WO2010049566A1 - Método de fabricación de un panel de geometría compleja en material compuesto preimpregnado - Google Patents
Método de fabricación de un panel de geometría compleja en material compuesto preimpregnado Download PDFInfo
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- WO2010049566A1 WO2010049566A1 PCT/ES2009/070466 ES2009070466W WO2010049566A1 WO 2010049566 A1 WO2010049566 A1 WO 2010049566A1 ES 2009070466 W ES2009070466 W ES 2009070466W WO 2010049566 A1 WO2010049566 A1 WO 2010049566A1
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- complex geometry
- panel
- layer
- composite material
- prepreg
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D99/00—Subject matter not provided for in other groups of this subclass
- B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
- B29D99/0014—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with ridges or ribs, e.g. joined ribs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/304—In-plane lamination by juxtaposing or interleaving of plies, e.g. scarf joining
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
- B29C70/345—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using matched moulds
-
- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—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
- B29C70/461—Rigid movable compressing mould parts acting independently from opening or closing action of the main mould
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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- 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
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/03—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers with respect to the orientation of features
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- 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
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/08—Interconnection of layers by mechanical means
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- 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
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
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- 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
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- 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
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- 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
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/514—Oriented
-
- 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
- B32B2607/00—Walls, panels
Definitions
- the present invention is intended for application in the aerospace and aerospace industry in which the weight of structural parts is a key factor.
- the present invention is considered suitable for application to the manufacture of large structural panels and closed contour panels such as cylinders or cones, for example aircraft fuselage sections of the wide-body type (WB, "Wide Body” ).
- WB wide-body type
- the general objective problem addressed by the present invention is to provide a method of manufacturing structural panels of complex geometry and low weight ensuring that the panels obtained have: maximum mechanical and structural integrity and maximum precision in terms of dimensional tolerance.
- panel is understood as a piece with a very small thickness compared to the surface along which it extends, or characteristic surface, this characteristic surface being open or closed contour (eg cylinders) or cones are considered closed contour surfaces).
- the low weight of the panel to be obtained as well as its required structural functionality directs the application of the invention to panels made of prepreg composite material, as expressed in the statement of this specification.
- the prepreg material consists essentially of a set of reinforcing fibers impregnated in a resin matrix and grouped in layers extending continuously along each layer, unidirectionally or in fabric (weft and warp).
- the prepreg is processed by spreading the layers, stacking them on a mold having a substantially smooth surface; The set of stacked prepreg layers spread over the mold is called stacking.
- stacking Once the stack is extended in the mold, it is compacted, usually by the vacuum technique. Then it is cured in an oven or autoclave by applying a curing cycle in which the stack is subjected to a suitable temperature and pressure, and once the curing cycle is finished, it separates from the mold resulting in the piece or panel to be obtained. .
- the prepreg can consist of sheets, tapes or bands, giving rise to the various known processes of obtaining panels in prepreg composite material called, respectively: laminate, curb, or fiber placement.
- the laminate can consist of a fabric of dimensional characteristics of wide variation; the tapes or bands are normally supplied with the fibers extending unidirectionally, with a width between a few millimeters and several centimeters.
- Prepreg is widely used in the art for its good mechanical behavior, derived from the stiffness provided by the fibers as they are arranged continuously along each layer. Likewise, it is possible to obtain panels with good surface finish and good dimensional tolerance, properties inherited from the surface accuracy with which it is possible to machine the mold on which the stack extends.
- the invention relates to panels called "complex geometry", unlike the manufacturing processes of conventional pre-impregnated composite panels mentioned.
- complex geometry panels are understood in the present invention to be those panels that have a characteristic surface of complex geometry, these surfaces being surfaces that, without necessarily being substantially smooth, are not substantially smooth.
- panels that follow surfaces with reliefs such as undulations, grooves or embossments are considered complex geometry panels.
- the solution provided by the present invention is based on the conventional processing of prepreg composite material, which as indicated above is carried out on sufficiently smooth mold surfaces.
- the invention is conceived for the technique in which the prepreg is automatically processed, through a head that sweeps the surface of the mold extending the material, this is the case of the processes known in the art as of automatic taping ("automatic tape lay-up") or fiber placement.
