• 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:
    The invention relates to a method for producing, by hot stamping, a composite piece with continuous fiber reinforcement in a thermoplastic matrix, characterized in that it comprises the steps of: a. providing a blank (160) comprising a ply laminate consisting of unidirectional webs (110) of prepreg fibers of a thermoplastic polymer; b. heating the blank (160) in the open air at a temperature greater than or equal to the melting point of the polymer constituting the matrix; vs. stamp the blank (160).
    公开号:FR3016314A1
    申请号:FR1363575
    申请日:2013-12-24
    公开日:2015-07-17
    发明作者:Julie Vaudour；Alexandre Pelard
    申请人:Daher Aerospace SAS；
    IPC主号:
    专利说明:

    [0001] The invention relates to a method and a device for stamping an unconsolidated thermoplastic matrix composite blank. The invention is more particularly, but not exclusively, adapted to obtain a shaped composite part, reinforced by continuous fibers of carbon, glass or aramid in a thermoplastic matrix, with mass reinforcement rates included between 50% and 70%, or less. Thus, the invention is more particularly adapted to the aeronautical field but is advantageously adaptable to other technical fields in which the requirements in terms of structure and reliability are similar. According to the prior art, a shaped thermoplastic matrix composite part is obtained by hot stamping a consolidated laminated composite blank. When the reinforcing phase of said composite consists of continuous fibers, forming the blank by stamping involves an interlaminar slip of the plies constituting the lamination of said composite. This interlaminar slip is only possible if the matrix of said composite is in a sufficiently fluid state during the embossing operation. This state is obtained by heating the blank, prior to stamping, at a temperature above the melting temperature of the polymer constituting the matrix of this composite. When this polymer is a high performance thermoplastic polymer such as a polyetheretherketone, or PEEK, this heating temperature is high, usually between 350 ° C and 440 ° C. This temperature must be reached throughout the volume of the blank, to allow the sliding of the continuous fiber folds, and to avoid the introduction of tension in the fibers, dewatering between the fibers and fiber undulation, these defects having disastrous consequences on the mechanical characteristics of the part thus obtained. Thus, it is generally accepted and observed experimentally that the blank subject of this stamping operation must be free from defects such as porosities. In fact, according to the experimental findings of the prior art, the presence of an air gap in the stratification, even over a short distance, creates a lack of temperature uniformity at heating, a defect which is reflected in a point fixation between the folds or the fibers concerned, which fixing point locally opposes interlaminar sliding.
    [0002] In addition, this air knife collects degassing products during heating of the blank and will not be closed during stamping. Thus, according to the prior art, the process for using a thermoplastic matrix composite material by stamping, on the basis of the fact that any porosity present in the blank will be present in the final piece resulting from the stamping of this blank. Thus, the embossing method according to the prior art is implemented by means of blanks cut out in panoplie in a consolidated plate, particular care being taken in the production of said plate, which is subject to controls as well. severe than on the final part, which increases the cost of parts obtained by this method of the prior art. WO 2013/127965 describes a method for obtaining such a consolidated plate. The consolidation of a composite comprising a matrix consisting of a thermoplastic polymer comprises three phenomena: an essentially mechanical phenomenon, which under the effect of the pressure and the viscosity of the polymer tends to create an intimate contact between the plies; an essentially chemical phenomenon called self-adhesion, which causes adhesion of the folds between them by the diffusion of the molecular segments through the interface and then the entire thickness of the folds; - A phenomenon of polymer flow, sometimes called impregnation, and which allows to fill the closed voids remaining in the material. FR 2 987 304 discloses a method of hot stamping a composite material with continuous reinforcement, using a blank in a so-called pre-consolidated state, obtained by placing fibers and a partial self-adhesion between the plies, c that is to say an adhesion of the folds to each other over their entire contact interface, with no gap at the interface, the molecular chain segments of the polymer constituting the diffusing matrix on a very limited thickness between the folds, on either side of the interface. This state is distinguished from the so-called consolidated state, where self-adhesion is important, the molecular chains of the polymer constituting the matrix extending and intermingling throughout the thickness of the folds. Although this method provides an improvement over the prior art, it nevertheless requires to achieve an even higher level of blank quality, with a porosity of less than 1%. Also, since the process is carried out at a high temperature, that is to say at a temperature above the melting point of the material, the impregnation phenomenon occurs and makes it possible to achieve this low level of porosity. Document FR 2 922 276 describes a process for obtaining a shaped part, using an assembly of unconsolidated folds. This method is not a stamping process, it is a process similar to a molding, the unbound assembly of folds undergoing a complete cycle of cooling heating, including its consolidation, within a closed mold whose cavity is drawn to vacuum. The productivity of such a process is modest compared to the stamping process.
