• 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:
    A method for manufacturing a composite material part (1), comprising the steps of: arranging the long reinforcing fibers (24) and the resin in a preforming tool (16) so as to form a preform (32) of the part (1); heat-shaping this preform (32) in a shaping tool, making sure to contain and organize in the matrix the fibers according to the defined geometry, to obtain the piece; cool the room by keeping it under pressure. The invention applies to the manufacture of structural mechanical parts such as aeronautical or automotive structural parts.
    公开号:FR3032144A1
    申请号:FR1550866
    申请日:2015-02-04
    公开日:2016-08-05
    发明作者:Henri Perrin；Jean Pierre Cauchois；Philippe Mayer；Antoine Bastien；Bruno Kaici；Regis Bigot；Eric Becker；Jean-Marie Risser
    申请人:Setforge Soc Now；
    IPC主号:
    专利说明:

    [0001] The invention relates to a method for manufacturing a piece of composite material, for example a three-dimensional piece or solid, such as a joint or a connecting rod, while giving it a high mechanical strength. BACKGROUND OF THE INVENTION It is known to manufacture composite material parts by incorporating short reinforcing fibers into thermoplastic resin, and by forming the parts in press. With this method, the length of the fibers is limited to twenty or thirty millimeters, because these fibers are randomly oriented in the thermoplastic resin. This method, which is part of the so-called SEC (Sheet Molding Compound) processes, makes it possible to manufacture parts having a fiber density of between thirty and forty percent, in general, which corresponds to loosely charged parts thus having a relatively low mechanical strength. In practice, this method makes it possible to manufacture parts of regular and relatively small thickness, such as fairing or cowling parts for the automotive industry. According to another known method, a plane fabric of reinforcing fibers, which may have a relatively substantial thickness, is impregnated with thermoplastic resin before being installed in a press to be deformed so as to give it a curve. Several elements of this type can be manufactured before being glued to each other by hot stamping.
    [0002] It is for example possible to bring an L-section piece on a flat portion, to produce a three-dimensional piece with a T-section. This process, which was developed by the Carbon Forge company, makes it possible to manufacture pieces with longer fibers. (between fifty and one hundred millimeters), having a higher fiber density (between fifty-five and sixty percent). This method makes it possible to obtain a higher mechanical strength, especially since the orientation of the fibers is substantially controlled instead of being disordered. In practice, this other method makes it possible to manufacture structural parts but having small dimensions, for example one hundred and fifty by one hundred and fifty millimeters, and shapes that must nevertheless be relatively simple. Recently was developed a new method for manufacturing a composite material in a blank having a solid shape and / or three-dimensional, comprising the steps of: - hot place at least one reinforcing fiber strand impregnated with thermoplastic resin in excess amount to constitute a preform of the fabricated part; hot die this preform to give it a desired shape while evacuating the excess resin; - Cool the stamped preform by maintaining it under pressure to form the blank. This process, known from FR-A-2981001, makes it possible to produce a three-dimensional part having a high density of fibers which are oriented along the path used during the winding, which contributes to increasing the mechanical strength while allowing the manufacture of three-dimensional and / or massive pieces. OBJECT OF THE INVENTION The object of the invention is to further improve the mechanical performance of thermoplastic matrix composite material parts. SUMMARY OF THE INVENTION To this end, the subject of the invention is a method for manufacturing a composite material having a solid and / or three-dimensional shape, comprising the steps of: placing the reinforcing fibers and the resin in a preforming tool so as to constitute a preform of the part; the fibers being arranged to extend at least in part according to at least one direction of mechanical stressing of the workpiece; - Hot forming this preform in a shaping tool, making sure to contain the fibers in the tool to get the piece; cool the room by keeping it under pressure. Thus, the stamping operation reinforces the penetration of the resin between the reinforcing fibers without risking a cut in the fibers which would alter the mechanical strength of the part. The fibers extending at least in part according to at least one direction of mechanical stressing of the workpiece are thus arranged and oriented in a predefined geometry to ensure mechanical performance of the workpiece.
