• 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:
    Manufacturing process of reinforced structures and structure obtained, wherein the process comprises arranging a structural mold, applying a first coating of composite material (1) on the structural mold, applying first structural reinforcements of composite material (2) directly on the first coating (1) by means of a rewind technique of composite material, apply a second coating of composite material (5) on the assembly formed by the first coating (1) and the first structural reinforcements (2), apply heat to the assembly formed by the first lining (1), the first structural reinforcements (2) and the second lining of composite material (5) until completely cured. (Machine-translation by Google Translate, not legally binding)
    公开号:ES2725897A1
    申请号:ES201830306
    申请日:2018-03-28
    公开日:2019-09-30
    发明作者:Martinez Manuel Torres
    申请人:Torres Martinez M；
    IPC主号:
    专利说明:

    [0001]
    [0002]
    [0003]
    [0004] Technical sector
    [0005]
    [0006] The present invention is related to the sector of composite materials, proposing a method of manufacturing structures with reinforcements that remain integrated forming a single piece with said structure. Also the object of the invention is the structure obtained by said method, applicable in multiple sectors such as the wind sector or the land and air transport sector.
    [0007]
    [0008] State of the art
    [0009]
    [0010] The manufacture of structures from composite materials has more and more prominence, standing out from the rest of the sectors, the aeronautical, the automobile and the wind. The reason lies in the characteristics of this material, where the mechanical properties of the fiber are comparable to those of metals but with the advantage of having a lower weight. In applications where the need to reduce the weight of the structure for economic and operational reasons is crucial, there is an increasing commitment to carbon fiber and glass element manufacturing solutions.
    [0011]
    [0012] The main problem is the automation of the manufacturing process, since the treatment of fiber composite materials is complex, but it is necessary since the manipulation of the same manually increases the possibility of errors due to the human factor. .
    [0013]
    [0014] Currently, the manufacture of large elements, such as the fuselage of an airplane, the cars of a train or the body of a vehicle, must be done in parts, subsequently having to use a large number of rivets, stringers and reinforcement rings for the union of the parts.
    [0015]
    [0016] A solution is needed that allows the automated manufacturing of large structures with a revolution core that integrates the necessary reinforcements to ensure integrity of the structure without the need to use external reinforcing or joining elements.
    [0017]
    [0018] Object of the invention
    [0019]
    [0020] The invention relates to a method of manufacturing structures and reinforcements that remain integrated in the structure. The invention is of preferential application in the sectors of air and land transport, both by road and rail, or sectors such as wind, sectors where the development of large light structures is more relevant. Also object of the invention is the structure directly obtained from said process.
    [0021]
    [0022] The method of manufacturing reinforced structures of the invention comprises:
    [0023]
    [0024] - arrange a structural mold,
    [0025] - applying a first composite coating on the structural mold, - applying first structural reinforcements of composite material directly on the first coating using a composite rewind technique, - applying a second composite coating on the assembly formed by the first coating and the first structural reinforcements,
    [0026] - Apply heat to the assembly formed by the first coating, the first structural reinforcements and the second composite coating until completely cured.
    [0027]
    [0028] In this way a reinforced structure of composite material formed by the cohesion of all the components that comprise it is obtained. The structure obtained allows eliminating or at least reducing the need for rivets as much as possible, since it is not necessary to assemble different parts to complete the structure. This entails not only a significant reduction in weight, time, and manufacturing costs, but also an expedited certification process.
    [0029]
    [0030] Optionally, before applying the first structural reinforcements and / or before applying the second coating of composite material, partial or total curing is performed by heat application. Thus, heat can be applied to partially or completely cure the assembly formed by the first coating and the structural mold, and / or heat can be applied to partially or totally cure the assembly formed by the first coating, the first reinforcements and the structural mold.
    [0031]
    [0032] Preferably, a second structural reinforcements of composite material are manufactured in the geometries where a winding process on the first coating is not feasible, and the second structural reinforcements already manufactured are applied on the first composite coating. The manufacturing of the second structural reinforcements is carried out by means of a rewind process similar to that used for the manufacture of the first reinforcements but on an external mold or frame instead of on the first coating.
