BR112021011626A2 - Método para preparar o material compósito em forma de sanduíche - Google Patents

Método para preparar o material compósito em forma de sanduíche Download PDF

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Publication number
BR112021011626A2
BR112021011626A2 BR112021011626-5A BR112021011626A BR112021011626A2 BR 112021011626 A2 BR112021011626 A2 BR 112021011626A2 BR 112021011626 A BR112021011626 A BR 112021011626A BR 112021011626 A2 BR112021011626 A2 BR 112021011626A2
Authority
BR
Brazil
Prior art keywords
core
sandwich
outer layers
insert
polymeric material
Prior art date
Application number
BR112021011626-5A
Other languages
English (en)
Inventor
Gaëtan MAO
Nicolas DUMONT
Original Assignee
Saint-Gobain Performance Plastics France
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Saint-Gobain Performance Plastics France filed Critical Saint-Gobain Performance Plastics France
Publication of BR112021011626A2 publication Critical patent/BR112021011626A2/pt

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D24/00—Producing articles with hollow walls
    • B29D24/002—Producing articles with hollow walls formed with structures, e.g. cores placed between two plates or sheets, e.g. partially filled
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/16—Cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0001—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0005—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor using fibre reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14467—Joining articles or parts of a single article
    • B29C45/14508—Joining juxtaposed sheet-like articles, e.g. for making trim panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/72—Heating or cooling
    • B29C45/7207—Heating or cooling of the moulded articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
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    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/18—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length in the form of a mat, e.g. sheet moulding compound [SMC]
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    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/467—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements during mould closing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
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    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
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    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/541—Positioning reinforcements in a mould, e.g. using clamping means for the reinforcement
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/70—Completely encapsulating inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
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    • B29D24/002—Producing articles with hollow walls formed with structures, e.g. cores placed between two plates or sheets, e.g. partially filled
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    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
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    • B29D99/0021—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with plain or filled structures, e.g. cores, placed between two or more plates or sheets, e.g. in a matrix
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Abstract

método para preparar o material compósito em forma de sanduícheo. objeto da invenção pode ser um método de fabricação de um produto na forma de um sanduíche compreendendo um núcleo e camadas externas. as camadas externas podem ser compostas de material compósito compreendendo uma matriz polimérica reforçada com fibra. o método usa uma inserção de material resistente ao calor, por exemplo, silicone. o objetivo desta invenção pode ser fornecer um método para fabricar um sanduíche que dissocia a escolha do material do núcleo do sanduíche da escolha do material das camadas externas.

Description

“MÉTODO PARA PREPARAR O MATERIAL COMPÓSITO EM FORMA DE SANDUÍCHE” DESCRIÇÃO DETALHADA
[0001] A invenção se refere ao campo de produtos feitos de material compósito ou materiais compósitos. Produtos feitos de materiais compósitos significam um produto que pode incluir uma matriz de resina consistindo de um material polimérico, em particular, material termoplástico ou termoendurecível. Esta matriz pode ser reforçada por um material que pode ter um ponto de fusão superior ao ponto de fusão do material polimérico. FRP geralmente se refere a "plástico reforçado com fibra".
[0002] Os materiais compósitos do tipo FRP têm boa resistência mecânica em relação ao peso do material. Eles também têm uma resistência muito boa à corrosão. Eles têm propriedades superiores às dos componentes considerados separadamente. Permitem nomeadamente, no domínio da indústria automóvel ou aeronáutica, a redução de peso de peças tradicionalmente feitas de aço. Eles também têm boa resistência à fadiga.
[0003] Os reforços do compósito podem ser obtidos de diferentes formas: pela adição de fibras minerais dispersas na matriz, pela utilização de uma estrutura de suporte em aço ou material sintético, pela utilização de um tecido de fibra de reforço, pela utilização de não-tecidos ou esteiras ou outros produtos obtidos por métodos têxteis.
[0004] Os reforços de tecido podem ter uma estrutura plana e podem ser compósitos de fio de trama e fio de urdidura que se cruzam e se entrelaçam perpendicularmente. Sua fabricação pode exigir o uso de um carretel separado por fio de urdidura.
[0005] Mais recentemente, reforços de malha têm sido usados. Os reforços tricotados podem significar um produto geralmente obtido a partir de fio contínuo onde o fio forma malhas entrelaçadas, dispostas em carreiras sucessivas. A produção de uma malha tradicional requer apenas um carretel de fio para a malha de fios.
