FR3089854A1 - Procede de preparation d’un materiau composite sous forme de sandwich - Google Patents
Procede de preparation d’un materiau composite sous forme de sandwich Download PDFInfo
- Publication number
- FR3089854A1 FR3089854A1 FR1873207A FR1873207A FR3089854A1 FR 3089854 A1 FR3089854 A1 FR 3089854A1 FR 1873207 A FR1873207 A FR 1873207A FR 1873207 A FR1873207 A FR 1873207A FR 3089854 A1 FR3089854 A1 FR 3089854A1
- Authority
- FR
- France
- Prior art keywords
- core
- sandwich
- insert
- outer layers
- manufacturing
- Prior art date
- Legal status (The legal status 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 status listed.)
- Granted
Links
- 238000000034 method Methods 0.000 title claims abstract description 25
- 239000002131 composite material Substances 0.000 title claims abstract description 15
- 238000002360 preparation method Methods 0.000 title description 2
- 239000000463 material Substances 0.000 claims abstract description 43
- 238000004519 manufacturing process Methods 0.000 claims abstract description 22
- 239000000835 fiber Substances 0.000 claims abstract description 16
- 239000011159 matrix material Substances 0.000 claims abstract description 7
- 229920001296 polysiloxane Polymers 0.000 claims abstract description 6
- 239000004744 fabric Substances 0.000 claims description 32
- 238000002844 melting Methods 0.000 claims description 16
- 230000008018 melting Effects 0.000 claims description 16
- 238000010438 heat treatment Methods 0.000 claims description 14
- 239000012779 reinforcing material Substances 0.000 claims description 13
- 238000007596 consolidation process Methods 0.000 claims description 12
- 229920005989 resin Polymers 0.000 claims description 11
- 239000011347 resin Substances 0.000 claims description 11
- 229920001169 thermoplastic Polymers 0.000 claims description 8
- 239000004416 thermosoftening plastic Substances 0.000 claims description 8
- 239000003365 glass fiber Substances 0.000 claims description 7
- 238000009940 knitting Methods 0.000 claims description 7
- 239000004697 Polyetherimide Substances 0.000 claims description 6
- 239000004743 Polypropylene Substances 0.000 claims description 6
- 229920001601 polyetherimide Polymers 0.000 claims description 6
- -1 polypropylene Polymers 0.000 claims description 6
- 229920001155 polypropylene Polymers 0.000 claims description 6
- 238000001816 cooling Methods 0.000 claims description 5
- 239000004643 cyanate ester Substances 0.000 claims description 5
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 4
- 239000004593 Epoxy Substances 0.000 claims description 4
- 239000004696 Poly ether ether ketone Substances 0.000 claims description 4
- 239000004917 carbon fiber Substances 0.000 claims description 4
- 238000002347 injection Methods 0.000 claims description 4
- 239000007924 injection Substances 0.000 claims description 4
- 229920002530 polyetherether ketone Polymers 0.000 claims description 4
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 4
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 4
- 239000002861 polymer material Substances 0.000 claims description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 3
- 229910052799 carbon Inorganic materials 0.000 claims description 3
- 238000003780 insertion Methods 0.000 claims description 3
- 230000037431 insertion Effects 0.000 claims description 3
- 239000004417 polycarbonate Substances 0.000 claims description 3
- 229920000515 polycarbonate Polymers 0.000 claims description 3
- 229920001187 thermosetting polymer Polymers 0.000 claims description 3
- 239000004760 aramid Substances 0.000 claims description 2
- 229920001568 phenolic resin Polymers 0.000 claims description 2
- 239000005011 phenolic resin Substances 0.000 claims description 2
- 229920000728 polyester Polymers 0.000 claims description 2
- 239000002952 polymeric resin Substances 0.000 claims description 2
- 238000000926 separation method Methods 0.000 claims description 2
- 229920003002 synthetic resin Polymers 0.000 claims description 2
- 229920006231 aramid fiber Polymers 0.000 claims 1
- 239000006261 foam material Substances 0.000 claims 1
- 239000003779 heat-resistant material Substances 0.000 abstract description 4
- 229920000642 polymer Polymers 0.000 abstract 1
- 229910000831 Steel Inorganic materials 0.000 description 10
- 239000010959 steel Substances 0.000 description 10
- 239000006260 foam Substances 0.000 description 7
- 230000002787 reinforcement Effects 0.000 description 6
- 229920006362 Teflon® Polymers 0.000 description 5
- 239000004809 Teflon Substances 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 4
- 230000001070 adhesive effect Effects 0.000 description 4
- 230000000694 effects Effects 0.000 description 3
- 239000003292 glue Substances 0.000 description 3
- 238000005470 impregnation Methods 0.000 description 3
- 230000003014 reinforcing effect Effects 0.000 description 3
- 229920003235 aromatic polyamide Polymers 0.000 description 2
- 238000010411 cooking Methods 0.000 description 2
- 230000004927 fusion Effects 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000012528 membrane Substances 0.000 description 2
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 2
- 239000004810 polytetrafluoroethylene Substances 0.000 description 2