    [0033]
    [0034] Optionally, before applying the second coating of composite material, partial or total curing is carried out by heat application of the assembly formed by the first coating and the structural reinforcements.
    [0035]
    [0036] Structural reinforcements are manufactured by rewinding multiple layers of composite material by wrapping a given geometry. It is a unidirectional material tape that, by rotating the entire piece or a geometric reference frame, is stacked in a certain number of layers until the desired material thickness is reached.
    [0037]
    [0038] Within a preferred embodiment of the invention, these layers may be based on carbon fiber, fiberglass, or a mixture of both, using a material for a number of layers and the other for the rest. The process can work with dry fiber and an infusion stage or with prepreg material, both with thermosetting and thermoplastic resins, or even using a hybrid material, with reinforcing filaments and thermoplastic resin filaments.
    [0039]
    [0040] Preferably, before applying the second coating, a filling foam is applied as an additional reinforcement component, so that the spaces existing between the structural reinforcements are filled with a low density material that lightens the weight of the structure finally obtained.
    [0041]
    [0042] Preferably, polishing is performed on the filler foam and structural reinforcements to obtain a uniform surface on which to apply the second coating.
    [0043]
    [0044] The composite materials used in the manufacture of the structures are a material in dry fiber format that is impregnated with resin through an infusion process, or they are a material in fiber format pre-impregnated with resin, the material being cured in fiber format applying heat at a temperature less than or equal to the curing temperature of the resin until a curing reaction progress of at least 40% is achieved in the case of using thermosetting resins. In the case of using thermoplastic resins, the temperature is raised until a melt of the material sufficient to achieve the required properties is achieved.
    [0045]
    [0046] The curing or fusion of the materials by means of a process at temperature can be carried out after each of the indicated manufacturing stages, or carried out jointly after the total or a set of them. Similarly, when using thermosetting resins, curing of the intermediate components can be complete or partial, and be completed separately or in a joint process with several components at the same time.
    [0047]
    [0048] Optionally, the structural mold can remain integrated as part of the structure, or it can be removed after obtaining the structure.
    [0049]
    [0050] With all this, the invention results in a structure manufactured as a single piece, with reinforcement components integrated in the manufacturing, thus avoiding practically all the additional rivets and joining systems between components, of very low weight and low manufacturing costs thanks to the great automation of the process and the reduction of direct labor necessary, reducing in turn the problems derived from manual labor and increasing productivity with respect to the current state of the art.
    [0051]
    [0052] Description of the figures
    [0053]
    [0054] Figure 1 shows a perspective view of the reinforced structure of the invention after the application of the first composite coating on the structural mold.
    [0055]
    [0056] Figure 2 shows a perspective view of the reinforced structure of the invention with the first coating, and the first structural reinforcements positioned on the first coating.
    [0057]
    [0058] Figure 3 shows a perspective view of the reinforced structure of the invention with the first coating, the first structural reinforcements and the second structural reinforcements that are positioned in doors, windows and areas that require additional reinforcement.
    [0059]
    [0060] Figure 4 shows a perspective view of the reinforced structure of the invention with the first coating, the first and second structural reinforcements and the low density foams positioned on the surface of the structure in areas where there are no reinforcements of any kind.
    [0061]
    [0062] Figure 5 shows a perspective view of the reinforced structure of the invention with the second outer covering over the whole assembly.
    [0063]
    [0064] Figures 6 to 9 show, from left to right and from top to bottom, a succession of sectional views of the elements that form the reinforced structure according to a preferred embodiment of the invention, adding a new layer per figure.
    [0065]
    [0066] Figures 10 to 14 show the manufacturing process of a reinforced structure of cylindrical configuration, such as for example the plane fuselage section.