    [0003] The invention aims at solving the drawbacks of the prior art and for this purpose concerns a process for producing, by hot stamping, a composite piece with continuous fiber reinforcement in a thermoplastic matrix, which process comprises the steps of : at. obtaining a blank comprising an unconsolidated layering of plies consisting of unidirectional sheets of fibers preimpregnated with a thermoplastic polymer; b. heating the blank in the open air at a temperature greater than or equal to the melting temperature of the polymer constituting the matrix; vs. stamp the blank.
    [0004] Thus, surprisingly and contrary to the certitudes of those skilled in the art; the exclusive use of unidirectional webs for the constitution of the folds allows direct stamping of the blank thus formed, unconsolidated, even in the absence of any assembly of the folds between them, without creating defects in the piece thus obtained. The terms "unconsolidated" refer to both a stack of folds free of any adhesion between the folds, an assembly of folds or the adhesion between the folds is discretely distributed in the volume of the blank, leaving macroscopic areas where the folds are not assembled together at all, and the case where the folds adhere to each other over all their contact interfaces, but at least one of the three phenomena making it possible to achieve the consolidation does not occur so that there remains a high porosity rate in the blank. The blank is heated in the open air, that is to say that the method which is the subject of the invention does not require the vacuum of the stack constituting the blank to be drawn out and is implemented, from the point of view of stamping, under the same conditions as the stamping of a consolidated blank according to the prior art. The term "prepreg" for thermoplastic fibers is here used in the sense of thermoplastic locks calendered with a polymer film, powdered with a thermoplastic polymer or comprising thermoplastic fibers co-mixed with the reinforcing fibers. In all cases, the reinforcing fibers themselves are not impregnated or only partially impregnated with this polymer. This type of product corresponds to the products actually commercially available under the improper name of prepreg. The invention is advantageously implemented according to the embodiments described below which are to be considered individually or in any technically operative combination. According to a particular embodiment of the method which is the subject of the invention, step a) comprises a step of assembling the folds by welding spots. Thus, the cohesion of the blank before its stamping is improved. The limitation of the assembly of the plies together at soldering points makes it possible to retain the surprising effect. According to another particular embodiment of the method which is the subject of the invention, each fold consists of strips assembled edge to edge by a weld. This embodiment makes it possible to easily obtain blanks of large width, in particular which comprise fibers oriented in oblique directions, by giving said blank 15 sufficient cohesion so that it can be handled without risk of disorienting said strips. According to a third embodiment, the method which is the subject of the invention comprises, before step a), a step consisting in: d. selecting, for constitution of the matrix, a thermoplastic polymer having a recrystallization temperature between the glass transition temperature, Tg, and the melting temperature, Tf, of said polymer; step a) comprising a step of: ai. draping the plies, in the form of pre-impregnated strips, by means of a drapering machine comprising a means of heating said strip, during the removal, the heating temperature being lower than the melting point of the polymer and greater than the recrystallization temperature. This embodiment, including a selection of the characteristics of the polymer constituting the matrix, makes it possible, under specific conditions, to assemble the plies together over their entire contact surface and to produce a blank by automatic draping means. Thus, a crude, in the form of a large plate, is obtained economically, and, although it is not consolidated, or even partially consolidated, the cohesion of said crude allows the realization of blanks of complex shapes for example, by clipping. Alternatively the blank is obtained directly by layering wide strips or by automatic placement of fibers. In the latter case, the method that is the subject of the invention makes it possible to better respect the orientation of the fibers with respect to the outline of the blank, in particular for curved pieces. Said crude or said blank are produced economically without a consolidation step. The heating of the strips deposited under the conditions of the method which is the subject of the invention makes it possible to confer on said strips sufficient tackiness for automatic draping, without consolidation of the folds. According to a second surprising effect, the combination of the selection of the material and the use of a reduced assembly temperature of the unidirectional strips during draping, makes it possible to obtain a part free from defects in direct stamping, that is, that is, without a consolidation step between draping and stamping.