- Automatic prepreg processing provides the additional advantages compared to manual processing to improve the production rate and reduce costs, by reducing manufacturing time and reducing waste material, as well as providing greater precision, due to the uniformity of pressures in the prepreg extension and the compaction of the piled up.
- a possible technical solution to the problem of obtaining complex geometry panels in prepreg composite material would be to extend the prepreg into a mold that incorporates reliefs (male or female) on its surface, so that the prepreg extends over the entire surface including the faces of the surface of the reliefs, and giving rise to a stack that had the final shape of the panel.
- said solution is not feasible in the state of the art for automatic prepreg processing, since to be able to automatically extend the prepreg over the mold surface it is required that the surface be sufficiently smooth.
- the present invention provides a technical solution for obtaining a pre-impregnated composite panel of complex geometry in which said automatic processing is applicable without limitation Conventional prepreg.
- the invention is based on the application of conventional hot forming and pressing techniques, such that reliefs, grooves, corrugations, embossments, etc. of the complex geometry panel can be formed, from a flat stack of prepreg, once arranged on the mold, and with the use of a mold that has the appropriate shape with the negative of the surface of the respective complex geometry panel a obtain.
- compression molding processes of manufacturing structural parts in material composed by the technique known as "compression molding” are known.
- This technique consists in preparing a mass of reinforcement fibers previously cut and impregnated in resin and then introducing said mass, which is called a preform, into a mold that is subjected to a high compression pressure.
- the different existing methods for obtaining the preform give rise to the different types of compression molding process known in the art, which are:
- US 5609805 patent document includes an embodiment of the referred compression molding technique.
- the essential characteristic that makes it possible to produce the necessary molding deformation until the preform acquires the final shape of the piece, determined by the inner contour of the mold, is the stiffness of the preform material, which It is small enough, mainly due to the elasticity of the resin and because the fibers are arranged upturned and cut inside, not coercing the deformation of the preform, since it can be moved relatively without opposition inside the resin during molding.
- thermoforming or hot forming and pressing manufacturing processes of parts in composite material pre-impregnated by thermoforming or hot forming and pressing are known. These processes can be applied, like the present invention, also to prepregnated. In these processes a prepreg of prepreg composite material is formed directly by the application of heat and certain pressure that causes the deformation of the material against a mold that has the shape of the negative of the surface to be obtained.
- thermoforming and pressing processes that makes it possible to produce the necessary molding deformation until the prepreg preforms acquires the final shape of the part is that the prepreg preform It extends over a sufficiently small area and that the contour of the preform is open or free from application of clamping pressure during pressing of the preform. But said method does not allow its application to prepregs whose size is large enough and / or the preform remains trapped by an outer contour. This method would also not apply to closed contour panels such as cylindrical panels or cones.
- the characteristics of the present invention determine that the proposed method, unlike the known technique, is applicable without limitation to obtaining pre-impregnated composite panels of sufficiently large size and complex geometry panels, having reliefs with more complex forms than those that can be obtained with the current technique.
- the method allows manufacturing through automatic prepreg processing, using the known techniques of "fiber placement” and “automatic tape lay-up", allowing a high rate of production and low cost and ensuring that the panels obtained have a maximum mechanical and structural integrity as well as maximum precision in terms of dimensional tolerance.
- the method comprises the following stages: a first stage, which is called “stacking”, a second stage which is called “forming”, and a third stage, which is called “finishing”.
- the prepreg is spread on a mold resulting in stacking.
- the mold to be used in the present invention has cavities corresponding to the negative of the complex geometry of the panel to obtain.
- said cavities can be partially or totally occupied by a filling element, to facilitate the application of the prepreg when necessary, so that the filling element provides a smooth auxiliary support surface that fits with the mold surface for the placement of the different layers of the stack.
- the filling elements are removed from the mold cavities, where appropriate.
- the characteristic of the method of the present invention is that during this first stage of stacking, the prepreg extends over the mold with at least one discontinuity or cut in the fibers of each layer.
- the discontinuity or cutting of the fibers of each layer defines a line of discontinuity in the prepreg layers, according to the endpoints of the fiber discontinuities.
- the "prepreg layer section” is defined as the portion of the prepreg layer in which the prepreg fibers extend continuously, ie without discontinuity, as in each layer of the prepreg conventionally processed.
