WO2014107555A1 - Induction heating compaction system and method of compacting - Google Patents
Induction heating compaction system and method of compacting Download PDFInfo
- Publication number
- WO2014107555A1 WO2014107555A1 PCT/US2014/010138 US2014010138W WO2014107555A1 WO 2014107555 A1 WO2014107555 A1 WO 2014107555A1 US 2014010138 W US2014010138 W US 2014010138W WO 2014107555 A1 WO2014107555 A1 WO 2014107555A1
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- WO
- WIPO (PCT)
- Prior art keywords
- compaction
- preg material
- roller
- induction heating
- preg
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—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
- B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—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
- B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
- B29C70/386—Automated tape laying [ATL]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
- B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
- B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/16—Cooling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
- B29C65/1403—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the type of electromagnetic or particle radiation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
- B29C65/36—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
- B29C66/112—Single lapped joints
- B29C66/1122—Single lap to lap joints, i.e. overlap joints
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/349—Cooling the welding zone on the welding spot
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/45—Joining of substantially the whole surface of the articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/818—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
- B29C66/8181—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
- B29C66/836—Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table
- B29C66/8362—Rollers, cylinders or drums moving relative to and tangentially to the parts to be joined
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—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
- B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
- B29C70/386—Automated tape laying [ATL]
- B29C70/388—Tape placement heads, e.g. component parts, details or accessories
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
- B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
- B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
- B29C2035/0811—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using induction
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
- B29C65/36—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
- B29C65/3604—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint
- B29C65/3608—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint comprising single particles, e.g. fillers or discontinuous fibre-reinforcements
- B29C65/3616—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint comprising single particles, e.g. fillers or discontinuous fibre-reinforcements comprising discontinuous fibre-reinforcements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/7394—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/0872—Prepregs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2307/00—Use of elements other than metals as reinforcement
- B29K2307/04—Carbon
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0012—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular thermal properties
- B29K2995/0013—Conductive
Definitions
- Composite products can be made from plies of pre-impregnated (pre-preg) material.
- Pre-preg material includes fibers surrounded by a matrix material, such as a thermosetting or thermoplastic resin or a ceramic matrix.
- a matrix material such as a thermosetting or thermoplastic resin or a ceramic matrix.
- Consolidation of individual ply layers together to form a composite laminate in a buildup is often critical to the quality of the finished composite product. Lack of compaction within the laminate during lamination, before it sees additional consolidation from something like a cure process or press or other means, can result in wrinkling of the fibers in the laminate, reducing mechanical performance and affecting dimensional characteristics of the finished product.
- During consolidation it is common to apply heat to the plies of pre- preg material to heat up the matrix material to make the plies more compliant during consolidation.
- Typical methods of heating and consolidating composites include: using hot gas to flood the area in front of a compaction member, using infrared heat to warm the material in front of a compaction member, and using a laser beam to heat material before it is rolled and compacted.
- Each of these methods requires space allocaton for their heating source and space allocation for their compaction member. Many of these systems are energy and time intensive, or have inherent safety issues when an operator is in close proximity.
- an induction heating compaction system includes an induction heating system and a compaction member.
- the induction heating member is configured to generate an electromagnetic field at a select frequency.
- the select frequency causes at least one of the fibers and matrix in pre-preg material to heat up.
- the compaction member is configured and arranged to extract heat from the pre-preg material while compacting the pre-preg material.
- another induction heating compaction system in another embodiment, is provided.
- the system includes a compaction member, an induction heating member and a cooling assembly.
- the compaction member is configured and arranged to compact ply layers of pre-preg material.
- the induction heating member is received within the compaction member.
- the induction heating member is configured to generate an electromagnetic field at a select frequency.
- the select frequency causes at least one of the fibers and matrix in pre-preg material to heat up.
- the compaction member has at least a portion that is made from a material that is transparent to the select frequency of the electromagnetic field generated by the induction heating member, such that the induction field can be directed at a composite pre-preg material to be consolidated, while not heating up the compaction device.
- the cooling assembly is configured and arranged to extract heat from the pre-pre material to solidify the ply layers of pre-preg material in a compact configuration during an in-situ compaction buildup process.
- a method of consolidating pre-preg material ply layers includes: inductively heating an area of at least one of fibers and matrix in at least one first pre-preg material ply layer to soften the matrix in the heated area; and compacting the heated area of the at least one first pre-preg material ply layer during layup of the at least one first pre-preg material ply layer over a second pre-preg material ply layer.
