EP2715742B1 - Semi-finished product in the form of a conductive strip that can be embedded in a composite material, and method for manufacturing such a strip - Google Patents

Semi-finished product in the form of a conductive strip that can be embedded in a composite material, and method for manufacturing such a strip Download PDF

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Publication number
EP2715742B1
EP2715742B1 EP12722133.1A EP12722133A EP2715742B1 EP 2715742 B1 EP2715742 B1 EP 2715742B1 EP 12722133 A EP12722133 A EP 12722133A EP 2715742 B1 EP2715742 B1 EP 2715742B1
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EP
European Patent Office
Prior art keywords
semifinished product
layers
product according
conductive layer
semi
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EP12722133.1A
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German (de)
French (fr)
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EP2715742A1 (en
Inventor
Jesus Aspas Puertolas
Nicolas Maisonnave
Mathieu SAUZEDDE
Michel Bermudez
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Airbus SAS
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Airbus SAS
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/08—Flat or ribbon cables
    • H01B7/0838—Parallel wires, sandwiched between two insulating layers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/02—Disposition of insulation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H01B13/10—Insulating conductors or cables by longitudinal lapping
    • H01B13/103—Insulating conductors or cables by longitudinal lapping combined with pressing of plastic material around the conductors
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing

Definitions

  • the invention relates to a semifinished product in the form of an integrated conductive strip in a laminated composite material.
  • the invention is more particularly, but not exclusively, applicable in the aeronautical field for producing elements made of composite materials reinforced by a fibrous reinforcement in a matrix made of a polymer, in order to confer on these structural elements capabilities electrical conduction.
  • Structural elements made of a laminated composite material with fiber reinforcement and having, moreover, electrical conduction properties are described in the prior art and in particular in the document FR-A-2924894 .
  • This document discloses a laminated structural part comprising, between two fibrous reinforcement plies, a layer comprising a network of conductive cables.
  • Said document also describes a method for obtaining such a structural element, wherein layers of conductive cables are inserted between one or more pairs of structural folds, so as to constitute a dry preform, the assembly then being impregnated with a resin by a resin transfer process to form the matrix and to provide the cohesion of the composite material.
  • This method of obtaining by resin transfer is however not suitable, or proves to be unproductive, for certain parts, particularly thin and large parts, such as fuselage panels, where such a method can not be used. to compete, in terms of productivity, especially with processes implementing draping pre-impregnated folds.
  • the document US 2006/169481 A1 discloses a flat wire rope 10 having in its cross-section: a first conductive layer 12 made of an electrically conductive material; two electrically insulating layers 14, 16 made of a dielectric material; two connecting layers 28 extending in thickness on either side of the insulating layers outside the semi-product.
  • the document US 2001/011603 A1 discloses a flat wire rope 11 having in its cross-section: a first conductive layer 11c made of an electrically conductive material; two electrically insulating layers 11b made of a dielectric material completely enclosing the conductive layer and whose width in section is greater than the width of the conductive layer.
  • the semi-finished product according to the invention comprises connecting layers making it possible, on the one hand, to ensure the connection of said semi-product with a preform at the time of draping, and on the other hand, the cohesion of the layer.
  • conductive with all the stratification of the composite material, during the cooking or consolidation of the stack constituting the part in which is integrated said conductive layer.
  • such a part, incorporating a conductive layer can be achieved by manual or automated draping techniques, implementing pre-impregnated folds.
  • the invention can be implemented according to the advantageous embodiments, described below, which can be considered individually or in any technically operative combination.
  • the insulating layers consist of a partially vulcanized elastomer.
  • this elastomer layer gives the laminated piece having a conductive layer integrated in said part via a semi-finished product according to the invention, vibroacoustic absorption capabilities and ability to mechanically protect said conductive layer.
  • the partial vulcanization of the insulating layers makes it possible to perfect this vulcanization during the firing of the laminated part incorporating the semi-finished product according to the invention, and thus to ensure a strong cohesion of the conductive layer with the rest of the part.
  • the insulating layers consist of a partially vulcanized elastomer with a vulcanization rate of the order of 60%.
  • a vulcanization rate of the order of 60%.
  • Such partial vulcanization is achieved by heating for a short time.
  • the heating temperature is generally of the order of 110 ° C.
  • the bonding layers consist of a thermosetting glue.
  • the semifinished product has adequate tackiness for its deposition by draping on a preform.
  • the tie layers consist of a thermoplastic polymer. This feature improves the resistance to impact and thermal stresses of the entire laminate in which such a semi-product is integrated.
  • the thermoplastic polymer comprises polyetherimide or PEI. Since this polymer is at least partially miscible in many thermosetting and thermoplastic resins, this characteristic makes it possible to ensure a strong cohesion of the conductive layer with the rest of the laminated composite part.
  • the insulating layers and the bonding layers consist of a partially polymerized thermosetting resin.
  • the semi-product object of the invention fits perfectly by draping in a lamination of pre-impregnated plies of such a thermosetting resin.
  • the partial polymerization makes it possible at one and the same time to preserve the cohesion of the semifin object of the invention during draping, but also to preserve the flexibility required for this draping operation.
  • the insulating layers and the bonding layers consist of a partially polymerized thermosetting resin, with a resin polymerization rate of 60 to 80%.
  • a partial polymerization is carried out by heating for a short time.
  • the heating temperature is of the order of generally around 80 ° C. to 110 ° C., depending on the resins used.
  • the insulating layers and the tie layers consist of a thermoplastic elastomer comprising polyetherimide (PEI). So the semi-product The subject of the invention is capable of being integrated in a stratification constituting a thermoplastic or thermosetting matrix composite.
  • PEI polyetherimide
  • the conductive layer consists of a metal foil, a braid or a metal cable.
  • the finesse of such a foil allows the band to marry any type of shape including shapes double curvature.
  • said metal foil is made of an aluminum alloy which can be obtained by rolling in extremely thin thickness and has a low density.
  • the metal foil may also be made of a copper alloy.