[0006] O fio pode ser do tipo monofilamento ou multifilamento. O multifilamento pode ser uma mecha (isto é, uma montagem de filamentos contínuos paralelos montados sem torção), um fio fiado (isto é, um conjunto de fibras curtas montadas com torção). O fio também pode ser uma montagem de vários fios ou filamentos de diferentes materiais. Esta montagem pode ser feita girando, enrolando. É portanto possível produzir fio compreendendo material polimérico e material de reforço. Por exemplo, é possível montar fios de reforço do tipo aramida, carbono, vidro e fios termoplásticos (isto é, polipropileno, policarbonato, polieterimida (PEI)). Este tipo de fio pode então ser denominado fio misto.
[0007] A tricotagem deste tipo de fio misto pode permitir a obtenção de uma pré-forma, contendo tanto o reforço quanto a matriz. Esta pré-forma é dita "seca", ao contrário do tecido pré-impregnado de resina pegajosa e grudenta comumente chamado de "prepreg".
[0008] Também é possível produzir produtos na forma de um sanduíche que pode incluir duas camadas externas, ou películas, feitas de material compósito do tipo FRP e um corpo central, ou núcleo, de material mais leve do tipo espuma ou material alveolar celular. Graças à sua construção em forma de sanduíche, estes produtos podem atingir, com igual peso, desempenhos muito melhores.
[0009] A impregnação das películas e a ligação destas ao núcleo podem influenciar as propriedades finais do compósito sanduíche. A boa impregnação das películas geralmente requer um método de consolidação em várias etapas; que consome tempo e recursos. Este é particularmente o caso quando o produto finalizado tem uma forma 3D complexa.
[00010] Os métodos tradicionais para fazer um sanduíche geralmente podem incluir as seguintes etapas: produção das camadas externas a partir de películas pré- impregnadas com material polimérico; justaposição das camadas externas em cada lado de um núcleo, por exemplo, colmeia ou espuma; consolidação das camadas externas para garantir a fusão do material polimérico, garantindo a conexão de todas as camadas ao núcleo.
[00011] Dependendo da espessura das películas, pode ser necessário empilhar várias dobras. Vários ciclos de cura podem ser necessários para garantir uma boa consolidação das dobras do tecido de cada película e garantir uma boa adesão entre as películas e o núcleo. Com este tipo de método de fabricação, o núcleo do sanduíche pode ser escolhido especificamente para resistir à cura das camadas externas. Em alguns casos, verificou-se que é prejudicado pela submissão de temperatura e pressão. Foi observado, por exemplo, que os núcleos de espuma podem ceder ou encolher durante este tratamento.
[00012] Além disso, também parecia que durante a cura, o material polimérico poderia fluir para as células da colmeia.
[00013] O documento EP 0 770 472 A1 descreve um método para fabricar um painel sanduíche de material compósito com um núcleo formado por uma estrutura de célula aberta e películas formadas por fibras e resina. Para evitar o derretimento da resina nas células abertas do núcleo, o documento prevê a interposição de uma membrana estanque e um filme de cola entre as películas e o núcleo. Após o fechamento do molde, um único ciclo térmico permite polimerizar a cola e, em seguida, injetar a resina sob pressão nas fibras e finalmente polimerizar a resina.
[00014] Este método, no entanto, tem a desvantagem de exigir o uso de várias camadas e, em particular, de uma membrana estanque. Isso aumenta os custos do produto acabado.
[00015] O documento EP 1 086 801 A1 descreve um método de fabricação de um painel sanduíche pela técnica de injeção de resina, RTM. Para evitar o enchimento da estrutura em colmeia, este método requer o estabelecimento no molde de uma película de material intumescente e um tecido de barreira em cada uma das faces do núcleo.
[00016] O método de acordo com a invenção utiliza uma inserção de material resistente ao calor, para formar as camadas externas, em vez do núcleo e a substituição da inserção pelo núcleo quando as camadas externas são consolidadas. Tudo o que resta então é realizar um tratamento térmico para unir as camadas externas ao núcleo.
[00017] De acordo com uma primeira modalidade, o método de acordo com a invenção pode incluir as seguintes etapas:
[00018] Modalidade de películas externas ou películas pré- impregnadas, por exemplo, tricotando ou tecendo fios que podem incluir material polimérico e material de reforço; Justaposição em um molde, de uma camada externa, uma inserção de material resistente ao calor e uma segunda camada externa; Modelagem das películas por cura a uma temperatura e pressão que pode permitir a consolidação e fusão do material polimérico sem atingir o ponto de fusão do material de reforço; Remoção da inserção e introdução do núcleo do sanduíche, por exemplo, de espuma ou colmeia, entre as 2 películas pré-formadas; Cura da montagem a uma temperatura que permita a adesão entre as camadas externas e o núcleo do sanduíche.