- Figure 1 is a block diagram of an induction heating compaction system of one embodiment of the present invention
- Figure 2 is a block diagram of another induction heating compaction system of one embodiment of the present invention.
- Figure 3 is an in-situ compaction buildup process flow diagram of one embodiment of the present invention.
- Figure 4A is a side perspective view of an induction heating compaction system of one embodiment of the present invention.
- Figure 4B is a side view of a portion of the induction heating compaction system of Figure 4A;
- Figure 5A is a side perspective view of another induction heating compaction system of one embodiment of the present invention.
- Figure 5B is a side perspective view of the induction heating compaction system of Figure 5 A;
- Figure 5C is a side perspective view of the induction heating compaction system of Figure 5 A;
- Figure 6A is a front view of an induction heating compaction roller used in the induction heating compaction system of Figure 4A;
- Figure 6B is a front perspective view of the induction heating compaction roller of Figure 6A;
- Figure 6C is a front perspective exploded view of the induction heating compaction roller of Figure 6A;
- Figure 7A is a side perspective view of an induction heating compaction foot used in the induction heating compaction system of Figure 5 A;
- Figure 7B is a side perspective exploded view of the induction heating compaction foot of Figure 7A.
- induction heating is used to heat conductive fibers in pre-preg material that in turn melts or softens the surrounding matrix to allow tight nesting or consolidation of one ply to a previous laid ply or plies, generally known as an "on-the-fly" or "in-situ” process.
- An example type of conductive fiber used in the pre-preg material is carbon fiber. Since carbon fiber is conductive it will heat up when subject to an alternating electromagnetic field of a given frequency, provided by an induction heater assembly.
- non-conductive fibers that are metallically coated could be used.
- the matrix is formulated to react directly to the induction heating.
- the matrix may be loaded with conductive particles. Those particles could be metallic, carbon nanofibers, nanofillers, etc.
- the conductivity components of the matrix would absorb the induction heating and soften the pre-preg.
- both the fiber and matrix may react to the induction heating.
- a compaction member is then used to compact the plies while still warmM ot as part of the in-situ compaction buildup process.
- the compaction member extracts heat from the pre-preg material while compacting the lamina or laminate in a consolidated or cured state.
- the compaction member is actively cooled for higher temperature materials or to allow faster process speeds.
- portions of a compaction member, particularly in the "field of view", so to speak, of the induction field directed towards the composite material are made from a material that is not affected by the select frequency of the electromagnetic field used to heat up the composite pre-preg material.
- at least a portion of the compaction member is made from material that is transparent to the frequency of the electromagnetic field created by the induction heating member.
- at least some portions of the compaction member that are not transparent to the frequency of the electromagnetic field are shielded from the induction field.
- FIG. 1 illustrates a block diagram of an induction heating compaction system 100 of one embodiment.
- the induction heating compaction system 100 includes a positioning assembly 106 that is coupled to a compaction member 110.
- the positioning assembly 106 is configured to position the compaction member 110 in relation to pre-preg material as further discussed below.
- the positioning assembly 106 is controlled by a controller 102. Controller 102 controls functions of the induction heating compaction system 100.
- the controller 102 receives commands from a user input 104.
- the compaction member 110 is designed to consolidate plies of the pre-preg material as further discussed below.
- the compaction member 110 in this embodiment, includes a heating member 112 and a cooling assembly 111.
- the compaction member 110 of this embodiment has a heating member 112 and a cooling member 1 11 within its assembly. Placing the heating member 112 and cooling member 111 within the compaction member 110 provides a compact assembly.
- the heating member 112 is an induction heating member that produces an electromagnetic field of a given frequency that heats up the fibers and or matrix in the pre-preg material.
- the heating member 112 is in electrical communication with a power source 108 that provides an energy source for the heating members 112 operation.
- the controller 102 controls the power level and time of the energy coming from power source 108.
- the compaction member 110 further includes a cooling assembly 111.
- the cooling assembly 111 may be passive (in that it does not requires an external energy source) such as, but not limited to, cooling passages and heat sink material or may be an active cooling assembly such as, but not limited to, a fan driven system or a coolant pumping system. If the cooling system is active, the controller 102, in an embodiment, is in
- Figure 2 illustrates another induction heating compaction system 200. This system 200 is similar to the system 100 described in relation to Figure 1. However, in the
- a heating member 122 is positioned proximate the compaction member 120 but not within the compaction member 120.
