MACHINE FOR ADAPTING A FIBRE STRUCTURE TO A MOULD FOR MANUFACTURING PARTS OF COMPOSITE MATERIAL

Abstract

The machine comprises a solid matrix (1), a deformable body (2) joined to the surface of said matrix (1), a shaping mould (3) and a securing system system (5) for the fibre structure (4). The matrix (1) is a solid element having a functional face, the geometry of which depends on the part to be manufactured. The deformable body (2) has an initial geometry that depends on the geometry to be given to the fibre structure (4). The shaping mould (3) has the geometry to be given to the fibre structure (4) during the process of adaptation to the shaping mould (3), and the shaping mould (3) is located such that the deformable body (2) is located between said shaping mould (3) and the matrix (1).

Claims

1. A machine for adapting a fibre structure to a mould for manufacturing parts of composite material comprising: a solid matrix; a deformable body that is joined to the surface of said matrix, which can have various shapes and which encompasses an area greater than or equal to the area of the part to be shaped; a shaping mould; a securing system for the fibre structure; wherein: said matrix is a solid element having a functional face the geometry of which depends on the part to be manufactured; wherein the deformable body is joined to the functional face of the matrix, which is configured to move towards the shaping mould by means of a linear guide system actuated by means of an actuator; said deformable body is made of a material that has a rigidity at least 100 times lower than the matrix and the shaping mould; wherein the deformable body has an initial geometry that depends on the geometry to be given to the fibre structure; and wherein the progressive compression of said deformable body against said shaping mould is what causes the effect of adaptation of the fibre structure to the shaping mould; said shaping mould has the geometry to be given to the fibre structure during the process of adaptation to the shaping mould, and the shaping mould is located such that the deformable body is located between said shaping mould and the matrix; characterised in that: said securing system of the fibre structure encompasses at least one portion of the contour of the fibre structure by means of at least one securing element that is configured to be able to move during the adaptation of the fibre structure to the shaping mould; wherein each securing element comprises: a lower frame which covers an area greater than or equal to an effective securing area; wherein said lower frame includes an anchoring system to an element such as a tool or a robotic mechanism that enables the securing element to move during the adaptation; separation sheets, which cover at least the effective securing area, located on said lower frame; wherein the planes of said separation sheets and the plane of said lower frame are parallel; wherein between said separation sheets are placed layers that form part of the fibre structure to be secured; and wherein each layer is always separated from another adjacent layer by means of one of said separation sheets; an upper closure frame, which covers at least the effective securing area, located on the separation sheets; wherein the plane of said upper frame and the planes of the separation sheets are parallel; wherein said separation sheets are located between the lower frame and the upper frame; and wherein the upper frame includes an anchoring system to an element such as a tool or a robotic mechanism that enables the securing element to move during the adaptation; a coupling system which links the lower frame, separation sheets and upper frame; wherein said coupling system is configured to prevent the relative displacement with respect to the planes in which said elements are located; a closure system which prevents the relative displacement between the lower frame, the separation sheets and the upper frame with respect to the direction normal to the planes in which said elements are located; wherein said closure system is configured to exert the required closing force.

2. The machine for adapting a fibre structure to a mould for manufacturing parts of composite material, according to claim 1, comprising: an elastic film which is configured to be placed between the deformable body and the fibre structure; wherein the deformable body is a material of high plasticity, with low elongation at break, less than 20%, by virtue of which it is permanently plastically deformed during the process of adaptation to the shaping mould.

3. The machine for adapting a fibre structure to a mould for manufacturing parts of composite material, according to claim 1, wherein the deformable body includes therein a series of watertight cavities (6), filled with a fluid selected between a gas and a liquid; wherein the deformable body is an elastic body with high elongation at break, greater than 100%, by virtue of which it does not undergo permanent deformations during the process of adaptation to the shaping mould [[(3)]].

4. The machine for adapting a fibre structure to a mould for manufacturing parts of composite material, according to claim 1, wherein the deformable body includes therein a series of watertight cavities, filled with a fluid selected between a gas and a liquid; wherein said watertight hollow structure connects with a fluid injection and evacuation system configured to vary the volume of the deformable body and to vary the degree of compression of the deformable body on the fibre structure against the shaping mould; and wherein the deformable body is an elastic body with high elongation at break, greater than 100%, by virtue of which it does not undergo permanent deformations during the process of adaptation to the shaping mould.

