Method and apparatus for producing dry preform for composite material

• US 20040134593A1
• Filed: 05/28/2003
• Published: 07/15/2004
• Est. Priority Date: 01/14/2003
• Status: Active Grant

• Current Assignee: Shikibo Limited
• Original Assignee: Shikibo Limited
• Inventors: Iriguchi, Akira, Hashimoto, Koichi, Ishibashi, Masayasu, Sakonjo, Hideki, Tanamura, Takeshi, Hirokawa, Tetsuro, Morimoto, Kazunori
• Granted Patent: US 7,384,585 B2
• Time in Patent Office: Days
• US Class Current: 156/180
• CPC Class Codes: B29B 11/16 comprising fillers or reinforcement non-woven fabrics per se D04H1/00, D04H3/00
• CPC Class Codes: B29C 70/207 arranged in parallel planes of fibres crossing at substantial angles
• CPC Class Codes: B29C 70/222 the structure being shaped to form a three dimensional configuration

Abstract

A novel process for producing a dry preform for a composite material takes advantage of the fact that a reinforcing filament assembly, when consisting of a fiber reinforcement layer a, formed by stringing a first set of parallel strands of fiber reinforcement over a part or all of the plane within any desired shape along the straight axis 2, and a fiber reinforcement layer b, formed by stringing a second set of parallel strands of fiber reinforcement over the plane at an angle θ with respect to the straight axis 2, such that 0°<θ<180°, the part of the reinforcing filament assembly that consists solely of the fiber reinforcement b can be deformed as desired. According to this process, strands c of fiber reinforcement are strung using a fiber reinforcement string jig as shown in FIGS. 8(A) and 8(B). The layers of the strung strands of fiber reinforcement are brought together by a simple means such as stitching. The integrated layer is then shaped into the reinforcing filament assemblies 3, 4, which are combined to form a dry preform 1 for making a composite material having any desired alignment of fiber reinforcement.

Claims

1. A method for producing a dry preform for a composite material for use as a structural material, comprising the step of

before or after unifying a reinforcing filament assembly including a first fiber reinforcement layer and a second fiber reinforcement layer, deforming the reinforcing filament assembly in and/or out of plane to form the dry preform with a complex cross-sectional shape, the first fiber reinforcement layer formed by stringing a first set of parallel strands of fiber reinforcement over a part or all of the plane within any shape along a predetermined axis contained within the plane, the second fiber reinforcement layer formed by stringing a second set of parallel strands of fiber reinforcement over the plane of the shape at an angle with respect to the axis.

2. A method for producing a dry preform for a composite material for use as a structural material according to claim 1, wherein

the step of, before or after unifying the reinforcing filament assembly including the first fiber reinforcement layer and the second fiber reinforcement layer, deforming the reinforcing filament assembly in and/or out of plane is performed to form the dry preform with the complex cross-sectional shape and continuously varying thickness and/or width, the first fiber reinforcement layer formed by stringing the first set of parallel strands of fiber reinforcement over a part or all of the plane within any shape with continuously varying thickness and/or width along the predetermined axis contained within the plane, the second fiber reinforcement layer formed by stringing the second set of parallel strands of fiber reinforcement over the plane of the shape at the angle with respect to the axis.

3. A method for producing a dry preform for a composite material for use as a structural material according to claim 1, wherein

after unifying the reinforcing filament assembly including the first fiber reinforcement layer and the second fiber reinforcement layer, the reinforcing filament assembly is deformed out of plane to form the dry preform with the complex cross-sectional shape and a curved profile, the first fiber reinforcement layer formed by stringing the first set of parallel strands of fiber reinforcement over a part or all of the plane within any curved shape along a curved axis contained within the plane, the second fiber reinforcement layer formed by stringing the second set of parallel strands of fiber reinforcement over the plane of the shape at an angle with respect to the curved axis.

