so as to pierce the ends of the preform 5 to be injected and not to damage the central part thereof. These projections 2 are preferably placed at the inlet and outlet ports of the resin in the mold, that is to say at the inlet and outlet baths of the resin. The movements of the folds are then strongly limited under the effect of the high injection pressures of the high-performance thermoplastic resin. Advantageously, the device comprises means for creating the vacuum in the mold (not shown), these means being in fluid communication with the mold.
On injecte la résine thermoplastique à hautes performances à l'état visqueux dans le moule pour imprégner l'ensemble. La haute perméabilité de l'organe drainant 4 contribue avantageusement à augmenter la perméabilité globale de la préforme 5 et à faciliter l'imprégnation de celle-ci dans le sens plan. Les pressions engendrées par l'injection de la résine dans la préforme sont également réduites par la présence de cet organe drainant 4. Enfin, on consolide la résine thermoplastique dans la préforme 5. La Figure 3 montre l'organe drainant 4 partiellement retiré pour faire apparaître la pièce composite 6 imprégnée et consolidée. The high performance thermoplastic resin in the viscous state is injected into the mold to impregnate the assembly. The high permeability of the draining member 4 advantageously contributes to increasing the overall permeability of the preform 5 and to facilitate the impregnation thereof in the planar direction. The pressures generated by the injection of the resin into the preform are also reduced by the presence of this draining member 4. Finally, the thermoplastic resin is consolidated in the preform 5. Figure 3 shows the draining member 4 partially removed to reveal the composite part 6 impregnated and consolidated.

Claims

REVENDICATIONS
1. Procédé de moulage d'une pièce en matériau composite par l'injection d'une résine thermoplastique à hautes performances dans une préforme (5) placée dans un moule, ladite préforme (5) comportant des plis non liés entre eux, caractérisé en ce qu'on réalise les étapes suivantes :1. A method of molding a composite material part by injecting a high performance thermoplastic resin in a preform (5) placed in a mold, said preform (5) comprising folds not bonded together, characterized in what we do the following steps:
- on place un organe drainant (4) ayant une haute perméabilité directement en contact avec ladite préforme (5),a draining member (4) having a high permeability is placed directly in contact with said preform (5),
- on place et on maintient en position chaque élément dudit ensemble ainsi obtenu dans ledit moule (1 ),placing and holding in position each element of said assembly thus obtained in said mold (1),
- on injecte ladite résine à l'état visqueux dans ledit moule (1 ) pour imprégner ledit ensemble,said resin is injected in the viscous state into said mold (1) to impregnate said assembly,
- on consolide ladite résine dans ladite préforme (5).said resin is consolidated in said preform (5).
2. Procédé selon la revendication 1 , caractérisé en ce que ledit organe drainant (4) est un grillage rigide.2. Method according to claim 1, characterized in that said draining member (4) is a rigid grid.
3. Procédé selon la revendication 1 ou 2, caractérisé en ce que préalablement à l'étape de mise en place de l'ensemble préforme/organe drainant dans le moule, on recouvre ledit organe drainant (4) d'un agent démoulant. 3. Method according to claim 1 or 2, characterized in that prior to the step of placing the preform assembly / draining member in the mold, covering said draining member (4) of a release agent.
4. Procédé selon l'une quelconque des revendications 1 à 3, caractérisé en ce qu'on maintient en position chaque élément dudit ensemble préforme/organe drainant par ses extrémités au moyen de saillies pointues (2, 3).4. Method according to any one of claims 1 to 3, characterized in that in position holds each element of said preform assembly / draining member by its ends by means of pointed projections (2, 3).
5. Procédé selon l'une quelconque des revendications 1 à 4, caractérisé en ce qu'on place le volume intérieur dudit moule (1 ) sous vide.5. Method according to any one of claims 1 to 4, characterized in that places the internal volume of said mold (1) under vacuum.
6. Dispositif pour la mise en œuvre du procédé de moulage d'une pièce en matériau composite selon l'une quelconque des revendications 1 à 5, ledit dispositif comportant un moule destiné à recevoir une résine liquide pour l'imprégnation d'une préforme (5) placée dans ledit moule, ladite préforme (5) comportant des plis non liés entre eux, caractérisé en ce que ledit moule comporte des moyens (2, 3) pour maintenir en position au moins lesdits plis de la préforme (5) dans ledit moule lors de l'injection de ladite résine liquide.6. Device for implementing the method of molding a composite material part according to any one of claims 1 to 5, said device comprising a mold for receiving a liquid resin for impregnating a preform ( 5) placed in said mold, said preform (5) comprising folds not bonded together, characterized in that said mold comprises means (2, 3) for holding in position at least said folds of the preform (5) in said mold during injection of said liquid resin.
7. Dispositif selon la revendication 6, caractérisé en ce que ledit moule comprenant une première partie de moule (1 ) et une deuxième partie de moule, destinées à coopérer pour assurer l'étanchéité dudit moule dans une position de moulage, lesdits moyens pour maintenir en position au moins lesdits plis comprennent des saillies (2) placées sur ladite première partie de moule (1 ), chacune desdites saillies (2) comportant une extrémité pointue (3) et un ou plusieurs creux placés sur ladite deuxième partie et destinés à recevoir lesdites extrémités pointues (3) lorsque lesdites première et deuxième parties sont dans leur position de moulage.7. Device according to claim 6, characterized in that said mold comprising a first mold part (1) and a second mold part, intended to cooperate to seal said mold in a mold. molding position, said means for holding in position at least said folds comprise projections (2) placed on said first mold part (1), each of said projections (2) having a pointed end (3) and one or more placed recesses on said second portion and for receiving said pointed ends (3) when said first and second portions are in their molding position.
8. Dispositif selon la revendication 7, caractérisé en ce que lesdites saillies (2) sont placées sur au moins une partie du pourtour de la partie centrale de ladite première partie de moule (1 ) de manière à maintenir la périphérie de ladite préforme (5).8. Device according to claim 7, characterized in that said projections (2) are placed on at least a part of the periphery of the central part of said first mold part (1) so as to maintain the periphery of said preform (5). ).
9. Dispositif selon la revendication 7 ou 8, caractérisé en ce que lesdites saillies (2) sont placées au niveau des ports d'entrée et de sortie de ladite résine dans ledit moule.9. Device according to claim 7 or 8, characterized in that said projections (2) are placed at the inlet and outlet ports of said resin in said mold.
10. Dispositif selon l'une quelconque des revendications 6 à 9, caractérisé en ce qu'il comprend des moyens pour créer le vide dans ledit moule, lesdits moyens étant en communication de fluide avec ledit moule. 10. Device according to any one of claims 6 to 9, characterized in that it comprises means for creating the vacuum in said mold, said means being in fluid communication with said mold.
PCT/EP2009/050435 2008-01-16 2009-01-15 Method and device for moulding a part of a composite material WO2009090221A1 (en)

