Abstract
A method for making a fibrous strip configured for making a ribbon with a thickness ranging between 0.1 mm and 1 mm and a width ranging between 2 mm and 10 mm. The ligneous logs or cans are cut into square-edged plank with a predefined length. The strip is separated from a surface of the square-edged plank by an orthogonal cutting process. The depth of cut is equal to the thickness of the strip. The cutting speed direction is parallel to the fibers of the square-edged plank. Also, a fibrous reinforcement is obtained using the method and a device for implements the method.
Claims
1. A method for making a plurality of fibrous strips and a ribbon of ligneous fibers comprising an assembly of the plurality of fibrous strips, wherein the ribbon has a calibrated thickness ranging between 0.1 mm and 1 mm, and equally an calibrated width ranging between 2 mm and 10 mm, comprising the steps of: cutting ligneous logs or canes into square-edged planks, each having a predefined length; and separating the plurality of strips from a surface of one of the square-edged planks by an orthogonal cutting process with a depth of cut substantially equal to the thickness of each of the plurality of strips, wherein cutting is parallel to the fibers of the square-edged plank, and wherein the width of the plurality of the strips is more than 1 mm; aligning the plurality of the strips according to their fiber direction; assembling the plurality of the strips to make the ribbon; winding the ribbon into a reel; and weaving the wound ribbon to make a reinforcing fabric.
2. The method according to claim 1, wherein the ribbon is made of bamboo fibers.
3. The method according to claim 1, comprising the step of sorting each of the plurality of the strips according to their thickness.
4. The method according to claim 1, wherein the step of aligning the plurality of strips comprises aligning the plurality of strips in a stack of two layers of strips, and the step of assembling the plurality of strips comprises joining the two layers of strips at a surface, wherein a strip of a first layer of the two layer of strips is joined to two strips of a second layer of the two layers of strips, and wherein the joining of the strip of the first layer with the two strips of the second layer is located on the same surface of the strip of the first layer.
5. The method according to claim 1, wherein the step of assembling the plurality of strips into a ribbon comprises assembling a first strip of the plurality of strips to a second strip and a third strip of the plurality of strips at opposite ends of said first strip; and wherein said second strip and said third strip are joined to a top surface and a bottom surface, respectively, of said first strip.
6. The method according to claim 1, wherein the step of aligning the plurality of strips comprises aligning the plurality of strips in juxtaposition and wherein the step of assembling the plurality of strips comprises assembling the plurality of strips at their ends.
7. The method according to claim 1, further comprising the steps of assembling juxtaposed strips by compression at their stacked ends so that a thickness of the ribbon is uniform over its length.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The invention is described below in its preferred embodiments, which are not limitative in any way, and by reference to FIGS. 1 to 12, wherein:
(2) FIG. 1 represents a chart of the method according to the invention;
(3) FIG. 2 is a perspective view of a bamboo cane used as the raw material in one embodiment of the invention;
(4) FIG. 3 is an example of the square-edged extracted from the raw material of FIG. 2, FIG. 3A is a front view before the implementation of the method according to the invention, FIG. 3B is a perspective view during the implementation of the method according to the invention;
(5) FIG. 4 is a perspective view of an example of an orthogonal cutting process implemented for extracting a strip from a square-edged according to an exemplary embodiment of the method according to the invention;
(6) FIG. 5 is a side view along a section AA, defined in FIG. 3A, of an orthogonal cutting process with a type I separation mode of the strip;
(7) FIG. 6 is a side view of a schematic exemplary embodiment of the device according to the invention;
(8) FIG. 7 is a perspective view of an exemplary embodiment of a blade comprising a plurality of cutting edges;
(9) FIG. 8 is a perspective view of an exemplary embodiment of a blade suitable for extracting reinforcing fibers;
(10) FIG. 9 is a perspective view of an alternative exemplary embodiment of a blade suitable for extracting strips;
(11) FIG. 10 is a side view along the edge of the ribbon of three embodiments, FIGS. 10A to 10C, of a ribbon from strips assembled by stacking, in an exemplary embodiment of the method according to the invention;
(12) FIG. 11 is a top view of an exemplary ribbon obtained in one exemplary embodiment of the method according to the invention, wherein the strips are assembled by juxtaposition; and
(13) FIG. 12 is a side view of an exemplary ribbon obtained in one embodiment of the method according to the invention, wherein the assembled ends of the strips are compressed.
