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    • 专利摘要:
    APPLIANCE TO PRODUCE A SPREADED FIBER BEAM, METHODS TO PRODUCE A SPREADED FIBER BEAM, FOR THE CONTINUOUS PRODUCTION OF PRE-IMPREGNATED WRAPPED, AND, COMPOSITE PROCESSING SYSTEM. Apparatus for producing bundles of fibers spread by the strategic use of tension control across the entire device and use of higher speed differentials between driven rollers and line speed of the circulating fiber bundle are provided here, along with methods for produce scattered, pre-impregnated fibers and articles made from them.
    公开号:BR112012028029B1
    申请号:R112012028029-5
    申请日:2011-04-29
    公开日:2021-01-19
    发明作者:Shawn Walden Junker；Shaun Michael Poh；Ping YEE；Scott Alfred Rogers；Thomas A. Vanhorne
    申请人:Cytec Technology Corp.；
    IPC主号:
    专利说明:

    BACKGROUND OF THE INVENTION 1. Field of the Invention
    [001] The invention relates to the uniform spreading of bundles of multiple filament fibers and unidirectional arrangement in parallel for the continuous production of prepregs having reduced interstices and better distribution of fiber resin. More specifically, the invention relates to an apparatus using tension control across the entire apparatus and higher speed differentials between the surface periphery of driven rollers and the line speed (or running speed) of the fiber bundle, and methods for the use of it to obtain pre-impregnated material used to manufacture articles of fiber-reinforced plastic, which have a uniform thickness and few defects in appearance. 2. Description of the Related Art
    [002] Prepregs, where reinforcement fibers are impregnated with a matrix resin, are well known in the art and are widely used in various industrial / high performance fields, such as for aircraft and automobile materials, medical materials, and conformed materials for sports and leisure (for example, fishing rods, golf club clubs, badminton rackets, tennis rackets, etc.).
    [003] The production of more uniform prepregs with less irregularity in thickness is preferable and critical to the overall quality of the products. In order to achieve this, it is necessary to open (that is, spread) the bundle of reinforcement fibers before impregnating it with a matrix resin when forming a prepreg, to reduce the thickness of the bundle of reinforcement fibers and to allow the matrix resin to sufficiently fill the gaps between the single fibers of the reinforcement fiber bundle.
    [004] Therefore, the technique to open or spread the crude bundles of reinforcement fibers efficiently and appropriately is critical to producing a prepreg having uniform thickness, reduced interstices between fibers, and appropriate fiber-resin distribution. Various apparatus and methods for spreading bundles of fibers and / or producing prepregs are known in the art and include, for example, those described in US Patent Nos. 4,495,017; 5,042,122; 5,182,839; and 6,743,392.
    [005] Additionally, it is generally known that tension is the main driver for spreading bundles of fibers containing multiple filaments. Thus, higher tension typically creates wider spread of the fibers in the bundle. However, too high a tension makes impregnation difficult due to the lower permeability of the fiber in relation to the resin, fiber decay, and damaging the fibers (thus causing defibration or lint) or breaking the fiber. The increased tension also increases forces and torques across the entire device, which leads to high process costs.
    [006] Therefore, the apparatus and methods for spreading multiplicities of bundles of adjacent fibers having multiple filaments for the continuous production of prepreg require further improvement. Apparatus and methods that uniformly spread bundles of continuous multi-filament fibers and unidirectionally arrange fibers spread in parallel for the continuous production of prepregs having reduced interstices and better distribution of fiber resin would be a useful advance in the art and could find rapid acceptance in the industry. SUMMARY OF THE INVENTION
    [007] It has now been realized that bundles of fibers of multiple continuous filaments can be spread evenly at lower stresses, thus increasing the permeability to resins, decreasing interstices from decay, and decreasing lint due to damage, thus providing a superior pre product -impregnated and finally a superior article of manufacture made from it. Such improvements are achieved by the strategic use of tension control through the entire spreading apparatus. This advance drives the tension of the fiber bundles to a very high value and then decreases it to a very low value so that, through the use of moderate stresses across the entire apparatus, the fiber spread is increased without use of extremely high voltages, which were otherwise thought to be necessary to achieve such goals. In addition, the use of higher speed differentials between the driven roller bar and the bundle of circulating fibers has also been shown to improve the mechanical properties of fiber scattering.
    [008] Accordingly, in one aspect, the invention provides an apparatus for producing a scattered fiber bundle having a tension control module that includes a tension forming unit configured as a series of static bars and a stress reduction unit. tension configured as a series of driven rollers, in which the static bars and driven rollers are configured perpendicular to the direction of a bundle of circulating fibers that makes direct wrapping contact with the surface of the series of static bars and driven rollers, and in which the peripheral surface speed of the driven rollers is operated at least three times the line speed of the circulation fiber bundle.
    [009] In another aspect, the invention provides methods for producing a scattered fiber bundle using an apparatus as described here by running a bundle of fibers in direct wrapping contact with the surface of a series of static bars and / or driven rollers , and control the tension of the fiber through the apparatus by operating the driven rollers at a higher differential speed in relation to the speed of the circulation fiber bundle, thus spreading the fiber bundle.
    [0010] The invention, as described here in detail, also relates to the production of prepreg. Therefore, in another aspect the invention provides methods for the continuous production of pre-impregnated laminate unidirectionally arranged and having uniform distribution between fibers by integrating an apparatus as described here as part of a composite processing machine, running a plurality of bundles of adjacent fibers in direct contact with the surface of a series of static bars and / or driven rollers, spread the plurality of bundles of adjacent fibers by operating the driven rollers at a higher differential speed compared to the speed of the fiber bundle circulation, and impregnate the scattered fiber bundles with a predetermined amount of resin.