4. A method for producing a dry preform for a composite material for use as a structural material according to claim 2, wherein

after unifying the reinforcing filament assembly including the first fiber reinforcement layer and the second fiber reinforcement layer, the reinforcing filament assembly is deformed out of plane to form the dry preform with the complex cross-sectional shape and a curved profile, the first fiber reinforcement layer formed by stringing the first set of parallel strands of fiber reinforcement over a part or all of the plane within any curved shape along a curved axis contained within the plane, the second fiber reinforcement layer formed by stringing the second set of parallel strands of fiber reinforcement over the plane of the shape at an angle with respect to the curved axis.

5. A method for producing a dry preform for a composite material for use as a structural material according to claim 1, comprising the steps of:

unifying the reinforcing filament assembly including at least one first fiber reinforcement layer and a plurality of second fiber reinforcement layers, wherein the first fiber reinforcement layer is formed by stringing a first set of parallel strands of fiber reinforcement over the part of the plane within the any shape along a straight axis contained within the plane, the second fiber reinforcement layer is formed by stringing a second set of parallel strands of fiber reinforcement over the plane of the shape at an angle with respect to the straight axis;

bending the reinforcing filament assembly consisting of the first fiber reinforcement layer and the second fiber reinforcement layers onto the same curvature on the same plane;

deforming out of plane a portion that consists solely of the second fiber reinforcement layers; and

forming the dry preform having a complex cross-sectional shape and a curved profile using either one or a plurality of the bended and deformed reinforcing filament assembly.

6. A method for producing a dry preform for a composite material for use as a structural material according to claim 2, comprising the steps of:

unifying the reinforcing filament assembly including at least one first fiber reinforcement layer and a plurality of second fiber reinforcement layers, wherein the first fiber reinforcement layer is formed by stringing a first set of parallel strands of fiber reinforcement over the part of the plane within the any shape along a straight axis contained within the plane, the second fiber reinforcement layer is formed by stringing a second set of parallel strands of fiber reinforcement over the plane of the shape at an angle with respect to the straight axis;

bending the reinforcing filament assembly consisting of the first fiber reinforcement layer and the second fiber reinforcement layers onto the same curvature on the same plane;

deforming out of plane a portion that consists solely of the second fiber reinforcement layers and forming the dry preform having a complex cross-sectional shape and a curved profile by using either one or a plurality of the bended and deformed reinforcing filament assembly.

7. A method for producing a dry preform for a composite material for use as a structural material according to claim 1, the method comprising the steps of:

deforming the reinforcing filament assembly including the first fiber reinforcement layer and the second fiber reinforcement layer in plane, the first fiber reinforcement layer formed by stringing the first set of parallel strands of fiber reinforcement over a part or all of the plane within any straight shape along a straight axis contained within the plane, the second fiber reinforcement layer formed by stringing the second set of parallel strands of fiber reinforcement over the plane of the shape at the angle with respect to the straight axis;

unifying the deformed reinforcing filament assembly with curved shape; and

deforming the unified reinforcing filament assembly out of plane to form the dry preform with the complex cross-sectional shape and a curved profile.

8. A method for producing a dry preform for a composite material for use as a structural material according to claim 2, the method comprising the steps of:

deforming the reinforcing filament assembly including the first fiber reinforcement layer and the second fiber reinforcement layer in plane, the first fiber reinforcement layer formed by stringing the first set of parallel strands of fiber reinforcement over a part or all of the plane within any straight shape along a straight axis contained within the plane, the second fiber reinforcement layer formed by stringing the second set of parallel strands of fiber reinforcement over the plane of the shape at the angle with respect to the straight axis;

unifying the deformed reinforcing filament assembly with curved shape; and

deforming the unified reinforcing filament assembly out of plane to form the dry preform with the complex cross-sectional shape and a curved profile.

9. A method for producing a dry preform for a composite material for use as a structural material according to claim 5, wherein

a tension acting upon the strands of fiber reinforcement is maintained at a constant value, before or after the reinforcing filament assembly is deformed in plane to form the dry preform with a curved profile without unifying the reinforcing filament assembly including the first fiber reinforcement layer and the second fiber reinforcement layer, the first fiber reinforcement layer formed by stringing the first set of parallel strands of fiber reinforcement over a part or all of the plane within the straight shape along a straight axis contained within the plane, the second fiber reinforcement layer formed by stringing the second set of parallel strands of fiber reinforcement over the plane of the shape at the angle with respect to the straight axis.