- This embodiment also illustrates the use of a second cooling member 121 that can be positioned proximate the compaction member 120 but not within the compaction member 120.
- the controller 102 activates the cooling source 109 to provide a cooling medium for the cooling members 111 and 121.
- the cooling members 1 11 and 121 and/or the heating members 112 and 122 include one or more temperature sensors that are used by the controller 102 at least in part to control the amount of heat produced by the heating members 1 12 and 122; and the amount of cooling provided to the cooling members 111 and 121.
- an in-situ compaction buildup process flow diagram 300 that describes a method of implementing systems of an embodiment is illustrated.
- the process starts by first placing a layer or layers of pre-preg material on a tool surface, or on at least one other ply/plies of pre-preg material that is laid up on a tool (302).
- the layers can be compacted on each other one at a time or several at a time depending on the application and desired outcome.
- the compaction member 120 is then positioned in relation to the pre-preg material (304). Once the compaction member 120 is in the correct position to start compaction, the induction heating member 1 12 is started (306).
- the induction heating member 112 uses electromagnetic waves of a select power, frequency and time that excites electrons in
- the compaction member engages the pre-preg material therein compacting the pre-preg material (310).
- the compaction member is also pulling heat from the pre-preg material (312). Accordingly, the heat along with the compaction member allows a tight nesting or consolidation of the plies of pre-preg material and the extracting of the heat by the compaction member solidifies the laminate in a laminated state (i.e. a partially or fully consolidated state depending on the composite material used in the process).
- the process continues at step (302) by applying another ply/plies of pre-preg material over the prior laminated and compacted plies on the forming tool at step (302). If it is the last ply/plies (314), the process ends.
- the ply layers can be added in the in-situ process so they totally cover previously formed ply layers or the subsequent ply layers may only cover portions of previously formed ply layers depending on the desired outcome.
- FIG. 4A An example of an induction heating compaction system 400 of an embodiment is illustrated in Figure 4A.
- This embodiment uses a compaction roller 450.
- the induction heating compaction system 400 includes a positioning holding head 402.
- the positioning holding head 402 includes a mounting plate 420 that can be coupled to a further positioning system arm (not shown).
- the mounting plate 420 is coupled to a bracket assembly 422.
- the bracket assembly 422 includes a pivot connection 424 that allows the positioning holding head 402 to be pivoted to position the positioning holding head 402 in a desired orientation.
- Extending from the bracket assembly 422 is a spacer 426.
- the spacer 426 is coupled to one or more actuators 427 that selectively move the spacer 426 up and down.
- a holding bracket 428 is coupled to the spacer 426.
- the holding bracket 428 is designed to hold the compaction roller 450.
- the holding bracket 428 includes a first holding arm 428a and a spaced second holding arm 428b.
- a roller axel 462 of the compaction roller 450 is coupled between the first and second holding arms 428a and 428b of the holding bracket 428.
- Figure 4A further illustrates the compaction roller 450 engaging plies of pre-preg material 406 that have been laid up on a forming tool 404.
- Figure 4A illustrates the compaction (in-situ) of a ply layer or ply layers 406a on one or more ply layers 406 that have been laid up on a forming tool 404.
- Figure 4B illustrates the induction field 440 that is produced by an induction heating member that is housed within the compaction roller 450 as further described in relation to Figure 6C below.
- the induction field 440 heats ply layer or ply layers 406a.
- heat 447 from the ply layers 406 is extracted back to the compaction roller 450 and the ply layers are solidified in the compact state.
- Compaction roller 450 in this embodiment includes cooling passages 451 that help maintain the compaction roller 450 in a cool state.
- Figure 4B further illustrates a temperature sensor 429 positioned to view and sense the temperature of material 406a and provide feeback to controller 102.
- a second induction temperature sensor (not shown) can be used to measure the temperature of the compaction roller cover 452 and provide feedback to controller 102.
- a material dispensing member 425 that is designed to dispense and position the one or more ply layers 406a in respect to the roller 450.
- the material dispensing member 425 typically includes capability to cut and restart the material as needed in the layup.
- FIG. 5A Another example embodiment of an induction heater compaction system 500 is illustrated in Figure 5A.
- a compaction foot 502 (or compaction shoe) is used as the compaction member.
- the compaction foot 502 is coupled to the positioning holding head 402 via the holding bracket 428.
- the compaction foot 502 is coupled between the first and second holding arms 428a and 428b of the holding bracket 428.