  • the conductive layer consists of a plurality of metallic conductors electrically insulated from one another.
  • the conductive layer consists of several different electrical signals can be transmitted in each of the conductors and the lateral separation of the conductors from one another makes it possible to use thicker conductors without impairing the shaping capacity of the semi-finished product.
  • the method which is the subject of the invention makes it possible to manufacture automatically large quantities of semi-finished products, in the form of strips or coils, which coils can be stored and integrated as much as necessary into laminates constituting parts in material composite.
  • Figure 1 according to a first embodiment of a semifinished product (101, 102) according to the invention, the latter comprises, at the core, a conductive layer (105, 106) which, according to a first variant (101) of embodiment, may consist of a metal foil (105), Figure 1A , or, in a second variant (102), consisting of a plurality (106) of conductors, Figure 1B arranged in a sheet, preferably in the form of so-called flat metal cables.
  • This conductive layer (105, 106) is sandwiched between two insulating layers (121, 122) made of a dielectric material, preferably, but not exclusively, an elastomer.
  • the semifinished product (101, 102) comprises two layers (111, 112) called connection layers having interface characteristics rendering said semi-finished product (101, 102) capable of being draped on a machine. automatic draper and able to form a cohesive interface with fibrous reinforcement layers pre-impregnated following a cooking or consolidation operation.
  • Said bonding layers (111, 112) may be layers attached to the insulating layers, by impregnation of these layers hot or cold, or be an integral part of said insulating layers.
  • Said insulating layers (121, 122) must be sufficiently thick to ensure complete electrical insulation of the conductive layer (105, 106) of its environment in the finished product, ie after the semi-finished product ( 101, 102) object of the invention has undergone a form of draping, to insert it in the heart of a laminate, and then a cooking or consolidation operation at high temperature and under pressure.
  • This insulation must be total and effective, especially for high voltages, of the order of 3000 volts.
  • the insulating layers (121, 122) must also be watertight, but retain sufficient flexibility to allow the semi-finished product (101, 102) to be rolled for installation on an automatic draper machine, and to be able to undergo a peel-press operation on the preform without the integrity of said layers being degraded by these mechanical stresses.
  • the semifinished product (101, 102) of the invention must ensure the transfer of mechanical loads between the folds located on either side of said semi-product, without constituting a weak zone in the stack and without losing its integrity with respect to its electrical insulation and sealing properties.
  • the conductive layer (105) consists of a foil.
  • Said foil (105) may consist of a copper foil or an aluminum alloy. Since said foil (105) is thin, it is easily adapted to draping operations.
  • the foil has a width of 20 mm, which for a conductive section of 1 mm 2 leads to a thickness (135) of said foil of 0.05 mm.
  • This foil of thin layer can be inserted in thin resin layers, thus, the insulating layers (121, 122) can consist of a thermosetting resin, partially polymerized, for example with a resin polymerization rate of the order of 60 at 80%.
  • This partial polymerization placing said resin in a so-called half-cooked state, makes it possible to preserve said resin with a certain tack, so that the bonding layers (111, 112) are constituted by the outside of the insulating layers (121, 122 ).
  • the flexibility of the band is then sufficient to be draped, but of sufficient rigidity to support said foil and prevent it from creasing during these draping operations.
  • the subsequent firing of the lamination corresponding to the finished part makes it possible, by the polymerization of the assembly, to produce a strongly cohesive connection of the semi-finished product (101) with the rest of the part.
  • the conductive layer (106) consists of a plurality of conductors, for example in the form of so-called flat cables.
  • This configuration makes it possible to transit different signals in each of the conductors.
  • the section of each conductor must be sufficient individually so that, compared to the foil (105), this technical solution leads to a substantially greater thickness (136) of each of the conductors.
  • each flat cable having a width (146) of 2 mm, a conductive section of 1 mm 2 is obtained for a thickness (136) of conductors of 0.5 mm.
  • this embodiment leads to a substantially higher semi-product thickness (102).
  • each flat cable must be spaced transversely from its neighbor by a distance (246) sufficient, typically of the same order of magnitude as the width (146) of the cable. This distance must also be filled by the insulating layers (121, 122).
  • the insulating layers (121, 122) are advantageously made of a partially vulcanized elastomer.
  • the flexibility of the insulating layers (121, 122) is controlled at different stages of manufacture of the semi-product (102) and its implementation for the constitution of a laminated structural part, by the vulcanization rate of said layers (121, 122) insulating.
  • the conductors or the foil are unwound from a roller (306) of great length.
  • a continuous surface treatment (310) two strips (321, 322) are attached to said conductors or foil by rolling (330) or calendering.
  • the two strips (321, 322) consist of a raw elastomer.
  • the strips (321, 322) of elastomer are very malleable and plastic and, during the calendering operation (330), they perfectly fit the conductors (306) and in particular fill the spaces between said conductors.
  • the assembly thus produced is then partially vulcanized by passing through a cooking station (340) for example with a vulcanization rate of the order of 60%.
  • the insulating elastomer layers achieve a cohesion and elastic behavior that allows to roll (350) the tape on a roll for installation on an automatic draper and the removal of the said tape by draping on a pegy preform.
  • the partially vulcanized semi-finished product is cooked or consolidated with said preform.
  • the rigidity thereof increases, so that a mechanical transfer of forces can be achieved through said semi-product.
  • the presence of polyetherimide in the elastomer constituting said insulating layers (121, 122) allows a strong chemical cohesion between the semi-finished product of the invention and the rest of the stratification, because of the at least partial miscibility of this polymer in both thermoplastic resins and thermosetting resins.
  • a very rigid laminate allows an effective transfer of forces on either side of the semi-product (101, 102) object of the invention when it is integrated into the final piece.
  • the elasticity of the semi-product gives the structural part incorporating said semi-product vibroacoustic damping capabilities.
  • the invention achieves the desired objectives, in particular it allows the continuous and economical manufacture of semifinished products (101, 102) ready to be draped with the aid of an automatic machine and integrable on demand in the lamination of a composite piece with fibrous reinforcement, giving said room capabilities for routing a signal or electrical power.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Laminated Bodies (AREA)
  • Moulding By Coating Moulds (AREA)