[00019] De acordo com outra modalidade, as películas podem ser feitas de um têxtil de material de reforço e o material polimérico pode ser fornecido por injeção.
[00020] O método pode então incluir as seguintes etapas: Justaposição em um molde de um tecido de reforço, uma inserção de material resistente ao calor e outro tecido de reforço; Injeção de resina; Remoção da inserção e introdução do núcleo do sanduíche, por exemplo de espuma ou colmeia, entre as 2 películas pré-formadas; Curar o todo a uma temperatura que permite a adesão entre as camadas externas e o núcleo do sanduíche.
[00021] A inserção pode ser rígida ou não. Em particular, pode ser silicone.
[00022] Em algumas modalidades, ele pode se expandir na temperatura. Isso pode permitir o aumento da compressão durante a consolidação.
[00023] A inserção pode fornecer uma forma particular ao produto finalizado, como, por exemplo, uma forma chanfrada.
[00024] Em algumas modalidades, uma camada adesiva pode ser inserida entre o corpo do sanduíche e as camadas externas. Este adesivo pode ser uma cola líquida, uma película adesiva ou uma pré-forma tricotada que compreende fibras termoplásticas.
[00025] As camadas externas podem ser iguais ou diferentes.
[00026] Vantajosamente, para obter um bom efeito de sanduíche, a espessura do núcleo pode ser geralmente de pelo menos cerca de 2 mm e não maior do que cerca de 50 mm, de preferência pelo menos cerca de 3 mm e não maior do que cerca de 40 mm, e mais preferencialmente pelo menos cerca de 5 mm e não maior que cerca de 25 mm, e a espessura da película pode ser pelo menos cerca de 0,2 mm e não maior que cerca de 5 mm, de preferência pelo menos cerca de 0,4 mm e não maior que cerca de 2 mm, e mais preferencialmente pelo menos cerca de 0,5 mm e não maior do que cerca de 1 mm.
[00027] O objetivo desta invenção pode ser fornecer um método alternativo de fabricação de um sanduíche, em particular, fornecer um método de fabricação que dissocia a escolha do material do corpo do sanduíche e a escolha do material das camadas externas.
[00028] O material polimérico pode incluir materiais termoplásticos, como, por exemplo, policarbonato (PC), poliéterimida (PEI), polipropileno (PP), poli (tereftalato de etileno) (PET), poli(éter-éter-cetona) (PEEK) ou materiais termoendurecíveis, como por exemplo epóxi, éster de cianato, resina fenólica, poliéster.
[00029] O material de reforço pode incluir materiais sintéticos, como para-aramida, polipropileno, materiais naturais, como linho, materiais inorgânicos, como vidro, quartzo, carbono, basalto, metal.
[00030] O método de acordo com a invenção revelou-se particularmente vantajoso porque pode permitir dissociar a escolha do tipo de núcleo do sanduíche da escolha do método de transformação. O método de acordo com a invenção pode permitir obter uma boa impregnação das películas exteriores.
[00031] Muitos aspectos e modalidades diferentes são possíveis. Alguns desses aspectos e modalidades são descritos neste documento. Depois de ler este relatório descritivo, os técnicos no assunto apreciarão que esses aspectos e modalidades são apenas ilustrativos e não limitam o escopo da presente invenção. As modalidades podem estar de acordo com qualquer uma ou mais das modalidades listadas abaixo.
[00032] Modalidade 1. Método de fabricação de um produto de material compósito em forma de sanduíche, em que o produto de material compósito em forma de sanduíche compreende duas camadas externas e um núcleo, as camadas externas tendo uma matriz de material polimérico reforçado com fibra, o material polimérico tendo um ponto de fusão abaixo do ponto de fusão do material que constitui as fibras; em que o método é caracterizado por usar uma inserção consistindo de material com um ponto de fusão superior ao ponto de fusão do material polimérico, no qual as camadas externas são consolidadas; e em que esta inserção é subsequentemente substituída pelo núcleo do sanduíche, sendo a montagem então submetida a um tratamento de consolidação para unir as camadas externas ao núcleo.