    [0003] Other features and advantages of the invention will become apparent on reading the following description of particular and non-limiting embodiments of the invention. BRIEF DESCRIPTION OF THE FIGURES Reference will be made to the accompanying drawings, in which: FIG. 1 is a top view of a double rod manufactured with the method according to the invention; FIG. 2 shows in perspective the winding of a strand; reinforcement fibers around the reliefs of a winding tool for manufacturing the connecting rod of FIG. 1 according to the invention; - Figure 3 is a detail view showing in perspective a winding relief of the tool of Figure 2 in the form of a stud having a shoulder; - Figure 4 is a sectional view showing a possibility of winding a reinforcing fiber strand around a shoulder stud; - Figure 5 is a view showing a face of a stamping tool in which is installed a part being stamped; FIG. 6 is a perspective view of an articulation made with the method according to the invention; - Figure 7 is a partial schematic view of the winding tool used for the manufacture of the preform of the joint, the tool being presented after winding; - Figure 8 is a schematic view, exploded perspective, of this winding tooling; Figure 9 is a schematic exploded perspective view of a stamping tool used for the forging of the joint; - Figure 10 is a sectional view along a vertical plane of this tool, before the forging operation; - Figure 11 is a view similar to that of Figure 10, during the forging operation; Figure 12 is a view similar to that of Figure 10 at the end of the forging operation; - Figure 13 is a view similar to that of Figure 10, a second version of a stamping tool used for the forging of the joint. DETAILED DESCRIPTION OF THE INVENTION The process of the invention is here described in application to the manufacture of two parts, it being understood that these are only two examples of implementation of the process. In the first embodiment, the part to be manufactured is a double rod 1 shown in FIG. 1. The double rod 1 comprises a central bearing 2 oriented along a principal axis AP corresponding to an axis normal to the plane of FIG. , and two lateral arms 3 and 4 oriented transversely extending along an axis AT perpendicular to the axis AP, and which depart from the central bearing 2 in opposite directions. Each arm is terminated by a corresponding bearing, and these lateral bearings, marked by 6 and 7, are oriented parallel to the central bearing 2. Each of the three bearings has a generally cylindrical wall shape with a circular base, the central bearing having a diameter significantly greater than that of the lateral bearings.
    [0004] The arm 3 has a flat wall 9 extending in a plane normal to the main direction AP, that is to say in the plane of Figure 1, and two ribs 11 and 12 bordering the region 9. Each rib is a wall extending perpendicularly to the plane wall 9, and which connects the central bearing 2 to the lateral bearing 6. The two ribs 11 and 12 are located on either side of the transverse axis AT, which in turn passes through the central axis of each of the bearings 2, 6 and 7. The central region 9 has a relatively small thickness relative to the height of the bearings along the main direction AP, while the lateral ribs 11 and 12 each have a height close to the height of the bearings. The double rod 1 has a shape which is symmetrical with respect to a plane normal to the transverse axis AT and containing the main axis AP which moreover coincides with the central axis of the main bearing 2. Thus, the arm 4 is the symmetrical arm 3, so it also includes two ribs of the same type.
    [0005] The double rod 1 is also symmetrical with respect to a plane containing the transverse axis AT and the main axis AP, and it is also symmetrical with respect to a plane normal to the main axis AP and containing the transverse axis AT.