- the compaction foot 502 is positioned to compact the plies of pre-preg material 406 positioned on the tool 404.
- the cooling members includes cooling passages 508b.
- the cooling passages 508b in the compaction foot 502 help maintain the compaction foot 502 in a cool state to allow the compaction foot 502 to extract heat from the pre-preg material to solidify the plies in a compacted state.
- roller and foot configuration examples of the compaction member are provided, other configurations can be used and the present invention is not limited to just roller and foot configurations.
- FIG 5B an illustration of the induction heating compaction system 500 positioned to provide induction heat 530 to the pre-preg material 406 is provided. As illustrated, in this embodiment, the compaction foot 502 is spaced a select distance from the pre-preg material 406 when providing the induction field 530.
- the compaction foot can already be in motion to make contact or already be in contact with the pre-preg when the induction field is energized.
- the compaction foot 502 of the induction heating compaction system 500 compacts the pre-preg material as illustrated in Figure 5C. Also illustrated in Figure 5C is the heat 520 being extracted from the pre-preg material 406 into the compaction foot 502 to solidify the pre-preg material in a compact configuration.
- the compaction roller 450 is further illustrated in Figures 6A through 6C.
- Figure 6A illustrates a front view of the assembled compaction roller 450
- Figure 6B illustrates a front perspective view of the compaction roller 450
- Figure 6C illustrates an exploded unassembled view of the compaction roller 450.
- the compaction roller 450 in this embodiment includes, a roller axel 462 that has a cylindrical mid-portion 462a and opposed first and second end portions 462b and 462c.
- the first and second end portions 462b and 462c have smaller diameters than the mid-portion 462a.
- a pair of stub shafts are used instead of the roller axel 462.
- the pair of stubs would function as the first and second end portions 462b and 462c of the roller axel 462.
- a cylindrical shielding 453 is received over the mid-portion 462a of the roller axel 462 in this embodiment.
- the shielding 453 shields at least a portion of the roller axel 462 from the electromagnetic waves generated by an induction heating member 458.
- the shielding 453 is made with electromagnetic wave shielding material.
- the shielding material could be made from thin sheets of copper and/or aluminum or high nickel content foil that is tailored to the frequencies used in the process. For example, the higher the frequency the thinner the sheets used. Other types of electromagnetic wave shielding material know in the art could also be used.
- a pair of lead wires 457a and 457b that provide energy from the power source to the induction heating member 458 are also illustrated in Figure 6C.
- a first bearing 456 is received on the first end portion 462b of the roller axel 462. The first bearing 456 engages a first shoulder 462d formed between the first end portion 462b and the mid-portion 462a of the roller axel 462.
- a second bearing 464 is received on the second end portion 462c of the roller axel 462. The second bearing 464 engages a second shoulder 462e formed between the second end portion 462c and the mid-portion 462a of the roller axel 462.
- a main roller support 454 is received over the roller axel 462.
- the main roller support 454 engages the first and second bearings 456 and 464 such that the main roller support 454 is rotationally coupled to the roller axel 462.
- the main roller support 454 in this embodiment includes a plurality of cooling passages 451 as best seen in Figure 6B.
- a cooling device 466 is mounted on the second end portion 462c of the roller axel 462.
- the cooling device 466 in this embodiment provides flow of fluids or gas through the plurality of cooling passages 451 in the main roller support 454. In other embodiments passive cooling may be used and cooling device 466 may not be needed.
- a roller cover 452 is received over the main roller support 454.
- the roller cover 452 is designed to compact ply layers of pre-preg material.
- the roller cover 452 may be solid or a compliant material to conform to the shape being consolidated.
- the roller cover 452 is designed to be replaced.
- FIG. 7A An embodiment that uses a compaction foot (or shoe) 502 is illustrated in the assembled side perspective view of Figure 7A and the exploded (unassembled) side perspective view of Figure 7B.
- the compaction foot 502 includes a stamp member 508.
- the stamp member 508, in this embodiment, has a rectangular base portion 507e.
- the stamp member 508 further has opposed first and second end walls 507a and 507b that extend from opposed ends of the rectangular base portion 507e.
- the stamp member 508 also has opposed first and second side walls 507c and 507d that extend from opposed sides of the rectangular base portion 507e.
- the first and second end walls 507a and 507b, the first and second side walls 507c and 507d and the base portion 507e form and inner chamber 509 of the stamp member 508.
- a plurality of cooling passages 508a and 508b extend through the first and second side sidewalls 507c and 507d of the stamp member 508 and form at least part of a cooling assembly.