    [0067]
    [0068] Detailed description of the invention
    [0069]
    [0070] The invention relates to a method of manufacturing reinforced structures, which can be used as aircraft fuselages, train cars, car bodies, satellite shuttle rockets, or structures with similar requirements.
    [0071]
    [0072] The figures show an exemplary non-limiting embodiment of the process of the invention applied to obtaining a reinforced structure for use in means of transport that benefit from weight reduction such as aeronautical transport, road transport or Rail transport, especially high speed.
    [0073] First, the process of the invention comprises arranging a structural mold on which a first composite lining (1) is applied. Then as shown in Figure 2 on the first coating (1), first structural reinforcements of composite material (2) are applied, the reinforcements (2) being applied by a composite rewind technique
    [0074]
    [0075] The reinforcements (2) can be applied using a fiber wrapping head, where preferably for the application the head is fixed being the rotational structural mold, or even simpler rewind and pressure application systems. The head may have some displacement in the axial direction of the component to generate these reinforcements (2) with a slight deviation in the orientation of the fibers, offering better properties in that direction.
    [0076]
    [0077] The first structural reinforcements of composite material (2) are arranged transversely to the longitudinal section of the structural mold and function as structural reinforcing frames of the structure.
    [0078]
    [0079] Independently, that is to say in an isolated process, a second structural reinforcements of composite material (3) are manufactured, also manufactured by a technique of rewinding composite material. These second structural reinforcements (3) are not applied directly by rewinding on the first coating (1), but once manufactured they are arranged on the first coating (1), as shown in Figure 3.
    [0080]
    [0081] The second structural reinforcements of composite material (3) are arranged on the first lining (1) in areas of the structure that must be reinforced, so that they are preferably used to function as frames for doors or windows of the structure finally obtained. .
    [0082]
    [0083] The composite rewind technique with which both the frames (3) for reinforcement of doors and windows are manufactured, as well as the reinforcements (2) of frames type, is based on a rewind of strips of composite material on a piece or structure with a desired geometry. In the case of the frames (3) they are rewound on a door or window-shaped mold that will then be removed and, in the case of the frames (4), it is rewound directly on the structure once it has been applied the first coating (1).
    [0084] In both cases, the material adapts to said geometry through the rewind process, and it is wrapped generating a stack of successive layers until a certain required thickness is reached.
    [0085]
    [0086] Preferably, strips of composite material with unidirectional continuous fibers are used so that, when stacking several layers, the orientation of the fibers is always the same and the reinforcement has a single direction, that required by the structure in each case, although said orientation It can have a slight component in the axial direction, similar to the result of a winding. The fibers used can be carbon fiber, fiberglass, or a combination of both that allows to generate a non-uniform laminating along the thickness.
    [0087]
    [0088] In a preferred application, the second structural reinforcements (3) are arranged on the first coating (1) without curing them, and the assembly formed by the first coating (1) and the structural reinforcements (2,3) is subjected to the application of heat to obtain a partial or total cure of it. In another application, the first coating (1) is initially cured and then the structural reinforcements (2,3) are cured on said first coating (1). In any case, a total or partial cure can be performed after one or all steps of the procedure, that is, a total or partial cure can be performed after applying the first coating (1), and / or after applying the first structural reinforcements (2), and / or after applying the second structural reinforcements (3).
    [0089]
    [0090] According to another example of the invention, the second structural reinforcements (3) are partially or totally cured, and independently, before being arranged on the first coating (1) and subsequently the assembly formed by the first coating (1) and the structural reinforcements ( 2,3) undergo heat application to obtain partial or total cure of the whole.
    [0091]
    [0092] After curing of the first coating (1) and structural reinforcements (2,3), whether partial or complete curing, a filler foam (4) is applied on the first coating (1) covering spaces between reinforcements structural (2,3), so that the filling foam (4) allows to lighten the weight of the structure finally obtained. Preferably a low density foam is used, such as for example a density between 80kg / m3 and 300kg / m3.
    [0093] Preferably after the application of the filler foam (4) a polishing is performed to obtain a uniform surface of the filler foam (4) and the structural reinforcements (2.3).