- 229920002994 synthetic fiber Polymers 0.000 description 2
- 239000004753 textile Substances 0.000 description 2
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- 239000002313 adhesive film Substances 0.000 description 1
- 150000001408 amides Chemical class 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000001413 cellular effect Effects 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 239000002557 mineral fiber Substances 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 239000002990 reinforced plastic Substances 0.000 description 1
- 239000012783 reinforcing fiber Substances 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 239000012815 thermoplastic material Substances 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- 238000009941 weaving Methods 0.000 description 1
Classifications
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- 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
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C35/16—Cooling
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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
- B29C45/0001—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
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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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
- B29C45/14—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
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- 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
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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
- 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
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- 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
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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
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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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
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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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
- B29D24/005—Producing articles with hollow walls formed with structures, e.g. cores placed between two plates or sheets, e.g. partially filled the structure having joined ribs, e.g. honeycomb
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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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- B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
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Abstract
L'objet de l'invention est un procédé de fabrication d'un produit sous forme de sandwich comportant une âme et des couches extérieures. Les couches extérieures sont composées d’un matériau composite comportant une matrice polymérique renforcée de fibres. Le procédé utilise un insert en matière résistante à la chaleur, par exemple en silicone. Le but de la présente invention est de fournir un procédé de fabrication d’un sandwich qui permette de dissocier le choix de la matière de l’âme du sandwich et le choix de la matière des couches extérieures.
Description
Description
Titre de l’invention : PROCEDE DE PREPARATION D’UN MATERIAU COMPOSITE SOUS FORME DE SANDWICH
[0001] L’invention concerne le domaine des produits en matière composite ou matériaux composites. Par produits en matériaux composites, on entend un produit comportant une matrice en résine constituée d’une matière polymérique, en particulier, thermoplastique ou thermodurcissable, cette matrice étant renforcée par un matériau ayant un point de fusion plus élevé que le point de fusion de la matière polymérique. On parle généralement de LRP pour « Liber reinforced plastic ».
[0002] Les matériaux composites de type LRP sont bien connus depuis de nombreuses années. Ils présentent une bonne résistance mécanique par rapport au poids du matériau. Ils présentent également une très bonne résistance à la corrosion
[0003] Ils présentent des propriétés supérieures à celles des composants pris séparément. [0004] Ils permettent notamment, dans le domaine de l’automobile ou de l’aéronautique, l’allégement de pièces traditionnellement réalisées en acier.
[0005] Ils présentent également une bonne tenue à la fatigue.
[0006] Les renforts du composite peuvent être obtenus de différentes manières : par l’ajout de fibres minérales dispersées dans la matrice, par l’utilisation d’une armature en acier ou matériau de synthèse, par l’utilisation d’un tissu en fibres de renfort, par l’utilisation de non-tissés ou de mats ou autres produits obtenus par des procédés textiles..
[0007] Les renforts en tissus présentent une structure plane et sont composés de fils de trame et de fils de chaîne se croisant et s’entrelaçant perpendiculairement. Leur fabrication nécessite l’utilisation d’une bobine distincte par fil de chaîne.
[0008] Plus récemment, est apparu l’utilisation de renforts tricotés. Par renforts tricotés, on entend un produit obtenu généralement d’un fil continu où le fil forme des mailles entrelacées, disposées en rangs successifs. La réalisation d’un tricot traditionnel ne nécessite qu’une bobine de fil pour le fil de maille.