Description

L'invention concerne un semi-produit sous la forme d'une bande conductrice intégrable dans un matériau composite stratifié. L'invention est plus particulièrement, mais non exclusivement, applicable dans le domaine aéronautique pour la réalisation d'éléments constitués de matériaux composites renforcés par un renfort fibreux dans une matrice constituée d'un polymère, afin de conférer à ces éléments de structure des capacités de conduction électrique.The invention relates to a semifinished product in the form of an integrated conductive strip in a laminated composite material. The invention is more particularly, but not exclusively, applicable in the aeronautical field for producing elements made of composite materials reinforced by a fibrous reinforcement in a matrix made of a polymer, in order to confer on these structural elements capabilities electrical conduction.

Des éléments structuraux constitués d'un matériau composite stratifié à renfort fibreux et présentant, par ailleurs, des propriétés de conduction électrique sont décrits dans l'art antérieur et notamment dans le document FR-A-2924894 . Ce document divulgue une pièce structurale stratifiée comprenant, entre deux plis de renfort fibreux, une couche comportant un réseau de câbles conducteurs. Ledit document décrit également un procédé d'obtention d'un tel élément structural, dans lequel des couches de câbles conducteurs sont insérées entre une ou plusieurs paires de plis structuraux, de sorte à constituer une préforme sèche, l'ensemble étant ensuite imprégné d'une résine par un procédé de transfert de résine afin d'en constituer la matrice et d'apporter la cohésion du matériau composite. Ce procédé d'obtention par transfert de résine n'est cependant pas adapté, ou s'avère peu productif, pour certaines pièces notamment les pièces de faible épaisseur et de grande dimension, telles que des panneaux de fuselage, où un tel procédé ne peut rivaliser, en termes de productivité, notamment avec des procédés mettant en oeuvre le drapage de plis pré-imprégnés.Structural elements made of a laminated composite material with fiber reinforcement and having, moreover, electrical conduction properties are described in the prior art and in particular in the document FR-A-2924894 . This document discloses a laminated structural part comprising, between two fibrous reinforcement plies, a layer comprising a network of conductive cables. Said document also describes a method for obtaining such a structural element, wherein layers of conductive cables are inserted between one or more pairs of structural folds, so as to constitute a dry preform, the assembly then being impregnated with a resin by a resin transfer process to form the matrix and to provide the cohesion of the composite material. This method of obtaining by resin transfer is however not suitable, or proves to be unproductive, for certain parts, particularly thin and large parts, such as fuselage panels, where such a method can not be used. to compete, in terms of productivity, especially with processes implementing draping pre-impregnated folds.

Le document US 2006/169481 A1 décrit un câble métallique plat 10 comportant dans sa section transversale: - une première couche 12 conductrice constituée d'un matériau électriquement conducteur; - deux couches 14, 16 isolantes électriquement constituées d'un matériau diélectrique; - deux couches 28 de liaison s'étendant en épaisseur de part et d'autre des couches isolantes à l'extérieur du semi produit.The document US 2006/169481 A1 discloses a flat wire rope 10 having in its cross-section: a first conductive layer 12 made of an electrically conductive material; two electrically insulating layers 14, 16 made of a dielectric material; two connecting layers 28 extending in thickness on either side of the insulating layers outside the semi-product.

Le document US 2001/011603 A1 décrit un câble métallique plat 11 comportant dans sa section transversale: - une première couche 11c conductrice constituée d'un matériau électriquement conducteur; - deux couches 11b isolantes électriquement constituées d'un matériau diélectrique enserrant complètement la couche conductrice et dont la largeur en section est supérieure à la largeur de la couche conductrice.The document US 2001/011603 A1 discloses a flat wire rope 11 having in its cross-section: a first conductive layer 11c made of an electrically conductive material; two electrically insulating layers 11b made of a dielectric material completely enclosing the conductive layer and whose width in section is greater than the width of the conductive layer.

Afin de résoudre les inconvénients de l'art antérieur, l'invention propose un semi-produit selon la revendication 1, sous la forme d'une bande, apte à être déposé par drapage pour la constitution d'un matériau composite stratifié lequel semi-produit comprend selon une section transversale et sur toute sa longueur :

  1. a. une première couche conductrice constituée d'un matériau électriquement conducteur ;
  2. b. deux couches isolantes électriquement constituées d'un matériau diélectrique enserrant complètement la bande conductrice et dont la largeur en section est supérieure à la largeur de la bande conductrice ;
  3. c. deux couches de liaison s'étendant en épaisseur de part et d'autre des couches isolantes à l'extérieur du semi-produit.
In order to overcome the drawbacks of the prior art, the invention proposes a semi-finished product according to claim 1, in the form of a strip, capable of being deposited by draping for the constitution of a laminated composite material which semi-product comprises in a cross section and over its entire length:
  1. at. a first conductive layer made of a material electrically conductive;
  2. b. two electrically insulating layers consisting of a dielectric material completely enclosing the conductive strip and whose section width is greater than the width of the conductive strip;
  3. c. two connecting layers extending in thickness on either side of the insulating layers outside the semi-finished product.