    [0094]
    [0095] Subsequently, on the assembly formed by the first coating (1) and the structural reinforcements (2,3), a second coating of composite material (5) is applied, and then heat is applied until the assembly is completely cured, so that a composite structure where the structural reinforcements (2,3) are directly integrated into the structure.
    [0096]
    [0097] According to another example of the invention, the first coating (1) and the structural reinforcements (2.3) remain uncured until the application of this second coating (5), at which time they are jointly subjected to the application of heat to obtain a total cure of the whole.
    [0098]
    [0099] If the structure to be obtained has a geometry from which the structural mold is easily removable, a relatively open geometry at least from one of its ends as shown in the figures, a single piece structural mold is used which will be subsequently extracted after the manufacture of the structure. In this case, a metal structural mold is preferably used.
    [0100]
    [0101] If, on the contrary, the geometry of the structure is more complex and the extraction of the mold is complicated, especially geometries with a certain taper at both ends that makes it difficult to extract complete molds, a structural mold of composite material is used that will become part of the structure and, therefore, it will not be necessary to extract. Preferably, said structural mold is formed by segments and is partially cured when applied to the first coating so that, when the entire assembly is finally cured, it will be integrated into the structure.
    [0102]
    [0103] According to an example of the invention, the composite material used is in dry fiber format, so that the dried fiber is impregnated with resin through an infusion process and is partially cured by applying heat at a temperature below the curing temperature of the resin until a percentage of progress of the curing reaction is achieved between 40% and 80%. The composite material can also be completely cured, applying heat to the curing temperature of the resin during the time required by the specific type of resin used.
    [0104]
    [0105] According to another example of the invention, the composite material used is in a prepreg fiber format, where the fiber is partially cured by applying heat at a temperature below the curing temperature of the resin until a percentage of advance of the curing reaction is achieved. between 40% and 80%. The prepreg fiber can also be fully cured, applying heat in this case to the resin curing temperature for the time required by the specific type of resin used.
    [0106]
    [0107] The composite material used in the coatings (1,5), in the frames (3) or in the reinforcements (2) can be any type of composite material, some non-limiting examples being carbon fiber, glass fiber, hybrid materials with thermoplastic resins, or combinations of any of them. Preferably carbon fiber will be used in areas where the reinforcement should be greater.
    [0108]
    [0109] In the case of using thermosetting resins, the assembly formed by all of the components that make up the structure is completely cured by applying heat to the resin cure temperature until a 100% cure reaction progress is achieved. In the case of using thermoplastic resins, the necessary temperature will be applied to reach the melting point required by the resin to ensure proper structural cohesion.
    [0110]
    [0111] The reinforced structure obtained by the process of the invention thus comprises internal (1) and external (5) composite coverings, frames (2) and integrated composite frames (3), and low density foams (4) to complete the structure and lighten it.
    [0112]
    [0113] Additionally, if a structural mold formed by joining segments instead of a removable one is used, it will also be integrated into the final reinforced structure. Said mold may have internal frames that are generated by the joining of segments due to internal shapes that the segments themselves have. The external frames (2), previously described and obtained by the rewind technique, will be more numerous than the internal frames generated by the segments and will provide greater reinforcement since, since the internal frames are dispensable, the structural mold segments will be great length so the joints will be scarce.
    [0114]
    [0115]
    [0116] Figures 1 to 5 show the manufacturing process of a rectangular structure, while Figures 10 to 14 show a manufacturing process identical to that described for Figures 1 to 5 but applicable to a cylindrical structure instead of rectangular which could be, for example, an airplane fuselage section.
    权利要求:
    Claims (11)
    [1]
    1. - Procedure for manufacturing reinforced structures, characterized in that it comprises:
    - arrange a structural mold,
    - applying a first composite coating (1) on the structural mold, - applying first structural reinforcements of composite material (2) directly on the first coating (1) by a composite rewind technique,
    - applying a second composite coating (5) on the assembly formed by the first coating (1) and the first structural reinforcements (2),
    - Apply heat to the assembly formed by the first coating (1), the first structural reinforcements (2) and the second composite coating (5) until completely cured.
