• 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:
    Modular cover for molding tool. A modular cover is provided to cover a molding tool, the cover comprising a plurality of sheets configured to engage each other in such a way as to cover at least a portion of the surface of the molding tool, fixing means configured to fix the plurality of sheets with respect to the molding tool, wherein each of the plurality of sheets comprises at least one coating of reflective material. A system and a method for the manufacture of a structural element is further provided. (Machine-translation by Google Translate, not legally binding)
    公开号:ES2785423A1
    申请号:ES201930299
    申请日:2019-04-02
    公开日:2020-10-06
    发明作者:Rodelgo Alvaro Jara；Castro Jesús Javier Vazquez；Sanchez Pablo Vazquez
    申请人:Airbus Operations SL；
    IPC主号:
    专利说明:

    [0002] OBJECT OF THE INVENTION
    [0004] The present invention is directed to a cover that allows covering tools used for the shaping of preforms and / or the curing of composite material that is subjected to a thermodynamic cycle, for example a mold used as part of an RTM system.
    [0006] This invention is also directed to a system and method that make it possible to minimize thermal losses through the border of the mold in contact with the atmosphere and to improve the thermal control of the process.
    [0008] BACKGROUND OF THE INVENTION
    [0010] In the industry for the production of composite materials, there are numerous manufacturing processes that are chosen based on different parameters such as the mechanical characteristics to be obtained, the nature of the reinforcing material or the polymeric material used, or the associated cost. to said manufacturing process, among others. Due to the delicate nature of the materials used and the demanding requirements imposed both in tolerances and in service behavior, a wide range of systems and tools are used, such as vacuum bags, autoclaves, presses, or molds, among others.
    [0012] For the production of the composite material, it is subjected to a thermodynamic cycle by applying pressure and temperature for curing the polymeric material. Due to this, as a general rule, the tooling used must be compatible and adapt to said thermodynamic cycle while ensuring the best thermal and dimensional stability conditions for said production process.
    [0014] The choice of the manufacturing material for the tooling used will be a compromise solution that will be determined taking into account its manufacturing cost, the coefficient of thermal expansion, the possibility of receiving surface treatments. with products to facilitate the detachment of the composite material once the polymeric material has cured, the behavior and response to a machining process if necessary, the useful life, or the thermal conductivity, among others. Generally, metallic materials are good candidates to be used as a base for the manufacture of such tooling.
    [0016] In particular, one of the most widespread composite material manufacturing methods in the industry due to its versatility in order to obtain composite material structures with relatively complex geometries is known as RTM (Resin Transfer Molding). In it, a preform of reinforcing material, normally carbon fiber or fiberglass to which a certain structure is provided (for example through a method known as hot forming), is located inside a mold where subsequently a polymeric material will be injected, generally a thermosetting resin.
    [0018] With regard to the preparation of the preforms, for example in the case of those composed of carbon fibers that are provided in the form of laminates, it is necessary to apply a previous hot molding process to adapt them to the final shape that you want them to have. once introduced into the mold.
    [0020] For this, in the industry metal structures are used, generally made of steel alloys, which are heated by means of resistances distributed on a surface of said structure, so that the heat progresses towards the interior of the structure, generating a gradient that transfers thermal energy to the preform located in the structure. Due to the high thermal inertia of the steel alloys used, it is very complex to control and maintain the correct temperature throughout the cycle. Additionally, there is a very high loss of thermal energy due to contact of the metallic structure with the external atmosphere, which drastically increases the energy expenditure necessary to carry out said cycle, reducing the efficiency of the process.
    [0022] Likewise, once the desired preform has been obtained, and after its insertion into the mold to carry out the RTM process, there is the same problem associated with the tools and metal structures used during the application of the thermodynamic cycle. In other words, when heat is applied to the mold where the resin is injected, for its curing by means of, for example, electrical resistances, a large part of that heat is lost through the border of the mold in contact with the outside atmosphere. Thus, control over desired temperature is much less fine than would be desired. Likewise, the efficiency of the process is drastically reduced, resulting in high energy costs with its associated particular problems, which may be, among others, a greater environmental impact.
