WO2024094970A1

WO2024094970A1 - Compactor assembly

Info

Publication number: WO2024094970A1
Application number: PCT/GB2023/052816
Authority: WO
Inventors: Graeme Jones
Original assignee: Cygnet Texkimp Limited
Priority date: 2022-10-31
Filing date: 2023-10-27
Publication date: 2024-05-10

Abstract

Compactor assembly (200) for resin-impregnation of fibrous material comprising a first roller (210), a second roller (220), and a third roller (230) provided in series along an alignment direction (Y) such that the three axis of rotation (214, 224,234) of the rollers are parallel, and perpendicular to the alignment direction (Y). A first gap (250) is defined between the first roller (210) and the second roller (220), and a second gap (260) is defined between the second roller (220) and the third roller (230). The compactor assembly is configured to receive a fibrous material into the first gap to travel in a first direction (D1) through the first gap and to convey the fibrous material from the first gap to the second gap to travel in a second direction (D2) through the second gap, wherein the second direction (D2) is opposite to the first direction (D1).

Description

COMPACTOR ASSEMBLY

The present disclosure relates to a compactor assembly.

In particular the present disclosure is concerned with a compactor assembly for resinimpregnation of fibrous material.

Background

Fibre pre-impregnated with resin, or ‘prepreg’ for short, is a reinforcing material that may be applied to a structure and then cured to make a reinforced structure. Fabrication of a prepreg involves fully impregnating a fibrous material with a resin, such that the resin is distributed substantially uniformly over as well as throughout the fibrous material.

According to known fabrication processes, the resin is transferred onto the fibrous material from a transfer sheet by multiple stages of compaction, as shown in Figure 1 . Each stage involves a pair of compaction rollers. These compaction rollers are large items of equipment required to operate at low tolerances.

A critical indicator for the quality of the prepreg is area weight, which is decided by the positions of the rollers. Hence the pairs of compaction rollers are spaced apart along the production line. The production line comprises a supply unwind 10 providing fibrous material and transfer sheets. The production line further comprises multiple pairs of compaction rollers 20, 30, 40 that are spaced apart for access purposes. The production line further comprises a rewind 50 onto which the impregnated fibrous material is wound.

While highly effective at producing the prepreg, a problem with this arrangement is that each roller pair must be synchronised to rotate at the same speed as the others or the tension in the material between adjacent pairs of rollers will be different. This may lead to over stressing the material, or cause it to slacken locally, either of which may (at least) reduce the consistency of the final product and (at most) cause a failure in the material.

Additionally, since it is important to have the fibrous material and resin at an optimum temperature during the process, having the impregnated fibrous material pass through a space between pairs of adjacent rollers may result in the material cooling between leaving one pair of rollers and arriving at the next pair of rollers. This may affect the quality of the impregnation, and also may mean the rollers need to run adequately slowly so that the material can reach optimum temperature as it is compressed by a pair of rollers.

Hence a compactor assembly which overcomes the issue of synchronising roller speeds and reduces cooling effect between compression stages is highly desirable. Summary

According to the present disclosure there is provided an apparatus as set forth in the appended claims. Other features of the invention will be apparent from the dependent claims, and the description which follows.

There may be provided a compactor assembly (200) for resin-impregnation of fibrous material (112). The compactor assembly (200) may comprise: a plurality of rollers (210, 220, 230, 240) comprising a first roller (210), a second roller (220), and a third roller (230); the first roller (210) being rotatable about a first axis of rotation (214), the second roller (220) being rotatable about a second axis of rotation (224), and the third roller (230) being rotatable about a third axis of rotation (234). The first roller (210), second roller (220) and third roller (230) may be provided in series along an alignment direction (Y) such that the first axis of rotation (214), the second axis of rotation (224) and the third axis of rotation (234) are parallel, and the first axis of rotation (214), the second axis of rotation (224) and the third axis of rotation (234) are perpendicular to the alignment direction (Y).

A first gap (250) may be defined between the first roller (210) and the second roller (220), and a second gap (260) may be defined between the second roller (220) and the third roller (230); the compactor assembly (200) being configured to receive a fibrous material (112) into the first gap (250) to travel in a first direction (D1) through the first gap (250); and to convey the fibrous material (112) from the first gap (250) to the second gap (260) to travel in a second direction (D2) through the second gap (260), wherein the second direction (D2) is opposite to the first direction (D1).

The compactor assembly (200) may further comprise an actuator (400) which is operable to drive synchronously each of the plurality of rollers (210, 220, 230, 240).

The first roller (210) and the third roller (230) may be operable to be driven by the actuator (400) to rotate in a first rotational direction (RD1) around the first axis of rotation (214) and third axis of rotation (234) respectively, and the second roller (220) is operable to be driven by the actuator (400) to rotate in a second rotational direction (RD2) about the second axis of rotation (224), wherein the second rotational direction (RD2) is opposite to the first rotational direction (RD1).