    [0011] In other respects, the invention provides methods for producing a prepreg by impregnating a predetermined amount of resin in a scattered fiber bundle produced according to the methods described in detail here.
    [0012] In another aspect, the invention provides prepreg materials produced according to the methods described in detail here, as well as articles of manufacture made from prepregs made according to those methods.
    [0013] In another aspect, the invention provides a composite processing system having two or more fiber spreading devices according to the invention, described here in detail, in which each spreading device is located on a different path and receives a set different from a plurality of bundles of adjacent fibers.
    [0014] These and other objectives, characteristics and advantages of this invention will be apparent from the detailed description of the various aspects of the invention taken in conjunction with FIGS. and attached examples. BRIEF DESCRIPTION OF THE DRAWINGS
    [0015] FIG. 1 provides a profile view of an apparatus according to an embodiment of the invention, in which a single bundle of fibers having multiple filaments is seen making direct wrapping contact with the surface of a series of static bars and rollers driven to provide a fiber spread, optimally tensioned and evenly distributed,
    [0016] FIG. 2 is a perspective view of an apparatus according to another embodiment of the invention that provides a voltage measurement unit as part of the apparatus.
    [0017] FIG. 3 is a perspective view of another embodiment of the apparatus according to the invention, which is provided as a component of a composite processing machine. Such equipment can be used in carrying out the methods for the continuous production of pre-impregnated laminate according to the invention. In the particular embodiment shown, two fiber spreading devices according to the invention are positioned on separate paths and are available to receive, each, a set of multiple adjacent fiber bundles, wound on multiple spools that are positioned on one or more pitchers voltage (not shown). The fiber spreading devices are positioned downstream of the tension chamber and upstream of a composite processing system, such as a prepreg processing machine having an impregnation device. DETAILED DESCRIPTION OF CERTAIN MODALITIES OF THE INVENTION
    [0018] The present invention provides an apparatus for producing a bundle of fibers spread by the strategic use of tension control through the entire spreading device and use of higher speed differentials between the driven rollers and the beam line speed of fibers, along with methods to produce scattered and pre-impregnated fibers and articles of manufacture from them. As summarized above, it was invented that the spreading of fiber spreading mechanics known in the art can be greatly improved by the strategic use of tension control across the entire spreading apparatus and the use of higher speed differentials between bar surfaces of rollers and fiber line speed. Stress is the main factor in the spreading of multi-filament fiber bundles, but it is also the main factor (for example, too high a tension) in the decay, reducing the permeability to resin impregnation, and defects, such as fluff (also called lint balls), pitting interstices, fiber disorder, etc. Increasing, maintaining, and then reducing tension through the scattering cycle provides the necessary means to combat fiber decay and other unwanted properties, but also to maximize scattering, thereby opening the bundle of fibers and controlling (that is, increasing or decreasing) the permeability to resin impregnation. As the ratio between the surface speed of the roller bar and the linear speed / running speed of the fiber bundle increases by more than 2 times, significant spreading gains are seen. The gains decay with logarithmic behavior, however. Improvements in the mechanical properties of fiber spreading finally lead to improvements in the products and pre-impregnated articles made from them, since the uniformity of thickness and occurrence of interstices, together with distribution of fiber-resin, are critical to the overall quality of the product. product. Gadgets
    [0019] Therefore, in one aspect, the invention provides an apparatus for producing a scattered fiber bundle having a tension control module that includes a tension forming unit configured as a series of static bars and a reduction unit for tension tension configured as a series of driven rollers, in which the static bars and driven rollers are configured perpendicular to the direction of a bundle of circulating fibers that makes direct wrapping contact with the surface of the series of static bars and driven rollers, and in which the driven rollers of a tension forming unit are operated in such a way that their peripheral surface speed is at least three times the line speed of the circulating fiber bundle.
    [0020] The fiber bundles used in the apparatus according to the present invention are those composed of a large number of simple filaments (for example, 6K / bundle, 12K / bundle, or higher) and preferably they are wires or cables composed of bundles of long continuous filaments. For example, bundles of fibers may include, but are not limited to, organic fibers, such as polyamide, polyester, polyacrylonitrile, polyvinyl alcohol, etc .; heat-resistant organic fibers, such as aromatic polyamide fibers (for example, Kevler® (Dupont, US), polyfluorocarbon, phenolic resin (Kynol®; carbonorandam, US), polyamide-imide, polyimide, etc .; rayon and natural fibers, inorganic fibers, such as glass fibers, boron nitride, carbon (including carbonaceous, graphite, and flame resistant fibers), silicon nitride, silicon carbide, alumina, zirconia, asbestos, etc .; metal such as copper fibers, tungsten alloy, iron, aluminum, stainless steel, etc., composite fibers such as boron fibers with a tungsten core, boron carbide with a tungsten core, silicon carbide with a tungsten, boron, etc. and all others having a fiber shape. It is also possible to use bundles of fibers composed of a combination of two or more of the aforementioned fibers. Bundles of fibers may have a bonding agent or oil deposited on the same for ease of m anipulation and to prevent damage to the fibers. typical and suitable sizing agents are known to those of ordinary skill in the art and can include, for example, those described in US Patent No. 4,495,017. In one embodiment, the bundle of circulating fibers is chosen from carbon, glass, polyamide, polyamide-imide, polyimide, aramid, and combinations thereof.