    [0005] Advantageously, step d) comprises the steps of: performing differential scanning calorimetry analysis of the prepreg; dii. selecting said prepreg if the result of said differential scanning calorimetry results in heating an exothermic peak between the glass transition temperature and the polymer melting temperature. Thus, a simple method of characterization makes it possible to verify the adaptation of the prepreg to the successful implementation of the method that is the subject of the invention in its embodiments comprising a continuous assembly of the folds or strips constituting the folds. According to the invention, the temperature at which the exothermic peak occurs is called the "recrystallization temperature", such a recrystallization phenomenon being the most likely to explain the presence of such an exothermic peak on the calorimetric heating analysis curve, without to be bound by any theory.
    [0006] According to a particular embodiment, the polymer constituting the matrix is a semi-crystalline polyetheretherketone whose crystallinity level at room temperature is between 5% and 20%. This particular selection of the polymer constituting the matrix, compatible with steps di) and dii) of the method that is the subject of the invention, makes it possible to considerably reduce the cost of obtaining a high performance composite part. Advantageously, when the polymer is a PEEK, step a1) is carried out at a temperature of between 200 ° C. and 330 ° C., preferably 250 ° C. In addition to the advantages described above, this draping with heating at low temperature makes it possible to improve the quality of the blank or the crude, while avoiding the phenomena of oxidation of the PEEK during draping. According to a particular embodiment of the method which is the subject of the invention, step a) is carried out by stacking the folds on a so-called transfer tool, comprising means for positioning and maintaining the folds on their periphery. This embodiment allows the creation of a stamping blank from unassembled folds and thus completely eliminates the step of the prior art of making a consolidated crude.
    [0007] Advantageously, the transfer tool is a frame in step b) being performed while the folds stacked during step a) are on said frame. According to an alternative embodiment, the transfer tool comprises a polyimide film, the folds being assembled and held on said film by an adhesive tape on their periphery. This embodiment is particularly simple to implement.
    [0008] The invention is explained below according to its preferred embodiments, in no way limiting, and with reference to FIGS. 1 to 3, in which: FIG. 1 schematically shows an embodiment of the method which is the subject of the invention, implementing a unidirectional strip assembly, illustrated in Figure 1A in a view from above, heating the stack thus produced, illustrated in Figure 1B in a sectional view AA defined in Figure 1A, and a stamping shown in Figure 1C in a sectional view AA; FIG. 2 represents an example of differential thermal analysis curves performed on two thermoplastic prepregs; - And Figure 3 is a schematic perspective and exploded view of an example of assembly of unidirectional bands on a transfer tool consisting of a polyimide film, according to an embodiment of the method object of the invention.
    [0009] FIG. 1A, according to an exemplary embodiment of the method that is the subject of the invention, strips (110), constituted by unidirectional fiber sheets pre-impregnated with a thermoplastic polymer, are placed on a tool (100), called a transfer frame. Said tooling comprises a support frame on which are fixed plates (101), each of these plates having means (105) for positioning, for example, in the form of a finger projecting from said plate (101). ). Each band (110) unidirectional comprises one or more lights (111, 112) adapted to cooperate with said means (105) positioning. The unidirectional strips (110) individually have sufficient rigidity to be so placed manually or via an automatic means, for example a pick and place robot equipped with a suction cup, on said frame (100). ). A stack of unidirectional folds is thus obtained without neither the folds nor the bands being linked together. 1B, according to an exemplary embodiment, the frame (100) is used as a transfer frame 15 and the stack thus produced, constituting the blank (160) for stamping, is placed under heating means (120), for example, radiant panels. Said heating means carry the blank (160) at a temperature higher than the melting temperature, Tf, of the thermoplastic polymer. By way of non-limiting example, if said polymer is a PEEK, this heating temperature reaches 440 ° C. 1C, after this heating step, the blank (160) is embossed by deforming it between a die (150) and an effector (not shown) of complementary shape to that of the die (150) so as to constitute a piece in shape. The piece thus obtained is, surprisingly, free from defects. 3, according to an alternative embodiment, the strips (310) of unidirectional layers 25 are placed on a temperature-resistant polyimide film (300) obtained during the stamping process, and which is used as transfer tooling. According to this embodiment, said strips (310) are simply held on their periphery on said film (300), by means of adhesive tapes (305), adapted to the process temperature of the process. The heating operation prior to stamping and the stamping operation itself are carried out while the strips (310) are on the polyimide film (300) according to techniques known from the prior art.