10. A method for producing a dry preform for a composite material for use as a structural material according to claim 6, wherein

a tension acting upon the strands of fiber reinforcement is maintained at a constant value, before or after the reinforcing filament assembly is deformed in plane to form the dry preform with a curved profile without unifying the reinforcing filament assembly including the first fiber reinforcement layer and the second fiber reinforcement layer, the first fiber reinforcement layer formed by stringing the first set of parallel strands of fiber reinforcement over a part or all of the plane within the straight shape along a straight axis contained within the plane, the second fiber reinforcement layer formed by stringing the second set of parallel strands of fiber reinforcement over the plane of the shape at the angle with respect to the straight axis.

11. A method for producing a dry preform for a composite material for use as a structural material according to claim 1 wherein

proper means selected from stitching, knitting, tufting, needle punch, and thermoplastic resin is used either independently or in combination, in the step of unifying the reinforcing filament assembly including the first fiber reinforcement layer and the second fiber reinforcement layer, the first fiber reinforcement layer formed by stringing the first set of parallel strands of fiber reinforcement over a part or all of the plane within the shape along the predetermined axis contained within the plane, the second fiber reinforcement layer formed by stringing the second set of parallel strands of fiber reinforcement over the plane of the shape at the angle with respect to the axis.

12. A method for producing a dry preform for a composite material for use as a structural material according to claim 2 wherein

proper means selected from stitching, knitting, tufting, needle punch, and thermoplastic resin is used either independently or in combination, in the step of unifying the reinforcing filament assembly including the first fiber reinforcement layer and the second fiber reinforcement layer, the first fiber reinforcement layer formed by stringing the first set of parallel strands of fiber reinforcement over a part or all of the plane within the shape along the predetermined axis contained within the plane, the second fiber reinforcement layer formed by stringing the second set of parallel strands of fiber reinforcement over the plane of the shape at the angle with respect to the axis.

13. A method for producing a dry preform for a composite material for use as a structural material according to claim 3 wherein

proper means selected from stitching, knitting, tufting, needle punch, and thermoplastic resin is used either independently or in combination, in the step of unifying the reinforcing filament assembly including the first fiber reinforcement layer and the second fiber reinforcement layer, the first fiber reinforcement layer formed by stringing the first set of parallel strands of fiber reinforcement over a part or all of the plane within the shape along the predetermined axis contained within the plane, the second fiber reinforcement layer formed by stringing the second set of parallel strands of fiber reinforcement over the plane of the shape at the angle with respect to the axis.

14. A method for producing a dry preform for a composite material for use as a structural material according to claim 4 wherein

proper means selected from stitching, knitting, tufting, needle punch, and thermoplastic resin is used either independently or in combination, in the step of unifying the reinforcing filament assembly including the first fiber reinforcement layer and the second fiber reinforcement layer, the first fiber reinforcement layer formed by stringing the first set of parallel strands of fiber reinforcement over a part or all of the plane within the shape along the predetermined axis contained within the plane, the second fiber reinforcement layer formed by stringing the second set of parallel strands of fiber reinforcement over the plane of the shape at the angle with respect to the axis.

15. A method for producing a dry preform for a composite material for use as a structural material according to claim 5 wherein

proper means selected from stitching, knitting, tufting, needle punch, and thermoplastic resin is used either independently or in combination, in the step of unifying the reinforcing filament assembly including the first fiber reinforcement layer and the second fiber reinforcement layer, the first fiber reinforcement layer formed by stringing the first set of parallel strands of fiber reinforcement over a part or all of the plane within the shape along the predetermined axis contained within the plane, the second fiber reinforcement layer formed by stringing the second set of parallel strands of fiber reinforcement over the plane of the shape at the angle with respect to the axis.

16. A method for producing a dry preform for a composite material for use as a structural material according to claim 6 wherein

proper means selected from stitching, knitting, tufting, needle punch, and thermoplastic resin is used either independently or in combination, in the step of unifying the reinforcing filament assembly including the first fiber reinforcement layer and the second fiber reinforcement layer, the first fiber reinforcement layer formed by stringing the first set of parallel strands of fiber reinforcement over a part or all of the plane within the shape along the predetermined axis contained within the plane, the second fiber reinforcement layer formed by stringing the second set of parallel strands of fiber reinforcement over the plane of the shape at the angle with respect to the axis.