    [0021] The bundle of fibers includes a plurality of filaments that are arranged as a reinforcing fiber in parallel which can be on a spool. The fiber spools can be placed on a tension tube so that the plurality of bundles of reinforcement fibers can be applied by a comb or rake at evenly spaced intervals, as presented to the apparatus. When used here, the term “circulation fiber bundle” has its common meaning known to those of ordinary knowledge in the art and refers to fibers being pulled from a spool on a tension tube, for example, by a drum. pull or tension roller through the device. In certain embodiments, the bundle of circulating fibers may include multiple adjacent bundles. In other embodiments, two or more sets of multiple adjacent fiber bundles may be provided on separate paths, to be spread over a corresponding number of fiber spreading devices according to the invention.
    [0022] The increase in tension of the fiber bundle before the drive rollers maximizes fiber spreading without requiring undue increase in tension. In the present invention, tension is initially increased through the use of a tension forming unit. In certain modalities, and includes an element chosen from a tension chant; one or more driven rollers operating at a slower speed than the linear speed of the circulating fiber bundle (i.e., a slow speed roller); one or more static bars (that is, a fixed type bar that does not rotate); and combinations thereof. In some embodiments, a tension forming unit can be provided for a series of driven low speed rollers and static bars. In other embodiments, a stress-forming unit may be provided for one or more static bars.
    [0023] In certain embodiments, the apparatus may include a tension measuring section positioned downstream of the tension forming section and having a series of static bars and one or more driven rollers operating at a speed faster than the linear speed of the circulation fiber bundle (ie, fast or high speed roller). This section can be used to adjust the tension of the fiber bundle down on the driven rollers while forming the tension of the fiber bundle reserve when the fiber comes into direct wrapping contact with the surface of the static bars, thus still opening / spreading the bundle of fibers with each repeated cycle. In some embodiments, a tension mediation section may have rollers driven at high speed and static bars in alternating positions. In other embodiments, high speed rollers can sandwich one or more of the static bars. The static bars and driven rollers of a fiber spreading apparatus can be arranged in a horizontal alignment or in vertical alignment provided that the bundle of circulating fibers is in direct wrapping contact with the surface of the driven rollers and the static bars.
    [0024] The apparatus according to the invention also includes a tension reduction section / unit having a series of high speed driven rollers that help to reduce tension in the circulation fiber bundle. When used here, the term "series" has its common meaning known to those of knowledge in the art and refers to two or more of the objects it modifies.
    [0025] The running speed of the fiber bundle (ie transfer speed) can vary from 2 m / min. at 20 m / min, with a preference of 2 to 10 m / min. In some embodiments, the peripheral surface speed of the high speed driven rollers varies from 3 to 100 times the speed of the circulation fiber bundle. For example, in certain embodiments, the peripheral surface speed of the high speed rollers can vary from 3 to 50 times the speed of the circulation fiber bundle; 3 to 25 times the speed of the circulation fiber bundle; or 3 to 10 times the speed of the circulation fiber bundle.
    [0026] Static bars and driven rollers (or spreading bodies as they are sometimes called), having at least a part of the curved surface of a column or cylinder, are solid or hollow columns or cylinders, and also a part of a surface curved cut from a column or cylinder of a large diameter can be used. The material is not particularly specified, but it is preferable to select one that has a small coefficient of friction, is not extremely deformed or worn by friction with the bundles of fibers, and does not oxidize with sharp crystalline structures. Usually, stainless steel is used, but a static bar or driven roller made of a metal covered with a synthetic resin, such as teflon, etc., iron, copper, etc. and inorganic substances, such as glass, alumina, etc. can be used. The diameter, number, type of combination and spatial arrangement are selected considering the balance between the stacking width and the damage of the fiber bundles, and therefore, they cannot be definitively determined, but for fiber bundles that have a high modulus of elasticity, spreader bodies with a large diameter are used, and it is desirable that the number, type of combination and spatial arrangement of the spreader bodies should be selected taking into account the length of contact between the fiber bundles and the curved surfaces, and the pressure force against the spreading bodies caused by the tension. The type of spreader bodies, whether they are fixed (ie, static) or drive type, which provides a differential peripheral speed in the direction of displacement of the fiber bundles, has a great influence on the spreading effects. (the stacking width and damage of the fiber bundles). Therefore, in carrying out the process of the present invention, it is desirable to take the above-mentioned effects into account when using the various types of rollers individually or in combination with two or more types. In addition, the tension and speed of the fiber bundles must, of course, be uniform so that any disorder of the fiber bundles does not occur, and they are selected in relation to the scattering effects.
    [0027] The use of a surface finish on both static bars and driven rollers can also be included in the apparatus according to the present invention, thus further reducing the tension required to open the bundle of fibers and obtain a particular width of fiber. The static bars and driven rollers can be made of stainless steel, for example, and sanded in the axial direction with sandpaper of various granulations. For example, in some embodiments, the static bars and driven roller bars may have a surface finish provided by sanding with grit sandpaper 180 to 400 grit, and preferably with grit 180 to 220 grit. In still other embodiments, add spreading bodies they can be finished surface with a magnitude of shot, while other spreading bodies are finished surface with a different size of shot. Similarly, spreader bodies can also have different surface finishes. In some embodiments, for example, spreader bodies can be either wrinkled and sanded, or some wrinkled and some sanded. In other embodiments, the spreader bodies may be surface-finished by any means known to those of ordinary skill in the art, which reduce the coefficient of friction of the fiber on the spreader bodies and simultaneously spread the bundle of fibers at lower stresses.