The first roller (210) and the second roller (220) may be spaced apart by a distance configured to compact the fibrous material (112) in the first gap (250), and the second roller (220) and the third roller (230) may be spaced apart by a distance configured to compact the fibrous material (112) in the second gap (260). The plurality of rollers (210, 220, 230, 240) may comprise a fourth roller (240), the fourth roller (240) being rotatable about a fourth axis of rotation (244), wherein the first roller (210), second roller (220), third roller (230) and fourth roller (240) are provided in series along the alignment direction (Y) such that the first axis of rotation (214), the second axis of rotation (224), third axis of rotation (234) and fourth axis of rotation (244) are parallel, and the first axis of rotation (214), the second axis of rotation (224), the third axis of rotation (234) and fourth axis of rotation (244) are perpendicular to the alignment direction (Y); and such that a third gap (270) is defined between the third roller (230) and the fourth roller (240), and the compactor assembly (200) being configured to convey the fibrous material (112) from the second gap (260) to the third gap (270) to travel in the first direction (D1) through the third gap (270).

The fourth roller 240 maybe operable to be driven by the actuator (400) to rotate in the second rotational direction (RD2) about the fourth axis of rotation (244).

The third roller (230) and the fourth roller (240) may be spaced apart by a distance configured to compact the fibrous material (112) in the third gap (270).

Each of the plurality of rollers (210, 220, 230, 240) may have the same diameter along their length.

At least one of the plurality of rollers (210, 220, 230, 240) may have a diameter which is different to other rollers of the plurality of rollers (210, 220, 230, 240).

The compactor assembly (200) may further comprise a drive unit (402) which couples to an output from the actuator (400) and couples to each of the plurality of rollers (210, 220, 230, 240) such that the plurality of rollers (210, 220, 230, 240) are rotatable synchronously by a single actuator (400).

The drive unit (402) may be configured to rotate the plurality of rollers (210, 220, 230, 240) so that the speed at the surface of each roller is the same.

The second roller (220) may define a second roller surface (222).

The compactor assembly (200) may be configured such that the fibrous material (112) is conveyed from the first gap (250) to the second gap (260) on the second roller surface (222).

The third roller (230) may define a third roller surface (232).

The compactor assembly (200) may be configured such that the fibrous material (112) is conveyed from the second gap (260) to the third gap (270) on the third roller surface (232).

The first roller (210) may define a first roller surface (212).

The compactor assembly (200) may be configured such that the fibrous material (112) is received on the first roller surface (212) at a first circumferential position (P1) A degrees around the first roller surface (212) from the first gap (250) in the first rotational direction (RD1), where A has a value of no less than 90 and no more than 270. The fourth roller (240) may define a fourth roller surface (242).

The compactor assembly (200) may be configured to release the fibrous material (112) from the fourth roller surface (242) at a second circumferential position (P2) B degrees around the fourth roller surface (242) from the third gap (270) in the second rotational direction (RD2), where B has a value of no less than 90 and no more than 270.

The plurality of rollers (210, 220, 230, 240) may be operable to be heated to thereby heat the fibrous material (112).

The compactor assembly (200) may be further configured to convey the fibrous material (112), a first resin release carrier (122) and a second resin release carrier (124) from the first gap (250) to the second gap (260), the first resin release carrier (122) being provided on a first side (114) of the fibrous material (112) and the second resin release carrier (124) being provided on a second side (116) of the fibrous material (1 12).

The compactor assembly (200) ay be configured to convey the fibrous material (112), the first resin release carrier (122) and the second resin release carrier (124) from the second gap (260) to the third gap (270).

The first resin release carrier (122) may comprise a first belt (500) operable to transfer a coating of resin to the fibrous material (112).

The second resin release carrier (124) may comprise a second belt (502) operable to transfer a coating of resin to the fibrous material (112).

The compactor assembly (200) may further comprise a first pass-back roller (410) configured to convey the fibrous material (112) from the first gap (250) to the second gap (260), and a second pass-back roller (420) configured to convey the fibrous material (112) from the second gap (260) to the third gap (270).

There may be provided a production line (1000) for fabrication of resin-impregnated fibrous material (112), the production line (1000) comprising the compactor assembly (200) according to the present disclosure, the production line (1000) further comprising: a first supply (110) configured to supply a fibrous material (112), a second supply (120) configured to supply a transfer sheet (122, 124), wherein the first gap (250) and the second gap (260) are configured to receive the fibrous material (112) and the transfer sheet (122, 124).

Hence there is provided a compactor assembly which overcomes the issue of synchronising roller speeds and reduces cooling effect between compression stages. Brief Description of the Drawings

Examples of the present disclosure will now be described with reference to the accompanying drawings, in which:

Figure 1 shows a conventional compactor assembly (related art);

Figure 2 illustrates a first example of a compactor assembly according to the present disclosure;

Figure 3 is a view of the rollers of the of the compactor assembly shown in figure 2;

Figure 4 illustrates a variation of the first example shown in figure 2;

Figure 5 illustrates an adaption of the example shown in figure 4;

Figure 6 illustrates a second example of a compactor assembly according to the present disclosure;

Figure 7 illustrates a third example of a compactor assembly according to the present disclosure;

Figure 8 illustrates a fourth example of a compactor assembly according to the present disclosure; and

Figure 9 illustrates how the rollers of the compactor assembly may be driven.

Detailed Description

The present disclosure relates to an apparatus for resin impregnation of fibrous material. Exemplary applications of the apparatus relate to prepreg fabrication, which includes towpreg. The apparatus is applicable to all suitable fibrous materials, including nonwoven fibrous material. That is to say, the present disclosure relates to a compactor assembly 200 for resin-impregnation of fibrous material, examples of which are shown in figures 2 to 8.