- a section of the prepreg layer can be obtained by cutting a prepreg layer by the dashed line.
- the sections of the prepreg layer when the prepreg extension is performed automatically, by automatic taping ("automatic tape lay up") or by fiber placement would be obtained directly by extending the tapes or bands to the dashed line, where the tape or band is cut automatically.
- the second stage, of forming consists in the application to the stacking of the hot forming and pressing technique. For this, during this phase, a combined cycle of temperature and pressure is executed on the stack, with or without vacuum, until the stack acquires the shape of the final panel to be obtained.
- the existence in the stacking of the discontinuity lines allows during this second stage of forming, the stack can be deformed locally in an environment of the relief, by making it possible to slide between the adjacent pre-impregnated layer sections of the stack, otherwise impossible on sufficiently large panels or closed contour panels, thanks to the pressure and temperature action, until the final shape of the complex geometry panel to be acquired is acquired.
- the third stage, of finishing consists in the realization of conventional operations on the stacking that lead to the obtaining of the finished panel with its final physical constitution.
- This stage includes curing of the prepreg resin by applying the corresponding pressure and temperature cycle, co-curing, coping the panel with another piece or panel made of composite material, also where appropriate, etc.
- Copegado is understood as the union of the complex geometry panel cured to a piece as a smooth panel with adhesive. Such joining could be done with other conventional means such as riveting.
- Co-curing means curing of the complex geometry panel assembly with a piece such as a smooth panel made of composite material.
- a first technical aspect would be the distribution of the discontinuity lines. This is a technical aspect to be determined depending on the shape of the reliefs of the complex geometry panel to be obtained and the prepreg conformability.
- the formability is defined as the ease of relative displacement between layers, and in general depends on the adhesion of the stack to the mold and the adhesion between the layers, which in turn depends on the viscosity of the prepreg resin, on the temperature and of the pressure applied during forming, as well as the thickness of the stack.
- the discontinuity line of each layer is distributed in an environment of the stack sufficiently close to the relief to be obtained, such that if the discontinuity line were disposed outside said environment, at a distance sufficiently far from the reliefs, the adhesion between the layers of the stack, for the values of pressure and temperatures set in the process, would prevent the relative displacement between the adjacent layer stretches of the stack and therefore the forming of the material would not be possible.
- this environment could be deduced technically close enough to the relief considering the tension state of the stack subjected to the forming forces that originate its deformation.
- an isostatic line that borders the relief to be obtained and in which the main tension due to the application of the forming under its particular conditions would be null could be considered as a contour line of said environment sufficiently close.
- the line of discontinuity of each layer could be defined along any one of the isostatic lines parallel to said contour.
- grooved reliefs are defined as those reliefs that are obtained from sections, generally with different shapes (polygonal or curved), projected according to a generatrix line.
- grooved reliefs would be those that would be obtained from the projection of a section along a straight guideline, which would define a guiding direction of the relief.
- the fibers are arranged aligned along different directions according to each layer of the prepreg following a sequence and with a relative offset or inclination between the fibers of the different layers, for example typical sequences of the fibers are 0 ° , +60 °, -60 °, or 0 °, + 45 °, -45 °, 90 °; In this way it is possible to provide the panel with optimized properties according to the type and direction of the efforts to be supported.
- a symmetrical stacking sequence is contemplated with respect to the generatrix direction of the relief.
- symmetrical sequence with respect to the generatrix direction of the relief is meant that whenever the stack includes fibers oriented in a certain direction, the stack also includes symmetrical fibers of the previous fibers, in the adjacent layers, with respect to a direction perpendicular to the generatrix direction of the relief.
- a stacking sequence of the layers with 0 °, + 45 °, -45 °, 90 ° would be symmetric with respect to the generatrix direction of the relief if it were arranged with the different oriented layers forming 90 °, -45 °, 45 °, 0 or , respectively, with respect to the generatrix direction of the relief.
- the use of a symmetrical sequence would favor the formability of the stack, avoiding distortion between layers or fibers.
- a third technical aspect of the invention is derived from a property of the stack consisting in that the adhesion between two adjacent layers of the stack during shaping is smaller the smaller the gap between the direction of their respective fibers.
