• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    Fiber conditioning process, fiber conditioning installation and conditioned fiber tape obtained, wherein the conditioning process comprises the steps of continuously supplying a fiber bundle (1), applying a first resin (51) on the bundle of fibers (1) by an electrostatic deposition of particles of the first resin (51), fixing the particles of the first resin (51) to the fiber bundle (1) by a heating process, and applying a surface coating on at least one side of the fiber bundle (1) by means of a filament deposition of a second resin (91), so that the obtained fiber ribbon has a minimum resin load in relation to the fiber used. (Machine-translation by Google Translate, not legally binding)
    公开号:ES2655497A1
    申请号:ES201630984
    申请日:2016-07-20
    公开日:2018-02-20
    发明作者:Manuel Torres Martinez
    申请人:Manuel Torres Martinez；
    IPC主号:
    专利说明:

    FIBER CONDITIONING PROCESS, INSTALLATION OFFIBER CONDITIONING AND CONDITIONED FIBER TAPE OBTAINED
    Technical sector
    The present invention is related to the conditioning of fibers for obtaining tapes for use in wrapping processes, proposing a process and installation
    10 of fiber conditioning where the conditioned fiber tape obtained has a minimum resin load in relation to the fiber used, due to the application of a first resin by controlled electrostatic deposition and the application of a partial and permeable surface coating of a second resin by means of a spiraling or flocking process.
    State of the art
    The conditioned fiber tapes are obtained from a reinforcement material generally in the form of a bundle of fibers ("tow"), such as carbon fibers or glass fibers, and a cohesion material, such as a resin. The current demand rhythms of the industry have meant that the manual manufacturing of composite parts has been replaced by automatic wrapping processes, such as ATL (“Automated Tape Laying”) or AFP (“Automated Fiber Placement”), in where the fiber bundle must be conditioned to give the fibers enough consistency to avoid damage
    25 or deviations from their orientation in the tape wrapping process.
    Currently, fiber belts are obtained from dry fibers, preimpregnated fibers (prepegs) or semi-preimpregnated fibers.
    30 Dry fibers do not introduce the main resin load in their conditioning process, but the main resin load is applied in the part manufacturing process itself, such as infusion processes or transfer molding processes of resin RTM ("Resin Transfer Molding"). There are several methods for making dry fiber preforms, such as braiding, three-dimensional fabric or sewing, this being
    35 last one that currently provides more compact and adequate results for

    be used in automatic wrapping processes.
    A document describing a dry fiber conditioning process is document US20150375461, which describes a dry fiber material to be used in automatic wrapping processes that contains as a base a layer of unidirectional fibers, to which a thermoplastic veil is added attached at least to one of its faces, achieved either by short fibers, a thermoplastic grid or a porous thermoplastic membrane, in addition to one or two binders, applied in solution, which ensure cohesion.
    The preimpregnated fibers can be both unidirectional and woven fibers, which are preimpregnated with the amount of resin necessary to produce a piece, usually a thermosetting resin, although it can also be a thermoplastic resin. Generally when the resin is thermoset, it is partially cured to facilitate handling of the prepreg fiber, the mixture must be kept in a cold environment to avoid complete crosslinking. Preimpregnated fibers are obtained by a hot melt process, or a solvent immersion process. Hot melting consists of coating the reinforcing material with a thin film of hot resin, then applying pressure and heat to carry out the impregnation of the reinforcing material with the resin. The immersion process consists in dissolving the resin in a solvent bath and immersing the reinforcement material therein, subsequently evaporating the solvent thereof.
    Some documents describing pre-impregnated fiber conditioning processes are for example JP2010260888, which describes a method of manufacturing a pre-impregnated material that prevents the accumulation of air and irregular impregnation, which includes the application of heat and pressure to the material for transfer the resin. JPH09241403 describes a system of deposition of adherent powder on the surface of a prepreg, in order to improve its adhesiveness. JPS61220808 describes a resin deposition system on a ribbon of carbon fibers by electrostatic means, together with a subsequent heating step above the melting temperature of the resin, to form a completely prepreg. JP2007099926 describes a method for producing a prepreg material, using a conductive sheet on one side of the fiber tape and a powder resin loaded on the opposite side of said beam, the resin being deposited between the fiber filaments by electrostatic force to later heat and melt that resin and form, again, a prepreg.