    [0028] Additionally, it may be desirable to arrange the position of the unidirectional fiber bundles, which are parallel and adjacent to each other, by making the fiber bundles pass through a comb type structure, called a rake. In some embodiments, such a rake can be positioned downstream of the canopy and upstream of a tension forming unit so that the bundles of fibers are positioned within a width corresponding to the final width of the prepreg sheet. In other embodiments, another rake can be positioned between a tension forming unit and a tension reducing unit. If there is more than one set of multiple adjacent fiber bundles on separate paths, a rake may be present in each path for each set of multiple adjacent fiber bundles for passing through it. In such a case, the rakes for each set of multiple adjacent bundles of fibers can be slightly offset so that the bundles spread out from each bundle are arranged in such a way as to reduce the incidence of interstices and promote uniform fiber distribution -resin.
    [0029] An apparatus according to the present invention may also include a heating source positioned to heat the bundle of reinforcement fibers. The heating source can be provided by any means including, but not limited to, conduction, convection, or radiation devices. Heating the bundle of reinforcing fibers can be advantageous in order to soften the bonding agent or oil that can be deposited on it, and to generally improve the efficiency of the spreading action by reducing the friction coefficient between the fiber and bodies spreaders (ie static bars and driven rollers). In some embodiments, the heating source may be provided as an indirect heating source, such as by blown gas or radiant heat. In other embodiments, the static bars and / or self-driven rollers can be heated so that the contact surface of the roller bar becomes heated. It is preferable that the bundle of circulating fibers be exposed to a heating temperature range from 50 ° to 250 ° C (depending on a fiber design used), with 70 ° to 180 ° C being the most common.
    [0030] In some embodiments, a fiber spreading apparatus of the present invention can be a unique component. In certain embodiments, the apparatus may be a component of a composite processing machine, such as, for example, a prepreg processing machine. In a set of this type, the apparatus according to the invention can be positioned downstream of a tension tube containing spools of bundles of fibers and upstream of an impregnation system. In certain embodiments, two or more fiber spreading devices can be integrated into a prepreg processing machine, such as where there are two or more sets of multiple adjacent fiber bundles running on separate paths. In other embodiments, a fiber spreading apparatus according to the invention can be a component of a weaving loom and can be positioned downstream of a tensioning chamber and upstream of a composite processing machine.
    [0031] Certain embodiments of the invention will be described below with reference to the drawings.
    [0032] FIG. 1 shows a perspective view of an apparatus according to the invention, as described above. In FIG. 1, a fiber spreading device 10 is shown and includes a stress-forming section 2 and stress-reducing section 3, in which a single running bundle of fibers 1, provided by a fiber spool as over a tension tube (not shown) moves in the direction of the arrow and enters stress-forming section 2 in direct wrapping contact with the surface of a series of static bars 2a on the route to stress-reducing section 3, which contains a series of high speed rollers 3a, with which the fiber bundle maintains its direct wrapping contact. High speed driven rollers are independently rotated by a drive motor 3b or other devices known to those of skill in the art. As shown, the fiber spreading device 10 drives the tension of the circulation fiber bundle 1 very high through a series of static bars 2a in a tension forming unit 2 and then reduces the tension of the fiber bundle 2 very low form through a series of high speed driven rollers 3a in a stress reduction unit 3, thus spreading / opening the bundle of fibers further with each alternation of a high speed driven roller and without the use of extremely high stresses . Immediately downstream of the fiber spreading device 10 and ready to receive the now open fiber bundle is a composite processing machine or impregnation system (not shown) known to those of ordinary skill in the art. Although the fiber spreading device 10 is only represented with a single bundle of circulating fibers 1, those of ordinary skill in the art will immediately understand and appreciate that multiple bundles of unidirectionally arranged fibers (that is, parallel to each other) can be arranged, and that additional fiber spreading devices may be present for embodiments in which there is a corresponding number of sets of multiple adjacent fiber bundles on separate paths.
    [0033] FIG. 2 shows a profile view of an apparatus according to another embodiment of the invention, as described above. In FIG. 2, a fiber spreading device 20 is shown and includes a stress-forming section 22, a stress-moderating section 23, and a stress-reducing section 3, wherein a single bundle of circulating fibers 21 provided by a fiber spool / coil as on a tension tube (not shown) moves in the direction of the arrow and enters the tension forming section 22 in direct wrapping contact with the surface of a series of static bars S en route to a stress moderation section 23, where the bundle of circulating fibers is placed in direct wrapping contact with the surface of an alternating series of rollers driven at low and / or high speeds D and static bars S, and then continues to run through of a stress reduction unit 24, where the bundle of circulating fibers is placed in direct wrapping contact with the surface of a series of rollers driven at high speed D. As shown, the spreading device of fiber 20 drives the tension of the circulation fiber bundle 21 very high by placing it in direct wrapping contact with a series of static bars S in a stress forming unit 22 and then alternates the low to high tension by placing the bundle of circulating fibers in direct wrapping contact with a series of low and / or high speed rollers D and static bars S in a stress moderating unit 23, and finally reduces the fiber tension very low by placing the bundle of fibers in direct wrapping contact with a series of high-speed rollers in a stress reduction unit 24, thus spreading / opening the bundle of fibers further with each wrapping contact with a drive bar and without use extremely high voltages. As in FIG. 1, immediately downstream of the fiber spreading device 20, a composite processing machine or impregnation system (not shown), known to those of ordinary skill in the art, can be placed ready to receive the now open fiber bundle. Alternatively, the fiber can be stretched over a pull / pull drum / roller. Methods
    [0034] In another aspect, the invention provides methods for producing a spread bundle of fibers by running a bundle of fibers through an apparatus as described in detail here, and operating the driven rollers of the apparatus at a differential speed relative to the speed of the circulation fiber bundle, thus controlling the fiber tension across the entire apparatus and spreading / opening the fiber bundle.