The compactor 200 may form part of a production line 1000 for fabrication of resin- impregnated fibrous material. A side view of such a production line 1000 is shown in figure 2. For reasons of clarity, only the rollers and path of materials is shown in figures 5 to 8. That is to say, the four roller examples of figure 4 to 8 may be used in place of the three roller example shown in figure 2.

The production line 1000 provides a system for impregnating fibrous material with a resin. In the figures, the direction of operation is generally from left to right. The production line 1000 comprises a supply unwind unit 100, a compactor assembly 200, and a rewind unit 300. A fibrous material 112 is passed from the supply unwind unit 100 to the compactor assembly 200 then to downstream processes (e.g. the rewind unit 300). The supply unwind unit 100 comprises a fibrous material supply unwind unit 110 configured to supply the fibrous material 1 12. The fibrous material 1 12 may comprise a fibre or fabric, which may include natural and synthetic materials such as petrochemical-based fibres, metallic, glass or carbon fibres.

The supply unwind unit 100 comprises a source of resin. Any conventional means of providing resin to the fibrous material may be employed.

The compactor assembly 200 comprises a plurality of rollers 210, 220, 230, 240 comprising a first roller 210, a second roller 220, and a third roller 230. In the example of figure 2 there are provided three rollers 210, 220, 230. However, there may be provided four of more rollers in the same configuration. Figures 4 to 8 illustrate side views of different examples of compactor assemblies having four rollers 210, 220, 230, 240.

In the example of figure 2, the supply unwind unit 100 comprises a pair of transfer sheet supply units 120 configured to supply transfer sheets 122 carrying suitable resin. In alternative examples, not shown, the resin may be applied to the rollers in advance of the contact position with the fibrous material 112. Both such resin supply arrangements may be a conventional kind.

From the supply unwind unit 100, the fibrous material 112 and the transfer sheets 122 are conveyed to the compactor assembly 200, where an application of heat and compression causes the resin on the transfer sheets 122 to liquify and permeate the fibrous material 112. Thus, the fibrous material 112 is embedded in the resin. That is to say full impregnation of the fibrous material 112 may be achieved.

From the compactor assembly 200, the fibrous material 112 and the transfer sheets 122 are conveyed to the rewind unit 300. The rewind unit 300 is configured to rewind the impregnated fibrous material 112 for storage.

In the example shown in figure 2, the rewind unit 300 comprises a fibrous material rewind unit 310 configured to receive the fibrous material 112, and a pair of release paper rewind units 320 configured to receive the release papers 122, 124. The rewind unit 300 may be of a conventional kind.

In the example shown in figure 2, the transfer sheets 122, 124 are removed from the impregnated fibrous material 112 after it leaves the compactor assembly 200 and before it enters the rewind unit 300.

In other examples, the transfer sheets 122, 124 are left in place on the impregnated fibrous material 112 and wound up with it in the rewind unit 300.

In some examples, the transfer sheets 122, 124 are replaced by backing sheets to provide protective covers. As illustrated in figure 3, each roller 210, 220, 230, 240 has a first end 216, 226, 236, 246 and a second end 218, 228, 238, 248.

The first roller 210 is rotatable about a first axis of rotation 214 which extends longitudinally between the first end 216 and second end 218 of the first roller 210. The second roller 220 is rotatable about a second axis of rotation 224 which extends longitudinally between the first end 226 and second end 228 of the second roller 220. The third roller 230 is rotatable about a third axis of rotation 234 which extends longitudinally between the first end 236 and second end 238 of the third roller 230. As shown in figures 4 to 6, the plurality of rollers 210, 220, 230, 240 may comprise a fourth roller 240. As shown in figure 3, the fourth roller 240 (shown in a dashed line) is rotatable about a fourth axis of rotation 244 which extends longitudinally between the first end 246 and second end 248 of the fourth roller 240.

As shown in figures 3 to 8, the first roller 210, second roller 220 and third roller 230 are provided in series along an alignment direction Y. Hence the first axis of rotation 214, the second axis of rotation 224 and the third axis of rotation 234 are parallel, and the first axis of rotation 214, the second axis of rotation 224 and the third axis of rotation 234 are perpendicular to the alignment direction Y. Additionally a first gap 250 is defined between the first roller 210 and the second roller 220, and a second gap 260 is defined between the second roller 220 and the third roller 230.

Also as shown in figures 3 to 8, in examples in which a fourth roller 240 is present, the first roller 210, second roller 220, third roller 230 and fourth roller 240 are provided in series along the alignment direction Y such that the first axis of rotation 214, the second axis of rotation 224, third axis of rotation 234 and fourth axis of rotation 244 are parallel, and the first axis of rotation 214, the second axis of rotation 224, the third axis of rotation 234 and fourth axis of rotation 244 are perpendicular to the alignment direction Y. In such an arrangement, as shown in figure 4 to 8, a third gap 270 is defined between the third roller 230 and the fourth roller 240.

As shown in figure 2, the plurality of rollers 210, 220, 230, 240 may be provided vertically (e.g. in a vertical stack).

In alternative examples (not shown) the plurality of rollers 210, 220, 230, 240 may be provided horizontally (e.g. in a horizontal stack).

In alternative examples (not shown) the plurality of rollers 210, 220, 230, 240 may be provided at an angle to the vertical and horizontal.