    Semi-impregnated fiber tapes are obtained by applying a resin film on the fibers, but without completely wetting them with the resin until they are subjected to high temperatures and pressures during the manufacturing process of the piece.
    5 Some documents describing semi-impregnated fiber conditioning processesare for example US20110171034, which describes a semi-impregnated material comprising a first layer of thermosetting resin, coated on bothfaces by layers of fibrous reinforcements, one of the layers being coated with a secondresin layer with a certain level of adhesion. JP2012107160
    10 describes a composite material based on a woven fiber that has a matrix in part of thermosetting resin and partly of thermoplastic resin, the latter adhered by electrostatic spinning, and formed by a nonwoven fabric composed of nanofibers. None of these solutions is intended, however, to condition a fiber bundle in a continuous format for the generation of a cohesive dry fiber tape and
    15 conditioned, capable of being used in automatic wrapping processes, and maintaining the capacity of conditioned fiber tape obtained from being introduced in manufacturing processes based on infusion or RTM.
    Object of the invention
    The object of the present invention is a fiber conditioning process, an installation for carrying out the conditioning process, and a conditioned fiber tape obtained by the conditioning process.
    The fiber conditioning process of the invention comprises at least the following steps:
    - continuously supply a fiber bundle, preferably at a speed between 1m / min and 100m / min,
    30 - applying a first resin on the fiber bundle by electrostatic deposition of particles of the first resin, where preferably the amount of the first resin applied is less than 10% of the fiber bundle weight, and where the particles of The first resin preferably has a size between 50 microns and 300 microns, and can be applied on one or both sides of the beam
    35 - fixing the particles of the first resin to the fiber bundle by means of a heating process, which allows the particles to be partially or totally melted,
    - applying a partial and permeable surface coating on at least one face of the fiber bundle by means of a deposition of filaments of a second resin, the thickness of the surface coating being preferably less than 0.2 mm.
    Preferably, the first resin is applied directly on the fiber bundle and the surface coating of the second resin is applied on the fiber bundle with the first resin, however, without altering the concept of the invention, the surface coating of the second resin can be applied directly to the fiber bundle and the
    The first resin can be applied on the fiber bundle with the surface coating of the second resin.
    The process additionally comprises a stage prior to the application of the first and second resin where the width of the fiber bundle is adjusted, the adjustment of the width of the fiber bundle comprising a first sub-stage where the fiber bundle is passed through of first rollers with a concave surface that reduce the width of the fiber bundle and a second sub-stage where the fiber bundle is passed through a second cylindrical surface rollers that are facing and separated from each other to increase the beam width of fibers to a desired value by controlled friction of the beam of
    20 fibers on the second rollers (and additionally on the first).
    The process of the invention additionally also comprises a stage where heat and pressure are applied to the particles of the first resin so that they diffuse in the fiber bundle.
    According to an embodiment of the invention, the surface coating is obtained by depositing molten filaments of the second spiral-shaped resin on at least one face of the fiber bundle and subsequently applying a stream of air over the coated fiber bundle for cooling. .
    According to another embodiment of the invention, the surface coating is obtained by depositing filaments of the second resin by electrostatic deposition on at least one side of the fiber bundle, and subsequently applying heat to the filaments to melt the second resin and stick or diffuse in the fiber bundle and applying a stream of air over the coated fiber bundle for cooling.
    The application of the surface coating, in any of its versions, is intended to provide cohesion to the fiber belt and improve its permeability in the direction parallel to the plane, commonly defined by means of the characteristic parameters of the material k11 and k22.
    Additionally, the process of the invention also comprises a step where through grooves are made in the fiber bundle, said through grooves extending in a direction parallel to the fiber bundle. This stage improves the permeability of the fiber belt in the direction perpendicular to the plane, commonly defined by means of the parameter
    10 characteristic of the material k33, without damaging the mechanical properties of the tape.
    With all this, a fiber conditioning process is obtained that allows to obtain a conditioned fiber tape with improved characteristics with respect to other dry fiber conditioning procedures.
    Description of the figures
    Figure 1 shows a schematic view of a first embodiment of the installation for carrying out the process of the invention.