[0009] Un fil peut être de type monofilament ou multifilaments. Le multifilaments peut être un roving (c’est-à-dire ensemble de filaments continus parallèles assemblés sans torsion), un filé de fibres (c’est-à-dire un ensemble de fibres courtes discontinues assemblées par torsion) Un fil peut également être un assemblage de plusieurs fils ou filaments de matières différentes. Cet assemblage peut se faire par retordage, guipage... Il est donc possible de réaliser un fil comportant de la matière polymérique et de la matière de renfort. Par exemple, il est possible de réaliser l’assemblage d’un un fil de renfort de type aramide, carbone, verre... et d’un fil thermoplastique (Polypropylène, Polycarbonate, Polyetherimide (PEI)...). Ce type de fil est alors appelé fil mixte.
[0010] Le tricotage de ce type de fil mixte, permet d’obtenir une préforme, contenant à la fois le renfort et la matrice. Cette préforme est dite « sèche », par opposition au tissu préimprégné de résine gélifiée et collante appelé couramment « prepreg ».
[0011] Il est en outre possible de réaliser des produits sous forme de sandwich comportant deux couches extérieures, ou peaux, en matière composite de type FRP et un corps central, ou âme, en matière plus légère de type mousse ou en matière alvéolaire de type nid d’abeille. Grace à leur construction sous forme de sandwich, ces produits peuvent atteindre, à poids égal, de bien meilleures performances.
[0012] L’imprégnation des peaux et la liaison de celles-ci à l’âme influencent les propriétés finales du composite sandwich. Une bonne imprégnation des peaux requière généralement un procédé de consolidation en plusieurs étapes; ce qui est consommateur de temps et de ressources. Ceci est particulièrement le cas lorsque le produit fini a une forme 3D complexe.
[0013] Les procédés traditionnels pour réaliser un sandwich comportent généralement les étapes suivantes :
[0014] - réalisation des couches extérieures à l’aide de peaux préimprégnées de matière polymérique ;
- juxtaposition des couches extérieures de part et d’autre d’une âme, par exemple en nid d’abeille ou mousse ;
- consolidation des couches extérieures pour assurer la fusion de la matière polymérique, tout en assurant la liaison de l’ensemble des couches à l’âme.
[0015] Suivant l’épaisseur des peaux, il peut être nécessaire de superposer plusieurs plis. Plusieurs cycles de cuisson peuvent alors être nécessaires pour assurer une bonne consolidation des plis de tissu composant chaque peau et assurer une bonne adhérence entre les peaux et l’âme Avec ce type de procédé de fabrication, l’âme du sandwich doit être choisie de manière spécifique pour résister à la cuisson des couches extérieures. Dans certains cas, il est apparu qu’elle se trouve altérée par la mise sous température et pression. Il a été observé par exemple que des âmes en mousse pouvaient s’affaisser ou rétrécir lors de ce traitement.
[0016] De plus, il est aussi apparu que lors de la cuisson, de la matière polymérique pouvait couler dans les alvéoles du nid d’abeille.
[0017] On connaît par le document EP 0 770 472 Al, un procédé de fabrication d’un panneau sandwich en matériau composite avec une âme formée d’une structure à cellules ouvertes et des peaux formées de fibres et de résine. Pour éviter la fusion de la résine dans les cellules ouvertes de l’âme, le document prévoit d’interposer une membrane étanche et un film de colle entre les peaux et l’âme. Après fermeture du moule, un cycle thermique unique permet de polymériser la colle puis d’injecter la résine sous pression dans les fibres et enfin de polymériser la résine.
[0018] Ce procédé a cependant l’inconvénient de nécessiter l’utilisation de plusieurs couches et notamment une membrane étanche. Ce qui augmente les coûts du produit fini.
[0019] Le document EP 1 086 801 Al décrit un procédé de fabrication d’un panneau sandwich par la technique d’injection de résine, RTM. Pour éviter le remplissage de la structure en nid d’abeille, ce procédé nécessite la mise en place dans le moule d’un film d’un matériau intumescent et d’un tissu barrière sur chacune des faces de l’âme.
[0020] Le procédé selon l’invention utilise un insert en matière résistante à la chaleur, pour former les couches extérieures, en lieu et place de l’âme et le remplacement de l’insert par l’âme lorsque les couches extérieures sont consolidées. Il ne reste plus alors qu’à effectuer un traitement thermique pour liaisonner les couches extérieures à l’âme.