    [0006] This connecting rod is manufactured using the tools shown in FIGS. 2 to 5, namely a preforming tool 16 and a stamping or stamping tool 31. The preforming tool 16 here comprises a plate or sole 13 having a face upper plane 14, this plate being provided with seven winding reliefs which are here pads, identified by the references 17 to 23. More concretely, the pad 17 corresponds to the bearing 6, the pads 18 and 19 correspond to the space between the ribs 11 and 12 of the arm 3, the stud 20 corresponds to the central bearing 2, the studs 21 and 22 correspond to the space between the ribs of the arm 4, and the stud 23 corresponds to the bearing 7. As shown in FIG. 2, a strand 24 of reinforcing fibers impregnated with thermoplastic resin is wound on the preforming tool 16, around the studs 1723, so as to follow a path that delimits at the same time the three bearings or clevises 2, 6, and 7 , and the ribs 11 and 12 of the arm 3 and the corresponding ribs of the arm 4. The fiber strand is arranged to extend in a path coinciding with the directions of stress of the workpiece. The strand 24 of reinforcing fibers may be in various forms: it may be a set of fibers organized parallel to each other or helically; it may also be a set of fibers braided with each other to form a flexible braid extending generally in a main direction, but consisting of spindle fibers oriented in multiple directions. The strand 24 impregnated with thermoplastic resin is wound around the different pads so that, as can be seen in FIG. 2, it completely surrounds the bearing 6 to then pass on the same side of the pads 18 and 19 before changing sides for surround one half of the central block 20 to then return on the same side of the pads 21 and 22 before completely surrounding the second side pad 7 to return in a symmetrical path to the first side pad 6, which corresponds to a turn full. The strand 24 can thus be wound on several turns around the various pads, the number of turns being conditioned by the diameter of the section of the strand vis-à-vis the dimensions of the part to be manufactured. In the example of Figure 2 which is given mainly didactic to understand the trajectory of the strand, it is wound on a turn and a half. As can be seen in the figures, the studs 17 and 23 are shouldered studs: they are studs of revolution comprising a cylindrical base extended by a coaxial stud of smaller diameter than the base. This form of the studs 17 and 23 makes it possible to make bearings or clevises whose inner surface is itself chamfered, that is to say that it comprises two zones having two different diameters. In particular, and as visible in Figures 3 and 4, the strand 24 can be wound on a large number of turns being arranged to form a single circumferential layer 26 around the base of the pad 17, and two circumferential layers concentric 27 and 28 around the upper end of the pad 17 which has a significantly smaller diameter than its base. Thus, different solutions can be envisaged with regard to the winding of the strand on the preforming tool 16, depending on the particularities of shapes that one wishes to obtain in the part to be manufactured. The strand 24 impregnated with thermoplastic resin is wound on the tool 16 hot, so as to have the flexibility required to allow accurate winding. Advantageously, the winding tool is of the heating type, and the winding as such can be achieved by means of a robotic arm.
    [0007] When the winding of the strand 24 is completely finished, it constitutes a preform 32 of the part to be manufactured. This preform is left to cool so that it solidifies in its own shape. When the preform 32 is solidified, it is extracted from the preforming tool 16. As such, the relief elements that constitute the pads 17-23 are advantageously provided retractable relative to the plate 13 which carries them. In this case, the detachment of the preform is obtained by controlling the retraction of the studs 17-23 before grasping this preform 32 to put it in place in the stamping tool 31. The stamping tool 31, shown in FIG. 5 , comprises a plate 33, forming a matrix, in which is machined an impression 34 of the outer shape of the double-rod 1 to be manufactured. This matrix is installed in a press which carries at the end of its cylinder a punch having a shape complementary to the impression. When the preform 32 has been installed in the impression of the stamping tool 31, the stamping cycle can begin. The press is then controlled to bring the punch and the matrix together, until a predetermined pressure is established for a predetermined duration. The matrix and the punch cooperate together in such a way that the resin is contained, i.e. it does not leak from the matrix. It is also ensured that no fiber protrudes from the die during the insertion of the punch to prevent it from being sheared by the punch.
    [0008] This stamping operation is carried out hot: as such, the stamping tool 31 is advantageously provided heating and preheated to heat the preform before the start of the stamping cycle.
    [0009] Stamping can be done in a single operation or in several operations, using different pairs of stamping tools, to gradually reduce the volume of the double rod to be manufactured. For example, a first stamping tool can be used to form a first blank from the preform 32 by stamping it. Once this first blank is finished, this first blank is placed in a second stamping tool, to further reduce its volume and constitute the double rod in the form of a blank The various stamping operations are here carried out at a temperature between one hundred sixty-two hundred degrees Celsius to obtain a softening of the thermoplastic resin.
    [0010] The part is advantageously cooled, at least partially before its transfer from a stamping tool to another stamping tool. After the last stamping operation, it is allowed to cool the tooling as well as the part it contains before demolding. This cooling is performed while maintaining the matrix and the punch under pressure for the duration necessary for the solidification of the thermoplastic resin, which allows to extract from the matrix a double raw rod undeformed.
    [0011] According to the invention, the manufacture of a part having a geometry different from this double rod is ensured with similar tools adapted to this other geometry as will be seen in the second embodiment which will be described in relation with Figures 6 to 12. In this second implementation, the method of the invention is used to achieve the double joint shown in Figure 6 and generally designated 100.