The first roller 210 defines a first roller surface 212. The second roller 220 defines a second roller surface 222. The third roller 230 defines a third roller surface 232. The fourth roller 240 defines a fourth roller surface 242. In relation to the rollers, the word “surface” is intended to mean an “outer circumferential surface” of the roller which extends along the length (i.e. axis of rotation) of the respective roller. The compactor assembly 200 is configured to receive the fibrous material 112 into the first gap 250 to travel in a first direction D1 through the first gap 250 and to convey the fibrous material 112 from the first gap 250 to the second gap 260 to travel in a second direction D2 through the second gap 260, wherein the second direction (D2) is opposite to the first direction D1 .

In examples where a fourth roller 240 is present, the compactor assembly 200 is configured to convey the fibrous material 112 from the second gap 260 to the third gap 270 to travel in the first direction D1 through the third gap 270.

Hence the compactor assembly 200 defines a processing path 202 through the gaps 250, 260, 270 along which the fibrous material 1 12 and resin are conveyed (howsoever the resin may be provided, for example on a resin release carrier or “transfer sheet” 122, 124). Along the processing path 202, the compactor assembly 200 compresses and heats the fibrous material 112 and resin, to thereby soften the resin and impregnate the fibrous material 112 under pressure.

That is to say, the compactor assembly 200 defines a plurality of gaps (or ‘processing gaps’) between the rollers 210, 220, 230, 240. The fibrous material 112 and resin are passed through the first gap 250 for compaction by means of the first roller 210 and the second roller 220, and then the second gap 260 for compaction by means of the second roller 220 and the third roller 230, and then (in examples where present) the third gap 270 for compaction by means of the third roller 230 and the fourth roller 240.

In examples in which the resin is provided on resin release carrier (or “transfer”) sheets 122, 124, these may also pass through the gaps with the fibrous material 1 12.

The compactor assembly 200 may further comprise an actuator 400 which is operable to drive synchronously each of the plurality of rollers 210, 220, 230, 240.

The compactor assembly 200 may further comprise a drive unit 402 which couples to an output from the actuator 400 and couples to each of the plurality of rollers 210, 220, 230, 240 such that the plurality of rollers 210, 220, 230, 240 (e.g. whether three or more rollers) are rotatable synchronously by a single drive unit 402.

For example, and as illustrated in figure 9, the actuator 400 may be coupled to each of the plurality of rollers 210, 220, 230, 240 using a drive unit 402 comprising an endless belt, gear box or other conventional solution.

In other examples, each of the plurality of rollers 210, 220, 230, 240 may each be driven by a dedicated actuator (i.e. one per roller), each of which is synchronised to rotate at the same speed as the others so the rollers rotate at a common consistent speed. That is to say, each of the plurality of rollers 210, 220, 230, 240 may each be driven by a dedicated actuator (i.e. one actuator per roller), each actuator being synchronised with the other actuators to drive its respective roller at the same common and consistent speed as the other rollers. In another example, each of the plurality of rollers 210, 220, 230, 240 may each be driven by a dedicated actuator (i.e. one per roller), each of which is synchronised to rotate so that the speed at the surface of each of the rollers is the same. That is to say, each of the plurality of rollers 210, 220, 230, 240 may each be driven by a dedicated actuator (i.e. one actuator per roller), each actuator being synchronised with the other actuators to drive its respective roller so that the speed at the surface of each of the rollers is the same.

In further examples, some of the plurality of rollers 210, 220, 230, 240 may be driven by a common actuator (e.g. two or more rollers driven by common actuator), the remaining rollers driven by a different actuator or actuators, where each of the actuators is synchronised to rotate at the same speed as the others so the rollers rotate at a common consistent speed.

In another example, some of the plurality of rollers 210, 220, 230, 240 may be driven by a common actuator (e.g. two or more rollers driven by common actuator), the remaining rollers driven by a different actuator or actuators, where each of the actuators is synchronised to rotate so that the speed at the surface of each of the rollers is the same.

In further examples, at least one the plurality of rollers 210, 220, 230, 240 may be driven directly by an actuator, the remaining rollers being driven by virtue of their coupling to the directly driven roller(s). For example, at least one the plurality of rollers 210, 220, 230, 240 may be driven directly by an actuator and the remaining rollers may be indirectly driven by the actuator. That is to say, at least one the plurality of rollers 210, 220, 230, 240 may be driven directly by an actuator and the remaining rollers may be coupled to the actuator only via adjacent rollers. Put another way, at least one the plurality of rollers 210, 220, 230, 240 may be driven directly by an actuator, the remaining rollers being operable to rotate in response to the rotation of an adjacent roller. Since adjacent rollers are in direct contact with one another, or in contact with one another via the fibrous material between them, the rotation of a roller which is directly driven by an actuator (e.g. coupled to an actuator by one or more gears, chain or a belt or the like) will cause rotation of the rollers which are not directly driven by an actuator (e.g. which are not coupled to an actuator by one or more gears, chain or a belt or the like). Hence, in such an example, the actuator is operable to drive synchronously each of the plurality of rollers 210, 220, 230, 240. Put another way, in such an example, the actuator is operable to drive synchronously each of the plurality of rollers 210, 220, 230, 240, even though the actuator is coupled to some, but not all, of the rollers 210, 220, 230, 240. In such an example, the actuator is operable to drive each of the plurality of rollers 210, 220, 230, 240, even though the actuator is coupled to some, but not all, of the rollers 210, 220, 230, 240. In further examples, at least one the plurality of rollers 210, 220, 230, 240 may be driven by a first actuator, at least one of the plurality of rollers 210, 220, 230, 240 may be driven by a second actuator, the remaining roller(s) being driven by virtue of their coupling to the directly driven roller(s). For example, at least one the plurality of rollers 210, 220, 230, 240 may be driven directly by a first actuator, at least one of the plurality of rollers 210, 220, 230, 240 may be driven directly by a second actuator, and the remaining rollers may be indirectly driven by the first actuator and/or second actuator. That is to say, at least one the plurality of rollers 210, 220, 230, 240 may be driven directly by a first actuator, at least one the plurality of rollers 210, 220, 230, 240 may be driven directly by a second actuator, and the remaining rollers may be driven by the first and/or second actuator only via adjacent rollers. Since adjacent rollers are in direct contact with one another, or in contact via the fibrous material between them, the rotation of rollers which are directly driven by an actuator (e.g. coupled to one of the actuators by one or more gears, chain or a belt or the like) will cause rotation of the remaining roller(s) which is/are not directly driven by an actuator (e.g. which are not coupled to an actuator by one or more gears, chain or a belt or the like). Put another way, in such an example, the actuators are operable to drive synchronously each of the plurality of rollers 210, 220, 230, 240, even though the actuators are coupled to some, but not all, of the rollers 210, 220, 230, 240. In such an example, the actuators are operable to drive synchronously each of the plurality of rollers 210, 220, 230, 240, even though the actuators are coupled to some, but not all, of the rollers 210, 220, 230, 240.