    [0010] Without being bound by any theory, it is assumed that the use of unidirectional belts and the absence of continuous assembly between the folds makes it possible to evacuate the gases and the air during the expansion of the polymer during heating and during the stamping. This embodiment is suitable when the blank is of sufficiently small dimensions, or its shape is simple, so that the positioning of unidirectional webs of strips is achievable with a reduced number of positioning means. In other cases, an assembly of the folds or strips, is necessary. According to one embodiment, an assembly of the folds is achieved by welding points. This embodiment makes it possible to pre-assemble the folds constituting the blank according to the thickness of said blank. This spot welding is easily performed on the transfer tooling or outside said tooling, by means of a soldering iron capable of locally bringing to its melting temperature the polymer pre-impregnating the fibers. These weld points give the blank a certain cohesion which makes it possible to manipulate it outside the transfer tooling, without losing the advantages of the method that is the subject of the invention. According to another alternative embodiment compatible with the previous one, the strips (110, 310) are welded edge to edge by means of weld lines (140, 340). These weld lines extend over a small width on either side of the edges of the strips in contact and are obtained, for example, by means of a soldering iron capable of carrying the polymer pre-impregnating the strips (110, 310 ) at its melting temperature.
    [0011] Alternatively, said welding is performed by other means known from the prior art, for example, by means of laser beam heating. When the blank comprises a complex trimming that requires it to be cut in a blank, or when the piece form requires that the lamination be obtained by placing fibers, so that the fibers are properly oriented at all points relative to this form, or when the blank is large, said blank or blank are preferably obtained by automatic draping. Throughout the text, the term "draping" is understood to mean draping strips and placing fibers, the essential conditions for carrying out these methods being similar in the context of the invention.
    [0012] According to a third embodiment of the method which is the subject of the invention, the crude is produced by draping and assembling strips and plies between them. This draping is performed by automatic or manual removal of strips of width between 3 mm and 305 mm (12 "), which strips are assembled together over the entire surface of their interfaces .The removal of narrow strips (3 mm for example) is preferably obtained by means of a machine or robot capable of placing fibers, in the case of wide strips these are deposited by means of a draping machine or manually. surprisingly, to obtain a defect-free part, without going through a crude consolidation step This result is obtained by combining the three following implementation conditions: the draping is implemented by means of strips made of unidirectional fibers - the thermoplastic polymer impregnating the fibers comprises a recrystallization temperature between the glass transition temperature and the melting temperature; The heating of the strips during the deposition is greater than the recrystallization temperature and lower than the melting temperature, Tf, of the fiber-impregnating polymer. The heating of the pre-impregnated strips of a thermoplastic polymer is essential during draping. Indeed, said strips are not tacky, and must be heated to adhere to the already deposited preform. According to the prior art, machines capable of automatically draping fibers pre-impregnated with a thermoplastic polymer use for this purpose heating at a temperature equal to or greater than the melting temperature of said polymer. Thus, in the case where this polymer is a PEEK, whose melting temperature is 343 ° C., this heating temperature during removal, according to the prior art, is typically 400 ° C. or more. In the case of the method which is the subject of the invention, the heating temperature during removal is, according to an exemplary embodiment, limited to 250 ° C for a PEEK pre-impregnated strip. This low temperature does not produce the melting of said polymer. Thus, on the one hand, the impregnation phenomenon does not occur and there remains porosity in the assembly, on the other hand the molecular diffusion at the interface is slowed down and therefore does not allow the phenomenon of self-adhesion . However, this low temperature heating gives the strip, or the region of the strip thus heated, a stickiness sufficient to adhere to the preform. Without being bound by any theory, it is assumed that the adhesion between the folds occurs by the co-crystallization of the amorphous phases of the polymer, on either side of the interface. This co-crystallization is obtained by recrystallization on heating the polymer. This surprising possibility of limiting the heating temperature during the removal and then making a stamping from an unbound blank, while ensuring the quality of the material of the final piece, is verified only by using webs consisting of unidirectional fiber webs and selecting a thermoplastic polymer showing a recrystallization peak between its glass transition temperature and its melting temperature.