    [0012] The double joint 100 comprises two bearings 101, 102 of central axes parallel and connected to each other by a bridge generally designated 103. The bridge 103 comprises: a first frame 103.1 extending tangentially relative to the bearings 101, 102 and having a width equal to the length of the bearings 101, 102 (said widths and lengths being measured parallel to the central axes of the bearings); a second chord 103.2 spaced apart from the first chord 103.1 and curved towards the first chord 103.1; and a substantially X-shaped third chord 103.3 extending between the bearings 101, 102, the first and second chords 103.1, 103.2. The first frame 103.1 comprises a longitudinal rib 103.11 connecting the two bearings 101, 102.
    [0013] In this second embodiment, a mold, generally designated at 40 in FIGS. 7 and 8, comprising a cavity 45 with the external shape of the preform (referenced 320 in FIG. 10), is used as preforming tooling. cores 41, 42 to form the bearings 101, 102, a core 43 to form the first chord 103.1 (without the rib) and the portion of the third chord 103.3 opposite the first chord 103.1, and a core 44 to form the second chord 103.2 and the portion of the third chord 103.3 opposite the second chord 103.2. In the cavity 45 of the mold 40 is mounted a movable plate 40.1 which slides on the cores and which is in the shape of the preform. The mold 40 is closed by a cover 40.2 which is of the same shape as the plate 40.1 and which enters the cavity 45 of the mold 40. The stamping tool, shown in FIGS. 9 to 12, comprises a matrix 50 comprising a imprint 55 to the outer shape of the preform 320, two cores 51, 52 to form the bearings 101, 102, a core 53 to extend between the first chord 103.1 and the portion of the third chord 103.3 opposite the first chord 103.1, and a core 54 to extend between the second chord 103.2 and the portion of the third chord 103.3 opposite the second chord 103.2.
    [0014] The core 53 comprises a recess 56 to provide a space for the rib 103.11 so as to define one of the lateral surfaces and the extreme edge of the rib 103.11. The die 50 is closed on one side by a bottom 50.1 and on the other by a cover 57 to the outer shape of the preform 320 which partially penetrates into the cavity 55 of the die 50. The lid 57 comprises a portion projection 58 (visible in Figure 10) extending opposite the core 53 to define the other side surfaces of the rib 103.11. The bottom 50.1 and the cores are secured to a plate 59 secured to a plate of a press. The bottom 50.1 slides in the matrix parallel to the central axes of the cores. The lid is secured to a plate mounted on the cylinder of the press.
    [0015] During the manufacture of the preform 320, the fibers are arranged in the imprint 45 of the preforming tool, around the cores 41 to 44, so as to wind around the cores 41, 42 and to extend the along a longitudinal direction of future members 103.1 to 103.3. In this embodiment, the fibers are said to be continuous because they have a length of several times the length of the piece, five to six times the length of the piece. At the beginning of the placement of the fibers, the bottom plate 40.1 is towards the top of the mold 40 and goes down as the thickness of the wound fibers increases. Once the fiber placement is complete, thermoplastic resin is then introduced hot into the mold cavity 40 to fill it before closing the lid. The cover 40.2 is then put in place to slightly compress the assembly. After cooling the resin, the preform 320 is taken out of the mold 40.