    [2]
    2. - Method of manufacturing reinforced structures, according to claim 1, characterized in that before applying the first structural reinforcements (2) and / or before applying the second coating of composite material (5), a partial curing or Total by heat application.
    [3]
    3. - Process for manufacturing reinforced structures, according to any one of the preceding claims, characterized in that a second structural reinforcements of composite material (3) are manufactured and the second structural reinforcements (3) already manufactured are applied on the first coating of composite material (1).
    [4]
    4. - Process for manufacturing reinforced structures, according to the preceding claim, characterized in that the structural reinforcements (2,3) are manufactured by rewinding multiple layers of composite material.
    [5]
    5. - Manufacturing process of reinforced structures, according to claim 3 or 4, characterized in that before applying the second coating of composite material (5) a partial or total curing is carried out by heat application of the assembly formed by the first coating (1) and structural reinforcements (2,3).
    [6]
    6. - Process for manufacturing reinforced structures, according to any one of the preceding claims, characterized in that a filler foam (4) is applied before applying the second coating (5).
    [7]
    7. - Process for manufacturing reinforced structures, according to the preceding claim, characterized in that a polishing is performed on the filler foam (4) and structural reinforcements (2,3) to obtain a uniform surface on which to apply the second coating (5).
    [8]
    8. - Process for manufacturing reinforced structures according to claims 6 or 7, characterized in that the filling foam (4) used has a density between 80kg / m3 and 300kg / m3.
    [9]
    9. - Process for manufacturing reinforced structures, according to any one of the preceding claims, characterized in that the composite materials used in the manufacture of the structures are a dry fiber format material that is impregnated with resin through a process of infusion, or they are a material in fiber format preimpregnated with resin, the material in fiber format being cured by applying heat at a temperature less than or equal to the curing temperature of the resin until a percentage of advance of the cure reaction of at minus 40% in the case of using thermosetting resins, or raising the temperature until a melt of the material sufficient to achieve the required properties is achieved in the case of using thermoplastic resins.
    [10]
    10. - Process for manufacturing reinforced structures, according to any one of the preceding claims, characterized in that the structural mold is removed.
    [11]
    11. - Structure obtained by the method defined according to any one of the preceding claims.
    one
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    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
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    JPH1016085A|1996-07-04|1998-01-20|Mitsubishi Heavy Ind Ltd|Manufacture of fuselage skin of airplane|
    EP2433780A1|2010-09-28|2012-03-28|Eurocopter Deutschland GmbH|Improved automated manufacturing process for high performance composite material part|
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    GB1490575A|1974-12-02|1977-11-02|Pikaz Inzenyrsky Podnik|Body for a road or rail vehicle or for a container|
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    HU225708B1|2002-06-21|2007-06-28|Nabi Gyarto Es Kereskedelmi Kf|Body particularly for bus made of fibre reinforced plastic|
    US7204951B2|2002-07-30|2007-04-17|Rocky Mountain Composites, Inc.|Method of assembling a single piece co-cured structure|
    JP4820804B2|2007-11-16|2011-11-24|国立大学法人九州大学|Deep sea exploration vehicle pressure vessel|
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    法律状态:
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    优先权:
    申请号 | 申请日 | 专利标题
    ES201830306A|ES2725897B2|2018-03-28|2018-03-28|PROCEDURE FOR MANUFACTURING REINFORCED STRUCTURES AND OBTAINED STRUCTURE|ES201830306A| ES2725897B2|2018-03-28|2018-03-28|PROCEDURE FOR MANUFACTURING REINFORCED STRUCTURES AND OBTAINED STRUCTURE|
    CN201910242132.8A| CN110315772A|2018-03-28|2019-03-28|The manufacturing method of reinforcement structure and structure obtained|
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