    [0013] Figure 2, differential scanning calorimetry is a characterization technique known from the prior art. It makes it possible to measure the enthalpy change of the material during its heating and consists of heating two samples, one consisting of the material to be tested and the other of a control material. Both samples are heated in two separate furnaces maintaining a zero temperature difference between the two samples. The plot gives the heat flux (202) between the two samples as a function of the temperature (201). The appearance of a peak in this evolution testifies to the presence of a phase transition involving a latent heat of transition. Depending on the nature of the phase transition, said peak (232, 242) is pointed downwards, it is said to be "endothermic", or pointed upwards, it is then called "exothermic". The plot of the differential calorimetric analysis curve (230) corresponding to a prepreg of PEEK carbon fibers having a tau of crystallinity of 30% at room temperature, shows, on heating, a first (233) disturbance of the curve corresponding to the passage of the glass transition temperature (210) (Tg), then a peak (232) endothermic at the temperature (220) of melting (Tf) of the polymer. The plot of the differential calorimetric analysis curve (240) of a carbon-PEEK prepreg in which the PEEK has a degree of crystallinity of between 5% and 20% at ambient temperature, makes the heating appear a first perturbation (243). corresponding to the passage of the glass transition, Tg, then an exothermic peak (241), before the endothermic melting peak (242). This exothermic peak (241), occurring on heating, is interpreted as a recrystallization peak. The temperature (245) substantially centered on said exothermic peak (241) is said recrystallization temperature because it occurs on heating, the material being initially in the crystallized state. The material whose path (230) does not show such a peak (241) recrystallization, that is to say, according to this example, the prepreg of a PEEK whose crystallinity at room temperature is greater than 20 ° / (:), is not adapted to the embodiments of the method which is the subject of the invention, which implement an assembly of unidirectional webs of strips over their entire contact surface, that is to say, essentially, a removal of the strips by an automated draping means. On the other hand, the material whose path (240) of the calorimetric analysis reveals a heating-exothermic peak (241) allows unidirectional bands to be assembled over their entire surface, provided that this assembly is achieved by heating the strips in a temperature range (250) between the temperature (245) of the exothermic peak (241) and the melting temperature (220). For example, for a PEEK prepreg having a crystallinity level at room temperature of between 5 () / 0 and 20 ° / (°), the automatic draping of the prepreg strips can be carried out at a temperature of 250 ° C. This low temperature also makes it possible to avoid the phenomena of oxidation of said polymer during the corresponding heating. This continuous heating at low temperature makes it possible to give the prepreg strips sufficient tack to implement them according to an automated draping method.
    [0014] A thermoplastic prepreg not having such a recrystallization peak (241), for example a PEEK prepreg having a crystallinity level at room temperature of 30 ° / (), can not be assembled during a cooling operation. draping or fiber placement by heating in a range (250) of such low temperature, because such heating does not confer sufficient stickiness to allow adhesion of the strips on the preform. Also, in the case of automated draping of a PEEK prepreg having a crystallinity level at room temperature greater than 20 ° / (:), the heating temperature during draping must be greater than or equal to the temperature (220 ) PEEK melting, the adhesion of the strips deposited on the preform then being necessarily accompanied by a self-adhesion, even partial, folds between them. On the other hand, this PEEK, whose crystallinity level at room temperature is 20% or more, is suitable for being used by the embodiments of the method that is the subject of the invention without assembling the plies or with an assembly by partial welding, by point or by welding line. The foregoing description and the exemplary embodiments show that the invention achieves the intended objectives, in particular by the use of plies made of unidirectional fibers pre-impregnated with any thermoplastic polymer, it allows the stamping of unassembled folds or partially assembled by points, and, by a selection of a polymer impregnating the folds, which selection meets particular characteristics and is associated with specific draping conditions, the method which is the subject of the invention makes it possible to obtain a similar result. by implementing a crude obtained by automated draping. According to these two embodiments 10 of the method which is the subject of the invention, the step of obtaining a consolidated plate, a step considered unavoidable according to the prior art, is eliminated.