5. The machine for adapting a fibre structure to a mould for manufacturing parts of composite material, according to claim 2, further comprising: an additional mould configured to return the deformable body to the initial shape thereof by pressing the additional mould on said deformable body against the matrix; wherein said deformable body is located between the matrix and the additional mould; and wherein the additional mould is required when the deformable body is not a body of elastic material but a body of material with high plasticity, with low elongation at break, less than 20%.

6. The machine for adapting a fibre structure to a mould for manufacturing parts of composite material, according to claim 5, wherein the additional restoration mould and the shaping mould include movement systems that are configured to enable both moulds to be alternately positioned in alignment with the matrix.

7. The machine for adapting a fibre structure to a mould for manufacturing parts of composite material, according to claim 5, wherein the matrix includes a movement system configured to transfer said matrix, by means of a robotic mechanism, to a position wherein the additional restoration mould is located; and wherein said matrix is compressed against said additional mould.

8. (canceled)

9. The machine for adapting a fibre structure to a mould for manufacturing parts of composite material, claim 5, a film of elastic material, such as latex, which is located on the surface of the additional restoration mould; wherein said film is placed between the deformable body and said additional restoration mould; wherein the film is secured by means of a fastening system that does not invade the space of said additional mould; and wherein the film is a body selected between a porous body and a body that has perforations that enable the air enclosed between said film and the deformable body to be evacuated.

10. The machine for adapting a fibre structure to a mould for manufacturing parts of composite material, according to claim 9, wherein the fastening system of the film is solidly joined to the additional restoration mould or to the matrix.

11. (canceled)

12. (canceled)

13. (canceled)

14. The machine for adapting a fibre structure to a mould for manufacturing parts of composite material, according to claim 5, further comprising: an elastic gasket based on an elastic material with a great elongation at break, greater than 100%; wherein said elastic gasket (46) is configured to contain cavities, or reinforcements therein, wherein said elastic gasket (46) is either located in the contour of the additional mould (24) or the elastic gasket is solidly joined to the matrix, being located along the contour thereof; in which case said elastic gasket has a skirt towards an interior space of said matrix that is enclosed between said matrix and the deformable body.

15. The machine for adapting a fibre structure to a mould for manufacturing parts of composite material, according to claim 13 wherein the additional mould has on the contact surface thereof an air evacuation structure formed by grooves or pores that enables the evacuation of the air enclosed between the film and said additional mould during the recovery of the geometry of the deformable body that is facing the contact surface of the air evacuation structure.

16. (canceled)

17. The machine for adapting a fibre structure to a mould for manufacturing parts of composite material, according to claim 1 wherein the separation sheets comprise a material selected between a non-stick material, and any flexible material coated with said non-stick material.

18. The machine for adapting a fibre structure to a mould for manufacturing parts of composite material, according to claim 2, wherein the elastic film is fastened to an element selected between the matrix and the shaping mould or it is comprised in the fastening system of the fibre structure, in which case said elastic film is fastened either to the lower frame, to the upper frame or to both elements; wherein said elastic film is secured by means of a fastening system, such as clamps.

19. (canceled)

20. The machine for adapting a fibre structure to a mould for manufacturing parts of composite material, according to claim 1, wherein the coupling system that links the lower frame, separation sheets and upper frame, comprises at least one coupling element selected between a cylindrical pin and a threaded rod; wherein said coupling element is solidly joined to either the upper frame or the lower frame; said coupling element is arranged in a direction perpendicular to the planes of the lower frame, separation sheets and upper frame; the coupling element passes through the separation sheets and the respective frame through holes included in said separation sheets and in the respective frame.

21. (canceled)

22. (canceled)

23. (canceled)

24. The machine for adapting a fibre structure to a mould for manufacturing parts of composite material, according to claim 1, wherein the matrix is formed by several mobile parts that are configured to move towards the shaping mould; wherein said parts compress the deformable material against the shaping mould and are actuated by means of at least one mechanical actuator.

25. (canceled)

26. (canceled)

27. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0054] FIG. 1 shows a plan view of a fibre structure with the fibre securing system according to claim 1.

[0055] FIG. 2 shows a cross sectional view of the adaptation system in the initial moments of the adaptation phase according to claim 2.