    Figure 2 shows a schematic view of a second embodiment of the installation for carrying out the process of the invention.
    Figure 3 shows a schematic perspective view of the adjustment unit that regulates the width of the fiber bundle.
    Figure 4 shows a schematic representation of the conditioned fiber tape resulting from the process of the invention.
    30 Figure 5 shows a section of the conditioned fiber tape indicated with reference V-V in Figure 4.
    Detailed description of the invention
    35 Figure 1 shows an example of an installation for carrying out the

    fiber conditioning process of the invention, whereby a dry fiber tape is obtained which is used in subsequent automatic wrapping processes such as ATL ("Automated Tape Laying") or AFP ("Automated Fiber Placement"), or manual curb
    The dry fiber tapes obtained by the process of the invention are formed from a reinforcing material and a fiber cohesion material. As reinforcement material, carbon fibers, glass fibers, basalt fibers, natural fibers or any other material in fibrillar configuration oriented to the manufacture of composite materials are intended to be used, and as a cohesion material it is planned to use thermoplastic resins (co -polyamides, co-polyester, phenoxy, epoxy, or polyurethane resins), or thermosetting resins. Obtaining in any case through the process of the invention fiber belts with a minimum resin load in relation to the fiber used.
    In the sense of the present invention the units of the fiber conditioning installation have been described according to the direction of direction of the fiber bundle (1) represented with arrows in Figures 1 and 2, according to the direction from left to right indicated in these figures.
    The installation comprises means for continuously supplying a fiber bundle.
    (1) throughout the different stages of the conditioning installation, the fiber bundle delivery speed (1) being preferably between 1m / min and 100m / min, without being this limiting value, so that the fiber is it maintains tension throughout the conditioning process preventing ripples.
    Said means comprise a rewinder (2) and a rewinder (3) between which the fiber bundle (1) is supplied, which allow guiding the fiber bundle (1) so that the fibers remain flat and without undulations, thus how to regulate its tension and speed in order to adapt to different fiber formats in addition to varied widths and weights. The unwinder (2) can supply the fibers in "roving" format, or in "tow" format, that is, in the format of a set of unidirectional fiber filaments, for example a total width between 0.25 inches and 50 inches. , without being these limiting values.
    After the unwinder (2), in the direction of direction of the fiber bundle (1), the installation optionally comprises an adjustment unit (4) to regulate the width of the beam

    of fibers (1) and distribute the fibers so that optimum resin reception is achieved in the later stages of the installation.
    In Figure 3 a preferred embodiment of the adjustment unit (4) is observed, which comprises first rollers (41) configured to reduce the width of the fiber bundle (1), and second rollers (42) configured to increase the width of the fiber bundle (1), so that by alternating the operation of the rollers (41, 42), the fiber bundle (1) can be modified to adapt it to different widths and weights.
    The first set of rollers (41) comprises three concave surface rollers, so that the fiber bundle (1) rubs against the concave surface of the rollers (41) reducing its width. At least one roller of the first rollers (41) is motorized, so that by controlling the speed of rotation of at least one motorized roller, the reduction of the fiber beam width (1) can be controlled.
    The second set of rollers (42) comprises two cylindrical surface rollers that are facing and separated from each other, and between which the fiber bundle (1) is passed, so that when the fiber bundle (1) passes between The second rollers (42) produce a friction that reduces the thickness of the fiber bundle (1) and therefore increases its width. Thus, by controlling the separation distance between the second rollers (42) and the speed of rotation of at least one of them, the increase in the fiber beam width (1) can be controlled.
    After the adjustment unit (4) a first resin deposition unit is arranged
    (5) to apply particles of a first resin by electrostatic deposition
    (51) on the fiber bundle (1). The first resin deposition unit (5) has a spray nozzle that is configured to apply the first resin (51) in powder form with particles of a size preferably between 50 microns and 300 microns and an amount of first resin (51 ) less than 10% of the weight of the fiber bundle, for the usual surface weights. Specifically, given a section of the fiber bundle (1), on said section of the fiber bundle (1) an amount of the first resin (51) is applied which is less than 10% of the weight of said fiber bundle section ( one). The size of the particles and the amount of the first resin (51) applied allow optimum diffusion of the first resin
    (51) in the fiber bundle (1) once the particles have been heated at a later stage of the process. Likewise, the percentage of resin used does not affect the final mechanical properties of the fiber tape obtained or the weight of the

    pieces.