    [0024] DESCRIPTION OF THE INVENTION
    [0026] The present invention proposes a solution to the above problems by means of a modular cover for a molding tool according to claim 1, a system for the manufacture of a structural element according to claim 5, and a method of manufacturing a structural element according to claim 12. Preferred embodiments of the invention are defined in the dependent claims.
    [0028] Throughout this document the term "thermodynamic cycle" will be used. By this term it will be understood the application of both temperature and pressure on the element that is considered at that moment. To develop said thermodynamic cycle, use will be made of both "heating means" that will be responsible for developing the corresponding "thermal cycle", as well as "pressure means" that will be in charge of applying the necessary pressure to develop the desired thermodynamic cycle.
    [0030] A first inventive aspect provides a modular cover for a molding tool, the cover comprising:
    [0031] - a plurality of sheets configured to engage each other to cover at least a portion of the surface of the molding tool,
    [0032] - fixing means configured to fix the plurality of sheets with respect to the molding tool,
    [0033] wherein each of the plurality of sheets comprises at least one covering of reflective material.
    [0035] Advantageously, the modular cover according to the invention avoids the leakage of a large part of the thermal energy generated in the typical processes involved in the production of composite material comprising reinforcing material, such as carbon fiber, embedded in a polymeric material, such as a thermosetting resin.
    [0037] In particular, the cover prevents most of the thermal energy generated to the processes of forming the preform of reinforcing material and curing the composite material is lost as heat through the border of the mold in contact with the outside atmosphere. More particularly, the cover facilitates control of the thermal process, as will be described later.
    [0039] In techniques such as RTM, in a stage prior to the injection of polymeric material and its subsequent curing, it is necessary to provide the reinforcing material with a certain structure, called preform.
    [0041] Conventionally, the reinforcing material is provided in sheets or sheets, and it is necessary to apply a thermal process to be able to mold it to obtain said preform. Typically, for carbon fiber, temperatures on the order of 65 ° C are used. Said thermal process consists of placing the reinforcement material in a metal mold that will provide it with the final shape and transfer the thermal gradient necessary for forming.
    [0043] As previously described, much of the thermal energy imparted to the metal mold to maintain the reinforcing material at the required temperature leaks through the mold surface in contact with the outside atmosphere.
    [0045] Likewise, once the preform is obtained, it is introduced into another metal mold that will receive inside the injection of polymeric material, such as thermosetting resin and will provide the final shape to the composite material structure, as well as the thermal gradient necessary for the curing of said polymeric material. As was the case during the stage of forming the reinforcement material preform, this process presents large energy losses in the form of heat through the border of the mold in contact with the outside atmosphere.
    [0047] The modular cover according to the first inventive aspect is provided as a shield at said interface or border of the molding tool with the outside atmosphere.
    [0049] Thanks to the coating of reflective material that comprise the sheets that make up the cover, thermal energy is prevented from escaping by radiation and / or convection, and it is favored to be concentrated in the molding tool.
    [0051] Furthermore, there are many additional advantageous effects. On the one hand. When deleting in With practically all the energy losses, the amount of total energy required to carry out the shaping or curing processes is reduced, which results in greater process efficiency.
    [0053] As a consequence of requiring less energy to develop the thermal cycle, the thickness of the molds used can be reduced, as well as that of the elements that act to apply pressure to the resin, such as a press. Therefore, the total weight and cost of the systems used is considerably reduced.
    [0055] Likewise, the implementation of the invention in the RTM process described has a lower environmental impact, derived directly from said drastic reduction in energy input to control the temperature at which the material is subjected within the required ranges.
    [0057] In this line, the control of the energy supplied and the adjustment of the temperature at which the material is, as well as its maintenance, are more effective, by concentrating the thermal energy inside the molding tool, minimizing the effects of thermal inertia that condition temperature regulation due to large losses.
    [0059] Therefore, both the design of the heating means that are responsible for generating the required thermal energy and the mode of operation thereof will be simpler and more efficient. For example, installing electrical resistances that communicate pulses to regulate the temperature. The number of pulses and their intensity, when a fine control of the temperature is required, will be less.