17. A method for producing a dry preform for a composite material for use as a structural material according to claim 7 wherein

proper means selected from stitching, knitting, tufting, needle punch, and thermoplastic resin is used either independently or in combination, in the step of unifying the reinforcing filament assembly including the first fiber reinforcement layer and the second fiber reinforcement layer, the first fiber reinforcement layer formed by stringing the first set of parallel strands of fiber reinforcement over a part or all of the plane within the shape along the predetermined axis contained within the plane, the second fiber reinforcement layer formed by stringing the second set of parallel strands of fiber reinforcement over the plane of the shape at the angle with respect to the axis.

18. A method for producing a dry preform for a composite material for use as a structural material according to claim 8 wherein

proper means selected from stitching, knitting, tufting, needle punch, and thermoplastic resin is used either independently or in combination, in the step of unifying the reinforcing filament assembly including the first fiber reinforcement layer and the second fiber reinforcement layer, the first fiber reinforcement layer formed by stringing the first set of parallel strands of fiber reinforcement over a part or all of the plane within the shape along the predetermined axis contained within the plane, the second fiber reinforcement layer formed by stringing the second set of parallel strands of fiber reinforcement over the plane of the shape at the angle with respect to the axis.

19. A method for producing a dry preform for a composite material for use as a structural material according to claim 9 wherein

proper means selected from stitching, knitting, tufting, needle punch, and thermoplastic resin is used either independently or in combination, in the step of unifying the reinforcing filament assembly including the first fiber reinforcement layer and the second fiber reinforcement layer, the first fiber reinforcement layer formed by stringing the first set of parallel strands of fiber reinforcement over a part or all of the plane within the shape along the predetermined axis contained within the plane, the second fiber reinforcement layer formed by stringing the second set of parallel strands of fiber reinforcement over the plane of the shape at the angle with respect to the axis.

20. A method for producing a dry preform for a composite material for use as a structural material according to claim 10 wherein

proper means selected from stitching, knitting, tufting, needle punch, and thermoplastic resin is used either independently or in combination, in the step of unifying the reinforcing filament assembly including the first fiber reinforcement layer and the second fiber reinforcement layer, the first fiber reinforcement layer formed by stringing the first set of parallel strands of fiber reinforcement over a part or all of the plane within the shape along the predetermined axis contained within the plane, the second fiber reinforcement layer formed by stringing the second set of parallel strands of fiber reinforcement over the plane of the shape at the angle with respect to the axis.

21. An apparatus for producing a dry preform for a composite material having a curved shape, the apparatus comprising:

a plurality of pin members, each including a predetermined number of pins for stringing strands of fiber reinforcement, the pin members being arranged opposite one another and spaced apart by a distance corresponding to a width of the dry preform;

a space maintaining member for connecting the pin members to one another along a length of the dry preform in such a manner that the pin members can move toward or away from one another, and for keeping the distance between the opposed pin members; and

an end pin member provided on at least one longitudinal end thereof and extending along the width of the apparatus, and including a predetermined number of pins, the end pin member being able to pivot about a center as viewed along the width thereof so that a tension that is caused when the reinforcing filament assembly is deformed remains even,

the apparatus capable of deforming to describe an arch about its longitudinal axis.

22. An apparatus for producing a dry preform for a composite material for use as a structural material, comprising:

a set of fiber reinforcement guide pipes for stringing a first fiber reinforcement layer and a second fiber reinforcement layer, the number of the guide pipes corresponding to the number of strands of fiber reinforcement or the number of rows of strands of fiber reinforcement that are strung at a time;

a set of bars for securing the set of fiber reinforcement guide pipes and keeping the distance between the guide pipes;

an actuator for driving the set of fiber reinforcement guide pipes and the set of bars to either move the guide pipes and the bars along a straight axis or move the bars at an angle with respect to the straight axis; and

a creel unit for feeding the strands of fiber reinforcement to the set of fiber reinforcement guide pipes.