    [0016] Both the cover 40.2 and the bottom plate 40.1 are arranged so that there remains a local surplus of thermoplastic resin and fibers on the sides of the first frame 103.1 of the preform 320. Once cooled, the preform 320 is introduced into the tool. stamping which is heated to soften the preform 320 (Figure 10). The cover 57 is applied against the preform so as to reduce the thickness of the preform and bring it to that of the finished part (FIG. 11) and to form the rib (FIG. 12). The aforementioned local surplus of composite material (resin and fibers) is displaced and pushes a portion of the resin and fibers which is in the center of the future first frame towards the space left between the recess 56 of the core 53 and the portion 58 protruding from the cover 56 to form the variant rib of Figure 13, the cores 51, heating means. The die 50 and are thermally insulated from the support plates by insulating plates In the 52 are equipped the cover 56 the thermal press 61, 62 respectively. The placement of the fibers contributes to giving the piece manufactured a significant mechanical strength, in addition to allowing the manufacture of three-dimensional and / or massive parts that can have a complex shape. Generally speaking, the three-dimensional invention has the ability to achieve a high component fiber density of up to fifty-five to sixty-five percent fiber. Preferably, these fibers are in the form of one or more fiber strands used when continuous and oriented along the path of the winding. Long fibers are arranged and oriented to ensure the mechanical performance of the workpiece extending at least in part according to at least one direction of mechanical stress of the workpiece. Concretely, the entire phase of placement of the fibers makes it possible to position and orient the fibers in a state very close to that which they will have in the finished part: the orientation of the fibers can thus be completely optimized with respect to the fibers. technical and mechanical needs of the room. The stamping phase which follows the placement of the fibers makes it possible to obtain a desired geometry with a high degree of precision. Furthermore, it is possible to place an insert in the preform so that it is integrated into the finished part being rigidly secured to the body of the finished part in order, for example, to facilitate the transfer of forces. Such an insert is typically an element of a nature other than the body of the part, such as for example a metal type insert, a sensor, a bearing, a part of assembly or attachment. The method then comprises the step of placing in the preforming tool at least one insert so that the insert is integrated in the material of the preform. For this purpose, the insert or inserts are here arranged in the mold before placement of the fibers. Thus, this manufacturing method makes it possible to manufacture composite material initially made of steel or other parts, to replace them with parts made of composite material having a weight and / or a smaller volume and a comparable mechanical strength according to a load case. given.
    [0017] Note that the forming tool is preferably arranged so that the part obtained has the final geometric characteristics of the part to be manufactured. This makes it possible to limit the machining times to be performed after formatting.
    [0018] Of course, the invention is not limited to the embodiments described but encompasses any variant embodiment within the scope of the invention as defined by the claims. The method according to the invention makes it possible to manufacture parts having complex shapes, extending in three dimensions, and which can also be massive either in localized regions or on the whole of the part. In the first example, the piece is obtained by winding a single strand of fibers. But in the case of a piece of more complex shape, it is quite possible to wind several strands corresponding for example to several parts of the part to be manufactured. In the same embodiment, the reinforcing fibers are pre-impregnated with thermoplastic resin. Alternatively, to make the double rod, one could use dry fibers put in place in a mold tool in which the thermoplastic resin would be introduced later.
    [0019] Conversely, in the second embodiment, dry fibers are used. Alternatively, preimpregnated fibers could be used. The fibers may be of any material capable of mechanically reinforcing the thermoplastic material taking into account the desired performance and especially polyaramid, glass, carbon ... The fibers are long, that is to say they have a minimum length of substantially the order of the length of the piece. The fibers preferably have a length at least substantially equal to an integer multiple - for example two, three, four or more - of the length of the workpiece. Nevertheless, some of the fibers may be short, i.e. less than one length of the blank. Short fibers can be added in addition in certain areas. Fibers having a function other than the reinforcement may also be added to the resin or combined with the reinforcing fibers, and for example optical fibers or any other fibers capable of transmitting a signal. These signal-conducting fibers may, for example, have an end connected to a sensor embedded in the part and an opposite end opening outside the part to be connected to a signal processing unit.
    [0020] The process may comprise the step of compressing the preform before curing the resin to obtain a predetermined fiber volume ratio. The resin may be made of different thermoplastic materials and for example: polypropylene, polyamide, acrylic, polyethylene sulfone (PES polyether ester ketone (PEEK), polyetherketoneketone (PEKK), polyetherimide (PEI). The process may comprise the subsequent step of assembling a plurality of so-called intermediate pieces together to obtain a final piece.
    权利要求:
    Claims (15)
    [0001]
    REVENDICATIONS1. A method for manufacturing a composite material part (1), comprising the steps of: - arranging the long reinforcing fibers (24) and the resin in a preforming tool (16) so as to form a preform (32; 320) the piece (1); the long fibers being arranged to extend at least partly in at least one direction of mechanical stressing of the workpiece; heat-shaping this preform (32; 320) in a shaping tool, making sure to contain the fibers in the tooling to obtain the workpiece; cool the room by keeping it under pressure.
    [0002]
    2. Method according to claim 1, wherein the shaping tool is arranged so that the resulting piece has final geometric characteristics of the workpiece.
    [0003]
    3. Method according to any one of the preceding claims, wherein fibers of different functionalities of the reinforcing fibers are combined with the reinforcing fibers.