- An engaging member 510 (or engaging cover) is coupled to a bottom of the base portion 507e of the stamp member 508.
- the engaging member 510 can be a solid surface or a compliant surface to accommodate local contour. In one embodiment, the engaging member 510 it is covered with a low adherence material for easy release from the pre-preg material.
- the engaging member 510 is designed to engage and compact ply layers of pre-preg material.
- An induction heating member 506 is received in the inner chamber 509 of the stamp member 508.
- lead wires 519a and 519b that deliver power from the power source to the induction heating member 506.
- the compaction foot 502 of this embodiment further includes a shield member 504.
- the shield member 504 includes a shield top cover 504a and a shield side extending portion 504b that extends from the shield top cover 504a to form an inner camber in which the induction heating member 506 is received.
- the shield side extending portion 504b is in turn received in the inner chamber 509 of the stamp member 508.
- the shield top cover 504a covers the inner chamber 509 of the stamp member 508.
- the shield design may vary with the purpose to protect areas where the induction field is not desirable, and allow it to focus on the material to be compacted.
- the shield 504 is made from electromagnetic wave shielding material that shields other components from the electromagnetic field generated by the induction heating member 506.
- the compaction foot 502 is made up of sections that move independently to each other so that the compaction feet 502 can walk across the pre-preg material in the in-situ compaction buildup process.
- more than one compaction shoe 502 is used in the in-situ compaction buildup process.
- the compaction shoe 502 is illustrated as being rectangular in shape, the compaction shoe 502 can be in any shape that conforms the pre-preg layers to the desired shape of the formed composite structure. The same is true of the compaction roller 450 discussed above.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Health & Medical Sciences (AREA)
- Electromagnetism (AREA)
- Thermal Sciences (AREA)
- Toxicology (AREA)
- Oral & Maxillofacial Surgery (AREA)
- Robotics (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Heating, Cooling, Or Curing Plastics Or The Like In General (AREA)
- Moulding By Coating Moulds (AREA)
- General Induction Heating (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
Description
Claims
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
KR1020157021016A KR102001406B1 (en) | 2013-01-04 | 2014-01-03 | Induction heating compaction system and method of compacting |
CA2897194A CA2897194C (en) | 2013-01-04 | 2014-01-03 | Induction heating compaction system and related methods |
JP2015551767A JP6465304B2 (en) | 2013-01-04 | 2014-01-03 | Induction heating and compaction system |
EP14701134.0A EP2941343B1 (en) | 2013-01-04 | 2014-01-03 | Induction heating compaction system and method of compacting |
ES14701134T ES2821749T3 (en) | 2013-01-04 | 2014-01-03 | Induction heating compaction system and compaction method |
CN201480008588.3A CN104995014B (en) | 2013-01-04 | 2014-01-03 | Sensing heating compact system |
Applications Claiming Priority (2)
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US13/734,661 US9527237B2 (en) | 2013-01-04 | 2013-01-04 | Induction heating compaction system |
US13/734,661 | 2013-01-04 |
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WO2014107555A1 true WO2014107555A1 (en) | 2014-07-10 |
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PCT/US2014/010138 WO2014107555A1 (en) | 2013-01-04 | 2014-01-03 | Induction heating compaction system and method of compacting |
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US (2) | US9527237B2 (en) |
EP (1) | EP2941343B1 (en) |
JP (2) | JP6465304B2 (en) |
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CN (1) | CN104995014B (en) |
CA (1) | CA2897194C (en) |
ES (1) | ES2821749T3 (en) |
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Also Published As
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CN104995014A (en) | 2015-10-21 |
KR20150103263A (en) | 2015-09-09 |
KR102001406B1 (en) | 2019-07-18 |
JP2016508085A (en) | 2016-03-17 |
EP2941343B1 (en) | 2020-07-22 |
US20140190629A1 (en) | 2014-07-10 |
US20170080647A1 (en) | 2017-03-23 |
CN104995014B (en) | 2018-06-05 |
JP6689342B2 (en) | 2020-04-28 |
CA2897194A1 (en) | 2014-07-10 |
JP6465304B2 (en) | 2019-02-06 |
EP2941343A1 (en) | 2015-11-11 |
CA2897194C (en) | 2018-09-25 |
ES2821749T3 (en) | 2021-04-27 |
US9527237B2 (en) | 2016-12-27 |
JP2019024012A (en) | 2019-02-14 |
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