[00033] Modalidade 2. Método, de acordo com a modalidade 1, caracterizado por compreender as seguintes etapas: produção de pré-formas compostas de material polimérico reforçado com fibras destinadas a se tornarem as camadas externas do sanduíche, justaposição, em um molde, de uma primeira pré-forma, da inserção, e de uma segunda pré-forma,
consolidação das pré-formas para obtenção das camadas externas, por aquecimento e pressurização, para atingir a temperatura do ponto de fusão do material polimérico, sem atingir a temperatura do ponto de fusão do material de reforço ou do material da inserção, remoção da inserção, separação das camadas externas e inserção do núcleo do sanduíche, tratamento térmico para adesão das camadas externas ao núcleo, resfriamento do produto assim obtido.
[00034] Modalidade 3. Método, de acordo com a modalidade 2, caracterizado por as pré-formas serem feitas usando tecidos de resina de polímero pré-impregnados.
[00035] Modalidade 4. Método, de acordo com a modalidade 2, caracterizado por as pré-formas serem feitas tricotando um fio compreendendo o material de reforço e o material polimérico.
[00036] Modalidade 5. Método, de acordo com a modalidade 2, caracterizado por um custo de descascamento (peel cost) ser adicionado entre as pré-formas, nos locais destinados a formar uma zona sem núcleo.
[00037] Modalidade 6. Método, de acordo com a modalidade 1, caracterizado por compreender as seguintes etapas: justaposição, em um molde, de um tecido ou malha de material de reforço, a inserção, e um segundo tecido ou malha de material de reforço; injeção de uma resina de material polimérico sob pressão e temperatura; remoção da inserção e inserção do núcleo do sanduíche; cura de consolidação para aderir as camadas externas ao núcleo do sanduíche; resfriamento do produto assim obtido.
[00038] Modalidade 7. Método, de acordo com a modalidade 1, caracterizado por a inserção é feito de silicone.
[00039] Modalidade 8. Método, de acordo com a modalidade 1, caracterizado por o material de reforço ser escolhido entre fibras de vidro, carbono e aramida.
[00040] Modalidade 9. Método, de acordo com a modalidade 1, caracterizado pelo material polimérico ser do tipo termoplástico, em particular escolhido de policarbonato (PC), polieterimida (PEI), polipropileno (PP), poli(tereftalato de etileno) (PET), poli(éter-éter-cetona) (PEEK).
[00041] Modalidade 10. Método, de acordo com a modalidade 1, caracterizado por o material polimérico ser do tipo termoendurecível, em particular escolhido entre epoxi, éster de cianato, resinas fenólicas e poliéster.
[00042] Modalidade 11. Método, de acordo com a modalidade 1, caracterizado pelo núcleo do sanduíche consistir em material alveolar celular.
[00043] Modalidade 12. Método, de acordo com a modalidade 1, caracterizado pela espessura do núcleo ser de pelo menos cerca de 2 mm e não maior do que cerca de 50 mm.
[00044] Modalidade 13. Método, de acordo com a modalidade 1, caracterizado pela espessura de cada uma das camadas externas ser de pelo menos cerca de 0,2 mm e não maior do que cerca de 5 mm.
[00045] Os exemplos seguintes ilustram a invenção de uma maneira não limitativa.
EXEMPLOS EXEMPLO 1
[00046] Vários tecidos de fibra de carbono impregnados com éster de cianato "prepreg" são envolvidos em um molde de aço para formar a primeira película do sanduíche.
[00047] Uma inserção rígida (por exemplo, um bloco de Teflon® de alguns milímetros) é depositada sobre os tecidos.
[00048] A segunda película do sanduíche é feita colocando vários tecidos "prepreg" na inserção rígida.
[00049] O peel ply revestido com Teflon (fibras de vidro revestidas com PTFE) é colocado na junção entre as duas películas. A junção é a área onde as películas se unem para cobrir o campo do núcleo.
[00050] O molde é fechado por um contra-molde flexível.
[00051] As películas são consolidadas por tratamento térmico sob vácuo a cerca de 180-220 °C durante algumas horas.
[00052] A montagem pode esfriar e a inserção é removida.
[00053] Uma cola resistente a altas temperaturas é aplicada em cada uma das faces que devem estar em contato com o núcleo.
[00054] Um núcleo do tipo espuma de poliimida (densidade aproximada de 50 kg/m3) é introduzido no lugar da inserção.
[00055] O sanduíche inteiro é então submetido a um tratamento final de consolidação, sob vácuo a uma temperatura de cerca de 90-120 °C, de modo a garantir uma boa adesão das películas e do núcleo. EXEMPLO 2
[00056] A primeira película é formada por uma pilha de vários tecidos de reforço não impregnados, de fibras de carbono, depositados em um molde de aço.