DETAILED DESCRIPTION OF THE EMBODIMENTS
(14) In FIG. 1, in an example of the overall execution of the method according to the invention, after the raw material (110) is received, it is debited into square-edged during a cutting step (120). The fibers are then removed from said square-edged during a mechanical fiber removal step (130) consisting in extracting strips using an orthogonal cutting process with a blade with a geometrically defined cutting edge.
(15) Depending on the nature of the blade and the cutting conditions used for removing the fibers, the strips obtained are of two types: strips with a width that is substantially larger than their thickness, that is to say width at least 10 times greater than the thickness; strips with a width that is of the same order of magnitude as their thickness
(16) Each of these two semi-finished products comprises a plurality of ligneous fibers of the raw material.
(17) The first type of strip is assembled during an assembly step (142) so as to form a ribbon. In this exemplary embodiment, said ribbon is then wound into a reel during a packaging step (160); other packaging modes may be used.
(18) In the case of the second type of strips, they are sized during a sizing step (141). They are then spun during a spinning step (151) so as to constitute a fibrous reinforcement in the form of continuous threads or reinforcing fibers before they are also packaged (170).
(19) The reinforcing fibers and ribbons may then undergo weaving or miscellaneous assembly operations (180) in order to constitute reinforcements suitable for making up composite materials.
(20) In FIG. 2 of an exemplary embodiment of the method according to the invention, the raw material used takes the form of a bamboo cane (200). During the cutting step, said cane (200) is cut into sections and split along planes (211, 212, 213) that are substantially orthogonal so as to make square-edged. The number of splitting planes (212, 213) depends on the diameter of the cane (200).
(21) Thus, canes with small diameters are only split in two. Canes with larger diameters can be split into four, six or even more, if the diameter of the cane or log is very large.
(22) In FIG. 3, the strips are separated from the square-edged (300) by means of a mechanical cutting process with successive layers (310, 311, 312), so that the cutting surface (315) is substantially parallel to the fiber direction.
(23) In FIG. 4, the strips (420) are separated from the square-edged (300) by an orthogonal cutting process. That cutting process is carried out by a cutting tool (410) or blade, comprising a cutting edge (411). The cutting process is defined by its direction in relation to the overall direction of the fibers of the square-edged (300); that cutting direction is 90-0, that is to say the cutting edge (411) is directed along an angle (415) of 90 in relation to the fiber direction and the cutting speed (450), being the relative movement speed between the tool and the square-edged, is parallel to said fiber direction.
(24) Here, fiber direction means the majority direction of the fibers of the section, because the square-edged is made from a natural product and the ligneous fibers may individually and locally deviate substantially from the fiber direction.
(25) The kinematic and geometric conditions of cutting are fixed depending on the material and particularly its humidity rate, so as to extract the strip (420) using a separation mode known as the type I mode. Thus, the strip is not sheared along its thickness, which thickness (e.sub.2) of the strip (420) is equal to the depth of cut (e1)) of the blade (410) in the square-edged (300). To allow this material separation mode, the rake angle (412) measured in relation to the normal at the cutting surface is greater than 20 and preferably greater than 30. The cutting speed (450) ranges between 0.015 m.Math.s.sup.1 and 1 m.Math.s.sup.1, preferably between 0.025 m.Math.s.sup.1 and 0.05 m.Math.s.sup.1. These conditions make it possible to separate the strips using a type I mode without damaging the fibers in said strips, with a depth of cut (e.sub.1) ranging between 0.1 mm and 1 mm, corresponding to the thicknesses required. The kinematic and geometric conditions of orthogonal cutting make it possible to obtain a uniform flow speed field along the width (b) of the strip (420), which strip is thus free of curling.
(26) In FIG. 5, along a section perpendicular to the cutting edge (411) and parallel to the cutting speed (450), the type I separation mode is achieved by separating the strip (420) from the cutting surface by propagating an opening (520) before the cutting edge (411) of the blade (410). The cutting edge (411) is defined by the intersection of the rake face (512) and the flank face (511) of the blade. The flank face is turned at a flank angle (515) measured between the flank face and the cutting surface (315). The angle (516) between the rake face and the flank face defines the wedge angle of the blade. In each section perpendicular to the cutting edge, the sum of the rake angle (412), the wedge angle (516) and the flank angle (515) is equal to 90. According to the orthogonal cutting process used for extracting a strip (420) implemented by the method according to the invention, the rake angle (412) and the flank angle (515) of the blade are constant over the width of the extracted strip.