[0056] FIG. 3 shows a cross sectional view of the adaptation system at an intermediate point of the adaptation phase according to claim 2.

[0057] FIG. 4 is similar to FIG. 2, showing different features in the deformable body according to claim 3.

[0058] FIG. 5 is similar to FIG. 4, showing another method for deforming the deformable body according to claim 4.

[0059] FIG. 6 is similar to FIG. 2, showing a matrix formed by different elements with independent movement.

[0060] FIG. 7 is similar to FIG. 6, showing a system of cavities or pores in the deformable body.

[0061] FIG. 8 is similar to FIG. 3, showing a matrix formed by different joint elements operated by a single actuator.

[0062] FIG. 9 is similar to FIG. 8, showing different features in the deformable body, according to claim 3.

[0063] FIG. 10 shows a cross sectional view of the adaptation machine at the final moment of adaptation according to the preferred embodiment of the invention.

[0064] FIG. 11 shows a diagram of the complete process for obtaining an adapted part of fibres.

[0065] FIG. 12 shows a diagram of the restoration system integrated in the machine for adapting fibres according to claims 5 and 6.

[0066] FIG. 13 shows a plan view of a fibre structure secured by means of a fibre securing system according to claim 1.

[0067] FIG. 14 shows the cross section 14-14 of an element of the fibre securing system according to FIG. 13.

[0068] FIG. 15 shows the cross section 15-15, a cross section of an element of the fibre securing system according to FIG. 13.

[0069] FIG. 16 is similar to FIG. 14, showing the independent sliding that has occurred in the layers of fibres during adaptation.

[0070] FIG. 17 is similar to FIG. 14, showing in this case the elastic film and a fastening system.

[0071] FIG. 18 shows a perspective view of a securing element that is part of the fibre securing system.

[0072] FIG. 19 shows a diagram of the automated assembly of the fibre securing system.

[0073] FIG. 20 shows a cross section of the elements of the system for restoring the geometry of the deformable body according to claim 14.

[0074] FIG. 21 is similar to FIG. 20, showing in this case a gasket solidly joined to the matrix, according to claim 15.

[0075] FIG. 22 is similar to FIG. 20, showing in this case a cross section during the compression of the deformable body on an additional mould.

[0076] FIG. 23 shows a cross sectional view of a securing and guiding apparatus for elements of the fibre securing system.

[0077] FIGS. 24A and 24B show possible embodiments of the coupling system linked to the fibre securing system.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION

[0078] FIG. 1 shows a plan view of a fibre structure (4) according to claim 1 that will be subsequently shaped or adapted to the three-dimensional mould (3), and which is formed by a series of layers (13) of different geometry and oriented according to the load paths of the corresponding composite part. The layers (13) can be partially or entirely joined to each other by means of sewing or the use of adhesives. In the case of using fibres previously impregnated with resin, or prepregs, it is possible to use the adhesion generated by the resin itself to join said layers.

[0079] The objective of this joining is to transmit the stress generated by means of the fibre securing system (5) to the areas of the fibre structure (4) that require it, being able to otherwise not perform any joining between the layers (13). Said securing system (5), which is shown in detail in FIGS. 13-19, encompasses at least partially the contour of the fibre structure (4), and enables the fibres to slide where required, for example in areas where due to a more abrupt geometry, a greater quantity of fibres is needed. The fibre securing system (5) has anchoring points in each one of the elements (42) thereof that are not detailed, which enable, by means of a tool prepared for this purpose, all those elements (42) to be secured at the same time, preferably by means of a robot, to be transferred to the positions that are necessary, either in vacuum, or with the fibres (4) secured.

[0080] For example, to be transferred from the mounting area (19) of the securing system (5), which is detailed in FIG. 19, towards the adaptation area (20), specifically between the matrix (1) and the shaping mould (3).

[0081] Furthermore, the concept of securing system (5) that is presented, enables the intermediate storage of the same already mounted with the fibres (4), before being taken to the adaptation area (20), enabling the productive inequalities of the manufacturing phases to be absorbed.