[00057] Uma inserção macia (placa de silicone com alguns milímetros de espessura) é depositada no tecido.
[00058] A segunda película é formada por um tecido do mesmo tipo depositado na inserção.
[00059] O molde é fechado pelo contra molde de aço.
[00060] A resina de éster de cianato é injetada por um método conhecido do tipo RTM, a uma temperatura entre 80 e 120 °C sob uma pressão de 10 a 15 bar.
[00061] O tratamento térmico é prolongado por 4 horas.
[00062] O molde é deixado esfriar, então a inserção é removida e as películas são separadas removendo o peel ply.
[00063] Uma camada muito fina de resina de éster de cianato é adicionada às películas (nas faces que devem entrar em contato com a colmeia).
[00064] Um núcleo em colmeia é introduzido entre as duas películas, no lugar da inserção, para formar um sanduíche.
[00065] O sanduíche inteiro é submetido a um tratamento térmico (180-200 °C), sob vácuo, por 4 horas para a colagem das películas e do núcleo. EXEMPLO 3
[00066] Uma malha é feita com um fio misto compreendendo fibras de vidro e fibras termoplásticas.
[00067] Esta malha é depositada em um molde de aço para formar a primeira película.
[00068] Uma inserção de material expansível sob o efeito da temperatura é depositada na malha.
[00069] Uma segunda malha do mesmo tipo é depositada na inserção para formar a segunda película.
[00070] O peel ply revestido com Teflon (fibras de vidro revestidas com PTFE) é colocado na junção entre as duas películas. A junção é a área onde as duas películas se unem para cobrir o campo do núcleo.
[00071] O peel ply revestido com Teflon é colocado na junção entre as duas películas.
[00072] O molde é fechado por um contra molde de aço.
[00073] As películas são consolidadas por tratamento térmico a 200-250 °C, sob uma pressão de 3 a 10 bar durante algumas dezenas de minutos.
[00074] O molde é deixado esfriar, então a inserção é removida e as películas são separadas removendo o peel ply.
[00075] Uma pré-forma de malha de um fio termoplástico é depositada em cada lado de um núcleo em colmeia, de modo a formar uma camada de conexão entre o núcleo e as películas do sanduíche.
[00076] O núcleo em colmeia e as pré-formas de malha são introduzidos entre as duas películas, no lugar da inserção, para formar um sanduíche.
[00077] O sanduíche inteiro é submetido a um tratamento térmico (200-250 °C), sob vácuo, por algumas horas, de modo a unir as películas e o núcleo.
EXEMPLO 4
[00078] Uma malha é feita com um fio misto compreendendo fibras de vidro e fibras termoplásticas.
[00079] Esta malha é depositada em um molde de aço para formar a primeira película.
[00080] Uma inserção rígida de material expansível sob o efeito da temperatura é depositada na malha.
[00081] Uma segunda malha do mesmo tipo é depositada na inserção para formar a segunda película.
[00082] O peel ply revestido com Teflon é colocado na junção entre as duas películas.
[00083] O molde é fechado por um contra molde de aço.
[00084] As películas são consolidadas por um tratamento térmico a 200-250 °C, sob uma pressão de 3 a 10 bar durante algumas dezenas de minutos.
[00085] O molde é deixado esfriar, então a inserção é removida e as películas são separadas removendo o peel ply.
[00086] Um núcleo de espuma epóxi expandida é injetado entre as duas películas, no lugar da inserção, para formar um sanduíche.
[00087] Todo o sanduíche é submetido a um tratamento térmico (65-120 °C), sob vácuo, por algumas horas para ligar as películas e o núcleo. EXEMPLO 5
[00088] Uma malha é feita com um fio misto compreendendo fibras de vidro e fibras termoplásticas.
[00089] Uma primeira malha é colocada sobre uma bexiga de silicone e a montagem é depositada em um primeiro molde de aço para a consolidação da película externa. O molde é fechado e um vácuo é criado. O molde é pressurizado (3 a 10 bar) e aquecido rapidamente por aquecimento por indução a uma temperatura de 200 a 250 °C. A temperatura é mantida por alguns minutos. Após o resfriamento, a bexiga é removida e uma primeira película é produzida.
[00090] Uma segunda película (película interna) é feita da mesma maneira que a primeira em um segundo molde.
[00091] No ferramental utilizado para consolidar a película externa, são depositados sucessivamente: a película externa previamente consolidada, um filme de cola epóxi ou líquida, uma estrutura em colmeia, a película interna previamente consolidada do produto compósito final.