- this property can also be used in an embodiment of the invention to facilitate the formability of the material, as well as to enable displacement. Controlled grouping of several layer stretches during forming.
- a fourth technical aspect would be the distance between the lines of discontinuity of the prepreg layers.
- the options for the layers to extend during stacking are contemplated both by leaving a certain distance between the lines of discontinuity and without leaving any distance or even overlapping the sections of the adjacent layers.
- both stacks could be obtained that, once formed, turn out to have an overlap between adjacent layer sections, as well as stacks that do not have said overlap.
- One or the other configurations could be of interest in practice to improve the mechanical behavior required in the panel to be obtained, particularly as it allows to control the inertia of the reliefs obtained.
- distance between the discontinuity lines of adjacent layer sections is defined as the distance between said discontinuity lines, with a negative or positive sign depending on whether the adjacent layer sections are respectively overlapping, or not are overlapping.
- the pressure temperature it can be carried out in an oven or in an autoclave according to the magnitude of the required pressure.
- the pressure could be applied by any system known in the art such as compaction rollers, presses with footsteps and males, pressurized atmospheres with fluids or gases, etc. Both the pressure and the temperature influence the viscosity of the material, whose evolution is decisive throughout the manufacturing process, taking into account that as indicated above low viscosity values favor formability, as well as reflecting the curing state of the prepreg resin.
- Figure la.- Represents an example of a complex geometry panel.
- Figure Ib Shows a detail of an example of a groove-shaped relief of a complex geometry panel.
- Figure Ic- Shows a detail of another example of relief (drawing) of a complex geometry panel.
- Figure 2. Represents the extension of a prepreg band on a mold through a head of a "fiber placement" machine.
- Figure 3. It shows an embodiment of a mold and represents the moment of the process in which the stack has been extended on the mold, before starting the forming of the stack.
- Figure 4. Shows an embodiment of a mold and a press, and represents a moment of the process during the forming of the stack.
- Figure 5. Shows a perspective view of a mold for obtaining grooved reliefs and represents a distribution of the stacking lines of the stack, as well as an arrangement of the respective sections of the layer of the stack with their respective sequence.
- Figure 6a Shows a view of section A-A 'of the mold of fig. 5 and represents the stack of fig. 5 with their respective lines of discontinuity, once arranged on the mold before being shaped.
- Figure 6b Shows a view of section A-A 'of the mold of fig. 5 and represents the stack of fig. 5 with their respective lines of discontinuity, once formed.
- Figure 7. Shows a perspective view of a mold for obtaining a relief in the form of a groove crossing with a groove shape and represents a distribution of the stacking discontinuity lines.
- Figure 8a Represents different examples of distribution of the discontinuity lines of the different sections of the stack layer, once the stack is formed. These examples refer to stacks without overlap between layers once formed.
- Figure 8b Represents different examples of distribution of the discontinuity lines of the different layers of the stack, once the stack is formed. These examples refer to stacks with overlap between the layer sections once formed.
- Figure 9. Represents different examples of mold shapes for obtaining grooved reliefs.
- Figure lia.- Represents the different stages of the method (I, II and III) applied to an embodiment in which there is a single stage of curing after forming.
- the process time is represented on the abscissa axis and the Temperature (T), viscosity ⁇ ) and pressure (P) are represented on the ordinate axis.
- Figure 11b Represents the different stages of the method (I, II and III) applied to an embodiment in which there is a curing stage (III) comprising a second curing cycle (usually known as post-curing).
- a curing stage III
- a second curing cycle usually known as post-curing.
- T Temperature
- ⁇ viscosity
- P pressure
- Figures la, Ib and Ic show a complex geometry panel (1), to which the present invention relates.
- the complex geometry panel (1) comprises reliefs (3), such as grooves (Fig. Ib) or embossments (Fig. Ic), with or without smooth areas (2).
- the contour (4) of an environment sufficiently close to the relief of the complex geometry panel (1) to be obtained within which the stacking lines of the stack would be placed is generically represented.
- FIG. 1 shows a head (5) of a "fiber placement” machine during prepreg extension.
- the head (5) consists in a simplified manner of a collimator (6), which groups the preimpregnated fibers into a band, guide rollers (7), a cutter (8) and a compactor roller (9).