    [0035] In a scattered fiber bundle production method, several fibers can be used in the production of a scattered bundle of fibers, as described above. These fibers can also have various tensile strengths and elasticities, depending on the fiber used. The final spreading width of the fiber can be up to 4 times the original width of the fiber bundle and more typically it will be up to 3.5 times the original width. Typically, bobbins or spools having bundles of fibers wrapped around them and installed on a tension tube will serve as the supply of circulating fiber. The tension can be altered on the cantara, when desired, to stabilize the spreading state of the fiber bundle. In one mode, at least one static bar and / or driven roller will be heated. In another embodiment, the bundle of circulating fibers will itself be heated, such as by means of radiating heat. In certain embodiments for the methods of producing a scattered fiber bundle, a rake can be positioned between the tension cannula and fiber scattering apparatus so that any adjacent multiple fibers are evenly spaced.
    [0036] In another aspect, the invention provides methods for the continuous production of pre-impregnated laminate unidirectionally arranged and having uniform distribution between fibers. In certain embodiments, the method can be obtained by integrating a fiber spreading apparatus as described here in detail as part of a composite processing machine well known to those of skill in the art, running a set of a plurality of bundles of adjacent fibers in order to make direct wrapping contact with a series of static bars and / or driven rollers, thus spreading the fiber bundles, and impregnating the scattered fiber bundles with a predetermined amount of resin to form a pre-impregnated sheet . For example, a set of a plurality of bundles of adjacent fibers can include 2 or more bundles of fibers, and typically between 5 and 20 bundles of fibers. A second set may include the same number of bundles of fibers for the first set.
    [0037] In certain embodiments, the prepreg can be produced from two or more sets of a plurality of bundles of adjacent fibers moving in separate paths (ie, a pattern of 2 or spreading over 2 paths). In such embodiments, a corresponding number of fiber spreading devices according to the invention can be integrated into a composite processing system. FIG. 3 and example 1 describe and exemplify such a modality, but other multipath modalities are also contemplated by the invention.
    [0038] In a method for producing laminated prepreg, the resin used and the resin impregnation method are not particularly limited, as numerous resins and methods / apparatus for impregnation are known to those skilled in the art. Examples of resins that can be used include, but are not limited to, thermostable resins, such as epoxy resins (for example, bisphenol A epoxy resin, phenol novolak epoxy resin, cresol novolak epoxy resin, glycidylamine epoxy resin, alicyclic epoxy resin, modified urethane epoxy resin, and brominated bisphenol A epoxy resin), vinyl ester resins, unsaturated polyester resins and phenol resins, thermoplastic resins such as polyester resins, polyethylene resins, polycarbonate resins polyether, and polyamide resins, etc.
    [0039] Although a resin can be used, two or more resins can be used together. In addition, a liquid resin or a solid resin can be used and deposited on the fibers by, for example, immersion in solution or by suspension tank. A curing agent can be added to the resin system being used. For impregnation, a resin with lowered viscosity by heating or dissolving in a solvent can be impregnated in the fiber bundles. In another embodiment, the bundles of fibers can be held between two sheets of resin respectively obtained by finally and evenly applying a resin to such a sheet as treated paper or resin film to be releasable, and the laminate is pressurized using hot rollers etc. Other hot rollers, rollers, heating / cooling plates, rakes, rollers, etc. may be present throughout the composite processing machine.
    [0040] In certain modalities of the method for producing a continuous laminated prepreg, a fiber bundle spacing medium, such as a rake or comb, will be positioned between the tension cannula and a fiber spreading apparatus and between a fiber spreading apparatus and the composite processing machine in order to maintain uniformity between the fiber bundles. In certain embodiments, the method will include multiple spacing means, such as when there are multiple sets of a plurality of bundles of adjacent fibers. In such cases, the spacing means, close to the composite processing system, can be slightly offset in relation to each other to ensure that the fiber bundles leave the spreading device and enter the overlapping composite fiber processing system slightly to each other before they are compacted by the roller rollers in order to further reduce the interstices between fibers and promote the distribution of fiber-resin. The spacing means can be substantially the width corresponding to that of the prepreg sheet.
    [0041] In another aspect, the invention also provides articles of manufacture composed of a prepreg made according to the invention described here in detail. The articles can include any composite article made of fibers or sheets of pre-impregnated fibers, such as materials such as aerospace or industrial materials of high performance, automotive, or leisure.
    [0042] In a final aspect, the invention also provides a composite processing system having two or more fiber spreading devices according to the invention described here, in which each device is situated on a different path and capable of receiving a set a plurality of bundles of adjacent fibers.