Hence there may be provided a single actuator, or several actuators. In the present disclosure, where an actuator is referred to in the singular, this may also refer to examples in which more than one actuator is provided. That is, the term “actuator” can be taken to define a single actuator, or an actuator “system” comprising a plurality of actuators configured and operable to work in concert to synchronously drive the rollers at a common speed.

Regardless of the number of actuators, in an example in which all of the plurality of rollers 210, 220, 230, 240 have the same diameter, each of the plurality of rollers 210, 220, 230, 240 may be driven at the same rotational speed as the other rollers so all of the rollers rotate at a common and consistent rotational speed. Alternatively or additionally, in the same example, each of the plurality of rollers 210, 220, 230, 240 may be driven to rotate so that the speed at the surface of each of the rollers is the same.

Regardless of the number of actuators, in an example in which some, or at least one, of the plurality of rollers 210, 220, 230, 240 have/has a diameter which is different to other rollers of the plurality of rollers 210, 220, 230, 240, each of the plurality of rollers 210, 220, 230, 240 may be driven to rotate so that the speed at the surface of each of the rollers is the same.

Hence regardless of the diameter of each of the rollers, and regardless of the number of actuators employed to drive the rollers, each roller may be driven so that the speed at the surface of each of the rollers is the same. The compactor assembly 200 comprises a control unit 280. This is present in all examples, and illustrated in figure 2. For reasons of clarity, only the rollers and path of materials is shown in figures 5 to 8.

The control unit 280 is configured to control operation of the compactor assembly 200. In particular, the control 280 is configured to control the rollers 210, 220, 230, 240. Thus, the control unit 280 may control, for example, the compaction pressure (or ‘nipping pressure’) between the rollers; or the rotational speed of the rollers; or the heat generated by the rollers. The control unit 280 may also control the actuator(s) 400 and/or drive unit(s) 402.

As illustrated in figures 4 to 8, the first roller 210 and the third roller 230 are driven by the actuator 400 to rotate in a first rotational direction RD1 around the first axis of rotation 214 and third axis of rotation 234 respectively, and the second roller 220 is driven by the actuator 400 to rotate in a second rotational direction RD2 about the second axis of rotation 224, wherein the second rotational direction RD2 is opposite to the first rotational direction RD1 .

In examples in which a fourth roller 240 is present, the fourth roller is driven by the actuator 400 to rotate in the second rotational direction RD2 about the fourth axis of rotation 244.

Each of the plurality of rollers 210, 220, 230, 240 may have the same diameter along their length. Hence, in such an example, provided they are driven at the same rotational speed, the rotational speed at the surface of each roller will be the same. That is to say, in such an example, provided each roller rollers 210, 220, 230, 240 is driven at the same rotational speed, the surface speed of each roller will be the same.

In another example, at least some, or at least one, of the plurality of rollers 210, 220, 230, 240 may have a diameter which is different to other rollers of the plurality of rollers 210, 220, 230, 240. Hence, in such an example, at least some, or at least one, of the plurality of rollers 210, 220, 230, 240 may be driven at a different rotational speed to other rollers of the plurality of rollers 210, 220, 230, 240, the rotational speeds of each of the rollers chosen (i.e. synchronised, controlled) to ensure the surface speed of each of the plurality of rollers 210, 220, 230, 240 will be the same. Hence, in such an example, even though all of the rollers of the plurality of rollers 210, 220, 230, 240 may not be driven at the same rotational speed, the speed at the surface of each roller of the plurality of rollers 210, 220, 230, 240 may be controlled to be the same.

Hence with the configuration of the present disclosure, the rotational speed at the circumferential surface of each of the rollers is controlled to be the same. This is important to ensure that fibrous material being transported through the rollers has a constant speed as it travels through the compactor assembly 200. The first roller 210 and the second roller 220 are spaced apart by a distance configured to compact the fibrous material 112 in the first gap 250, and the second roller 220 and the third roller 230 are spaced apart by a distance configured to compact the fibrous material 112 in the second gap 260. In examples where a fourth roller 240 is present, the third roller 230 and the fourth roller 240 may be spaced apart by a distance configured to compact the fibrous material 112 in the third gap 270.