Ainsi, le semi-produit selon l'invention comprend des couches de liaison permettant, d'une part, d'assurer la liaison dudit semi-produit avec une préforme au moment du drapage, et d'autre part, la cohésion de la couche conductrice avec l'ensemble de la stratification du matériau composite, lors de la cuisson ou de la consolidation de l'empilement constituant la pièce dans laquelle est intégrée ladite couche conductrice. Ainsi, une telle pièce, intégrant une couche conductrice, peut être réalisée par des techniques de drapage manuelles ou automatisées, mettant en oeuvre des plis pré-imprégnés.Thus, the semi-finished product according to the invention comprises connecting layers making it possible, on the one hand, to ensure the connection of said semi-product with a preform at the time of draping, and on the other hand, the cohesion of the layer. conductive with all the stratification of the composite material, during the cooking or consolidation of the stack constituting the part in which is integrated said conductive layer. Thus, such a part, incorporating a conductive layer, can be achieved by manual or automated draping techniques, implementing pre-impregnated folds.

L'invention peut être mise en oeuvre selon les modes de réalisation avantageux, exposés ci-après, lesquels peuvent être considérés individuellement ou selon toute combinaison techniquement opérante.The invention can be implemented according to the advantageous embodiments, described below, which can be considered individually or in any technically operative combination.

Avantageusement, les couches isolantes sont constituées d'un élastomère partiellement vulcanisé. Outre le fait d'assurer l'isolation électrique de la couche conductrice, cette couche d'élastomère confère à la pièce stratifiée comportant une couche conductrice, intégrée dans ladite pièce par l'intermédiaire d'un semi-produit selon l'invention, des capacités d'absorption vibro-acoustique et une aptitude à la protection mécanique de la dite couche conductrice. La vulcanisation partielle des couches isolantes permet de parfaire cette vulcanisation lors de la cuisson de la pièce stratifiée intégrant le semi-produit selon l'invention, et d'assurer ainsi une forte cohésion de la couche conductrice avec le reste de la pièce.Advantageously, the insulating layers consist of a partially vulcanized elastomer. In addition to ensuring the electrical insulation of the conductive layer, this elastomer layer gives the laminated piece having a conductive layer integrated in said part via a semi-finished product according to the invention, vibroacoustic absorption capabilities and ability to mechanically protect said conductive layer. The partial vulcanization of the insulating layers makes it possible to perfect this vulcanization during the firing of the laminated part incorporating the semi-finished product according to the invention, and thus to ensure a strong cohesion of the conductive layer with the rest of the part.

Par exemple, les couches isolantes sont constituées d'un élastomère partiellement vulcanisé avec un taux de vulcanisation de l'ordre de 60 %. Une telle vulcanisation partielle est réalisée par chauffage pendant un temps court. A titre d'information, la température de chauffage est généralement de l'ordre de 110°C.For example, the insulating layers consist of a partially vulcanized elastomer with a vulcanization rate of the order of 60%. Such partial vulcanization is achieved by heating for a short time. AT As information, the heating temperature is generally of the order of 110 ° C.

Avantageusement, les couches de liaison sont constituées d'une colle thermodurcissable. Ainsi, le semi-produit présente une pégosité adéquate pour son dépôt par drapage sur une préforme.Advantageously, the bonding layers consist of a thermosetting glue. Thus, the semifinished product has adequate tackiness for its deposition by draping on a preform.

Selon un mode de réalisation particulier, les couches de liaisons sont constituées d'un polymère thermoplastique. Cette caractéristique améliore la tenue à l'impact et aux sollicitations thermiques de l'ensemble du stratifié dans lequel un tel semi-produit est intégré.According to a particular embodiment, the tie layers consist of a thermoplastic polymer. This feature improves the resistance to impact and thermal stresses of the entire laminate in which such a semi-product is integrated.

Selon ce mode de réalisation particulier, le polymère thermoplastique comporte du polyétherimyde ou PEI. Ce polymère étant au moins partiellement miscible dans de nombreuses résines thermodurcissables et thermoplastiques, cette caractéristique permet d'assurer une forte cohésion de la couche conductrice avec le reste de la pièce composite stratifiéeAccording to this particular embodiment, the thermoplastic polymer comprises polyetherimide or PEI. Since this polymer is at least partially miscible in many thermosetting and thermoplastic resins, this characteristic makes it possible to ensure a strong cohesion of the conductive layer with the rest of the laminated composite part.

Selon un autre mode de réalisation avantageux, les couches isolantes et les couches de liaison sont constituées d'une résine thermodurcissable partiellement polymérisée. Ainsi, le semi-produit objet de l'invention s'intègre parfaitement par drapage dans une stratification de plis pré-imprégnés d'une telle résine thermodurcissable. La polymérisation partielle permet à la fois de conserver la cohésion du semi-produit objet de l'invention au cours du drapage mais aussi de conserver à celle-ci la souplesse nécessaire à cette opération de drapage.According to another advantageous embodiment, the insulating layers and the bonding layers consist of a partially polymerized thermosetting resin. Thus, the semi-product object of the invention fits perfectly by draping in a lamination of pre-impregnated plies of such a thermosetting resin. The partial polymerization makes it possible at one and the same time to preserve the cohesion of the semifin object of the invention during draping, but also to preserve the flexibility required for this draping operation.

Par exemple, les couches isolantes et les couches de liaison sont constituées d'une résine thermodurcissable partiellement polymérisée, avec un taux de polymérisation de la résine de 60 à 80 %. Une telle polymérisation partielle est réalisée par chauffage pendant un temps court. A titre d'information, la température de chauffage est de l'ordre de généralement autour de 80°C à 110°C, selon les résines utilisées.For example, the insulating layers and the bonding layers consist of a partially polymerized thermosetting resin, with a resin polymerization rate of 60 to 80%. Such a partial polymerization is carried out by heating for a short time. By way of information, the heating temperature is of the order of generally around 80 ° C. to 110 ° C., depending on the resins used.