    The particles of the first resin (51) are electronegatively charged and sprayed onto an area of the fiber bundle (1) that is grounded, so that said fiber bundle zone (1) becomes an electrically neutral zone which attracts the particles of the first resin (51) negatively charged. Thus, the particles, upon contact with the fiber bundle (1), are retained in the area of the fiber bundle (1) on which they are deposited.
    The spray nozzle used allows to regulate both the intensity and the voltage applied to the particles of the first resin (51), being able to adjust said parameters and optimize the effectiveness of the process depending on the particle size, the distance from the spray nozzle to the beam of fibers (1), as well as other factors that influence the process (such as flow rates and air pressures). On the other hand, by controlling the speed of the fiber bundle (1) through the area of application of the first resin (51), the amount of first resin (51) deposited can be controlled, consequently the resin waste rate is lower. than in other conventional spray application techniques.
    After the first resin deposition unit (5) a heating unit (6), such as microwave, oven with resistors or infrared lamps, is arranged to, in case of using a thermoplastic resin, heat and melt in a controlled manner the resin allowing it to diffuse in the fiber bundle (1), or to, in case of using a thermosetting resin, partially cure the resin. The heating unit (6) can be oriented towards one or both sides of the fiber bundle (1), it is also possible that the heating unit (6) is oriented towards a face of the fiber bundle (1) and in the opposite face of the fiber bundle (1) a reflector is arranged to heat said opposite face of the fiber bundle (1).
    Optionally, a cooling unit (7) can be arranged immediately after the heating unit (6) to obtain controlled cooling of the fiber bundle (1) after heating of the first resin (51).
    Optionally, the installation can also provide a heat and pressure application unit (8) after the heating (6) and cooling (7) units arranged after

    the first resin deposition unit (5). The heat and pressure application unit (8) comprises traction rollers followed by a heating unit that apply heat and pressure to the particles of the first resin (51) to diffuse in the fiber bundle (1). The use of a first thermoplastic resin allows it to be reheated and, together with the pressure of the traction rollers, allows the first resin (51) to penetrate deeper and improve the cohesion of the fiber bundle (1).
    After the heat and pressure application unit (8) a second resin deposition unit (9) is configured to apply a partial and permeable surface coating on at least one side of the fiber bundle (1) by means of a deposition of filaments of a second resin (91). The second resin (91) may be the same or different from the first resin (51).
    The application of a surface coating of the second resin (91) creates a porous coating on the fiber bundle (1) that serves to generate a gap between fiber tapes when applied in subsequent wrapping processes to obtain composite parts, thus improving the permeability of the composite material in the direction parallel to the plane of the fibers by facilitating the flow of resin between tapes during the infusion or RTM process. The surface coating may be arranged on one of the faces of the fiber bundle (1), or on the two faces of the fiber bundle (1).
    According to the embodiment shown in Figure 1, the application of the surface coating is obtained by a spiraling process by depositing molten filaments of the second resin (91) in the form of a spiral or the like. For this, a nozzle is applied that applies the second resin (91) by means of small filaments of molten material, which are rotated to deposit on the fiber bundle (1) forming spirals, thus generating a permeable layer on the beam of fibers (1). The application of the second resin (91) is carried out based on a variable flow rate, adjusting in each case the speed of the fiber bundle (1) and the desired concentration of the second resin. Immediately after the second resin deposition unit (9) a cooling unit (10) is arranged to apply a stream of air on the resin-coated fiber bundle (1), such as for example the application of a stream of air with a “Vortex” type system, which is necessary to handle the fiber belt in subsequent processes, especially when such processes require high speeds.