That is to say, the first roller 210 and the second roller 220 are spaced apart by a distance configured to compact the fibrous material 112 and resin in the first gap 250, and the second roller 220 and the third roller 230 are spaced apart by a distance configured to compact the fibrous material 112 and resin in the second gap 260. In examples where a fourth roller 240 is present, the third roller 230 and the fourth roller 240 may be spaced apart by a distance configured to compact the fibrous material 112 and resin in the third gap 270.

In examples in which the resin is delivered to the fibrous material 112 on a resin release carrier 122 on one side of the fibrous material 112, or a pair of resin release carriers 122, 124 where a first resin release carrier 122 is provided on one side of the fibrous material 112 and a second resin release carrier 124 is provided on the other side of the fibrous material 112, the first roller 210 and the second roller 220 are spaced apart by a distance configured to compact the fibrous material 112, resin release carrier(s) 122, 124 and resin in the first gap 250, and the second roller 220 and the third roller 230 are spaced apart by a distance configured to compact the fibrous material 112, resin release carrier(s) 122, 124 and resin in the second gap 260. In examples where a fourth roller 240 is present, the third roller 230 and the fourth roller 240 may be spaced apart by a distance configured to compact the fibrous material 112, resin release carrier(s) 122, 124 and resin in the third gap 270.

Likewise, in arrangements in which there are five or more rollers in the stack along the alignment direction Y, adjacent rollers may be spaced apart by a distance configured to compact fibrous material and resin (and, where present, resin release carriers) in the gap formed between the adjacent rollers.

The plurality of rollers 210, 220, 230, 240 are operable to be heated to thereby heat the fibrous material 112. That is to say, in addition to compaction, the compactor assembly 200 is configured to heat the fibrous material 112 and resin conveyed along the processing path 202. Hence each of the rollers 210, 220, 230, 240 are configured to actively heat the fibrous material 112 and resin. For example, each roller 210, 220, 230, 240 may comprise a heat source.

As shown in the examples of figures 2 to 8 the second roller 220 defines a second roller surface 222. In the examples of figures 2, 4, 5, 7, 8 the compactor assembly 200 is configured such that the fibrous material 112 is conveyed from the first gap 250 to the second gap 260 on the second roller surface 222. The third roller 230 defines a third roller surface 232. In the example of figure 2 the compactor assembly 200 is configured such that the fibrous material 112 is conveyed away from the second gap 260 on the third roller surface 232.

In the examples of figures 4, 5, 7, 8 the compactor assembly 200 is configured such that the fibrous material 112 is conveyed from the second gap 260 to the third gap 270 on the third roller surface 232.

In the examples of figures 5, 6 the compactor assembly 200 is further configured to convey the fibrous material 112 and a first resin release carrier 122 (i.e. transfer sheet) from the first gap 250 to the second gap 260, and from the second gap 260 to the third gap 270, the first resin release carrier 122 (i.e. transfer sheet) being provided on a first side 114 of the fibrous material 112.

Optionally, and as shown in the examples of figures 5, 6, the compactor assembly 200 is configured to convey the fibrous material 112, the first resin release carrier 122 (i.e. transfer sheet) and a second resin release carrier 124 (i.e. transfer sheet) from the first gap 250 to the second gap 260, and from the second gap 260 to the third gap 270, the second resin release carrier 124 (i.e. transfer sheet) being provided on a second side 116 of the fibrous material 112. For the avoidance of doubt, the second side 116 is opposite to the first side 114.

In the example of figure 6, the compactor assembly 200 further comprises a first pass- back roller 410 configured to convey the fibrous material 112 from the first gap 250 to the second gap 260, and a second pass-back roller 420 configured to convey the fibrous material 112 from the second gap 260 to the third gap 270. A pass-back roller is sometimes termed a “turnaround roller”. The pass-back rollers 410, 420 may or may not be heated.

As shown in figure 6, the first pass-back roller 410 is on a first side of the plurality of rollers 210, 220, 230, 240, and the second pass-back roller 420 is on a second side of the plurality of rollers 210, 220, 230, 240. Hence the first pass-back roller 410 is spaced apart from the second pass-back roller 420 by the stack of the plurality of rollers 210, 220, 230, 240. That is to say, the first pass-back roller 410 is offset from the second pass-back roller 420. The first pass-back roller 410 may be spaced apart from the second pass-back roller 420 in a direction X. The direction X is at an angle to the direction Y. The direction X may be perpendicularto the alignment direction Y. The direction X may be in line with the direction of operation of the production line. The direction X may be parallel to a horizontal direction.

The first pass-back roller 410 may be spaced apart (i.e. offset) from the second roller 220. The first pass-back roller 410 may be spaced apart (i.e. offset) from the second roller 220 in the direction X. The second pass-back roller 420 may be spaced apart (i.e. offset) from the third roller 230. The second pass-back roller 420 may be spaced apart (i.e. offset) from the third roller 230 in the direction X. The first pass-back roller 410 defines a first pass-back roller surface 412, such that the fibrous material 112 is conveyed from the first gap 250 to the second gap 260 along the first pass- back roller surface 412. The second pass-back roller 420 defines a second pass-back roller surface 422, such that the fibrous material 112 is conveyed from the second gap 260 to the third gap 270 along the second pass-back roller surface 422.