Selon un mode de réalisation, alternatif au précédent, les couches isolantes et les couches de liaison sont constituées d'un élastomère thermoplastique comprenant du polyétherimyde (PEI). Ainsi, le semi-produit objet de l'invention est apte à être intégré dans une stratification constituant un composite à matrice thermoplastique ou thermodurcissable.According to one embodiment, alternative to the previous one, the insulating layers and the tie layers consist of a thermoplastic elastomer comprising polyetherimide (PEI). So the semi-product The subject of the invention is capable of being integrated in a stratification constituting a thermoplastic or thermosetting matrix composite.

Selon une première variante du semi-produit objet de l'invention, compatible avec tous les modes de réalisation précédents, la couche conductrice est constituée d'un clinquant métallique, d'une tresse ou d'un câble métallique. La finesse d'un tel clinquant permet à la bande d'épouser tout type de forme y compris des formes en double courbure.According to a first variant of the semi-product object of the invention, compatible with all the previous embodiments, the conductive layer consists of a metal foil, a braid or a metal cable. The finesse of such a foil allows the band to marry any type of shape including shapes double curvature.

Avantageusement, ledit clinquant métallique est constitué d'un alliage d'aluminium qui peut être obtenu par laminage en épaisseur extrêmement fine et présente une faible masse volumique. Le clinquant métallique peut également être constitué d'un alliage de cuivre.Advantageously, said metal foil is made of an aluminum alloy which can be obtained by rolling in extremely thin thickness and has a low density. The metal foil may also be made of a copper alloy.

Selon une deuxième variante, également compatible avec les modes de réalisation précédents, la couche conductrice est constituée d'une pluralité de conducteurs métalliques isolés électriquement les uns des autres. Ainsi, d'une part, plusieurs signaux électriques différents peuvent être transmis dans chacun des conducteurs et la séparation latérale des conducteurs entre eux permet d'utiliser des conducteurs plus épais sans nuire à la capacité de mise en forme du semi-produit.According to a second variant, which is also compatible with the previous embodiments, the conductive layer consists of a plurality of metallic conductors electrically insulated from one another. Thus, on the one hand, several different electrical signals can be transmitted in each of the conductors and the lateral separation of the conductors from one another makes it possible to use thicker conductors without impairing the shaping capacity of the semi-finished product.

L'invention concerne également un procédé pour la fabrication d'un tel semi-produit selon les différents modes de réalisation, lequel semi-produit comprend des couches isolantes en élastomère, ledit procédé comprenant les étapes consistant à :

  1. a recouvrir par une opération de calandrage une bande de matériau électriquement conducteur par deux couches d'élastomère cru ;
  2. b vulcaniser l'ensemble constitué lors de l'étape précédente ;
  3. c conditionner l'ensemble sous la forme d'un rouleau apte à être utilisé dans une machine à draper.
The invention also relates to a process for manufacturing such a semi-product according to the different embodiments, which semi-product comprises elastomer insulating layers, said method comprising the steps of:
  1. covering, by a calendering operation, a strip of electrically conductive material with two layers of raw elastomer;
  2. vulcanizing the assembly formed in the previous step;
  3. c conditioning the assembly in the form of a roll suitable for use in a draper machine.

Ainsi, le procédé objet de l'invention permet de fabriquer de manière automatique de grandes quantités de semi-produit, conditionné sous forme de bandes ou de bobines, lesquelles bobines peuvent être stockées et intégrées autant que de besoin à des stratifiés constituant des pièces en matériau composite.Thus, the method which is the subject of the invention makes it possible to manufacture automatically large quantities of semi-finished products, in the form of strips or coils, which coils can be stored and integrated as much as necessary into laminates constituting parts in material composite.

L'invention est exposée ci-après selon ses modes de réalisation préférés, nullement limitatifs, et en référence aux figures 1 à 3, dans lesquelles :

  • la figure 1 est une vue en éclaté et en section selon une coupe A-A, définie figure 2, de deux exemples de réalisation d'un semi-produit selon l'invention, figure 1A, selon une variante de réalisation comprenant un clinquant comme couche conductrice et figure 1B selon une variante de réalisation où cette couche conductrice comprend une pluralité de conducteurs ;
  • la figure 2 représente selon une vue en élévation, un semi-produit selon une variante de réalisation de l'invention comportant une pluralité de conducteurs dans la couche conductrice ;
  • et la figure 3 est un synoptique d'un exemple de procédé de réalisation en continu d'un semi-produit selon l'invention.
The invention is explained below according to its preferred embodiments, which are in no way limiting, and with reference to Figures 1 to 3 , in which :
  • the figure 1 is an exploded and sectional view in AA section, defined figure 2 of two embodiments of a semi-finished product according to the invention, Figure 1A according to an embodiment variant comprising a foil as conductive layer and Figure 1B according to an alternative embodiment wherein said conductive layer comprises a plurality of conductors;
  • the figure 2 represents in elevational view, a semi-product according to an alternative embodiment of the invention comprising a plurality of conductors in the conductive layer;
  • and the figure 3 is a block diagram of an exemplary method for continuously producing a semi-finished product according to the invention.