[0021] La présente invention a pour objet un procédé de fabrication d'un produit en matière composite en forme de sandwich, comportant deux couches extérieures et une âme, les couches extérieures comportant une matrice en matière polymérique renforcée par des fibres, la matière polymérique présentant un point de fusion inférieur au point de fusion de la matière constituant les fibres,
[0022] le procédé étant caractérisé en ce qu'il utilise un insert constitué de matière ayant un point de fusion supérieur au point de fusion de la matière polymérique, sur lequel les couches extérieures sont consolidées ;
[0023] cet insert étant par la suite remplacé par l’âme du sandwich, l’ensemble subit ensuite un traitement de consolidation permettant de liaisonner les couches extérieures à l’âme.
[0024] En particulier l’objet de la présente invention est un procédé de fabrication caractérisé en ce qu’il comporte les étapes suivantes :
[0025] - réalisation de préformes composées de matière polymérique renforcée de fibres destinées à devenir les couches extérieures du sandwich,
[0026] - juxtaposition, dans un moule, d’une première préforme, de l’insert, et d’une seconde préforme,
[0027] - consolidation des préformes pour obtenir les couches extérieures, par chauffage et mise sous pression, pour atteindre la température du point de fusion de la matière polymérique, sans atteindre la température du point de fusion du matériau de renfort, ni du matériau de l’insert,
[0028] - retrait de l’insert, séparation des couches extérieures et insertion de l’âme du sandwich,
[0029] - traitement thermique pour faire adhérer les couches extérieures à l’âme,
[0030] - refroidissement du produit ainsi obtenu.
[0031] Les préformes peuvent être réalisées à l’aide de tissus préimprégnés de résine polymérique ou sont réalisées par tricotage d’un fil comportant de la matière po4 lymérique.
[0032] Suivant un mode particulier de réalisation, une couche d’arrachage est ajoutée entre les préformes, aux endroits destinés à former une zone sans âme.
[0033] Suivant un premier mode de réalisation, le procédé selon l’invention comporte les étapes suivantes :
[0034] a. Réalisation des couches extérieures ou peaux préimprégnées par exemple par tricotage ou par tissage de fils comportant de la matière polymérique et de la matière de renfort ;
b. Juxtaposition dans un moule, d’une couche extérieure, d’un insert en matière résistante à la chaleur et d’une deuxième couche extérieure
c. Mise en forme des peaux par cuisson à une température et pression qui permettent la consolidation et la fusion de la matière polymérique sans atteindre le point de fusion de la matière de renfort
d. Retrait de 1’insert et introduction de l’âme du sandwich, par exemple en mousse ou nid d’abeille, entre les 2 peaux préformées ;
e. Cuisson de l’ensemble à une température pour permettre l’adhérence entre les couches extérieures et l’âme du sandwich.
[0035] Suivant un autre mode de réalisation, les peaux sont réalisées au départ d’un textile en matière de renfort, c’est-à-dire d’un tissu ou tricot constitué de matière de renfort, et la matière polymérique est apportée par injection.
[0036] Le procédé comporte alors les étapes suivantes :
[0037] a. Juxtaposition dans un moule d’un tissu ou tricot de renfort, d’un insert en matière résistante à la chaleur puis d’un autre tissu de renfort
b. Injection de résine de matière polymérique sous pression et température
c. Retrait de l’insert et introduction de l’âme du sandwich, par exemple en mousse ou nid d’abeille, entre les 2 peaux préformées
d. Cuisson de l’ensemble à une température permettant l’adhérence entre les couches extérieures et l’âme du sandwich
e. Refroidissement du produit ainsi obtenu
[0038] L’insert peut être rigide ou non. En particulier, il peut être en silicone.
[0039] Dans certains modes de réalisation, il peut se dilater à la température. Ceci permet d’augmenter la compression lors de la consolidation.
[0040] L’insert peut apporter une forme particulière au produit fini, telle que par exemple une forme en biseau.
[0041] Selon certains modes de réalisation, une couche d’adhésif peut être insérée entre le corps du sandwich et les couches extérieures. Cet adhésif peut être de la colle liquide, un film adhésif ou une préforme tricotée comportant des fibres thermoplastiques.
[0042] Les couches extérieures peuvent être identiques ou différentes.
[0043] Avantageusement, pour obtenir un bon effet sandwich, l’épaisseur de l’âme est généralement de l’ordre de 2 à 50 mm, de préférence comprise entre 3 et 40 mm et de manière encore préférée entre 5 et 25 mm., alors que l’épaisseur des peaux est de l’ordre de 0.2 à 5mm, de préférence entre 0.4 et 2 mm et de manière encore préférée entre 0.5 et 1 mm
[0044] Le but de la présente invention est de fournir un procédé alternatif de fabrication d’un sandwich, notamment de fournir un procédé de fabrication qui permette de dissocier le choix de la matière du corps du sandwich et le choix de la matière des couches extérieures.