- Other auxiliary elements such as voltage control means, thermocouples, etc. have not been represented.
- the head sweeps the surface of the mold (13) extending each section of prepreg layer, band by band (10), to a discontinuity line (12), located in the environment of the stack sufficiently close to the corresponding relief (3), where The band is cut by the cutter (8). Subsequently, the different sections of the layers extend continuously between / to or from the corresponding lines of discontinuity, thus giving rise to stacking (11).
- Figure 3 shows the stack (11) once extended on the mold (13).
- the mold (13) consists of female pieces (15) that include a cavity with the shape of the negative of the relief of the complex geometry panel (1) to be obtained.
- a filling element (14) can be accommodated in said cavity to facilitate stacking (I).
- the female parts (15) have conventional coupling means (16) to the mold.
- Figure 3 also shows schematically an installation embodiment for the application of vacuum pressure, with valves (22), fittings (23) and hoses (24).
- the prepreg stack (11) is deformed by application of pressure and temperature until it acquires the final shape.
- the forming (II) is represented in figure 4.
- the pressure is applied by means of a press (17) comprising conventional pressing elements such as a tread (18) or a male forming (19).
- said pressing elements incorporate sliding rods (20) subjected to the reaction of a spring (21).
- the mold cavities (13) can have different shapes, as shown in Figure 9.
- Figures 5, 6a and 6b represent the execution of the method of the invention applied to panels with grooved reliefs (30).
- Figure 5 shows a stack of eight layers, grouped into two groups (26) and (27) of four layers each.
- the discontinuity lines (12) coincide for the layer sections of the same group, so that in total there are two discontinuity lines in the stack, which are parallel to the generatrix direction of the relief in the form of a groove, as can be seen in the figure.
- the stacking sequence is symmetrical, as depicted in the detail views of the figure. It can also be seen how each of the two groups (26) and (27) in which the layers are grouped in the embodiment shown are packed between two layers with the fibers oriented according to the direction perpendicular to the generatrix direction of the relief in the form of groove.
- Figure 6a shows the stacking of the two groups of layers (26) and (27), in a view of section AA 'of Figure 5, where the distribution of the lines of discontinuity (12) can be seen, in the time to finish the stacking phase.
- Figure 6b shows the stack once formed.
- the distribution of the discontinuity lines (12) is such that after forming (II) the stack (11) turns out not to have overlapping adjacent layers, but the discontinuity presents a distancing with a positive sign.
- the discontinuity lines (12) could be such that after forming the distance between the discontinuity lines (12) of the different sections of the layer should be minimized (fig. 8a), or even that the layers or groups of adjacent layers overlap each other (distancing with a negative sign) (fig. 8b).
- Figure 7 represents, analogously to figure 5, the application of the method for obtaining a relief in the form of the cross-shaped relief of reliefs.
- finishing the finished panel can suffer for example a co-curing (with a second curing cycle, usually known as post-curing) or a coping of a smooth panel (31).