Figure 1, selon un premier exemple de réalisation d'un semi-produit (101, 102) objet de l'invention, celle-ci comprend, au coeur, une couche conductrice (105, 106) qui, selon une première variante (101) de réalisation, peut être constituée d'un clinquant (105) métallique, figure 1A, ou, selon une deuxième variante (102), constituée d'une pluralité (106) de conducteurs, figure 1B disposés en nappe, préférentiellement sous la forme de câbles métalliques dits plats. Cette couche conductrice (105, 106) est enserrée entre deux couches (121, 122) isolantes, constituées d'un matériau diélectrique, préférentiellement, mais non exclusivement, un élastomère. Avantageusement, le semi-produit (101, 102) selon l'invention comprend deux couches (111, 112) dites couches de liaison présentant des caractéristiques d'interface rendant ledit semi-produit (101, 102) apte au drapage sur une machine à draper automatique et apte à former une interface cohésive avec des couches de renfort fibreux pré-imprégnées à la suite d'une opération de cuisson ou de consolidation. Lesdites couches de liaison (111, 112) peuvent être des couches rapportées sur les couches isolantes, par imprégnation de ces couches à chaud ou à froid, ou faire partie intégrante desdites couches isolantes. Figure 1 according to a first embodiment of a semifinished product (101, 102) according to the invention, the latter comprises, at the core, a conductive layer (105, 106) which, according to a first variant (101) of embodiment, may consist of a metal foil (105), Figure 1A , or, in a second variant (102), consisting of a plurality (106) of conductors, Figure 1B arranged in a sheet, preferably in the form of so-called flat metal cables. This conductive layer (105, 106) is sandwiched between two insulating layers (121, 122) made of a dielectric material, preferably, but not exclusively, an elastomer. Advantageously, the semifinished product (101, 102) according to the invention comprises two layers (111, 112) called connection layers having interface characteristics rendering said semi-finished product (101, 102) capable of being draped on a machine. automatic draper and able to form a cohesive interface with fibrous reinforcement layers pre-impregnated following a cooking or consolidation operation. Said bonding layers (111, 112) may be layers attached to the insulating layers, by impregnation of these layers hot or cold, or be an integral part of said insulating layers.

Les dites couches isolantes (121, 122) doivent être suffisamment épaisses pour assurer une isolation électrique totale de la couche conductrice (105, 106) de son environnement dans le produit fini, c'est-à-dire après que le semi-produit (101, 102) objet de l'invention ait subi un drapage en forme, pour l'insérer au coeur d'un stratifié, puis une opération de cuisson ou de consolidation à haute température et sous pression. Cette isolation doit être totale et effective, surtout pour des hautes tensions, de l'ordre de 3000 volts. Ainsi, les couches isolantes (121, 122) doivent également être étanches, mais conserver une souplesse suffisante pour pouvoir autoriser la mise en rouleau du semi-produit (101, 102) en vue de son installation sur une machine à draper automatique, et pouvoir subir une opération de déroulage-pressage sur la préforme sans que l'intégrité desdites couches ne soit dégradée par ces sollicitations mécaniques. Finalement, une fois placée dans le produit fini au sein d'un empilement de plis renforcés par des fibres à haute performance, le semi-produit (101, 102) objet de l'invention doit assurer le transfert des charges mécaniques entre les plis situés de part et d'autre dudit semi-produit, sans constituer une zone faible dans l'empilement et sans perdre son intégrité vis-à-vis de ses propriétés d'isolation électrique et d'étanchéité.Said insulating layers (121, 122) must be sufficiently thick to ensure complete electrical insulation of the conductive layer (105, 106) of its environment in the finished product, ie after the semi-finished product ( 101, 102) object of the invention has undergone a form of draping, to insert it in the heart of a laminate, and then a cooking or consolidation operation at high temperature and under pressure. This insulation must be total and effective, especially for high voltages, of the order of 3000 volts. Thus, the insulating layers (121, 122) must also be watertight, but retain sufficient flexibility to allow the semi-finished product (101, 102) to be rolled for installation on an automatic draper machine, and to be able to undergo a peel-press operation on the preform without the integrity of said layers being degraded by these mechanical stresses. Finally, once placed in the finished product within a stack of plies reinforced with high performance fibers, the semifinished product (101, 102) of the invention must ensure the transfer of mechanical loads between the folds located on either side of said semi-product, without constituting a weak zone in the stack and without losing its integrity with respect to its electrical insulation and sealing properties.

La réponse à l'ensemble de ces spécifications conduit à des propriétés contradictoires. Ainsi, un transfert effectif des efforts au travers du semi-produit intégré dans le produit fini conduit à privilégier la rigidité de la bande, alors que les propriétés d'absorption vibro-acoustiques et protectrices des conducteurs conduisent à en privilégier la souplesse. Les conditions dépendent également de l'épaisseur du semi-produit (101, 102) et par conséquent de la section de la couche conductrice (105, 106) au coeur dudit semi-produit.The answer to all these specifications leads to contradictory properties. Thus, an effective transfer of forces through the semi-product integrated into the finished product leads to favoring the stiffness of the band, while the vibroacoustic and protective absorption properties of the conductors lead to favor the flexibility. The conditions also depend on the thickness of the semi-product (101, 102) and therefore the section of the conductive layer (105, 106) in the heart of said semi-product.

Ainsi, selon un exemple de réalisation, figure 1A, la couche conductrice (105) est constituée d'un clinquant. Ledit clinquant (105) peut être constitué d'une feuille de cuivre ou d'un alliage d'aluminium. Ledit clinquant (105) étant fin, il se prête facilement aux opérations de drapage. À titre d'exemple non limitatif, le clinquant a une largeur de 20 mm, ce qui, pour une section conductrice de 1 mm2 conduit à une épaisseur (135) dudit clinquant de 0,05 mm. Ce clinquant de faible épaisseur peut être inséré dans de fines couches de résine, ainsi, les couches isolantes (121, 122) peuvent être constituées d'une résine thermodurcissable, partiellement polymérisée, par exemple avec un taux de polymérisation de la résine de l'ordre de 60 à 80 %. Cette polymérisation partielle, plaçant ladite résine dans un état dit mi-cuit, permet de conserver à ladite résine une certaine pégosité, de sorte que les couches de liaison (111, 112) sont constituées par l'extérieur des couches isolantes (121, 122). La souplesse de la bande est alors suffisante pour être drapée, mais d'une rigidité suffisante pour soutenir ledit clinquant et éviter qu'il ne se froisse durant ces opérations de drapage. La cuisson ultérieure de la stratification correspondant à la pièce finie permet, par la polymérisation de l'ensemble, de réaliser une liaison fortement cohésive du semi-produit (101) avec le reste de la pièce.Thus, according to an exemplary embodiment, Figure 1A the conductive layer (105) consists of a foil. Said foil (105) may consist of a copper foil or an aluminum alloy. Since said foil (105) is thin, it is easily adapted to draping operations. By way of non-limiting example, the foil has a width of 20 mm, which for a conductive section of 1 mm 2 leads to a thickness (135) of said foil of 0.05 mm. This foil of thin layer can be inserted in thin resin layers, thus, the insulating layers (121, 122) can consist of a thermosetting resin, partially polymerized, for example with a resin polymerization rate of the order of 60 at 80%. This partial polymerization, placing said resin in a so-called half-cooked state, makes it possible to preserve said resin with a certain tack, so that the bonding layers (111, 112) are constituted by the outside of the insulating layers (121, 122 ). The flexibility of the band is then sufficient to be draped, but of sufficient rigidity to support said foil and prevent it from creasing during these draping operations. The subsequent firing of the lamination corresponding to the finished part makes it possible, by the polymerization of the assembly, to produce a strongly cohesive connection of the semi-finished product (101) with the rest of the part.

