WO2011131206A1 - Procédé et appareil pour fabriquer une pièce composite - Google Patents

Procédé et appareil pour fabriquer une pièce composite Download PDF

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Publication number
WO2011131206A1
WO2011131206A1 PCT/DK2011/050128 DK2011050128W WO2011131206A1 WO 2011131206 A1 WO2011131206 A1 WO 2011131206A1 DK 2011050128 W DK2011050128 W DK 2011050128W WO 2011131206 A1 WO2011131206 A1 WO 2011131206A1
Authority
WO
WIPO (PCT)
Prior art keywords
electro
activatable sheet
fibrous material
moulding support
sheet
Prior art date
Application number
PCT/DK2011/050128
Other languages
English (en)
Inventor
Bjarne F. Christensen
Original Assignee
Vestas Wind Systems A/S
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 Vestas Wind Systems A/S filed Critical Vestas Wind Systems A/S
Publication of WO2011131206A1 publication Critical patent/WO2011131206A1/fr

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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
    • B29C70/30—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
    • B29C70/342—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 isostatic pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding

Definitions

  • the invention relates to a method and an apparatus for manufacturing a composite part comprising a fibrous material, as well as a composite part manufactured by the method.
  • parts of fiber reinforces plastics reinforces plastics
  • a number of different methods can be used. Usually one or more plies of fibrous material are placed on a mould, and a resin is allowed to cure while impregnating the fibers so as to stabilise them, thus forming the composite part.
  • the fibers can be impregnated by hand, pre-impregnated, or the resin can be provided by vacuum via one or more conduits (resin infusion).
  • a breather cloth and a vacuum bag i.e. a plastic film
  • a vacuum bag i.e. a plastic film
  • the pressure reduces voids in the composite part.
  • a disadvantage of vacuum bag methods is that the pressure that can be obtained is limited to the atmospheric pressure. Also, the atmospheric pressure varies depending on the altitude and weather, so that the method presents an inconsistency.
  • An object of the invention is to improve manufacturing of composite parts comprising fibrous materials. Another object of the invention is to increase the fiber to resin ratio in composite parts.
  • a method for manufacturing a composite part comprising a fibrous material and a resin comprising providing a moulding support, placing at least one fibrous material layer on the moulding support, providing an electro-activatable sheet adapted change shape under the influence of electric power, placing the electro-activatable sheet on the moulding support so that the at least one fibrous material layer is located between the moulding support and the electro-activatable sheet, and supplying electric power to the electro-activatable sheet so that the shape of the electro-activatable sheet is changed so as to exert pressure onto the at least one fibrous material layer.
  • the electro-activatable sheet is preferably flexible so as to easily conform to the shape of the moulding support.
  • the electro-activatable sheet can comprise a so called electroactive polymer (EAP).
  • EAP electroactive polymer
  • the electro- activatable sheet can comprise a dielectric EAP, e.g. an electrostrictive polymer or a dielectric elastomer, in which the change of shape is caused by electrostatic forces between two electrodes which, when a DC voltage is applied to the electrodes, squeeze or stretch the polymer depending on the direction of the current.
  • Dielectric EAPs wherein an elastomer film is sandwiched between two compliant electrodes, require no power to be kept at a given position.
  • a silicone or an acrylic elastomer can be used.
  • the electrodes can comprise e.g. graphite powder, silicone oil / graphite mixtures, gold electrodes, etc.
  • a composite part comprising a fibrous material refers to an article comprising a fiber reinforced plastic.
  • the plastic, or resin could be a thermoset resin, e.g. epoxy, or a thermoplastic.
  • the composite part could be a separate article or a part of an article, for example a composite layer on a structure, for example also of a composite material
  • the moulding support could be a mould or some other structure.
  • the composite part produced by the inventive method is a composite layer on another composite structure, that structure could be the moulding support as understood in this presentation.
  • the at least one fibrous material layer can be provided on the moulding support before the electro-activatable sheet is placed on the moulding support, or the at least one fibrous material layer can be placed on the moulding support together with the electro-activatable sheet.
  • the method can of course include additional steps usually carried out in composite manufacturing.
  • a release agent could be placed on the moulding support.
  • a peelply, release film and/or a breather cloth can be placed between the at least one fibrous material layer and the electro-activatable sheet.
  • the method comprises, e.g. while placing the electro-activatable sheet on the moulding support, fixing the electro-activatable sheet to the moulding support along at least one portion of a periphery of the electro-activatable sheet.
  • a periphery of the electro-activatable sheet there could be two portions of the electro-activatable sheet periphery along which the electro-activatable sheet is attached to the moulding support, which portions are located opposite to each other so that the at least one fibrous material layer is located between said two portions of the periphery.
  • the at least one fibrous material layer can be located between said two parts of the portion of the electro- activatable sheet periphery.
  • the electro-activatable sheet is fixed to the moulding support along the entire periphery of the electro-activatable sheet.
  • the moulding support is convex and the change of the shape of the electro- activatable sheet is shrinkage, i.e. contraction in a direction of the extension of the electro-activatable sheet.
  • the moulding support is concave and the change of the shape of the electro-activatable sheet is stretching, i.e. expansion in a direction of the extension of the electro-activatable sheet.
  • the resin is supplied to the at least one fibrous material layer after the electro-activatable sheet has been placed on the moulding support, as for example in a resin infusion method.
  • the at least one fibrous material layer comprises a resin when the electro-activatable sheet is placed on the moulding support.
  • the fibrous material layer could be pre-impregnated with resin (prepreg), or it could be hand-impregnated with resin before the electro- activatable sheet has been provided on the moulding support.
  • the electric power is supplied with an alternating current so that the pressure exerted onto the at least one fibrous material is varied so as to provide a vibration to the at least one fibrous material.
  • the invention also relates to a composite part according to claim 8.
  • the objects are also reached with an apparatus according to any of the claims 9-12. DESCRIPTION OF THE FIGURES
  • fig. 1 shows a cross-section of an apparatus for manufacturing composite parts according to a first embodiment of the invention
  • fig. 2 and fig. 3 show cross- sections of an apparatus for manufacturing composite parts according to a second embodiment
  • fig. 4 and fig. 5 show diagrams of respective alternatives for electric currents supplied to an apparatus for manufacturing composite parts.
  • Fig. 1 shows a schematic cross-section of an apparatus for manufacturing a composite part comprising a fibrous material.
  • the apparatus comprises a moulding support in the form of a convex mould 1.
  • a laminate 2 of a plurality of fibrous material layers in the form of prepreg plies.
  • a breather cloth 3 is placed, and on the breather cloth 3 an electro-activatable sheet 4 is placed.
  • a plurality of fixing tools 102 are provided which serve to secure the electro-activatable sheet 4 to the mould all around the laminate 2.
  • the sheet 4 is fixed to the mould 1 along the periphery of the sheet 4.
  • FIG. 2 shows a schematic cross-section of another embodiment of an apparatus for manufacturing a composite part comprising a fibrous material.
  • the apparatus comprises a moulding support in the form of a concave mould 1.
  • a laminate 2 is placed on the mould 1
  • a breather cloth 3 is placed on the laminate 2
  • an electro-activatable sheet 4 is placed on the breather cloth 3.
  • a DC electric power source 401 is connected to the electro-activatable sheet 4, and when a voltage is supplied to the sheet 4, it tends to stretch so that it is pressed to the mould 1.
  • the tool 5 and the mould 1 are adapted to fix the layers 2, 3, 4 so as to secure that the stretching or expansion of the electro-activatable sheet 4 can be utilized for pressure on the laminate 2.
  • a distance Dl between the tool 5 and the mould 1 at the periphery of the mould is smaller than a distance D2 between the tool 5 and the mould 1 at a located remote from the mould periphery.
  • fig. 4 and fig. 5 showing alternatives to only supplying a direct current (DC) as exemplified above.
  • the electric power could be supplied with an alternating current (AC) so that the pressure exerted onto the at least one fibrous material is varied so as to provide a vibration to the laminate 2, in order to consolidate the fibrous material in the laminate 2.
  • the current (I) is provided in a sequence of alternating time periods of AC (dtAC) and time periods of DC (dtDC). Alternatively, an initial single time period of AC could be followed by a single time period of DC extending until the end of the curing process.
  • the current (I) is provided with a constant level (Is) and an overlapping varying level.
  • the frequency of the AC could be anywhere between a few Hz to several kHz, but is preferably chosen so as to be suitable for the fiber material consolidation purpose, for example within 10-500 Hz, more preferred 20-200 Hz, e.g. about 50 Hz.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