[00092] A bexiga de silicone usada para consolidar a película interna é colocada no lugar e o molde é fechado. Um vácuo é puxado ao máximo e a montagem é aquecida a uma temperatura de 65-120 °C por algumas horas (método de aquecimento em forno) para unir as películas e o núcleo.

Claims (13)

REIVINDICAÇÕES
1. Método para fabricar um produto de material compósito em forma de sanduíche em que o produto de material compósito em forma de sanduíche compreende duas camadas externas e um núcleo, as camadas externas tendo uma matriz de material polimérico reforçado com fibra, o material polimérico tendo um ponto de fusão abaixo o ponto de fusão do material que constitui as fibras; caracterizado por usar uma inserção consistindo de material com um ponto de fusão superior ao ponto de fusão do material polimérico, no qual as camadas externas são consolidadas; e em que esta inserção é subsequentemente substituída pelo núcleo do sanduíche, o conjunto então submetido a um tratamento de consolidação para unir as camadas externas ao núcleo.
2. Método, de acordo com a reivindicação 1, caracterizado por compreender as seguintes etapas: produção de pré-formas compostas de material polimérico reforçado com fibra destinada a se tornar as camadas externas do sanduíche, justaposição, em um molde, de uma primeira pré-forma, da inserção, e uma segunda pré-forma, consolidação das pré-formas para obtenção das camadas externas, por aquecimento e pressurização, para atingir a temperatura do ponto de fusão do material polimérico, sem atingir a temperatura do ponto de fusão do material de reforço ou do material da inserção, remoção da inserção, separação das camadas externas e inserção do núcleo do sanduíche, tratamento térmico para aderir as camadas externas ao núcleo, resfriamento do produto assim obtido.
3. Método, de acordo com a reivindicação 2, caracterizado pelas pré-formas serem feitas a partir de tecidos de resina polimérica pré- impregnados.
4. Método, de acordo com a reivindicação 2, caracterizado pelas pré-formas serem feitas por tricotagem de um fio compreendendo o material de reforço e o material polimérico.
5. Método, de acordo com a reivindicação 2, caracterizado por um custo de descascamento (peel cost) ser adicionado entre as pré-formas, nos locais destinados a formar uma zona sem núcleo.
6. Método, de acordo com a reivindicação 1, caracterizado por compreender as seguintes etapas: justaposição, em um molde, de um tecido ou malha de material de reforço, a inserção, e um segundo tecido ou malha de material de reforço; injeção de uma resina de material polimérico sob pressão e temperatura; remoção da inserção e inserção do núcleo do sanduíche; cura de consolidação para aderir as camadas externas ao núcleo do sanduíche; e resfriamento do produto assim obtido.
7. Método, de acordo com a reivindicação 1, caracterizado pela inserção ser feita de silicone.
8. Método, de acordo com a reivindicação 1, caracterizado pelo material de reforço ser escolhido entre fibras de vidro, carbono e aramida.
9. Método, de acordo com a reivindicação 1, caracterizado pelo material polimérico ser do tipo termoplástico, em particular escolhido de policarbonato (PC), polieterimida (PEI), polipropileno (PP), poli(tereftalato de etileno) (PET), poli(éter-éter-cetona) (PEEK).
10. Método, de acordo com a reivindicação 1, caracterizado pelo material polimérico ser do tipo termoendurecível, em particular escolhido de epóxi, éster de cianato, resinas fenólicas e poliéster.
11. Método, de acordo com a reivindicação 1, caracterizado pelo núcleo do sanduíche consistir em material alveolar celular.
12. Método, de acordo com a reivindicação 1, caracterizado pela espessura do núcleo ser de pelo menos cerca de 2 mm e não maior do que cerca de 50 mm.
13. Método, de acordo com a reivindicação 1, caracterizado pela espessura de cada uma das camadas externas ser de pelo menos cerca de 0,2 mm e não maior do que cerca de 5 mm.
BR112021011626-5A 2018-12-18 2019-12-16 Método para preparar o material compósito em forma de sanduíche BR112021011626A2 (pt)

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FR1873207 2018-12-18
FR1873207A FR3089854B1 (fr) 2018-12-18 2018-12-18 Procede de preparation d’un materiau composite sous forme de sandwich
PCT/EP2019/085359 WO2020127057A1 (en) 2018-12-18 2019-12-16 Method for the preparation of composite material in sandwich form

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