Selon un autre exemple de réalisation, figure 1B, la couche conductrice (106) est constituée d'une pluralité de conducteurs, par exemple sous la forme de câbles dits plats. Cette configuration permet de faire transiter différents signaux dans chacun des conducteurs. En contrepartie, la section de chaque conducteur doit être suffisante individuellement de sorte que, comparativement au clinquant (105), cette solution technique conduit à une épaisseur (136) nettement supérieure de chacun des conducteurs. À titre d'exemple, non limitatif, chaque câble plat ayant une largeur (146) de 2 mm, une section conductrice de 1 mm2 est obtenue pour une épaisseur (136) de conducteurs de 0,5 mm. Aussi, ce mode de réalisation conduit à une épaisseur de semi-produit (102) nettement plus élevée.According to another embodiment, Figure 1B , the conductive layer (106) consists of a plurality of conductors, for example in the form of so-called flat cables. This configuration makes it possible to transit different signals in each of the conductors. In return, the section of each conductor must be sufficient individually so that, compared to the foil (105), this technical solution leads to a substantially greater thickness (136) of each of the conductors. By way of nonlimiting example, each flat cable having a width (146) of 2 mm, a conductive section of 1 mm 2 is obtained for a thickness (136) of conductors of 0.5 mm. Also, this embodiment leads to a substantially higher semi-product thickness (102).

Par ailleurs, figure 2, chaque câble plat doit être éloigné transversalement de son voisin, d'une distance (246) suffisante, typiquement du même ordre de grandeur que la largeur (146) du câble. Cette distance doit également être comblée par les couches (121, 122) isolantes.Otherwise, figure 2 each flat cable must be spaced transversely from its neighbor by a distance (246) sufficient, typically of the same order of magnitude as the width (146) of the cable. This distance must also be filled by the insulating layers (121, 122).

En revenant à la figure 1B, selon ce mode de réalisation comprenant une couche conductrice (106) comportant une pluralité de conducteurs, les couches (121, 122) isolantes sont avantageusement constituées d'un élastomère partiellement vulcanisé. Ainsi, la souplesse des couches (121, 122) isolantes est contrôlée aux différents stades de la fabrication du semi-produit (102) et de sa mise en oeuvre pour la constitution d'une pièce structurale stratifiée, par le taux de vulcanisation desdites couches (121, 122) isolantes.Returning to Figure 1B according to this embodiment comprising a conductive layer (106) having a plurality of conductors, the insulating layers (121, 122) are advantageously made of a partially vulcanized elastomer. Thus, the flexibility of the insulating layers (121, 122) is controlled at different stages of manufacture of the semi-product (102) and its implementation for the constitution of a laminated structural part, by the vulcanization rate of said layers (121, 122) insulating.

Figure 3, selon un exemple de fabrication continue du semi-produit objet de l'invention, les conducteurs ou le clinquant sont déroulés depuis un rouleau (306) de grande longueur. Après un traitement de surface continu (310), deux bandes (321, 322) sont rapportées sur lesdits conducteurs ou clinquant par laminage (330) ou calandrage. Avantageusement, les deux bandes (321, 322) sont constituées d'un élastomère cru. Figure 3 , according to an example of continuous manufacture of the semi-product of the invention, the conductors or the foil are unwound from a roller (306) of great length. After a continuous surface treatment (310), two strips (321, 322) are attached to said conductors or foil by rolling (330) or calendering. Advantageously, the two strips (321, 322) consist of a raw elastomer.

Dans cet état cru, les bandes (321, 322) d'élastomère sont très malléables et plastiques et, lors de l'opération de calandrage (330), elles épousent parfaitement les conducteurs (306) et notamment comblent les espaces entre lesdits conducteurs. L'assemblage ainsi réalisé, est ensuite partiellement vulcanisé par le passage dans un poste de cuisson (340) par exemple avec un taux de vulcanisation de l'ordre de 60 %.In this green state, the strips (321, 322) of elastomer are very malleable and plastic and, during the calendering operation (330), they perfectly fit the conductors (306) and in particular fill the spaces between said conductors. The assembly thus produced, is then partially vulcanized by passing through a cooking station (340) for example with a vulcanization rate of the order of 60%.

À l'issue de cette vulcanisation partielle, les couches d'élastomère isolantes atteignent une cohésion et un comportement élastique qui permet d'enrouler (350) la bande sur un rouleau pour leur installation sur une machine à draper automatique et la dépose de la dite bande par drapage sur une préforme pégueuse.After this partial vulcanization, the insulating elastomer layers achieve a cohesion and elastic behavior that allows to roll (350) the tape on a roll for installation on an automatic draper and the removal of the said tape by draping on a pegy preform.