Abstract
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP09823120.2A EP2357075B1 (en) | 2008-10-30 | 2009-10-28 | Method for manufacturing a complex-geometry panel with pre-impregnated composite material |
BRPI0920231A BRPI0920231A2 (pt) | 2008-10-30 | 2009-10-28 | método de fabricar um painel de geometria complexa em material compósito pré-impregnado |
CN200980153362.1A CN102282006B (zh) | 2008-10-30 | 2009-10-28 | 在预浸渍复合材料中制造复杂几何形状面板的方法 |
CA2741486A CA2741486C (en) | 2008-10-30 | 2009-10-28 | Manufacturing method of a complex geometry panel in prepreg composite material |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
ESP200803085 | 2008-10-30 | ||
ES200803085A ES2338084B1 (es) | 2008-10-30 | 2008-10-30 | Metodo de fabricacion de un panel de geometria compleja en material compuesto preimpregnado. |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2010049566A1 true WO2010049566A1 (es) | 2010-05-06 |
Family
ID=42105786
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/ES2009/070466 WO2010049566A1 (es) | 2008-10-30 | 2009-10-28 | Método de fabricación de un panel de geometría compleja en material compuesto preimpregnado |
Country Status (7)
Country | Link |
---|---|
US (1) | US20100108246A1 (es) |
EP (1) | EP2357075B1 (es) |
CN (1) | CN102282006B (es) |
BR (1) | BRPI0920231A2 (es) |
CA (1) | CA2741486C (es) |
ES (1) | ES2338084B1 (es) |
WO (1) | WO2010049566A1 (es) |
Families Citing this family (16)
Publication number | Priority date | Publication date | Assignee | Title |
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US8123510B1 (en) * | 2008-03-24 | 2012-02-28 | Ebert Composite Corporation | Thermoplastic pultrusion die system and method |
US8747098B1 (en) | 2008-03-24 | 2014-06-10 | Ebert Composites Corporation | Thermoplastic pultrusion die system and method |
US8608597B2 (en) | 2011-09-08 | 2013-12-17 | Tzvi Avnery | Hockey stick |
US10723047B2 (en) | 2011-09-08 | 2020-07-28 | Tovi Llc | Hockey stick |
WO2013078647A1 (en) * | 2011-11-30 | 2013-06-06 | Airbus S.A.S. | Panel,component for an airplane airfoil comprising the panel,and method for producing the panel |
GB201120994D0 (en) * | 2011-12-07 | 2012-01-18 | Airbus Uk Ltd | Integral stiffener |
ES2413189B1 (es) * | 2012-01-10 | 2015-02-11 | Manuel Torres Martínez | Instalacion para fabricar larguerillos de fibra para estructuras aeroespaciales |
DE102012210043A1 (de) * | 2012-06-14 | 2013-12-19 | Airbus Operations Gmbh | Verfahren und Vorrichtung zur Herstellung einer Leichtbaustruktur sowie Leichtbaustruktur |
CN105984153A (zh) * | 2015-02-13 | 2016-10-05 | 全耐塑料公司 | 预成型预浸渍复合材料片时的铺设方法 |
GB201504498D0 (en) * | 2015-03-17 | 2015-04-29 | Penso Holdings Ltd | Method and apparatus for production of carbon fibre components |
US9969419B2 (en) * | 2016-04-01 | 2018-05-15 | Tk Holdings Inc. | Preimpregnated carbon fiber steering wheel |
FI127614B (en) * | 2017-04-07 | 2018-10-15 | Patria Aerostructures Oy | COMPOSITE ELEMENT AND METHOD FOR MANUFACTURING IT |
FR3071765B1 (fr) * | 2017-10-03 | 2020-11-20 | Safran Ceram | Realisation en materiau composite d'une structure a lobes de melangeur de flux |
EP3862170B1 (en) * | 2018-10-05 | 2023-09-27 | Fukui Prefectural Government | Automatic layering method and device for thin tape |
CN109551659B (zh) * | 2018-12-19 | 2021-03-23 | 航天特种材料及工艺技术研究所 | 一种复合浸渍工装及其应用 |
US20210060870A1 (en) * | 2019-08-30 | 2021-03-04 | Arris Composites Inc. | Progressive flow-forming method |
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- 2009-10-28 CN CN200980153362.1A patent/CN102282006B/zh not_active Expired - Fee Related
- 2009-10-28 EP EP09823120.2A patent/EP2357075B1/en not_active Not-in-force
- 2009-10-28 WO PCT/ES2009/070466 patent/WO2010049566A1/es active Application Filing
- 2009-10-28 BR BRPI0920231A patent/BRPI0920231A2/pt not_active IP Right Cessation
- 2009-10-28 CA CA2741486A patent/CA2741486C/en not_active Expired - Fee Related
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Also Published As
Publication number | Publication date |
---|---|
US20100108246A1 (en) | 2010-05-06 |
CN102282006B (zh) | 2015-02-18 |
EP2357075A1 (en) | 2011-08-17 |
BRPI0920231A2 (pt) | 2018-06-19 |
CA2741486C (en) | 2016-11-15 |
CN102282006A (zh) | 2011-12-14 |
EP2357075A4 (en) | 2012-08-15 |
ES2338084B1 (es) | 2011-03-14 |
EP2357075B1 (en) | 2015-07-08 |
ES2338084A1 (es) | 2010-05-03 |
CA2741486A1 (en) | 2010-05-06 |
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