Forming tool and method for forming a semi-finished product comprising reinforcement fibers and forming apparatus
10894344 ยท 2021-01-19
Assignee
Inventors
Cpc classification
B29C43/56
PERFORMING OPERATIONS; TRANSPORTING
B29C2043/3649
PERFORMING OPERATIONS; TRANSPORTING
B29C33/34
PERFORMING OPERATIONS; TRANSPORTING
B29K2105/256
PERFORMING OPERATIONS; TRANSPORTING
B29L2031/001
PERFORMING OPERATIONS; TRANSPORTING
B29C43/3642
PERFORMING OPERATIONS; TRANSPORTING
B29C2043/562
PERFORMING OPERATIONS; TRANSPORTING
B29C2043/3644
PERFORMING OPERATIONS; TRANSPORTING
B29C43/18
PERFORMING OPERATIONS; TRANSPORTING
B29C43/58
PERFORMING OPERATIONS; TRANSPORTING
Y02T50/40
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B29C43/34
PERFORMING OPERATIONS; TRANSPORTING
B29C2043/5808
PERFORMING OPERATIONS; TRANSPORTING
B29K2105/12
PERFORMING OPERATIONS; TRANSPORTING
International classification
B29C43/34
PERFORMING OPERATIONS; TRANSPORTING
B29C43/18
PERFORMING OPERATIONS; TRANSPORTING
B29C43/56
PERFORMING OPERATIONS; TRANSPORTING
B29C43/58
PERFORMING OPERATIONS; TRANSPORTING
B29C33/30
PERFORMING OPERATIONS; TRANSPORTING
B29C43/36
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A forming tool for forming a semi-finished product comprising reinforcement fibers and being conveyed to the forming tool in a continuous process. The forming tool comprises at least one pressure bag configured to be pressurized during a forming step of the semi-finished product, during which the semi-finished product is sandwiched between a forming surface of a forming element and the at least one pressurized pressure bag, such that the semi-finished product substantially takes on the shape of the forming surface. Further, a forming apparatus and a forming method for forming a semi-finished product comprising reinforcement fibers are provided.
Claims
1. A forming apparatus for forming a semi-finished product comprising reinforcement fibers, the forming apparatus comprising: a forming tool for forming a semi-finished product comprising reinforcement fibers and being conveyed to the forming tool in a continuous process; a forming element comprising a forming surface; and a conveying device for conveying the semi-finished product along a conveying direction, the forming tool comprising: at least one pressure bag configured to be pressurized during a forming step of the semi-finished product, during which forming step the semi-finished product is sandwiched between the forming surface of the forming element and the at least one pressurized pressure bag, such that the semi-finished product substantially takes on the shape of the forming surface, wherein a cross section of the forming element taken in a plane perpendicular to the conveying direction of the semi-finished product varies along the conveying direction; and at least one wrinkle reduction means comprising unidirectional structural reinforcements oriented parallel to a longitudinal axis of the at least one pressure bag configured to limit longitudinal stretch of the at least one pressure bag in the conveying direction wherein a structural configuration of the at least one pressurized bag limits a wrinkle formation in the semi-finished product, wherein the at least one pressure bag comprises a volume divided by membranes, wherein the unidirectional structural reinforcements comprise at least one of a thicker membrane portion and an additional material applied on at least one local portion of at least one of the membranes of the at least one pressurized bag pressure bag.
2. The forming apparatus according to claim 1, wherein the forming tool further comprises: a plurality of pressure bags configured to be pressurized during the forming step.
3. The forming apparatus according to claim 1, wherein the forming tool further comprises: at least one pressure distribution element different from a pressure bag.
4. The forming apparatus according to claim 1, wherein the forming tool further comprises: a controller configured to control at least one of an amount of pressure, a pressurizing start time, and a pressurizing end time of the at least one pressure bag.
5. The forming apparatus according to claim 1, wherein the forming tool further comprises: a fluid inlet for supplying the at least one pressure bag with a pressurized fluid; a fluid outlet for allowing the fluid to flow out of the at least one pressure bag; and a valve unit for controlling a fluid flow through the fluid inlet and the fluid outlet.
6. The forming apparatus according to claim 1, wherein the conveying device comprises at least two clamping apparatuses arranged consecutively in the conveying direction and configured to convey the semi-finished product or the forming element along the conveying direction.
7. The forming apparatus according to claim 1, further comprising: a preforming tool arranged in front of the forming tool in the conveying direction, wherein the preforming tool is configured to preform the semi-finished product.