    [0061] Also advantageously, the modular structure made up of different sheets, gives the roof great versatility and adaptability to the different geometries on which it is integrated. In addition, said modular structure makes it possible to select, in case of not wanting to completely cover the tool being operated on, which specific areas are provided with the benefits of thermal insulation, which results in greater versatility and variety of thermal processes.
    [0063] In a particular embodiment, the fixing means comprise at least one screw.
    [0065] In a particular embodiment, the fixing means comprise at least one latch.
    [0066] In a particular embodiment, each of the plurality of sheets comprises at least one sheet of metallic or polymeric material.
    [0068] Advantageously, the possibility of configuring different types of sheets depending on the sheets that make them up, their materials, and their thickness, will make it possible to select in what way and in what proportion the emission of thermal energy is allowed to the atmosphere outside the molding tool. Likewise, the presence of sheets of polymeric or metallic material in the outermost layer of the sheets that comprise the modular cover will facilitate their handling and protect the coating of reflective material.
    [0070] In particular, in a preferred configuration, the sheet comprises at least one metal foil of low thickness (<3 mm), together with at least one coating of reflective material, preferably of a thickness of around 0.5 mm. This embodiment presents an optimal behavior against energy losses, obtaining with that thickness of reflective material up to 97% reduction in losses. Also, due to the presence of at least one metal foil, this configuration offers optimal behavior against the thermal cycles induced in the areas in contact with the heating means, for example electrical resistances, avoiding the degradation of the materials involved. Furthermore, said at least one metallic foil provides rigidity and resistance against impacts.
    [0072] Advantageously, due to the use of the aforementioned thickness ranges, normally the relative weight increase of the tool when incorporating a modular cover according to this embodiment is below 1%.
    [0074] In an embodiment that incorporates polymeric instead of metallic sheets, the relative weight increase of a tool when incorporating a modular cover system according to the thicknesses of this embodiment is even less, being below 0.5%.
    [0076] In a second inventive aspect, a system is provided for the manufacture of a structural element comprising:
    [0077] - a molding tool comprising:
    [0078] • a mold configured to receive a starting material, and
    [0079] • heating means to apply a thermal cycle to the starting material within the mold, and
    [0080] - a modular cover according to any of the embodiments of the first inventive aspect.
    [0082] In a particular embodiment, the system additionally comprises:
    [0083] • injection means for injecting polymeric material inside the mold, and
    [0084] • pressure means for applying pressure to the polymeric material comprised within the mold.
    [0086] In a particular embodiment, the pressure means comprise a press.
    [0088] In a particular embodiment, the modular cover comprises a sheet configured to cover the pressure means. Advantageously, it is thus avoided that the thermal energy generated for the application of the thermal process escapes towards the external atmosphere through the surface of the pressure means in contact with said external atmosphere.
    [0090] In a particular embodiment, the plurality of sheets is in contact along their surface with the surface of the mold.
    [0092] In a particular embodiment, the heating means for applying a thermal cycle to the polymeric material comprise a plurality of resistors. Said resistors will preferably be located on the sides of the mold. Advantageously, the modular cover will be able to cover said heating means, thus helping to concentrate all the thermal energy generated by them inside the space delimited by the cover and, therefore, avoiding its loss. Likewise, it will protect said heating media from damage caused by interactions with external or internal elements of the system.
    [0094] In a third inventive aspect, a method of manufacturing a structural element is provided comprising the following steps:
    [0095] a) provide a system according to any of the embodiments of the second inventive aspect, and a starting material,
    [0096] b) place the starting material inside the mold,
    [0097] c) covering at least a portion of the outer surface of the mold with the modular cover, and
    [0098] d) applying a thermal cycle to the material contained in the mold.
    [0100] In a particular embodiment, the starting material is a reinforcing material and the structural element is a reinforcing material preform. Said starting material can be carbon fiber. Advantageously, in a hot forming process to obtain a carbon fiber preform as described above, the loss of thermal energy in the form of heat will be avoided thanks to the implementation of a stage in which the system is covered with a cover. modular according to any of the particular embodiments of the first inventive aspect.