[0082] It is important to note that the design of said securing system (5) mounted with the fibres (4) enables, after being installed between the matrix (1) and the shaping mould (3), each element (42) to have an independent movement during the adaptation of the fibres, thus being able to facilitate said adaptation in parts of complex geometry. This independent guide system is not detailed as it can be achieved by means of a wide variety of solutions on the market, such as robotic arms.

[0083] FIG. 2 shows a cross sectional view of the adaptation machine according to claim 2, specifically in the initial moments of the fibre adaptation phase. The system consists of a matrix (1) that can have different shapes, on the surface of which an easily deformable body (2) is adhered, which has a specific initial geometry and which depends on the shape of the part to be manufactured. The mould (3) is located such that the deformable body is located between said mould (3) and the matrix (1).

[0084] After positioning the fibre structure (4) supported by the fibre securing system (5) between the deformable body (2) and the mould (3), the matrix (1) is moved towards the mould at a certain speed, according to claim 2, preferably with the aid of a press, so that the deformable body is compressed against the mould (3), forcing the fibre structure (4) to progressively adopt the shape thereof, which enables the stress between layers to be reduced, avoiding the appearance of misalignments or wrinkles in the fibres (4) and making it possible to obtain preforms from fibres pre-impregnated with resin.

[0085] During the adaptation of the fibres (4) that are initially arranged in a two-dimensional plane, the fibres (4) slide with respect to the securing elements (42) as they take on a three-dimensional shape.

[0086] It is important to note that it is envisaged that the securing elements (42) have independent movement and according to the degrees of freedom that the adaptation of the fibres (4) requires. That is, said elements (42) could remain immobile throughout the entire process, move freely according to certain degrees of freedom, have forced movement according to said degrees of freedom, or a combination of the above.

[0087] FIG. 3 is similar to FIG. 2, showing in this case the adaptation phase in a more advanced state, wherein the fibre structure (4) has already partially adopted the shape of the mould (3). It should be noted that, in the example shown, the fibre securing system (5) maintains the necessary stress but at the same time enables the sliding thereof.

[0088] FIG. 4 is similar to FIG. 2, showing the deformable body (2) with different features, according to claim 3, said body (2) being elastically deformed, without reaching plasticity or creep, and having cavities, ducts, porosities or any combination of the above (6), and containing a gas or a liquid enclosed therein. By means of a suitable design of said cavities (6), the body is caused to be deformed according to the optimal sequence for adapting the fibre structure (4). Note that the adaptation effect is the same as in the case of FIGS. 2 and 3, and that the difference is the deformation phenomena that take place.

[0089] FIG. 5 shows a cross sectional view of the adaptation machine according to claim 4, wherein the deformable body (2) is made of an elastic material, which is deformed without reaching plasticity or creep, and which has cavities, ducts, porosities or any combination of the above (6), and containing therein a gas or a liquid connected to the outside through at least one duct (7).

[0090] In this case, instead of moving the matrix (1) towards the mould (3) to achieve the adaptation, a gas or a liquid is injected through at least one duct (7) into the deformable body (2) causing an increase in volume therein. By means of a suitable design of said cavities (6), the deformation sequence can be controlled to produce the desired adaptation.

[0091] FIG. 6 is similar to FIG. 2, showing in this case, as envisaged in claim 25, a matrix (1) divided into several elements (8) that are independently moved by means of mechanical actuators, preferably hydraulic cylinders (9), describing that stated in claim 2. Therewith, greater control of the deformation sequence is achieved, enabling the adaptation of more complex mould geometries.

[0092] FIG. 7 is similar to FIG. 6, showing in this case a deformable body (2) according to claim 3, which is elastically deformed, without reaching plasticity or creep, and which has cavities, ducts, porosities or any combination of the above (6), and containing a gas or a liquid enclosed therein.

[0093] FIG. 8 is similar to FIG. 3, showing in this case a matrix (1) divided into several elements (8) joined by means of any mechanism (10), stated in claim 26, which is actuated by means of a mechanical actuator, preferably a hydraulic cylinder (9). This figure shows an example of a mechanism (10) containing joints (11) and a spring (12), by means of which the entire system is caused to work with a single actuator (9).

[0094] FIG. 9 is similar to FIG. 8, showing in this case an elastic or viscoelastic deformable body (2) which has cavities, ducts, porosities or any combination of the above (6), according to claim 3, and containing a gas or a liquid enclosed therein. By means of a suitable design of said cavities (6), the body is caused to be deformed according to the optimal sequence for adapting the fibre structure (4).