8. The forming apparatus according to claim 1 further comprising a controller configured to pressurize the at least one pressurized bag in sequence wherein an excess matrix material of the semi-finished product is pushed to side portions of the semi-finished product.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Preferred embodiments of the invention now are described in greater detail with reference to the appended schematic drawings, wherein
(2)
(3)
(4)
(5)
(6)
(7)
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(9)
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
(10)
(11) In the first step S1 (placing step), the semi-finished material 2 is placed and fixed on a forming element 4 (a mandrel) by means of a placing tool. A surface of the forming element 4 onto which the semi-finished material 2 is placed corresponds to a forming surface of the forming element, wherein the forming surface has a desired shape of the final shaped semi-finished product (net shape or final form). In the embodiment shown in
(12) After the first step S1, the semi-finished material 2 stays on the forming element 4 and is conveyed in a conveying direction C, such that at a second tool a second step S2 can be carried out. The conveying is carried out by means of a conveying device, an example of which will be described in detail below with reference to
(13) In step S2 (heating step), the semi-finished material 2 is heated by a heating tool. Examples of a heating tool include a tunnel-type convection oven or an infrared radiator. In step S2, the semi-finished material 2 is heated up to a temperature, at which a matrix material of the semi-finished product (e.g., an epoxy resin) has reached a viscosity which enables forming of the semi-finished material 2 by applying a force. During the method for forming the semi-finished material 2, the semi-finished material 2 maintains a temperature which enables forming, at least until the final forming step S4 described below. In case a matrix material is used, which is already formable at room temperature, the heating step S2 may be omitted. The semi-finished material 2 stays on the forming element 4 and is further conveyed to a third tool, where a third step S3 is carried out.
(14) In step S3 (preforming step), the semi-finished material 2 is preformed by means of a preforming tool. The preforming tool forms the semi-finished product 2 to a near net shape geometry. In other words, the semi-finished product leaving the preforming tool has a form similar to the final form but between the initial form (e.g., planar) and the desired final form. For example, a degree of deformation applied by the preforming tool may be approximately 0.9 or at least 0.9. The preforming tool may comprise a preforming station, progressively corresponding to the desired final form of the semi-finished product 2. The preforming tool may comprise rolls and/or guide plates for preforming the semi-finished product 2. The semi-finished product 2 is preformed by applying a force to the semi-finished product 2 in a desired preforming direction. A possible embodiment of the preforming tool is configured to self-adjust to variable cross-sectional shapes of the forming element 4 and/or different forming elements 4. Thus, e.g., if a cross-sectional shape of the forming element 4 varies along the conveying direction C, the preforming tool may adapt to this variation, e.g., by moving rollers and/or guide plates in a direction of variation of the cross-sectional shape. Although the preforming step S3 is shown in the embodiment of
(15) In step S4 (forming step), the semi-finished 2 product is formed into its final form by the forming tool 6. Further details of the forming step S4 will be described later with reference to
(16) In step S5 (trimming step), flanges of the semi-finished product 2 are trimmed by means of a trimming tool. A possible embodiment of the trimming tool comprises at least one NC-cutting device arranged perpendicular to a flange of the forming element 4. However, step S5 may also be omitted, e.g., if flanges already have the net shape or if they are trimmed in a later step. After step S5, the semi-finished product 2 stays on the forming element 4 and is conveyed in the conveying direction C.
(17) The semi-finished product 2 may now be ready for a curing step by means of a curing tool. However, before curing, further material (e.g., a curable material like, e.g., epoxy resin) may be applied to the formed semi-finished product 2. The curing step may comprise an autoclave cycle. During the curing step, the semi-finished material 2 may stay on its forming element 4. However, due to different thermal expansion coefficients of the semi-finished product 2 and the forming element 4 (e.g., when a forming element 4 made of metal is used), the semi-finished product 2 may be transferred to a curing element. Preferably, the curing element has a thermal expansion coefficient similar to that of the semi-finished product 2. Desirable materials for a curing element may comprise invar, carbon-fiber-reinforced plastic (CFRP), or glass-fiber reinforced plastic (GRP).
(18) Further, a cooling step may be carried out after or during the forming step S4. Since the semi-finished product 2 shall keep its final form into which it has been formed by the forming tool 6, it is desirable that a viscosity of the matrix material is reduced after the shaping step S4. This change of viscosity may be achieved either by a dwell step at the surrounding temperature (e.g., room temperature) or by actively cooling the semi-finished product 2 during a cooling step. During the cooling step, the semi-finished material 2 may be actively cooled, e.g., by means of a cooling gas (e.g., cooling air) or a cooling liquid (e.g., cooling water). Additionally or alternatively, the forming element 4 may be cooled.
(19) In the description of
(20) However, according to a different embodiment, a position along the conveying direction of the semi-finished product 2 with respect to the forming element 4 may change during the method of steps S1-S5. For example, the semi-finished product may be shifted along the forming element 4, e.g., in the case that a cross-sectional shape of the forming element 4 does not change along the conveying direction C.
(21)
(22) The method described above may be carried out by a forming apparatus described herein. The forming apparatus comprises the tools necessary for carrying out the steps S1-S5 described above. Thus, the forming apparatus may comprise a placing tool, a heating tool, a preforming tool, a forming tool 6, and a trimming tool. The forming apparatus further comprises the forming element 4 and a conveying device for conveying the semi-finished product 2 along the conveying direction C. However, some of these steps and/or tools may be omitted and/or carried out by another device, such that the forming apparatus at least comprises the forming tool 6, the forming element 4, and the conveying device.