    [0043] Other embodiments of the invention include, but are not limited to, the following: 1. An apparatus for producing a scattered fiber bundle comprising: a tension control module comprising: i) a tension forming unit configured as a series static bars; and ii) a tension reduction unit configured as a series of driven rollers. in which the static bars and driven rollers are positioned perpendicular to the direction of a bundle of circulating fibers which makes direct wrapping contact with the surface of said driven bars and driven rollers, and in which the peripheral surface speed of the driven rollers is at least three times the speed of the circulation fiber bundle. 2. Apparatus according to modality 1, in which the bundle of circulating fibers is chosen from carbon, glass, polyamide, polyamide-imide, poly-imide, aramid, and combinations thereof. 3. Apparatus according to modalities 1 or 2, in which the bundle of circulating fibers comprises multiple adjacent bundles. 4. Apparatus according to any of the preceding modalities further comprising a second tension control module on a different path than that of the first apparatus, in which a second circulation fiber bundle comprising a plurality of multiple adjacent fiber bundles makes contact with direct involvement with the surface of the static bars and rollers driven by said second device. 5. Apparatus according to any of the preceding modalities, in which the final spreading width of the circulation fiber bundle is up to 3.5 times the original width of the fiber bundle. 6. Apparatus according to any of the preceding modalities, in which a tension forming unit is alternatively provided by a member chosen from: a tension tube; one or more low speed rollers driven operating at a slower speed than the speed of the circulating fiber bundle; and combinations of driven low speed rollers and static bars. 7. Apparatus according to any of the preceding modalities, further comprising a tension measurement unit comprising a series of driven rollers and static bars. 8. Apparatus according to any of the preceding modalities, in which a tension reduction unit is provided by a series of driven rollers. 9. An apparatus according to any of the preceding modalities, in which the peripheral surface speed of the driven rollers varies from 3 to 100 times the speed of the circulation fiber bundle. 10. Apparatus according to any of the preceding modalities, in which the peripheral surface speed of the driven rollers varies from 3 to 50 times the speed of the circulation fiber bundle. 11. Apparatus according to any of the preceding modalities, in which the peripheral surface speed of the driven rollers varies from 3 to 25 times the speed of the circulation fiber bundle. 12. Apparatus according to any of the preceding modalities, in which the peripheral surface speed of the driven rollers varies from 3 to 10 times the speed of the circulation fiber bundle. 13. Apparatus according to any of the preceding modalities, in which the static bars and / or driven rollers contain a surface morphology. 14. Apparatus according to modality 13, in which the surface morphology is axial to the direction of the driven roller and static bar. 15. Apparatus according to any of the preceding modalities, further comprising at least one rake. 16. Apparatus according to modality 15, in which the rake is located upstream of a tension forming unit. 17. Apparatus according to modalities 15 or 16, in which the rake is located between a tension forming unit and a tension reducing unit. 18. Apparatus according to any of the preceding modalities further comprising at least one heating source positioned to heat the fiber running. 19. Apparatus according to any of the preceding modalities, in which the apparatus is a component of a composite processing machine and is located downstream of a canteen and upstream of an impregnation system. 20. Apparatus in accordance with any of the foregoing modalities, in which the apparatus is a component of a weaving loom and is located downstream of a canteen and upstream of a composite processing machine. 21. Method for producing a scattered bundle of fibers using a device according to any of the modalities 1-20 comprising: a) running a bundle of fibers in direct wrapping contact with the surface of a series of static bars and driven rollers ; and b) control the tension of the fiber through the apparatus by operating the driven rollers at a higher differential speed in relation to the speed of the circulation fiber bundle, thus spreading the fiber bundle. 22. Method according to modality 21 further comprising, at any stage, heating at least one static bar and / or driven roller or heating the bundle of fibers by itself. 23. Method according to any of the modalities 21 22, further comprising, at any stage, uniformly spacing multiple bundles of adjacent fibers with a rake. 24. Method according to any of the modalities 21 23, comprising also applying a surface morphology to one or more rollers in the series. 25. Method according to any of the modalities 21 23, characterized by the fact that it additionally comprises stretching the scattered fiber with a stretching drum. 26. Method for the continuous production of unidirectionally laminated pre-impregnated arranged in parallel and having uniform distribution between fibers, the method comprising: a) impregnating an apparatus according to any of modalities 1-20 as part of a composite processing machine ; b) running a set of a plurality of bundles of adjacent fibers in direct wrapping contact with the surface of a series of static bars and rollers driven from the apparatus; c) spreading the plurality of bundles of adjacent fibers by operating the driven rollers at a higher differential speed in relation to the speed of the circulating fiber bundle; and d) impregnating the scattered fiber bundles with a predetermined amount of resin. 27. Method according to modality 29, in which step (a) additionally comprises integrating a second apparatus according to any of modalities 1-20 in the composite processing machine in a different path than that of the first apparatus, and at which stage (b) further comprises running a second set of a plurality of bundles of adjacent fibers in direct wrapping contact with the surface of a series of static bars and rollers driven from the second apparatus. 28. Method according to any of the 26-27 modalities further comprising uniformly spacing the plurality of bundles of adjacent fibers before contacting the fiber spreading apparatus with a spacing means. 29. Method according to any of the modalities 26-28, further comprising uniformly spacing the plurality of bundles of adjacent fibers before the impregnation step with a spacing means. 30. Method according to modality 29, in which the spacing means are displaced from each other when there are multiple sets of fiber bundles. 31. Method according to any of the 26-30 modalities, in which the resin is a thermoplastic or thermostable resin. 32. Method according to any of the modalities 26-31, in which the resin is applied both at the top and at the base of the scattered fibers, or immersed in a solution or suspension tank. 33. Method according to any of the modalities 26 32, in which the impregnation step is carried out by a series of one or more hot rolls, hot plates, and cooling plates, or by a solution or suspension tank. 34. Method for producing a pre-impregnated unidirectionally arranged in parallel, the method comprising impregnating a predetermined amount of resin in a scattered fiber bundle produced according to any of the modalities 21-25. 35. Pre-impregnated unidirectionally arranged in parallel made according to the method of any of the modalities 26-34. 36. Article of manufacture comprising a prepreg according to modality 35. 37. Composite processing system comprising two or more fiber spreading apparatus according to any one of modalities 1-20, in which each apparatus is located in a different path capable of receiving a set of a plurality of bundles of adjacent fibers. EXAMPLES
    [0044] The following examples are provided to assist a person skilled in the art to further understand certain embodiments of the present invention. These examples are intended for illustration and are not to be construed as limiting the scope of the various embodiments of the present invention. Example 1: Production of a pre-impregnated sheet having low weight per fiber area (FAW) of 70 grams per square meter (gsm).
