Process and system for fabricating a reinforcing preform

• US 7,115,180 B2
• Filed: 04/07/2004
• Issued: 10/03/2006
• Est. Priority Date: 04/17/2003
• Status: Active Grant

• Current Assignee: Hexcel Reinforcements
• Original Assignee: Hexcel Reinforcements
• Inventors: Bruyère, Alain
• Primary Examiner(s): Aftergut, Jeff H.
• Application Number:
  US10/820,573
• Publication Number:
  US 20050067731A1
• Time in Patent Office: 909 Days
• Field of Search: 156/166, 156/173, 156/175, 156/433, 156/441
• US Class Current: 156/166
• CPC Class Codes: B29B 11/16 comprising fillers or reinforcement non-woven fabrics per se D04H1/00, D04H3/00
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/336 of two or more materials
• CPC Class Codes: B29C 70/382 Automated fiber placement [AFP]
• CPC Class Codes: B29C 70/384 Fiber placement heads, e.g. component parts, details or accessories
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor

Abstract

Process and system for fabricating a multidirectional fibrous reinforcement designed to be a porous preform for producing a part made of a composite material. Reinforcing thread is deposited in successive layers on a support surface. A binder is provided in association with the reinforcing thread so as to adhere the reinforcing thread to the support surface and the successive layers of thread. The reinforcing thread is pressed against the support surface in a manner that exerts a pressure substantially perpendicular to the support surface at the point where the thread is deposited. The binder may be pre-applied to the support surface or it can be applied simultaneously with the reinforcement thread.

Claims

1. A process for fabricating a multidirectional fibrous reinforcement for use in producing a part made of a composite material, said process comprising the steps of:

providing a deposition finger for use in a deposition step to deposit at least one reinforcing thread in at least two successive layers on a support surface wherein said deposition finger comprises a presser head that is shaped to exert pressure on said reinforcing thread, said deposition finger extending from a deposition head and being movable relative to said deposition head;

providing a binder in association with said reinforcing thread so as to adhere said reinforcing thread to said support surface wherein said binder also provides a bond between said successive layers and wherein said binder is deposited on said support surface ahead of the reinforcing thread while the reinforcing thread is being deposited; and

using said deposition finger to press said reinforcing thread against the support surface during said depositing step in a manner that exerts a pressure substantially perpendicular to said support surface at the point where the thread is deposited.

2. A process for fabricating a multidirectional fibrous reinforcement according to claim 1 wherein said reinforcing thread is advanced as the reinforcing thread is deposited so as not to cause any tension in said reinforcing thread and so as to deposit the thread without tension.

3. A process for fabricating a multidirectional fibrous reinforcement according to claim 1 wherein said step of providing said binder in association with said reinforcing thread comprises the step of activating said binder as the reinforcing thread is deposited.

4. A process for fabricating a multidirectional fibrous reinforcement according to claim 1 wherein said deposit finger comprises a thread guide groove for leading said reinforcing thread to the presser head.

5. A process for fabricating a multidirectional fibrous reinforcement according to claim 1 wherein said pressure is exerted perpendicular to the surface of the presser head on the deposit finger and wherein the surface of the presser head is kept substantially tangent to the support surface while the reinforcing thread is being deposited thereon.

6. A process for fabricating a multidirectional fibrous reinforcement according to claim 1 wherein said step of depositing reinforcing thread comprises using a plurality of deposition fingers to simultaneously deposit several reinforcing threads on said support surface in parallel deposit trajectories.

7. A process for fabricating a multidirectional fibrous reinforcement according to claim 1 wherein said binder comprises a thermoplastic powder and wherein the area where the reinforcing thread is to be deposited is heated.

8. A process for fabricating a multidirectional fibrous reinforcement according to claim 7 wherein said support surface is covered at least partially with a thermoplastic powder prior to deposition of said reinforcing thread thereon.

9. A process for fabricating a multidirectional fibrous reinforcement according to claim 1 wherein said binder comprises a hot-melt resin that is deposited on said support surface when said reinforcing thread is being deposited thereon and wherein said hot-melt resin is deposited ahead of the deposit of the reinforcing thread on said support surface.

10. A process for fabricating a multidirectional fibrous reinforcement according to claim 1 wherein said binder comprises a pulverizable solution or emulsion of at least one adhesive resin.

11. A process for fabricating a multidirectional fibrous reinforcement according to claim 1 wherein said reinforcing thread is deposited in discontinuing segments.

12. A process for fabricating a multidirectional fibrous reinforcement according to claim 1 wherein said support surface comprises an area having a concave or convex shape and wherein said reinforcing thread is deposited at least in said area of the support surface that has said concave or convex shape.

13. A process for fabricating a multidirectional fibrous reinforcement according to claim 1 wherein said pressure exerted against said reinforcing thread by said presser head is between 0.01 and 30 bar.

14. A process for fabricating a multidirectional fibrous reinforcement according to claim 1 wherein the location where the reinforcing thread is deposited on said support surface is heated to a temperature of between 50 and 450 °

C.

15. A process for fabricating a multidirectional fibrous reinforcement according to claim 1 wherein said deposition finger includes a longitudinal axis which extends from said deposition head to said presser head and wherein said deposition finger is moved in relation to said deposition head during said deposition step by rotation about said longitudinal axis.

16. A process for fabricating a multidirectional fibrous reinforcement according to claim 15 wherein said deposition finger is extended and/or retracted along said longitudinal axis in relation to said deposition head during said deposition step.

17. A process for fabricating a multidirectional fibrous reinforcement according to claim 1 wherein said deposition finger includes a longitudinal axis which extends from said deposition head to said presser head and wherein said deposition finger is extended and/or retracted along said longitudinal axis in relation to said deposition head during said deposition step.

18. A process for fabricating a multidirectional fibrous reinforcement for use in producing a part made of a composite material, said process comprising the steps of:

providing a deposition finger for use in a deposition step to deposit at least one reinforcing thread in at least two successive layers on a support surface wherein said deposition finger comprises a presser head that is shaped to exert pressure on said reinforcing thread, said deposition finger extending from a deposition head and being movable relative to said deposition head;

providing a binder in association with said reinforcing thread so as to adhere said reinforcing thread to said support surface wherein said binder also provides a bond between said successive layers, said binder comprising a thermoplastic powder and wherein the area where the reinforcing thread is to be deposited is heated and wherein said thermoplastic powder is co-deposited onto said support surface with said reinforcing thread.

19. A process for fabricating a multidirectional fibrous reinforcement according to claim 18 wherein said reinforcing thread is covered at least partially with said thermoplastic powder.