    Optionally, a heating unit prior to the application of the spiral can be arranged to improve the adhesion of the second resin (91) on the fiber bundle (1), for which the heating unit of the heat and pressure application unit (8) or other additional. (8)
    According to another embodiment shown in Figure 2, the application of the surface coating is obtained by a flocking process by depositing filaments of the second resin (91) by electrostatic deposition. Unlike the electrostatic deposition of the first resin (51), instead of particles of reduced granulometry, resin filaments of thermoplastic material of reduced dimensions are deposited on the fiber bundle (1). In this exemplary embodiment, it is necessary to arrange a heating unit (11) after the second resin deposition unit (9), to melt the filaments of the second resin (91) and fix them to the fiber bundle (1), as well as providing a cooling unit (10) after the heating unit (11) to apply an air stream on the resin-coated fiber bundle (1), such as for example the application of an air stream with a “Vortex” type system, which, as in the spiraling process, is necessary to handle the fiber belt in subsequent processes, and especially for high speeds.
    In the first embodiment of Figure 1, behind the second resin deposition unit (9) and the cooling unit (10), or in the second embodiment of Figure 2, behind the second unit of resin deposition (9), the heating unit and the cooling unit (10), there is a cutting unit (12) configured to make through grooves in the fiber bundle (1), which extend in a direction parallel to the fiber bundle (1).
    Preferably, the cutting unit (12) has a rotating cutting roller with needles or cams arranged according to a triplet distribution to penetrate the fiber bundle (1). Optionally the roller has heating means for working at the adequate temperature On the other hand, the fiber bundle (1) in treatment can also have a cooling stage prior to grooving to achieve optimum results, which can be the cooling unit itself (10) or another cooling unit arranged immediately afterwards.
    The cutting unit (12) allows to generate grooves in the fiber bundle (1) without damaging the

    fibers that form it, generating spaces in the direction parallel to the beam that improve the permeability of the conditioned fiber tape finally obtained in the direction perpendicular to the plane of the fiber bundle (1) that composes it, thus the grooves facilitate the diffusion of the resin through them in the subsequent manufacturing process of the final piece of composite material, by infusion or RTM.
    After the cutting unit (12), and prior to the rewinder (3), optionally a final cooling unit (13) can be arranged to temper the fiber bundle (1) and leave it for final storage in coils that will be subsequently used in the curb processes.
    Preferably, the first resin (51) is applied directly on the fiber bundle (1) and on the fiber bundle (1) with the first resin (51) the surface coating of the second resin (91) is applied, such and as shown in figures 1 and 2, since with this order of application the first resin (51) diffuses better in the bundle of fibers (1) by cohesion, and the second resin (91) allows to improve the cohesion of the set of tapes of fiber conditioned in the subsequent wrapping process. However, it is possible that the surface coating of the second resin (91) is applied directly on the fiber bundle (1) and subsequently the first resin (51) is applied on the fiber bundle (1) coated with the second resin (91).
    Also, preferably the grooves (121) are made on the fiber bundle (1) coated with the first (51) and second resins (91), as shown in Figures 1 and 2, although the grooves (121 ) can be performed before applying the resins (51, 91), between their application, or in the absence of both.
    With all this, by means of the process of the invention, a conditioned and cohesive fiber tape is obtained in the form of dry fiber conditioned with an improved behavior with respect to conventional dry fibers, and which thanks to the application by electrostatic deposition of the first resin (51) and the surface coating of the second resin (91) allows to achieve a fiber tape conditioned and cohesive with a minimum amount of resin with respect to the fiber used.
    As seen in Figure 4, the conditioned fiber tape obtained by the process of the invention comprises a fiber bundle (1) that has been conditioned with particles of the first resin (51) and with a partial and permeable surface coating. of the second resin (91), wherein the particles of the first resin (51) are deposited randomly but homogeneously on the fiber bundle (1) and have a particle size between 50 microns and 300 microns with a lower weight at 10% of the fiber bundle weight, and in
    5 where the surface coating of the second resin (91) has a thickness of less than 0.2mm
    Said particles of the first resin (51), once attached to the fibers that make up the fiber bundle (1) offer cohesion to the whole of the fiber tape and also the ability to
    10 to adhere a fiber tape conditioned with another subsequent tape, by means of heat application in the subsequent wrapping process by AFP, ATL or manual, thus allowing the generation of self-supporting multilayer fiber tapes.
    By adhering the particles of the second resin (91) to the fibers that make up the fiber bundle
    15 (1), permeability is achieved between subsequent conditioned fiber straps in the directions parallel to the plane of the fibers (1), facilitating subsequent infusion or injection processes oriented to form the composite piece.