[0095] FIG. 10 shows a cross sectional view of the machine object of the present invention, at the moment when the adaptation of the fibres has been completed, specifically after the moment indicated in FIG. 3. In this case, the matrix (1) is lifted returning to the initial position thereof and releasing the already preformed fibres (4). It should be noted, as mentioned in claim 1, that the securing system (5) for the fibres enables the sliding thereof in the areas wherein it is necessary, being able to detach (14B) from said securing system (5) at the appropriate time, wherever the stress of the fibres is no longer required, or on the contrary, remain secured to the system (14A) until the end of the process of adaptation.

[0096] In the case shown in the present FIG. 10, the deformable body (2) is made of a material that is plastically deformed and that does not recover the initial geometry thereof when the pressure ceases, according to claim 2. It is therefore necessary to reshape said deformable body (2) to give it the initial shape thereof. That is why it is envisaged that the machine additionally comprises an additional restoration mould (24), as expressed in claim 5.

[0097] FIG. 11 shows a diagram of the process for obtaining the fibre preform, wherein the machine disclosed in the present invention is integrated, which corresponds in this case to areas (18) (19) and (20).

[0098] The area (17) corresponds to obtaining the fibre parts (13), by means of already existing processes such as cutting by numerical control (15) or automated fibre deposition systems (16), or AFP.

[0099] Next, the area (18) corresponds to the preparation of the layers of fibres (13) or layers, by means of an automated positioning system, such as the robot (21).

[0100] Within this space (18), the carrying out of joining processes between the layers that require it is also envisaged, such as sewing, the addition of an adhesive, or the application of pressure between two or more layers (13) in the case of being pre-impregnated with resin. Additionally, parts of core material for composites such as polymer foams, cork, wood or metal, and inserts of different materials can be inserted. It is important to note that the aforementioned additional processes that can take place during step (18) can be carried out in different positions within the production line, and are executed by automated tools such as the robots (39).

[0101] In the next area (19) the fibre structure (4) is fastened in the fibre securing system (5), which is detailed in FIG. 19, wherein the layers (13) are stacked and enclosed between the sheets (30) of the securing system, and can be previously stacked, sewn, with core material or presented individually. It is important to note that in the case of being presented individually, i.e., without additional sewing, core inserting or gluing operations, the layers (13) can come directly from the area (17) for obtaining said layers.

[0102] Regarding the fastening, note that it encompasses at least partially the contour of said layers (13).

[0103] In the area (20), corresponding to the adaptation, are located the shaping mould (3) and the matrix (1) together with the deformable body (2), wherein the securing system (5) is positioned, once it has been mounted together with the fibres (4) in the area (19). The placement of said securing system (5) together with the fibres (4) is preferably carried out by means of a robot (22) having a tool that secures each one of the elements (42) of the securing system.

[0104] The additional mould (24) for restoring the initial shape of the deformable body (2) is not detailed in the present figure.

[0105] FIG. 12 shows a diagram of the restoration system that is part of the fibre adaptation machine object of the present invention, wherein the fibre adaptation and restoration are carried out in the same place (20), and by means of the same press (23), according to claim 6, wherein it is stated that the mould (3) and the additional restoration mould (24) have a movement system (27) that enables them to be alternately aligned with the matrix (1). Note that when the additional restoration mould (24) is aligned with said matrix (1), in the press (23), the shaping mould (3) moves to another position (26) wherein a robot is expected to collect the adapted fibres (4), and position, on said shaping mould (3) new fibres by means of the securing system (5) proposed in the present invention.

[0106] The present figure shows the operation of the machine at the moment in which the fibre structure (4) has already adopted the required shape and the additional restoration mould begins the movement towards the position in alignment thereof with the matrix (1) at the same time in which the shaping mould (3) moves towards the area (26).

[0107] Once said additional restoration mould (24) is positioned in alignment with the matrix (1), the deformable body (2) is compressed by means of the press (23) between said elements (1) and (24) to recover the shape of said deformable body (2).

[0108] It is important to note that it is also envisaged that the restoration is carried out in a place other than that for adaptation of fibres (20), in which case, stated in claim 7, the matrix (1) has a system that enables it to uncouple from the press (23) to be transferred to the position occupied by the additional restoration mould (24).