    [0102] In a particular embodiment, the starting material is a reinforcing material preform, the structural element is a composite material element, the method additionally comprises injecting polymeric material inside the mold, and the thermal cycle is applied to the reinforcing material preform. reinforcement and polymeric material contained in the mold. Advantageously, in a composite material curing process to obtain a structural element by RTM as described above, the loss of thermal energy in the form of heat will be avoided thanks to the implementation of a stage in which the system is covered with a cover modular according to any of the particular embodiments of the first inventive aspect.
    [0104] In a particular embodiment, the system comprises pressure means, and the method additionally comprises applying pressure to the material contained in the mold, as well as covering at least a portion of the outer surface of the pressure means with the cover before applying the thermodynamic cycle. temperature and pressure.
    [0106] All features and / or method steps described herein (including claims, description, and drawings) may be combined in any combination, except combinations of such mutually exclusive features.
    [0108] DESCRIPTION OF THE DRAWINGS
    [0110] These and other characteristics and advantages of the invention will become more apparent from the detailed description that follows of a preferred embodiment, given solely by way of illustrative and non-limiting example, with reference to the accompanying figures.
    [0112] Figures 1a-c In these figures a first embodiment of the cover according to the invention is illustrated, in which the plurality of sheets partially cover a molding tool.
    [0114] Figures 2a-c In these figures a second embodiment of the cover according to the invention is illustrated, in which the plurality of sheets completely cover the lateral surface of an RTM mold.
    [0116] Figure 3 This figure illustrates a section of the cover located at a distance from the surface of the molding tool, and its operating mechanism is schematically represented.
    [0118] DETAILED EXHIBITION OF THE INVENTION
    [0120] Figures 1a-c show a schematic example of putting into service an embodiment of the modular cover (1) according to the invention, in which said cover (1) is fixed on a heated mold (2.1) for the shaping of reinforcing material preforms.
    [0122] In particular, figure 1a shows a metal mold (2.1) used for the shaping of reinforcing material preforms, for example carbon fiber, by applying temperature to said reinforcing material.
    [0124] In this embodiment said mold (2.1) has a quadrangular prism structure. The mold (2.1) has a groove on its upper base formed by bars (2.2) of square section that extend parallel to the longitudinal axis of the body of the mold (2.1). Said bars (2.2) comprise on their inner face thermoelectric resistances that impart heat to them. In turn, the bars transfer this heat to the reinforcing material to allow the reinforcement material to be molded into a preform with the final shape that is desired.
    [0126] Due to the conductivity and thermal emissivity of the metal body of the mold (2.1), a large part of the heat generated will be communicated to the atmosphere outside the mold (2.1) through the surface of the mold that is not in contact with the mold material. reinforcement.
    [0128] In figure 1b an example of a modular cover (1) is shown in a decoupled configuration, that is, the different sheets (1.1, 1.2, 1.3) that make up the cover (1) are separated from each other and with respect to the mold (2.1). . Said cover (1) is geometrically designed to couple to the mold (2.1) shown in figure 1a. For this, said modular cover (1) is composed of said sheets (1.1, 1.2, 1.3), which in this case have three types of geometries to allow their adjustment and coupling to a specific surface of the mold (2.1) each. Thus, the lateral sheets (1.1, 1.2) will be structurally coupled to the lateral surfaces of the mold (2.1), and the upper sheet (1.3) has a geometry destined to be structurally coupled with the grooves that make up the bars (2.2) present in the upper base of the mold body (2.1). The cover could include additional sheets to cover the other side surfaces of the mold (2.1).
    [0130] Figure 1c shows the example of a modular cover (1) shown in figure 1b in a configuration coupled to the mold (2.1) of figure 1a. For this, the sheets (1.1, 1.2, 1.3) are connected to each other by means of latches (3), and fixed with respect to the mold (2.1), completely covering the upper surface of the mold and partially the lateral surface of the same.