    The conditioned fiber tape obtained by the process of the invention also has
    20 through grooves (121) in the parallel direction the fiber bundle (1), which have dimensions of between 0.1 mm and 2 mm of equivalent diameter, which achieve a correct permeability of the fiber tape in the perpendicular direction to the fiber bundle (1), and which facilitate the infusion or injection processes necessary to form the piece of final composite material, but without causing a fiber break and with angular distortion
    25 very limited. As can be seen in Figure 4, the grooves (121) are preferably distributed in an aligned manner with respect to the longitudinal direction of the fiber bundle according to a triplet distribution, which allows a better structural integrity of the fiber bundle (1).
    权利要求:
    Claims (9)
    [1]
    1.-Fiber conditioning process, characterized in that it comprises the steps of: - continuously supplying a fiber bundle (1), 5 - applying a first resin (51) on the fiber bundle (1) by electrostatic deposition of particles of the first resin (51), - fixing the particles of the first resin (51) to the fiber bundle (1) by a heating process, and - applying a surface coating on at least one face of the fiber bundle ( 1) 10 by deposition of filaments of a second resin (91).
    [2]
    2. Fiber conditioning process according to claim 1, characterized in that the first resin (51) is applied directly on the fiber bundle (1) and the surface coating of the second resin (91) is applied on the beam of fibers (1) with the first
    15 resin (51).
    [3]
    3. Fiber conditioning process according to claim 1, characterized in that the surface coating of the second resin (91) is applied directly on the fiber bundle (1) and the first resin (51) is applied on the beam of fibers (1) with the coating
    20 surface of the second resin (91).
    [4]
    4. Fiber conditioning process according to any one of the preceding claims, characterized in that an amount of the first resin (51) less than 10% of the weight of the fiber bundle (1) is applied.
    5. Fiber conditioning process according to any one of the preceding claims, characterized in that the particles of the first resin (51) have a size between 50 microns and 300 microns.
    6. Fiber conditioning process according to any one of the preceding claims, characterized in that the surface coating of the second resin (91) has a thickness of less than 0.2 mm.
    [7]
    7. Fiber conditioning process according to any one of the preceding claims, characterized in that the fiber bundle (1) is supplied at a speed between

    1m / min and 100m / min.
    [8]
    8.-Fiber conditioning process according to any one of the claimsabove, characterized in that it additionally comprises a stage prior to application5 of the first (51) and second resin (91) where the width of the fiber bundle (1) is adjusted.
    [9]
    9.-Fiber conditioning process according to the preceding claim, characterized in that the adjustment of the width of the fiber bundle (1) comprises a first sub-stage in which the fiber bundle (1) is passed through first rollers (41 ) with a concave surface 10 that reduce the width of the fiber bundle (1) and a second sub-stage where the fiber bundle (1) is passed through a second roller (42) of cylindrical surface that are facing and separated between yes to increase and adjust the fiber beam width
    (1) by friction.
    15. Fiber conditioning process according to any one of the preceding claims, characterized in that it additionally comprises a stage where heat and pressure are applied to the particles of the first resin (51) to diffuse in the fiber bundle ( one).
    11. Fiber conditioning process according to any one of the preceding claims, characterized in that the surface coating is obtained by depositing molten filaments of the second resin (91) in the form of a spiral or the like on at least one side of the fiber bundle (1) and subsequently applying a stream of air over the coated fiber bundle (1) or equivalent cooling system.
    12. 12. Fiber conditioning process according to any one of claims 1 to 10, characterized in that the surface coating is obtained by depositing filaments of the second resin (91) by electrostatic deposition on at least one side of the fiber bundle, and subsequently applying heat to the filaments to melt the second resin
    30 (91) and fix the fiber bundle (1) and applying a stream of air over the coated fiber bundle (1) or equivalent cooling system.
    [13]
    13.-Fiber conditioning process according to any one of the preceding claims, characterized in that it additionally comprises a stage where they are carried out
    35 through slots (121) in the fiber bundle (1), extending said through slots (121) in a direction parallel to the fiber bundle.
    [14]
    14.-Installation of fiber conditioning for carrying out the process according to any one of the preceding claims.
    15. 15. Conditioned fiber tape obtained according to the method of any one of claims 1 to 13.
    DRAWINGS
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    RU2747940C2|2021-05-17|
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