[0109] FIG. 13 shows a partial plan view wherein two elements (42) that form part of the fibre securing system (5) can be seen. The fibre structure (4) is secured in those areas where it is necessary by means of at least one element (42), which have a closure system (28) that acts on at least one point of each element (42). Alternatively other types of closure are envisaged such as clamps, pins or threads. The upper or closure frame (31) is the element that gives consistency to the securing system together with the lower frame (29) located below, so it is not displayed in the present figure.

[0110] FIG. 14 shows a cross sectional view of cross section 14-14, indicated in FIG. 13, of an element (42) of the fibre securing system. It shows the lower frame (29) which, together with the upper or closure frame (31) provide consistency to the securing system, and can be manufactured from any material, according to the requirements of each preform, for example aluminium, steel sheet metal or a polymeric material. Between both frames (29) and (31) separation sheets (30) are located on both sides of each layer of fibres (13). Said sheets (30) are preferably made of a flexible material coated with a non-stick medium, such as Teflon or non-stick silicone, to enable the sliding of the fibre layers. Alternatively, they can be made directly of said non-stick material.

[0111] Between each one of the frames (29) and (31) and the adjacent separation sheets (30) an elastic element (32) is placed, such as a flexible polymer foam or an elastomer, which covers an area (38) greater than or equal to the effective securing area (36), i.e., the region of the fibres (13) that is covered by the securing element (42) at the initial moment of preforming. Said flexible material (32) envelops the fibres (13) and the objective thereof is to distribute the pressure exerted by the frames on the fibres (13) in a homogeneous way, thus avoiding pressure concentrations that can cause distortions in the directions of the fibres (13) when sliding relative to the sheets (30) due to an excessive frictional force.

[0112] In order to ensure the consistency of each securing element (42), a coupling system is placed so that the lower frame (29), the separation sheets (30) and the upper or closure frame (31) do not have relative displacement with respect to the plane thereof. This coupling system is, according to the present figure, a coupling element (33) (cylindrical pin) solidly joined to the lower frame (29) and which passes through the made-to-measure holes located in the sheets (30) and the upper frame (31), so that the only enabled movement of the elements relative to each other is according to the normal to the plane of the fibres.

[0113] Additionally, the closure (28) of the securing system is located, the objective of which is to exert adequate pressure on the fibres (13) to thus generate the necessary stress in the fibres by means of friction phenomena. In the present figure, said closure (28) is an element into which the coupling element (33) is inserted, one being retained with respect to the other, for example, by means of a threaded joint, a pin, etc. In this way the closure (28) exerts the required force on the upper or closure frame (31). It is important to note that the lower (29) and upper (30) frames are provided with anchoring elements that are not detailed, and that serve for the fastening thereof in the different areas of the adaptation machine, as well as for the transport or storage thereof.

[0114] FIG. 15 shows a cross sectional view of cross section 15-15, indicated in FIG. 13, of an element (42) of the fibre securing system, and is similar to FIG. 14. In this case, the coupling element (33) and the closure (28) are not seen since they are in another section of the securing element (42).

[0115] The fibre structure (4) protrudes (43) from the securing system to enable a greater sliding distance of the fibres during the preforming process, in areas that so require it. Note that the elastic element (32) encompasses the entire area (37) of the lower (29) and upper (31) frames.

[0116] FIG. 16 shows the same section as FIG. 14 at a later moment, specifically, during the preforming process, which shows how each one of the fibre layers (13) have slid independently with respect to the securing element (42), to the extent that is required by the process.

[0117] FIG. 17 shows the same cross section as FIG. 14, showing in this case an additional element, specifically, an elastic film (34), which is secured by means of a fastening system (35) that is not detailed, such as clamps or a tensioning frame, and which may or may not enable said film (34) to slide.

[0118] FIG. 18 shows a perspective view of a fibre securing element (42) according to the present invention, wherein the layers of fibres (13) are seen placed between the separation sheets (30) located in turn between the lower frame (29) and the upper or closure frame (31). The closure elements (28) provide the closure force that is transmitted to the fibres by means of the frames (29) and (31), thanks to which the tensioning effect is achieved by means of friction phenomena.