    [0132] The sheets (1.1, 1.2, 1.3) that constitute the exemplary embodiment of the modular cover (1) shown comprise a coating of reflective material (1.1.1) that prevents part of the heat generated to apply the thermal cycle that the material requires. The reinforcement for its shaping escapes towards the outside of the mold through the surface of the mold (2.1).
    [0134] Thus, essentially all the thermal energy generated by the thermoelectric resistors present on the inside surface of the bars (2.2) located at the upper base of the mold body (2.1) will be concentrated inside the cover (1).
    [0136] Figures 2a-b respectively show an example of a molding tool (2) for RTM and a modular cover (1) composed of different sheets (1.1, 1.2, 1.3, 1.4) configured to cover the lateral surface of said mold (2.1) once the sheets (1.1, 1.2, 1.3) are coupled to each other, fixing their position with respect to the system mold RTM. Figure 2c shows a commissioning example illustrating a system for curing composite material by RTM comprising a molding tool (2) and a cover (1) as shown in Figures 2a and 2b.
    [0138] In particular, figure 2a shows schematically an example of a molding tool (2) for RTM that comprises a metal mold (2.1) to house a preform of reinforcing material and receive inside the injection of polymeric material, such as a thermosetting resin. Furthermore, on the upper surface of said molding tool (2) a pressure means (2.3) in the form of a press is shown. The molding tool (2) also comprises heating means (2.2) in the form of thermoelectric resistors, which are attached and distributed on the outer lateral surface of the mold (2.1).
    [0140] Figure 2b shows an example of a modular cover (1) according to the invention composed of four sheets (1.1, 1.2, 1.3, 1.4) with different geometries. Said sheets (1.1, 1.2, 1.3, 1.4) are shown disconnected from each other and not fixed with respect to the molding tool (2). Said cover (1) is geometrically designed to engage the lateral surface of the mold shown in figure 2a. For this, the sheets (1.1, 1.2, 1.3, 1.4) that make up said modular cover (1) present in this case four types of different geometries to allow their adjustment and coupling to the lateral surfaces of the mold (2.1). Likewise, the sheets (1.1, 1.2, 1.3, 1.4) have indentations to allow the fitting of the thermoelectric resistors (2.2) located on the lateral surface of the mold (2.1).
    [0142] Figure 2c shows the example of a modular cover (1) shown in figure 2b in a configuration coupled to the mold (2.1) of the molding tool (2) for RTM shown in figure 2a. The sheets (1.1, 1.2, 1.3, 1.4) cover the entire lateral surface of the mold (2.1).
    [0144] The cover (1) could include a fifth sheet to cover the press (2.3) of the molding tool (2), thus further reducing the leakage of thermal energy towards the outside of the mold (2.1).
    [0146] Figure 3 schematically illustrates the operating mechanism of the present invention. Thus, a portion of a mold section (2.1) is observed, from whose surface in contact with the outside atmosphere flow lines (100) are born that represent the part of thermal energy generated for the thermal curing or molding process that escapes to the outside of the mold and, therefore, is not used, assuming an energy loss and a decrease in the performance of the process.
    [0148] Said flow lines (100) are reflected back towards the mold (2.1) after their contact with the reflective material coating (1.1.1) comprised in the section shown of one of the plurality of sheets (1.1) comprising the modular cover (1) of the invention.
    [0150] In this embodiment, the sheet (1.1) of the cover (1) comprises a sheet (1.1.2) of metallic or polymeric material adhered to the covering of reflective material (1.1.1). In the figure, the residual thermal energy of the thermal process that is lost through said sheet (1.1.2), communicated to the atmosphere outside the mold, is represented schematically by the flow line (200).
    权利要求:
    Claims (15)
    [1]
    1. - Modular cover (1) for molding tool (2), the cover (1) comprising:
    a plurality of sheets (1.1, 1.2, 1.3) configured to engage each other to cover at least a portion of the surface of the molding tool (2),
    fixing means (3) configured to fix the plurality of sheets with respect to the molding tool (2),
    where
    Each of the plurality of sheets (1.1, 1.2, 1.3) comprises at least one covering of reflective material (1.1.1).