[0045] Par matière polymérique, on peut citer les matières thermoplastiques telles que par exemple le polycarbonate (PC), le polyetherimide (PEI), le polypropylène (PP), le poly(téréphtalate d’éthylène) (PET), polyétheréthercétone (PEEK), ou les matières thermodurcissables telles que par exemple époxy, ester de cyanate, résine phénolique, polyester,
[0046] Par matière de renfort, on peut citer les matières synthétique, telle que le paraaramide, polypropylène, les matières naturelles, telle que le lin ; les matières inorganiques telles que le verre, le quartz, le carbone, le basait, le metal.
[0047] En particulier, la matière de renfort est choisie parmi les fibres de verre, de carbone, d’ar amide.
[0048] La méthode selon l’invention s’est révélée particulièrement avantageuse car elle permet de dissocier le choix du type de cœur du sandwich avec le choix du procédé de transformation. Le procédé selon l’invention permet d’atteindre une bonne imprégnation des peaux extérieures.
[0049] Les exemples qui suivent illustrent l’invention de manière non-limitative.
[0050] Exemples
Exemple 1
[0051] Plusieurs tissus de type « prepreg » en fibres de carbone imprégnés d’ester de cyanate sont drapés dans un moule en acier pour former la première peau du sandwich.
[0052] Un insert rigide (par exemple un bloc Téflon® de quelques millimètres) est déposé sur les tissus.
[0053] La deuxième peau du sandwich est réalisée en drapant plusieurs tissus « prepreg » sur l’insert rigide.
[0054] Un tissu d’arrachage téflonné (fibres de verre enduit de PTFE) est placé au niveau de la jonction entre les deux peaux. La jonction est la zone où les peaux se rejoignent pour couvrir le champ de l’âme.
[0055] Le moule est fermé par un contre-moule souple.
[0056] Les peaux sont consolidées par un traitement thermique sous vide à environ 180-220°C, durant quelques heures.
[0057] L’ensemble est laissé à refroidir puis 1’insert est retiré.
[0058] Une colle résistante à haute température est appliquée sur chacune des faces destinées à être en contact avec l’âme.
[0059] Une âme de type mousse de polyimide (densité approximative de 50 kg/m3) est introduite en lieu et place de 1’insert.
[0060] L’ensemble du sandwich est ensuite soumis à un traitement final de consolidation, sous vide à une température d’environ 90-120°C, de manière à assurer une bonne adhésion des peaux et de l’âme.
Exemple 2
[0061] La première peau est formée par un empilement de plusieurs tissus de renfort, non imprégné, en fibres de carbone, déposé dans un moule en acier.
[0062] Un insert souple (plaque silicone de quelques millimètres d’épaisseur) est déposé sur le tissu.
[0063] La deuxième peau est formée par un tissu de même type déposé sur 1’insert.
[0064] Le moule est refermé par le contre-moule en acier.
[0065] De la résine de type ester de cyanate est injectée par un procédé connu de type RTM, à une température comprise entre 80 et 120°C sous une pression de 10 à 15 bars.
[0066] Le traitement thermique est prolongé durant 4 h.
[0067] Le moule est laissé à refroidir puis l’insert est retiré et les peaux sont séparées en enlevant le tissu d’arrachage.
[0068] Une très fine couche de résine d’ester de cyanate est ajoutée sur les peaux (sur les faces destinées à entrer en contact avec le nid d’abeille).
[0069] Une âme en nid d’abeille est introduite entre les deux peaux, en lieu et place de l’insert, pour former un sandwich.
[0070] L’ensemble du sandwich est soumis à un traitement thermique (180-200°C), sous vide, durant 4h de manière à liaisonner les peaux et l’âme.
Exemple 3
[0071] Un tricot est réalisé à l’aide d’un fil mixte comportant des fibres de verre et des fibres thermoplastiques.
[0072] Ce tricot est déposé dans un moule en acier pour former la première peau.
[0073] Un insert en matière expansible sous l’effet de la température est déposé sur le tricot.
[0074] Un deuxième tricot de même type est déposé sur l’insert pour former la deuxième peau.