L'invention porte sur un procédé pour fabriquer une pièce composite comprenant une matière fibreuse (2) et une résine, le procédé comprenant l'utilisation d'un support de moulage (1), le placement d'au moins une couche de matière fibreuse sur le support de moulage (1), l'utilisation d'une feuille (4) activable par l'électricité, apte à changer de forme sous l'influence d'une énergie électrique, le placement de la feuille activable par l'électricité (4) sur le support de moulage (1) de telle manière que la ou les couches de matière fibreuse (2) sont placées entre le support de moulage (1) et la feuille activable par l'électricité (4), et l'application d'énergie électrique à la feuille activable par l'électricité (4) de telle manière que la forme de la feuille activable par l'électricité (4) est modifiée de manière à exercer une pression sur la ou les couches de matière fibreuse (2).
PCT/DK2011/050128 2010-04-22 2011-04-19 Procédé et appareil pour fabriquer une pièce composite WO2011131206A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
DKPA201070163 2010-04-22
DKPA201070163 2010-04-22
US32714010P 2010-04-23 2010-04-23
US61/327,140 2010-04-23

Publications (1)

Publication Number Publication Date
WO2011131206A1 true WO2011131206A1 (fr) 2011-10-27

Family

ID=44246500

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/DK2011/050128 WO2011131206A1 (fr) 2010-04-22 2011-04-19 Procédé et appareil pour fabriquer une pièce composite

Country Status (1)

Country Link
WO (1) WO2011131206A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2653297A1 (fr) 2012-04-20 2013-10-23 Nordex Energy GmbH Procédé de fabrication d'un composant d'éolienne

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5106568A (en) * 1991-11-15 1992-04-21 Mcdonnell Douglas Corporation Method and apparatus for vacuum bag molding of composite materials
US6830712B1 (en) * 2000-08-28 2004-12-14 Johnson & Johnson Vision Care, Inc. Deformable molds and methods for their use in the manufacture of ophthalmic lenses
US7422714B1 (en) * 2001-01-24 2008-09-09 Cornerstone Research Group, Inc. Method of using a shape memory material as a mandrel for composite part manufacturing

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5106568A (en) * 1991-11-15 1992-04-21 Mcdonnell Douglas Corporation Method and apparatus for vacuum bag molding of composite materials
US6830712B1 (en) * 2000-08-28 2004-12-14 Johnson & Johnson Vision Care, Inc. Deformable molds and methods for their use in the manufacture of ophthalmic lenses
US7422714B1 (en) * 2001-01-24 2008-09-09 Cornerstone Research Group, Inc. Method of using a shape memory material as a mandrel for composite part manufacturing

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2653297A1 (fr) 2012-04-20 2013-10-23 Nordex Energy GmbH Procédé de fabrication d'un composant d'éolienne

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