    [2]
    2. - Cover (1) modular according to claim 1, wherein the fixing means (3) comprise at least one screw.
    [3]
    3. - Modular cover (1) according to any of the preceding claims, wherein the fixing means (3) comprise at least one latch.
    [4]
    4. - Modular cover (1) according to any of the preceding claims, wherein each of the plurality of sheets (1.1, 1.2, 1.3) comprises at least one sheet (1.1.2) of metallic or polymeric material.
    [5]
    5. - System for the manufacture of a structural element comprising:
    - a molding tool (2) comprising:
    • a mold (2.1) configured to receive a starting material,
    • heating means (2.2) to apply a thermal cycle to the initial material included inside the mold (2.1), and
    - a modular cover (1) according to any of the preceding claims.
    [6]
    6. - System according to claim 5, further comprising:
    • injection means for the injection of polymeric material inside the mold (2.1), and
    • pressure means (2.3) to apply pressure to the polymeric material comprised inside the mold (2.1).
    [7]
    7. - System according to claim 6, wherein the pressure means (2.3) comprise a press.
    [8]
    8. - System according to claim 7, wherein at least one sheet of the plurality of sheets (1.1, 1.2, 1.3) is in contact along its surface with the surface of the press (2.3).
    [9]
    9. - System according to any of claims 5 to 8, wherein the heating means (2.2) comprise a plurality of electrical resistances.
    [10]
    10. - System according to any of claims 5 to 9, wherein at least one sheet of the plurality of sheets (1.1, 1.2, 1.3) is in contact along its surface with the surface of the mold (2.1).
    [11]
    11. - System (4) according to any of claims 5 to 10, wherein the plurality of sheets (1.1, 1.2, 1.3) completely covers the surface of the mold (2.1).
    [12]
    12. - Manufacturing method of a structural element that comprises the following stages:
    a) provide a system (4) according to any of claims 5 to 11, and a starting material,
    b) place the starting material inside the mold (2.1),
    c) covering at least a portion of the outer surface of the mold (2.1) with the modular cover (1), and
    d) applying a thermal cycle to the material contained in the mold (2.1).
    [13]
    13. - Manufacturing method according to claim 12, wherein the initial material is a reinforcing material and the structural element is a reinforcement material preform.
    [14]
    14. - Manufacturing method according to claim 12, wherein:
    the starting material is a preform of reinforcing material,
    the structural element is a composite material element,
    the method additionally comprises injecting polymeric material inside the mold (2.1), and
    the thermal cycle is applied to the reinforcement material preform and the polymeric material contained in the mold (2.1).
    [15]
    15.- Manufacturing method according to claim 14, wherein:
    the system comprises pressure means (2.3), and
    the method further comprises:
    apply pressure to the material contained in the mold (2.1), and
    covering at least a portion of the outer surface of the pressure means (2.3) with the modular cover (1) before applying the thermal cycle and applying pressure.
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    同族专利:
    公开号 | 公开日
    ES2785423B2|2021-02-25|
    EP3950287A1|2022-02-09|
    WO2020201602A1|2020-10-08|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    US5002476A|1989-11-24|1991-03-26|Lockheed Corporation|Tooling for composite parts|
    WO2012046246A1|2010-10-08|2012-04-12|Gosakan Aranvamudan|Manufacturing a composite|
    WO2015071844A1|2013-11-12|2015-05-21|Bombardier Inc.|Radiant curing system and method for composite materials|
    法律状态:
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    优先权:
    申请号 | 申请日 | 专利标题
    ES201930299A|ES2785423B2|2019-04-02|2019-04-02|MODULAR COVER FOR MOLDING TOOL|ES201930299A| ES2785423B2|2019-04-02|2019-04-02|MODULAR COVER FOR MOLDING TOOL|
    EP20783531.5A| EP3950287A1|2019-04-02|2020-04-01|Modular cover for a moulding tool|
    PCT/ES2020/070215| WO2020201602A1|2019-04-02|2020-04-01|Modular cover for a moulding tool|
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