[0075] Un tissu d’arrachage téflonné (fibres de verre enduit de PTFE) est placé au niveau de la jonction entre les deux peaux. La jonction est la zone où les deux peaux se rejoignent pour couvrir le champ de l’âme.
[0076] Un tissu d’arrachage téflonné est placé au niveau de la jonction entre les deux peaux.
[0077] Le moule est refermé par un contre-moule en acier.
[0078] Les peaux sont consolidées par un traitement thermique à 200- 250°C, sous une pression de 3 à 10 bars, durant quelques dizaines de minutes.
[0079] Le moule est laissé à refroidir puis l’insert est retiré et les peaux sont séparées en enlevant le tissu d’arrachage
[0080] Une préforme en tricot d’un fil thermoplastique est déposée de part et d’autre d’une âme en nid d’abeille, de manière à former une couche de liaison entre l’âme est les peaux du sandwich.
[0081] L’âme en nid d’abeille et les préformes en tricot sont introduites entre les deux peaux, en lieu et place de l’insert, pour former un sandwich
[0082] L’ensemble du sandwich est soumis à un traitement thermique (200°-250°C), sous vide, durant quelques heures, de manière à liaisonner les peaux et l’âme.
Exemple 4
[0083] Un tricot est réalisé à l’aide d’un fil mixte comportant des fibres de verre et des fibres thermoplastiques.
[0084] Ce tricot est déposé dans un moule en acier pour former la première peau.
[0085] Un insert rigide en matière expansible sous l’effet de la température est déposé sur le tricot.
[0086] Un deuxième tricot de même type est déposé sur l’insert pour former la deuxième peau;
[0087] Un tissu d’arrachage téflonné est placé au niveau de la jonction entre les deux peaux.
[0088] Le moule est refermé par un contre-moule en acier.
[0089] Les peaux sont consolidées par un traitement thermique à 200- 250°C, sous une pression de 3 à 10 bars, durant quelques dizaines de minutes.
[0090] Le moule est laissé à refroidir puis l’insert est retiré et les peaux sont séparées en enlevant le tissu d’arrachage
[0091] Une âme en mousse époxy expansée est injectée entre les deux peaux, en lieu et place de l’insert, pour former un sandwich
[0092] L’ensemble du sandwich est soumis à un traitement thermique (65-120°C), sous vide, durant quelques heures de manière à liaisonner les peaux et l’âme.
Exemple 5
[0093] Un tricot est réalisé à l’aide d’un fil mixte comportant des fibres de verre et des fibres thermoplastiques.
[0094] Un premier tricot est drapé sur une vessie en silicone et l’ensemble est déposé dans un premier moule en acier pour la consolidation de la peau externe. Le moule est refermé et le vide est tiré. Le moule est mis sous pression (3 à 10 bars) et en chauffe rapide par un chauffage de type à induction jusqu’à une température de 200 à 250°C.
La température est maintenue quelques minutes. Après refroidissement, la vessie est retirée et une première peau est ainsi réalisée.
[0095] Une seconde peau (peau interne) est réalisée de la même manière que la première dans un deuxième moule.
[0096] Dans l’outillage ayant servi à consolider la peau externe, on dépose successivement : la peau externe préalablement consolidée, un film de colle de type epoxy ou forme liquide, une structure en nid d’abeille, la peau interne préalablement consolidée du produit composite final.
[0097] La vessie en silicone ayant servi à consolider la peau interne est mise en place et le moule est refermé. Le vide est tiré au maximum et l’ensemble est porté à une température de 65 à 120°C pendant quelques heures (procédé de chauffe étuve) de manière à liaisonner les peaux et l’âme.