Après avoir été intégré dans la préforme, le semi-produit, partiellement vulcanisée est cuit ou consolidé avec la dite préforme. Au cours de cette cuisson, selon le taux de vulcanisation des couches (121, 122) isolantes, la rigidité de celles-ci augmente, de sorte qu'un transfert mécanique des efforts peut être réalisé à travers ledit semi-produit. La présence de polyétherimyde dans l'élastomère constituant lesdites couches (121, 122) isolantes, permet une forte cohésion chimique entre le semi-produit objet de l'invention et le reste de la stratification, du fait de la miscibilité au moins partielle de ce polymère tant dans les résines thermoplastiques que les résines thermodurcissables. Ainsi un stratifié très rigide, permet un transfert efficace des efforts de part et d'autre du semi-produit (101, 102) objet de l'invention lorsque celle-ci est intégrée dans la pièce finale. L'élasticité du semi-produit confère à la pièce structurale intégrant ledit semi-produit des capacités d'amortissement vibro-acoustiques.After having been integrated in the preform, the partially vulcanized semi-finished product is cooked or consolidated with said preform. During this cooking, according to the vulcanization rate of the layers (121, 122) insulating, the rigidity thereof increases, so that a mechanical transfer of forces can be achieved through said semi-product. The presence of polyetherimide in the elastomer constituting said insulating layers (121, 122) allows a strong chemical cohesion between the semi-finished product of the invention and the rest of the stratification, because of the at least partial miscibility of this polymer in both thermoplastic resins and thermosetting resins. Thus a very rigid laminate, allows an effective transfer of forces on either side of the semi-product (101, 102) object of the invention when it is integrated into the final piece. The elasticity of the semi-product gives the structural part incorporating said semi-product vibroacoustic damping capabilities.

La description ci-avant et les exemples de réalisation montrent que l'invention atteint les objectifs visés, en particulier elle permet la fabrication en continu et de manière économique de semi-produits (101, 102) prêts à être drapés à l'aide d'une machine automatique et intégrables à la demande dans la stratification d'une pièce composite à renfort fibreux, conférant à la dite pièce des capacités d'acheminement d'un signal ou d'une puissance électrique.The above description and the exemplary embodiments show that the invention achieves the desired objectives, in particular it allows the continuous and economical manufacture of semifinished products (101, 102) ready to be draped with the aid of an automatic machine and integrable on demand in the lamination of a composite piece with fibrous reinforcement, giving said room capabilities for routing a signal or electrical power.

Claims (11)

  1. Semifinished product in the form of a band (101, 102), capable of being deposited by drape forming in order to form a laminated composite material having fibrous reinforcement, the semifinished product comprises, along a cross section and over its entire length:
    a. a first conductive layer (105, 106) formed of an electrically conductive material;
    b. two electrically insulating layers (121, 122) formed of a dielectric material completely enclosing the conductive layer (105, 106), the sectional width of which is greater than the width of the conductive layer;
    c. two bonding layers (111, 112) extending in thickness on either side of the insulating layers (121, 122) on the outside of the semifinished product, the said two bonding layers exhibiting interfacial characteristics such that the semifinished product is capable of forming a cohesive interface with preimpregnated fibrous reinforcing layers subsequent to a curing or consolidation operation.
  2. Semifinished product according to Claim 1, characterized in that the insulating layers (121, 122) are formed of a partially vulcanized elastomer.
  3. Semifinished product according to Claim 2, characterized in that the bonding layers (111, 112) are formed of a thermosetting adhesive.
  4. Semifinished product according to Claim 2, characterized in that the bonding layers (111, 112) are formed of a thermoplastic polymer.
  5. Semifinished product according to Claim 4, characterized in that the thermoplastic polymer constituting the bonding layers (111, 112) comprises polyetherimide.
  6. Semifinished product according to Claim 1, characterized in that the insulating layers (121, 122) and the bonding layers (111, 112) are formed of a partially polymerized thermosetting resin.
  7. Semifinished product according to Claim 1, characterized in that insulating layers (121, 122) and the bonding layers (111, 112) are formed of a thermoplastic elastomer comprising polyetherimide.
  8. Semifinished product according to Claim 1, characterized in that the conductive layer (105) is formed of a metal foil.
  9. Semifinished product according to Claim 8, characterized in that the foil (105) is formed of an aluminium alloy.
  10. Semifinished product according to Claim 1, characterized in that the conductive layer is formed of a plurality (106) of metal conductors electrically insulated from one another.
  11. Process for the production of a semifinished product according to Claim 2, characterized in that it comprises stages consisting in:
    a. covering, by a calendering operation (330), a band (306) of electrically conductive material with two layers (321, 322) of raw elastomer;
    b. partially vulcanizing (340) the combination formed during the preceding stage;
    c. packaging (350) the combination in the form of a roll capable of being used in a draping machine.
EP12722133.1A 2011-05-27 2012-05-15 Semi-finished product in the form of a conductive strip that can be embedded in a composite material, and method for manufacturing such a strip Active EP2715742B1 (en)

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FR1154667A FR2975864A1 (en) 2011-05-27 2011-05-27 SEMI-PRODUCT IN THE FORM OF A CONDUCTIVE BAND INTEGRABLE IN A COMPOSITE MATERIAL AND METHOD OF MANUFACTURING SUCH A BAND
PCT/EP2012/059056 WO2012163674A1 (en) 2011-05-27 2012-05-15 Semi-finished product in the form of a conductive strip that can be embedded in a composite material, and method for manufacturing such a strip

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FR3039923B1 (en) 2015-08-04 2020-10-09 Abmi Sud Est METHOD OF MANUFACTURING A COMPOSITE MATERIAL
CN109988522B (en) * 2017-12-29 2020-11-06 宁德时代新能源科技股份有限公司 Adhesive tape and electrochemical device comprising same
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