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(25) The forming tool 6 comprises a fluid inlet 10 for supplying the pressure bag 8 with a pressurized fluid, a fluid outlet 12 for allowing the fluid to flow out of the pressure bag 8, and a valve unit 14 for controlling a fluid flow through the fluid inlet 10 and the fluid outlet 12. The pressurized fluid is, e.g., a gas or a liquid. The pressurized fluid may be pressurized by means of a pump. At a pressurizing start time, pressurized fluid starts to flow into the pressure bag 8. The pressurizing start time may be defined by a time when the valve unit 14 for the fluid inlet 10 is opened and/or by a time when a pump starts to pressurize the fluid. During a pressurizing dwell period, the pressurized pressure bag 8 maintains its pressure to the semi-finished product 2.
(26) In order to limit longitudinal stretch of the pressure bag 8 in the conveying direction C during the forming step, which might cause wrinkle formation of the semi-finished product 2, the pressure bag 8 may include structural reinforcements such as, e.g., woven cloth. In an embodiment, the pressure bag 8 comprises unidirectional reinforcements, oriented parallel to a longitudinal axis of the pressure bag 8.
(27) Further, by using a pressure bag 8, a pressure elevation in a radius area of the forming surface may be reduced, which lowers the risk of occurrence of so-called radius thin out of the semi-finished material 2 at a convex curved portion of the forming surface (radius area).
(28) In the forming step S4 described herein and by using the forming tool 6 described herein, no vacuum volume has to be hermetically sealed from the surrounding atmosphere. Thus, long structures of semi-finished products 2 (long final product forms) may be formed by forming adjacent parts of the semi-finished product 2 in consecutive forming steps of the same forming tool 6. In a vacuum forming tool (hot drape forming) of the prior art, for this, a hermetically sealed boundary has to be achieved between a membrane and the semi-finished product 2. Thus, the method, the forming tool and the forming apparatus described herein allow a faster and simplified forming of large semi-finished products 2, while less floor space footprint is required.
(29)
(30) Exemplarily, nine pressure bags 8a-e are shown in
(31) Each one of the pressure bags 8a-e may be pressurized individually. A controller (not shown) may be provided for controlling pressurizing start times, pressurizing end times, and/or an amount of pressure of the individual pressure bags 8a-e. Although only one inlet 10, one outlet 12, and one valve unit 14 are shown in
(32) When a plurality of pressure bags 8a-e are provided, as shown in
(33) By applying this pressurizing order, excess matrix material may be pushed to side portions of the semi-finished product 2 and the formation of wrinkles may be suppressed. Thus, a flat (wrinkle-free) surface of the final product may be achieved having a high quality and stability.
(34) Further, the pressures between the individual pressure bags 8a-e may vary. For example, a pressure applied to the semi-finished product 2 by the central pressure bag 8a may be higher than a pressure applied by the pressure bags 8c and 8d provided at convex shaped (radius) portions of the forming surface. Hence, the occurrence of radius thin out may be prevented.
(35) In an embodiment, the pressure applied to the pressure bags 8a-e and/or the pressurizing start times of the pressure bags 8a-e are the same.
(36)
(37) The pressure distribution element 9 may be controlled in a similar manner as one of the plurality of pressure bags 8a-e shown in
(38)
(39) Operation of the conveying device 20, like operation of the other components of the forming apparatus, is controlled by means of a central electronic control device. However, as an alternative to the central control device a plurality of separate control devices may be used. The control device controls the operation of the two clamping apparatuses 22, 24 in such a way that the first clamping apparatus 22 is situated in its open position and is moved counter to the conveying direction C of the semi-finished product 2 relative to the semi-finished product 2 from its release position into its clamping position when the second clamping apparatus 24 is situated in its closed position and is moved in the conveying direction C of the semi-finished product 2 jointly with the semi-finished product 2 from its clamping position into its release position.
(40) Conversely, the first clamping apparatus 22 is situated in its closed position and is moved in the conveying direction C of the semi-finished product 2 jointly with the semi-finished product 2 from its clamping position into its release position, when the second clamping apparatus 24 is situated in its open position and is moved counter to the conveying direction C of the semi-finished product 2 relative to the semi-finished product 2 from its release position into its clamping position. This oppositely directed operation of the two clamping apparatuses 22, 24 is also illustrated in the schematic diagram in
(41) As an alternative to the variant of a conveying device 20 shown in
(42) Although various features of the invention have been described here with reference to specific embodiments of a forming tool, a forming apparatus, and a forming method, these features may be combined in any desired manner with one another, unless explicitly mentioned otherwise.
(43) While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms comprise or comprising do not exclude other elements or steps, the terms a or one do not exclude a plural number, and the term or means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.