    [0045] With reference to FIG. 3, where corresponding elements are associated with common identifiers, and which represent two fiber spreading devices according to the invention, as components integrated in a composite processing system to carry out the continuous method of prepreg production according to invention, it is shown that two sets of a plurality of adjacent fiber bundles 31 (such as T650-35, a 12K fiber filament / bundle supplied by Cytec Carbon Fibers (South Carolina) and having a standard spreading module of 145 gsm) are running in a 2-spread pattern at a line speed of approximately 2-5 m / min. (ie, 2 m / min., 3 m / min., 4 m / min., or 5 m / min. as determined by the speed of a pull or pull roller (not shown) of the composite processing system) when they are unwound from coils fitted on a tension tube (not shown), adjusted uniformly by a low wrapping static bar 32, and are dosed with a comb 33. The cable tension of the fiber bundles 31 is increased when the plurality of bundles of adjacent fibers makes direct wrapping contact with a series of static bars provided by a tension forming unit 34a of a fiber spreading apparatus according to the invention 34, and which contain an applied surface morphology by grit sandpaper 180 in the axial direction. The bonding on the fiber bundles is preheated with a heat exchanger 35a positioned close to a stress forming unit 34a. The cable tension of the running fiber bundles is managed when they make direct wrapping contact with a series of driven rollers provided by a tension measuring unit 34b of a fiber spreading apparatus according to the invention 34, and which contain a surface morphology applied by sandpaper 180 in the axial direction. The driven rollers are rotated in the direction of the circulating fiber bundle at various speeds ranging from 0.5 to 11 times the line speed (that is, the speed of the running fiber bundles) to increase and then reduce tension levels just below fiber limitations. The continuous strip of cables is then heated up again with a 35b heat radiator before finally reducing the tension of the fiber bundles by placing them in direct wrapping contact with a series of high speed driven rollers provided by a pressure reduction unit. tension 34c of a fiber spreading apparatus according to the invention 34, and which contain a surface morphology applied by grit sandpaper 180 in the axial direction. A stress reduction unit 34c is positioned within close proximity to a roller roller 38 carrying a resin film 39, which film is placed on the spread fiber, which is then pulled (resin film on the spread fiber together) between rollers 38 and compacted at 35 grams per square meter per bundle of fibers.
    [0046] Thus, this process is carried out simultaneously with the upper set and the lower set of the plurality of bundles of adjacent fibers (from either the same or separate chamber), each being compacted to 35 gsm. The results produce a 70 gsm 40 tape, evenly spread, highly impregnated, without interstices or lint from the fiber, which is commonly only able to obtain a 145 gsm FAW (ie 72.5 gsm per set of multiple bundles) adjacent). Fiber temperature and stresses are important, as either too high a temperature (for example, above 130 ° F) or too high a tension (for example, above 4000 gram-force per cable) will cause this product to start forming fringes and , on the rollers driven at high speed, start to roll. Therefore, lower voltages and lower heater temperatures must be ensured for this type of fiber. Example 2: Production of a pre-impregnated sheet having low weight per fiber area (FAW) of 145 grams per square meter (gsm).
    [0047] A prepreg sheet with a standard fiber area weight (FAW) of 145 grams per square meter (gsm) using an intermediate module fiber (such as IM-7G ', a filament / fiber bundle of 12K supplied by Hexcel Corp. (Stamford, CT)) is made as in example 1. however, only two static bars are used in the tension forming section 34a and only two driven rollers are used in each of the tension management section 34b (low speed driven rollers and / or high speed driven rollers) and strain reduction section 34c (high speed driven rollers) of the fiber spreading device according to invention 34. Heaters 35a and 35b are not used . The continuous strand of cable (or bundles of fibers) is spread to a FAW of 72.5 gsm for each of the upper and lower bundles of multiple adjacent bundles of fibers, and then combined in the interstice 38 to produce a pre-impregnated sheet evenly spread, highly impregnated, with FAW of 145 gsm without interstices or fluff.
    [0048] Several patent references and / or scientific literature have been referred to throughout this application. The exposures of these publications in their entirety are hereby incorporated by reference as if they were described here. In view of the above description and examples, a person of specialized knowledge in the art will be able to reproduce the exhibition as claimed, without undue experimentation.
    [0049] Although the preceding description has shown, described, and highlighted the fundamental new features of the present teachings, it will be understood that various substitutions, and changes in the shape of the detail of the apparatus as illustrated, as well as the use thereof, can be done by those specialized in art, without escaping the scope of the present teachings. Consequently, the scope of the present teachings should not be limited to the preceding discussion, but should be defined by the appended claims.
    权利要求:
    Claims (16)
    [0001]
    1. Apparatus for producing a scattered fiber bundle, characterized by the fact that it comprises: a tension control module comprising: i) a tension forming unit comprising a series of static bars configured to increase tension in a fiber bundle of circulation moving in a direction of travel; and ii) a tension reduction unit comprising a series of driven rollers, in which the static bars and driven rollers are positioned perpendicular to the direction of the moving fiber bundle, configured to reduce tension in the circulating fiber bundle, each roller actuated by being independently rotating; where the stress reduction unit is positioned downstream of the stress forming unit along the direction of travel of the circulating fiber bundle so that, during operation, the circulating fiber bundle makes direct wrapping contact with the surface of said static bars before making direct wrapping contact with said driven rollers, and wherein the peripheral surface speed of the driven rollers is at least three times the speed of the circulation fiber bundle.
    [0002]
    Apparatus according to claim 1, characterized in that it additionally comprises a fiber spool to supply the circulation fiber bundle, in which the fiber spool is positioned upstream of the tension forming unit along the direction displacement of the circulation fiber bundle.