    [0004]
    4. Method according to any one of the preceding claims, comprising the step of placing in the preforming tool at least one insert so that it is integrated in the material of the preform.
    [0005]
    5. Method according to any one of the preceding claims, further comprising the step of assembling several pieces.
    [0006]
    The method of any one of the preceding claims, comprising the step of compressing the preform prior to curing the resin to obtain a predetermined fiber volume level.
    [0007]
    A method according to any one of the preceding claims, wherein preforming tooling (16) provided with reliefs for fiber placement is used.
    [0008]
    8. The method of claim 7, wherein the reliefs (17-23) are retractable.
    [0009]
    A method as claimed in any one of the preceding claims, wherein a preforming tooling (16) and a separate forming tool (31) are used, and wherein the preform (32) is cooled before being transferred. from the preforming tool to the tooling layout.
    [0010]
    10. A method according to any one of the preceding claims, wherein the fibers are pre-impregnated with resin before being put into place in the preforming tool.
    [0011]
    11. A method according to any one of claims 1 to 9, wherein the fibers are dry when they are put into place in the preforming tool.
    [0012]
    The method of any of the preceding claims, wherein the fibers have a length at least greater than or equal to an integer multiple of a length of the workpiece.
    [0013]
    13. A process according to any one of the preceding claims, wherein the relative amounts of fibers and resin are selected to achieve a fiber volume ratio of about 65% in the piece.
    [0014]
    14. A method according to any one of the preceding claims, wherein the preforming tool comprises a lower platen (40.1) slidably mounted in a fiber-receiving indentation, the lower platen (40.1) being upwardly disposed imprint at the beginning of the winding and descending as the thickness of the wound fibers increases.
    [0015]
    15. Method according to any one of the preceding claims, wherein, during preforming, a local surplus of material is provided in an area of the preform so as to form by displacement of material during forming a rib in another place in the room.
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    同族专利:
    公开号 | 公开日
    FR3032144B1|2017-01-27|
    EP3053734A1|2016-08-10|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    DE2945469A1|1979-11-10|1981-05-21|J.F. Rieleder GmbH & Co KG, 7100 Heilbronn|Textile element for flexible drive shaft coupling - has series of interleaved figure=of=eight thread coils forming flexible disc|
    US20110186212A1|2010-02-01|2011-08-04|Toyota Jidosha Kabushiki Kaisha|Method for molding continuous fiber prepreg part|
    FR2981001A1|2011-10-06|2013-04-12|Arts|Method for manufacturing three-dimensional composite material e.g. aeronautical structural part, involves stamping preform to provide desired form, and cooling stamped preform by maintaining stamped preform under pressure along with blank|WO2018229437A1|2017-06-13|2018-12-20|Conseil Et Technique|Method for producing a composite material part, and composite part obtained|
    EP3808546A1|2019-10-17|2021-04-21|Setforge Société Nouvelle|Method for manufacturing a part in a press with lockable-height tool|
    DE102017221235A1|2017-11-28|2019-05-29|Bayerische Motoren Werke Aktiengesellschaft|Fiber composite body and method for producing a fiber composite body|
    法律状态:
    2016-02-18| PLFP| Fee payment|Year of fee payment: 2 |
    2016-08-05| PLSC| Publication of the preliminary search report|Effective date: 20160805 |
    2017-02-17| PLFP| Fee payment|Year of fee payment: 3 |
    2018-02-23| PLFP| Fee payment|Year of fee payment: 4 |
    2020-02-19| PLFP| Fee payment|Year of fee payment: 6 |
    2021-02-24| PLFP| Fee payment|Year of fee payment: 7 |
    2022-02-16| PLFP| Fee payment|Year of fee payment: 8 |
    优先权:
    申请号 | 申请日 | 专利标题
    FR1550866A|FR3032144B1|2015-02-04|2015-02-04|PROCESS FOR MANUFACTURING PARTS OF COMPOSITE MATERIAL|FR1550866A| FR3032144B1|2015-02-04|2015-02-04|PROCESS FOR MANUFACTURING PARTS OF COMPOSITE MATERIAL|
    EP16154139.6A| EP3053734A1|2015-02-04|2016-02-03|Method for manufacturing parts in composite material|
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