Claims (1)
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Revendications [Revendication 1] Procédé de fabrication d'un produit en matière composite en forme de sandwich, comportant deux couches extérieures et une âme, les couches extérieures comportant une matrice en matière polymérique renforcée par des fibres, la matière polymérique présentant un point de fusion inférieur au point de fusion de la matière constituant les fibres, le procédé étant caractérisé en ce qu'il utilise un insert constitué de matière ayant un point de fusion supérieur au point de fusion de la matière polymérique, sur lequel les couches extérieures sont consolidées ; cet insert étant par la suite remplacé par l’âme du sandwich, l’ensemble subit ensuite un traitement de consolidation permettant de liaisonner les couches extérieures à l’âme. [Revendication 2] Procédé de fabrication selon la revendication 1, caractérisé en ce qu’il comporte les étapes suivantes : - réalisation de préformes composées de matière polymérique renforcée de fibres destinées à devenir les couches extérieures du sandwich, - juxtaposition, dans un moule, d’une première préforme, de l’insert, et d’une seconde préforme, - consolidation des préformes pour obtenir les couches extérieures, par chauffage et mise sous pression, pour atteindre la température du point de fusion de la matière polymérique, sans atteindre la température du point de fusion du matériau de renfort, ni du matériau de l’insert, - retrait de l’insert, séparation des couches extérieures et insertion de l’âme du sandwich, - traitement thermique pour faire adhérer les couches extérieures à l’âme, - refroidissement du produit ainsi obtenu. [Revendication 3] Procédé de fabrication selon la revendication précédente, caractérisé en ce que les préformes sont réalisées à l’aide de tissus préimprégnés de résine polymérique. [Revendication 4] Procédé de fabrication selon la revendication 2, caractérisé en ce que les préformes sont réalisées par tricotage d’un fil comportant de la matière de renfort et de la matière polymérique. [Revendication 5] Procédé selon l’une quelconque des revendications précédentes, caractérisé en ce qu’une couche d’arrachage est ajoutée entre les préformes, aux endroits destinés à former une zone sans âme. [Revendication 6] Procédé de fabrication selon la revendication 1, caractérisé en ce qu’il comporte les étapes suivantes : - juxtaposition, dans un moule, d’un tissu ou tricot constitué de matière de renfort, de l’insert, et d’un deuxième tissu ou tricot constitué de matière de renfort ; - Injection d’une résine de matière polymérique sous pression et température ; - retrait de l’insert et insertion de l’âme du sandwich ; - cuisson de consolidation pour faire adhérer les couches extérieures à l’âme du sandwich, - refroidissement du produit ainsi obtenu. [Revendication 7] Procédé de fabrication d'un produit en matériaux composites selon l’une quelconque des revendications précédentes, caractérisé en ce que l’insert est réalisé en silicone. [Revendication 8] Procédé selon l’une quelconque des revendications précédentes, caractérisé en ce que la matière de renfort est choisie parmi les fibres de verre, de carbone, d’aramide. [Revendication 9] Procédé selon l’une quelconque des revendications précédentes, caractérisé en ce que la matière polymérique est de type thermoplastique, en particulier choisie parmi le polycarbonate (PC), le polyetherimide (PEI), le polypropylène (PP), le polytéréphtalate d’éthylène) (PET), polyétheréthercétone (PEEK). [Revendication 10] Procédé selon l’une quelconque des revendications là 8, caractérisé en ce que la matière polymérique est de type thermodurcissable, en particulier choisie parmi l’époxy, l’ester de cyanate, les résines phénoliques, le polyester. [Revendication 11] Procédé de fabrication selon l’une quelconque des revendications précédentes, caractérisé en ce que l’âme du sandwich est constitué d’un matériau alvéolaire de type nid d’abeille. [Revendication 12] Procédé de fabrication selon l’une quelconque des revendications précédentes, caractérisé en ce que l’épaisseur de l’âme est comprise entre 2 et 50 mm. [Revendication 13] Procédé de fabrication selon l’une quelconque des revendications précédentes, caractérisé en ce que l’épaisseur de chacune des couches extérieures est comprise entre 0.2 et 5mm. RÉPUBLIQUE FRANÇAISE
Priority Applications (13)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