    [0003]
    Apparatus according to claim 1 or 2, characterized by the fact that the bundle of circulating fibers comprises multiple adjacent bundles.
    [0004]
    Apparatus according to any one of claims 1 to 3, characterized in that it additionally comprises a second voltage control module in a different path than said voltage control module, said second voltage control module comprising a a second stress-forming unit comprising a series of static bars, and a second stress-reducing unit comprising a series of driven rollers, each driven roller of the second stress-reducing unit being independently rotary, wherein the second stress-reducing unit tension is positioned downstream of the second tension forming unit along a direction of displacement of a second bundle of circulating fibers so that, during operation, the second bundle of fibers makes direct wrapping contact with the surface of the bars stresses of said second tension forming unit before making direct wrapping contact with the surface of the rollers actuated from said second voltage reduction unit.
    [0005]
    Apparatus according to any one of claims 1 to 4, characterized in that the final spreading width of the circulation fiber bundle exiting the tension reduction unit is up to 3.5 times the original width of the fiber bundle .
    [0006]
    Apparatus according to any one of claims 1 to 5, characterized in that the tension forming unit additionally comprises one or more low speed driven rollers operating at a speed slower than the speed of the circulation fiber bundle .
    [0007]
    Apparatus according to any one of claims 1 to 6, characterized in that it additionally comprises a tension moderating unit comprising a series of alternating driven rollers and static bars positioned between the tension forming unit and the reduction unit of tension along the direction of travel of the circulation fiber bundle.
    [0008]
    Apparatus according to any one of claims 1 to 7, characterized in that it additionally comprises a separate drive motor to independently rotate each driven roller so that the peripheral surface speed of the driven roller varies from 3 to 100 times the speed of the circulation fiber bundle.
    [0009]
    Apparatus according to any one of claims 1 to 8, characterized in that the static bars and / or driven rollers contain a sanded surface finish.
    [0010]
    Apparatus according to any one of claims 1 to 9, characterized in that it additionally comprises at least one rake located upstream of a tension forming unit or between the tension forming unit and the tension reducing unit .
    [0011]
    Apparatus according to any one of claims 1 to 10, characterized in that it additionally comprises at least one heating source positioned to heat the circulation fiber bundle.
    [0012]
    12. Method for producing a scattered bundle of fibers using an apparatus as defined in any of claims 1 to 11, characterized in that it comprises: a) running a bundle of fibers through the apparatus as defined in any of claims 1 to 11 so that the fiber bundle makes direct wrapping contact with the surface of the series of static bars before making direct wrapping contact with the driven roller series; and b) controlling the tension of the fiber bundle through the apparatus by operating the driven rollers at a peripheral surface speed that is at least three times the speed of the circulating bundle of fibers, thereby spreading the bundle of fibers.
    [0013]
    13. Method for the continuous production of pre-impregnated rolled unidirectionally arranged in parallel and having uniform distribution between fibers, characterized by the fact that the method comprises: a) integrating an apparatus as defined in claim 1 as part of a composite processing machine; b) running a set of a plurality of bundles of adjacent fibers in direct wrapping contact with the surface of a series of static bars and rollers driven from the apparatus; c) spreading the plurality of bundles of adjacent fibers by operating the driven rollers at a higher differential speed in relation to the speed of the circulating fiber bundle; and d) impregnating the scattered fiber bundles with a predetermined amount of resin.
    [0014]
    Method according to claim 13, characterized in that step (a) additionally comprises integrating a second apparatus as defined in claim 1 for a composite processing machine on a different path than that of the first apparatus, and at which stage (b) further comprises comprising running a second set of a plurality of adjacent fiber bundles through the second apparatus so that the fiber bundles make direct wrapping contact with the surface of a series of static bars before making direct wrapping contact with the series of driven rollers of the second device.
    [0015]
    Method according to claim 14, characterized in that it further comprises uniformly spacing the plurality of bundles of adjacent fibers before the step of impregnating with a spacing means and the spacing means are displaced from each other when multiple sets of spacing are present. bundles of fibers.
    [0016]
    16. Composite processing system, characterized by the fact that it comprises two or more fiber spreading devices as defined in any one of claims 1 to 11, in which each device is located on a different path and capable of receiving a set of one plurality of bundles of adjacent fibers.
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    同族专利:
    公开号 | 公开日
    CA2798216C|2017-10-31|
    US20120102678A1|2012-05-03|
    TWI583836B|2017-05-21|
    MY156861A|2016-04-15|
    WO2011142990A1|2011-11-17|
    JP2013528718A|2013-07-11|
    TW201211336A|2012-03-16|
    KR101840491B1|2018-03-20|
    ES2483244T3|2014-08-06|
    JP5726292B2|2015-05-27|
    BR112012028029A2|2016-08-02|
    KR20130105304A|2013-09-25|
    AU2011253365B2|2015-04-09|
    EP2569469A1|2013-03-20|
    CA2798216A1|2011-11-17|
    EP2569469B1|2014-05-14|
    CN102947496A|2013-02-27|
    CN102947496B|2015-03-25|
    US8490253B2|2013-07-23|
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    法律状态:
    2018-04-10| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-02-26| B06T| Formal requirements before examination [chapter 6.20 patent gazette]|
    2020-02-11| B07A| Application suspended after technical examination (opinion) [chapter 7.1 patent gazette]|
    2020-08-11| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|
    2020-12-01| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-01-19| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 29/04/2011, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
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    US33346110P| true| 2010-05-11|2010-05-11|
    US61/333461|2010-05-11|
    PCT/US2011/034477|WO2011142990A1|2010-05-11|2011-04-29|Apparatus and methods for spreading fiber bundles for the continuous production of prepreg|
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