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FR2966076B1 (en) * 2010-10-18 2013-10-11 Visteon Global Tech Inc SURINJECTION OF FIBROUS MAT AND PIECE OBTAINED
DE102013214480A1 (en) * 2013-07-24 2015-01-29 F&G Engineering Gmbh Tool, circuit board and method for producing workpieces
DE102014206500A1 (en) * 2014-04-04 2015-10-08 Bayerische Motoren Werke Aktiengesellschaft Tool for producing a fiber composite component

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EP1555104A1 (en) * 2002-10-09 2005-07-20 Toray Industries, Inc. Method of rtm molding
US20060068170A1 (en) * 2004-09-29 2006-03-30 Hanson Steven F Apparatuses, systems, and methods for manufacturing composite parts
EP1685947A1 (en) * 2005-02-01 2006-08-02 HONDA MOTOR CO., Ltd. manufacture of FRP composites
EP1721719A1 (en) * 2004-02-17 2006-11-15 Toray Industries, Inc. Rtm molding method and device

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Publication number Priority date Publication date Assignee Title
FR2383769A1 (en) * 1977-03-17 1978-10-13 Chrysler France Moulds with dowels to positively locate inserts - to inhibit displacement and to integrate insert bending or boring with moulding
EP1555104A1 (en) * 2002-10-09 2005-07-20 Toray Industries, Inc. Method of rtm molding
EP1721719A1 (en) * 2004-02-17 2006-11-15 Toray Industries, Inc. Rtm molding method and device
US20060068170A1 (en) * 2004-09-29 2006-03-30 Hanson Steven F Apparatuses, systems, and methods for manufacturing composite parts
EP1685947A1 (en) * 2005-02-01 2006-08-02 HONDA MOTOR CO., Ltd. manufacture of FRP composites

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