FR1873207A FR3089854B1 (fr) | 2018-12-18 | 2018-12-18 | Procede de preparation d’un materiau composite sous forme de sandwich |
PCT/EP2019/085359 WO2020127057A1 (fr) | 2018-12-18 | 2019-12-16 | Procédé de préparation d'un matériau composite sous forme de sandwich |
KR1020237005647A KR102656324B1 (ko) | 2018-12-18 | 2019-12-16 | 샌드위치 형태의 복합 재료의 제조를 위한 방법 |
KR1020217022700A KR102508576B1 (ko) | 2018-12-18 | 2019-12-16 | 샌드위치 형태의 복합 재료의 제조를 위한 방법 |
CN201980084765.9A CN113329866A (zh) | 2018-12-18 | 2019-12-16 | 制备夹层形式的复合材料的方法 |
EP19820762.3A EP3898208A1 (fr) | 2018-12-18 | 2019-12-16 | Procédé de préparation d'un matériau composite sous forme de sandwich |
US16/714,965 US11420368B2 (en) | 2018-12-18 | 2019-12-16 | Method for the preparation of composite material in sandwich form |
CA3122042A CA3122042A1 (fr) | 2018-12-18 | 2019-12-16 | Procede de preparation d'un materiau composite sous forme de sandwich |
BR112021011626-5A BR112021011626A2 (pt) | 2018-12-18 | 2019-12-16 | Método para preparar o material compósito em forma de sanduíche |
JP2021535650A JP7153801B2 (ja) | 2018-12-18 | 2019-12-16 | サンドイッチ状の複合材料の調製方法 |
IL284055A IL284055B1 (en) | 2018-12-18 | 2021-06-15 | A method for making a composite material in a sandwich structure |
US17/810,770 US20220339830A1 (en) | 2018-12-18 | 2022-07-05 | Method for the preparation of composite material in sandwich form |
JP2022159668A JP2023011570A (ja) | 2018-12-18 | 2022-10-03 | サンドイッチ状の複合材料の調製方法 |
Applications Claiming Priority (1)
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FR1873207A FR3089854B1 (fr) | 2018-12-18 | 2018-12-18 | Procede de preparation d’un materiau composite sous forme de sandwich |
Publications (2)
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FR3089854A1 true FR3089854A1 (fr) | 2020-06-19 |
FR3089854B1 FR3089854B1 (fr) | 2022-02-04 |
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FR1873207A Active FR3089854B1 (fr) | 2018-12-18 | 2018-12-18 | Procede de preparation d’un materiau composite sous forme de sandwich |
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US (2) | US11420368B2 (fr) |
EP (1) | EP3898208A1 (fr) |
JP (2) | JP7153801B2 (fr) |
KR (2) | KR102656324B1 (fr) |
CN (1) | CN113329866A (fr) |
BR (1) | BR112021011626A2 (fr) |
CA (1) | CA3122042A1 (fr) |
FR (1) | FR3089854B1 (fr) |
IL (1) | IL284055B1 (fr) |
WO (1) | WO2020127057A1 (fr) |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
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FR3089854B1 (fr) | 2018-12-18 | 2022-02-04 | Saint Gobain Performance Plastics France | Procede de preparation d’un materiau composite sous forme de sandwich |
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2018
- 2018-12-18 FR FR1873207A patent/FR3089854B1/fr active Active
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2019
- 2019-12-16 JP JP2021535650A patent/JP7153801B2/ja active Active
- 2019-12-16 KR KR1020237005647A patent/KR102656324B1/ko active IP Right Grant
- 2019-12-16 CA CA3122042A patent/CA3122042A1/fr active Pending
- 2019-12-16 BR BR112021011626-5A patent/BR112021011626A2/pt active Search and Examination
- 2019-12-16 US US16/714,965 patent/US11420368B2/en active Active
- 2019-12-16 WO PCT/EP2019/085359 patent/WO2020127057A1/fr unknown
- 2019-12-16 CN CN201980084765.9A patent/CN113329866A/zh active Pending
- 2019-12-16 EP EP19820762.3A patent/EP3898208A1/fr active Pending
- 2019-12-16 KR KR1020217022700A patent/KR102508576B1/ko active IP Right Grant
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- 2021-06-15 IL IL284055A patent/IL284055B1/en unknown
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2022
- 2022-07-05 US US17/810,770 patent/US20220339830A1/en active Pending
- 2022-10-03 JP JP2022159668A patent/JP2023011570A/ja active Pending
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Also Published As
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BR112021011626A2 (pt) | 2021-08-31 |
IL284055A (en) | 2021-08-31 |
KR102656324B1 (ko) | 2024-04-12 |
IL284055B1 (en) | 2024-07-01 |
WO2020127057A1 (fr) | 2020-06-25 |
US20200189157A1 (en) | 2020-06-18 |
JP7153801B2 (ja) | 2022-10-14 |
US20220339830A1 (en) | 2022-10-27 |
EP3898208A1 (fr) | 2021-10-27 |
CA3122042A1 (fr) | 2020-06-25 |
KR102508576B1 (ko) | 2023-03-15 |
KR20230030667A (ko) | 2023-03-06 |
US11420368B2 (en) | 2022-08-23 |
JP2022515398A (ja) | 2022-02-18 |
KR20210110837A (ko) | 2021-09-09 |
CN113329866A (zh) | 2021-08-31 |
FR3089854B1 (fr) | 2022-02-04 |
JP2023011570A (ja) | 2023-01-24 |
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