    权利要求:
    Claims (10)
    [0001]
    REVENDICATIONS1. Process for producing, by hot stamping, a composite piece with continuous fiber reinforcement in a thermoplastic matrix, characterized in that it comprises the steps of: a. obtaining a blank (160) comprising unconsolidated lamination of plies consisting of unidirectional webs (110, 310) of fibers preimpregnated with a thermoplastic polymer; b. heating the blank (160) in air to a temperature greater than or equal to the melting point (220) of the polymer constituting the matrix; vs. stamp the blank (160).
    [0002]
    2. The method of claim 1, wherein step a) comprises a step of assembling the folds by welding spots.
    [0003]
    3. The method of claim 1, wherein each fold of the blank consists of strips (110, 310) assembled edge to edge by a weld (140, 340).
    [0004]
    4. The method of claim 1, comprising before step a) a step of: d. selecting, for the constitution of the matrix, a thermoplastic polymer having a temperature (245), called recrystallization, between the glass transition temperature (210), Tg, and the melting temperature (220), Tf, of said polymer; and wherein step a) comprises a step of: ai. draping the plies, in the form of pre-impregnated strips, by means of a draper machine comprising a means for heating said strip, the heating temperature of the strip during the removal being lower than the melting temperature (220) of the strip; polymer and greater than the recrystallization temperature (245).
    [0005]
    The method of claim 4, wherein step d) comprises the steps of: performing differential scanning calorimetry analysis of the prepreg dii. selecting said prepreg if the result of said differential scanning calorimetry causes the heating to show an exothermic peak (241) between the glass transition temperature (210) and the polymer melting temperature (220), the temperature (245) of the exothermic peak being considered the recrystallization temperature.
    [0006]
    6. The method of claim 4, wherein the polymer constituting the matrix is a semicrystalline polyetheretherketone whose crystallinity at room temperature is between 5 () / 0 and 20%.
    [0007]
    7. The process according to claim 6, wherein step a1) is carried out at a temperature of between 200 ° C and 330 ° C, preferably 250 ° C.
    [0008]
    8. The method of claim 1, wherein step a) is performed by stacking the folds on a tool (100, 300), called transfer, comprising means (105, 305) for positioning and maintaining folds on their periphery.
    [0009]
    9. The method of claim 8, wherein the transfer tool is a frame (100) and step b) is performed while the folds stacked in step a) are on said frame (100).
    [0010]
    The method of claim 8, wherein the transfer tool comprises a polyimide film (300), the plies being assembled and held on said film by an adhesive tape (305) on their periphery.
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    同族专利:
    公开号 | 公开日
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    WO2015097301A1|2015-07-02|
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    DE102020206058A1|2020-05-13|2021-11-18|Ford Global Technologies, Llc|Connection element, component made from a composite material and method for manufacturing a component made from a composite material|
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    优先权:
    申请号 | 申请日 | 专利标题
    FR1363575A|FR3016314B1|2013-12-24|2013-12-24|METHOD AND DEVICE FOR STAMPING COMPOSITE FLAN WITH NON-CONSOLIDATED THERMOPLASTIC MATRIX|FR1363575A| FR3016314B1|2013-12-24|2013-12-24|METHOD AND DEVICE FOR STAMPING COMPOSITE FLAN WITH NON-CONSOLIDATED THERMOPLASTIC MATRIX|
    US15/107,425| US10773470B2|2013-12-24|2014-12-24|Method and device for stamping an unconsolidated composite blank with a thermoplastic matrix|
    EP14824847.9A| EP3096940B1|2013-12-24|2014-12-24|Method and device for stamping a composite blank with non-consolidated thermoplastic matrix|
    ES14824847T| ES2881218T3|2013-12-24|2014-12-24|Procedure and device for stamping a blank composed of an unconsolidated thermoplastic matrix|
    CA2934952A| CA2934952A1|2013-12-24|2014-12-24|Method and device for stamping a composite blank with non-consolidated thermoplastic matrix|
    PCT/EP2014/079340| WO2015097301A1|2013-12-24|2014-12-24|Method and device for stamping a composite blank with non-consolidated thermoplastic matrix|
    JP2016561080A| JP6722589B2|2013-12-24|2014-12-24|Hot stamping method for composite parts with continuous fiber reinforcement in part in thermoplastic matrix|
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