[0119] FIG. 19 shows a disassembled fibre securing system (5), wherein the ease of automation presented by said securing concept can be seen. For the assembly thereof, first of all, the lower frame (29) is placed on a surface or tool (40) located in the lower area (19B) for stacking layers (13) and for mounting the fibre securing system, wherein there is a support element (41) that prevents the layers (13) from sinking during stacking. Subsequently, preferably by means of an automated system that contains the remaining elements of the securing system (5), a separation sheet (30) is positioned. Next, preferably by means of an automated system, such as the robot (21), a layer of fibres (5) is placed in the desired position. The process is continued by alternately placing as many layers (13) and sheets (30) as necessary for each preform, placing a last sheet (30) followed by the upper or closure frame (31). Finally, the closure (28) is installed to apply the necessary force on the fibres (13), such that there is the required stress therein during the adaptation thereof to the shaping mould (3).

[0120] FIG. 20 shows a cross section of the restoration system indicated in claim 13, wherein the additional restoration mould (24) and the matrix (1) are positioned such that the deformable body (2) is located between the same. The elastic film (44) positioned by means of the securing or tool (45), separates the deformable body (2) so that it does not adhere to the additional restoration mould (24). Said film (44) has perforations (47) that enable the evacuation of the air that would otherwise be enclosed between the deformable body (2) and the film (44), said perforations being small enough to prevent the deformable body (2) from being extruded therethrough.

[0121] Therefore, by compressing the matrix (1) against the additional mould (24), the deformable body (2) is forced to acquire the shape of said additional restoration mould (24), which is the one required to redo the process of adaptation.

[0122] The system further has an elastic gasket (46) located on the edge of the additional mould (24) and on the elastic film (44). Said elastic gasket (46) is compressed together with the deformable body (2) to prevent said deformable body from leaving the volume comprised between the matrix (1) and the additional mould (24).

[0123] FIG. 21 is similar to FIG. 20, showing in this case a gasket (46) solidly joined to the matrix (1) and having a skirt (49) that is enclosed between said matrix and the deformable body (2), according to claim 14.

[0124] FIG. 22 is similar to FIG. 20, in this case showing a cross section during the compression of the deformable body (2) on the additional mould (24).

[0125] FIG. 23 shows a cross sectional view of a securing and guiding apparatus for the elements (42) of the securing system (5) for fibres (4), as described in claim 27. This system comprises a movement mechanism (52) that can be actuated by means of a robotic system, or pushed by an actuator (53) solidly joined to the matrix (1), and that enables the securing element (42) to be positioned in the suitable place during the adaptation. For this, there is a flexible arm (50) that is anchored at one end to the mobile element (54) of the movement mechanism (52), the other end being anchored to the fibre securing element (42). This arm can be deformed for flexing and twisting, enabling the securing element (42) to align freely with the direction of stress of the fibres, which is essential to prevent the layers of fibres (13) from adhering to each other before having correctly adapted to the shape of the mould (3). Since the arm is flexible, prior to adaptation, wherein the fibres are arranged in a two-dimensional plane, the securing elements (42) could fall by their own weight. To avoid this, a rigid support (51) located under the flexible arm (50) is inserted which is anchored to the mobile element (54) of the movement mechanism (52).

[0126] FIGS. 24.A and 24.B show possible embodiments of the coupling system linked to the fibre securing system (5), according to claim 1. Cross sectional views of a securing element (42) of said securing system (5) are represented.

[0127] FIG. 24.A shows a mixed embodiment of the coupling system between the lower frame (29), separation sheets (30) and upper frame (31), wherein the lower and upper frame (29,31) are linked by means of a first hinge mechanism (55) that enables a relative rotational movement, while the separation sheets (30) are linked to the lower frame (29) by means of a pin (33) that passes therethrough. The closure system is not represented in this figure, and it can be a rotary actuator acting on the first hinge mechanism (55) exerting the necessary force to compress the fibres (13) between the lower and upper frames (29,31).

[0128] FIG. 24. B shows a coupling system made up of a first hinge mechanism (55) that joins the upper and lower frames (31,29) on one side, and second hinge mechanisms (55′) that link the separation sheets (30) with the lower frame (29) on the other side. The closure system is not represented in this figure either.

INDUSTRIAL APPLICATION

[0129] Manufacture of structural composite parts that require high quality and high productivity.