Hence in the example of figure 6 contact between the fibrous material 112 and the second roller 220 occurs only at the first gap 250 and the second gap 260, and contact between the fibrous material 112 and the third roller 230 occurs only at the second gap 260 and the third gap 270.

In the example of figure 7, the first resin release carrier 122 comprises a first belt 500 operable to transfer a coating of resin to the fibrous material 112, and the second resin release carrier 124 comprises a second belt 502 operable to transfer a coating of resin to the fibrous material 112. That is to say, the belts 500, 502 are configured to be coated with resin and operable to transfer a coating of resin to the fibrous material 112. Any conventional means of driving the first belt 500 and the second belt 502 may be employed. For example the first belt 500 may be driven by first belt driver roller 450 and the second belt 502 may be driven by second belt driver roller 460.

In the example of figure 8, the compactor assembly 200 is configured such that the fibrous material 112 is received on the first roller surface 212 at a first circumferential position P1 A degrees around the first roller surface 212 from the first gap 250 in the first rotational direction RD1. A may have a value of no less than 90 and no more than 270. A may have a value of no less than 90 and no more than 180.

Also as shown the example of figure 8, the compactor assembly 200 is configured to release the fibrous material 112 from the fourth roller surface 242 at a second circumferential position P2 B degrees around the fourth roller surface 242 from the third gap 270 in the second rotational direction RD2. B may have a value of no less than 90 and no more than 270. B may have a value of no less than 90 and no more than 180.

As can be seen, in some examples (e.g. those of figure 2, 4, 5, 7, 8) the fibrous material 112 and resin (and where present, the resin release carriers 122, 124 carrying resin) are conveyed between roller gaps along the roller outer surface(s). During the time on the curved outer surface, the fibrous material 112 (and where present, the resin release carriers 122, 124) are in tension, which causes the fibrous material 112 to be further compressed against the roller and resin. In examples in which resin release carriers 122, 124 are present, the resin release carrier 122, 124 is also in tension, which causes the resin release carrier 122, 124 radially outward of the fibrous material 112 to urge the fibrous material 112 and the other resin release carrier 122, 124 against the roller outer surface. Thus, further compaction is achieved. Hence there is provided a compactor assembly which overcomes the issue of synchronising roller speeds and reduces cooling effect between compression stages.

Since pairs of rollers are aligned in the same stack, rather than being spaced apart along a line, keeping the fibre in contact with, or at least close to, the rollers between the application of pressure in the gaps between rollers, the fibrous material and resin may be kept at an optimum temperature during the process, with no opportunity for cooling as in the figure 1 example of the related art. This enables a more consistent quality of product to be produced, as well as meaning that the roller can run faster thereby allowing for a reduced production time.

Additionally, having the rollers adjacent to one another in a stack means that each of the rollers can be synchronised to rotate at the same speed and/or to have the same circumferential surface speed as each other (e.g. by driving from the same drive unit and/or actuator), thereby keeping tension in the material consistent between stages of the process. Hence both over stressing the material and localised slackening of the material can be avoided.

Thus the examples of the present disclosure allows for easier material handling and easier to maintain temperature. Further, stacking the rollers vertically results in a short production line, meaning less space is needed for the line.

Additionally, the arrangements of the present disclosure also result in the deflection of any individual roller being lessened by the others, particularly the rollers in the middle of the stack.

Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

1 . A compactor assembly (200) for resin-impregnation of fibrous material (112), comprising: a plurality of rollers (210, 220, 230, 240) comprising a first roller (210), a second roller (220), and a third roller (230); the first roller (210) being rotatable about a first axis of rotation (214), the second roller (220) being rotatable about a second axis of rotation (224), and the third roller (230) being rotatable about a third axis of rotation (234), wherein the first roller (210), second roller (220) and third roller (230) are provided in series along an alignment direction (Y) such that the first axis of rotation (214), the second axis of rotation (224) and the third axis of rotation (234) are parallel, and the first axis of rotation (214), the second axis of rotation (224) and the third axis of rotation (234) are perpendicular to the alignment direction (Y); and such that a first gap (250) is defined between the first roller (210) and the second roller (220), and a second gap (260) is defined between the second roller (220) and the third roller (230); the compactor assembly (200) being configured to receive a fibrous material (112) into the first gap (250) to travel in a first direction (D1) through the first gap (250); and to convey the fibrous material (112) from the first gap (250) to the second gap (260) to travel in a second direction (D2) through the second gap (260), wherein the second direction (D2) is opposite to the first direction (D1).

2. A compactor assembly (200) as claimed in claim 1 wherein the compactor assembly (200) further comprises an actuator (400) which is operable to drive synchronously each of the plurality of rollers (210, 220, 230, 240).

3. A compactor assembly (200) as claimed in claim 1 or claim 2 wherein the first roller (210) and the third roller (230) are operable to be driven by the actuator (400) to rotate in a first rotational direction (RD1) around the first axis of rotation (214) and third axis of rotation (234) respectively, and the second roller (220) is operable to be driven by the actuator (400) to rotate in a second rotational direction (RD2) about the second axis of rotation (224), wherein the second rotational direction (RD2) is opposite to the first rotational direction (RD1).

4. The compactor assembly (200) as claimed in any one of the preceding claims, wherein the first roller (210) and the second roller (220) are spaced apart by a distance configured to compact the fibrous material (112) in the first gap (250), and the second roller (220) and the third roller (230) are spaced apart by a distance configured to compact the fibrous material (112) in the second gap (260).

5. A compactor assembly (200) as claimed in any one of claims 1 to 4 wherein the plurality of rollers (210, 220, 230, 240) comprises a fourth roller (240), the fourth roller (240) being rotatable about a fourth axis of rotation (244), wherein the first roller (210), second roller (220), third roller (230) and fourth roller (240) are provided in series along the alignment direction (Y) such that the first axis of rotation (214), the second axis of rotation (224), third axis of rotation (234) and fourth axis of rotation (244) are parallel, and the first axis of rotation (214), the second axis of rotation (224), the third axis of rotation (234) and fourth axis of rotation (244) are perpendicular to the alignment direction (Y); and such that a third gap (270) is defined between the third roller (230) and the fourth roller (240), and the compactor assembly (200) being configured to convey the fibrous material (112) from the second gap (260) to the third gap (270) to travel in the first direction (D1) through the third gap (270).

6. A compactor assembly (200) as claimed in claim 5 wherein the fourth roller 240 is operable to be driven by the actuator (400) to rotate in the second rotational direction (RD2) about the fourth axis of rotation (244).

7. The compactor assembly (200) as claimed in any one of claims 5, 6, wherein the third roller (230) and the fourth roller (240) are spaced apart by a distance configured to compact the fibrous material (112) in the third gap (270).

8. A compactor assembly (200) as claimed in any one of claims 1 to 7 wherein each of the plurality of rollers (210, 220, 230, 240) have the same diameter along their length.

9. A compactor assembly (200) as claimed in any one of claims 1 to 7 wherein at least one of the plurality of rollers (210, 220, 230, 240) has a diameter which is different to other rollers of the plurality of rollers (210, 220, 230, 240).

10. A compactor assembly (200) as claimed in claim 2 further comprising a drive unit (402) which couples to an output from the actuator (400) and couples to each of the plurality of rollers (210, 220, 230, 240) such that the plurality of rollers (210, 220, 230, 240) are rotatable synchronously by a single actuator (400).

11. A compactor assembly (200) as claimed in claim 10 wherein the drive unit (402) is configured to rotate the plurality of rollers (210, 220, 230, 240) so that the speed at the surface of each roller is the same.

12. The compactor assembly (200) as claimed in any one of the preceding claims wherein: the second roller (220) defines a second roller surface (222), and the compactor assembly (200) is configured such that the fibrous material (112) is conveyed from the first gap (250) to the second gap (260) on the second roller surface (222).

13. The compactor assembly (200) as claimed in claim 12 when dependent on claims 5, 6: the third roller (230) defines a third roller surface (232), and the compactor assembly (200) is configured such that the fibrous material (112) is conveyed from the second gap (260) to the third gap (270) on the third roller surface (232).

14. The compactor assembly (200) as claimed in any one of the preceding claims wherein: the first roller (210) defines a first roller surface (212); the compactor assembly (200) is configured such that the fibrous material (112) is received on the first roller surface (212) at a first circumferential position (P1) A degrees around the first roller surface (212) from the first gap (250) in the first rotational direction (RD1), where A has a value of no less than 90 and no more than 270.

15. The compactor assembly (200) as claimed in claim 14 when dependent on claims 5, 6 wherein: the fourth roller (240) defines a fourth roller surface (242), and the compactor assembly (200) is configured to release the fibrous material (112) from the fourth roller surface (242) at a second circumferential position (P2) B degrees around the fourth roller surface (242) from the third gap (270) in the second rotational direction (RD2), where B has a value of no less than 90 and no more than 270.

16. The compactor assembly (200) as claimed in any one of the preceding claims, wherein the plurality of rollers (210, 220, 230, 240) are operable to be heated to thereby heat the fibrous material (112).

17. The compactor assembly (200) as claimed in claim 5, wherein the compactor assembly (200) is further configured to convey the fibrous material (112), a first resin release carrier (122) and a second resin release carrier (124) from the first gap (250) to the second gap (260), the first resin release carrier (122) being provided on a first side (114) of the fibrous material (112) and the second resin release carrier (124) being provided on a second side (116) of the fibrous material (112).

18. The compactor assembly (200) as claimed in claim 17 when dependent on claims 5, 6, wherein the compactor assembly (200) is configured to convey the fibrous material (112), the first resin release carrier (122) and the second resin release carrier (124) from the second gap (260) to the third gap (270).

19. The compactor assembly (200) as claimed in claim 18 wherein the first resin release carrier (122) comprises a first belt (500) operable to transfer a coating of resin to the fibrous material (112), and the second resin release carrier (124) comprises a second belt (502) operable to transfer a coating of resin to the fibrous material (112).

20. The compactor assembly (200) as claimed in claims 5, 6 further comprising a first pass-back roller (410) configured to convey the fibrous material (112) from the first gap (250) to the second gap (260), and a second pass-back roller (420) configured to convey the fibrous material (112) from the second gap (260) to the third gap (270).

21. A production line (1000) for fabrication of resin-impregnated fibrous material (112), the production line (1000) comprising the compactor assembly (200) as claimed in any one of the preceding claims, the production line (1000) further comprising: a first supply (110) configured to supply a fibrous material (112), a second supply (120) configured to supply a transfer sheet (122, 124), wherein the first gap (250) and the second gap (260) are configured to receive the fibrous material (112) and the transfer sheet (122, 124).