(27) In FIG. 6, the device (600) according to the invention comprises a carriage (620) capable of supporting the blade (420). Motor-driving and guiding means (631) make it possible to move said carriage (620) along a cutting movement and control the cutting speed. Motor-driving and guiding means (632) make it possible to communicate the engagement movement to the carriage (620). The cutting cycle comprises a feed movement (651) followed by a to-and-fro cutting movement (661) along the square-edged (300) at the defined cutting speed. The strip is created during the outward movement. When the carriage (620) supporting the blade (410) returns to its initial position, a new feed movement (652) is applied to the carriage, which carries out another to-and-fro movement on the square-edged (300) so as to create a new strip and so on. In this embodiment, the length of the strip created is equal to that of the square-edged. That length may be controlled by making a square cycle, with a clearance movement contrary to the feed movement (651, 652) after the outward movement and before the return movement. The device also comprises means to measure the total number (650) of depth of cuts. Because the mechanical properties of fibers vary depending on their position in a cane of bamboo, the strips are advantageously sorted on the basis of their position of extraction using that information (650) relating to the total number of depth of cuts. The square-edged plank (300) is placed in the device according to the invention and held in position by means (641) that oppose the cutting force. Those means for holding in position do not completely join the square-edged (300) with the device. In this exemplary embodiment, the flank angle of the blade (410) is 0, so that the flank face is in contact with the cutting surface along a surface that is substantially flat. The square-edged is not fixed, and it turns naturally along its fiber direction, so that the cut is made using a 90-0 mode, which is the easiest cutting mode. A pressure roller (642) that moves at the same time as the blade-holder carriage (620) cooperates with the flank face and the means (641) for holding the square-edged to stabilize it during cutting.
(28) In FIG. 7, in one embodiment, the blade (710) of the device according to the invention comprises a plurality of cutting edges (711) so as to extract several parallel strips using an orthogonal or semi-orthogonal cutting process during the same movement of said blade (711) on the square-edged. The cutting edges (711) of the plurality are separated from each other by separating edges (712), projecting and extending from the rake face or the flank face, which cut the strips laterally before the extraction cut, so that the extraction cut is always an orthogonal cut. Thus, the width of the strips depends on the length of each cutting edge (711) of the plurality. For making ribbons, the width of said strips ranges between 1 mm and 10 mm, and the depth of cut is in such a case selected below 1/10.sup.th of the width of the strip.
(29) In FIG. 8, in another embodiment, the blade (810) comprises cutting edges with lengths ranging from 0.1 mm to 0.5 mm; such a blade (810) combined with depth of cuts of the same order of magnitude makes it possible to extract reinforcing fibers.
(30) In FIG. 9, in another exemplary embodiment, the blade (910) comprises a plurality of cutting edges (911) separated by spaces with a width l.sub.1. The cut is then semi-orthogonal but the sharpness of the corners of edges and the symmetry from one cut to another makes it possible to retain a separation mode of type I and the absence of curling or shearing in the thickness of the strip. In order to retain a flat cutting surface, the use of this type of blade (910) comprises, in a particular embodiment, movements during which the blade (910) is laterally offset parallel to the cutting edges (911) with a value at least equal to l.sub.1.
(31) In FIG. 10, in a first exemplary embodiment, in a case of extraction of wide strips (421, 422), the strips are assembled in two layers with one side against another so as to make up ribbons (1021, 1022, 1023). In FIG. 10A, in a first alternative of the ribbon (1021) according to the invention, the strips (421, 422) of the two layers are assembled one side against another in staggered formation so that the assembly is carried out over the totality of the surface of the sides of the strips. This embodiment makes for a ribbon (1021) that is mechanically stronger.
(32) In FIG. 10B, in a second alternative of the ribbon (1022) according to the invention, the strips (421, 422) are assembled one side against another, alternating the assembly side at each end of each strip. Compared to the previous alternative embodiment (FIG. 10A), the overlap of the strips at the assembly interface is small but at least greater than 0.5 mm. That alternative embodiment makes for a ribbon (1022) that is more flexible.
(33) In FIG. 10C, in a third alternative embodiment of the ribbon (1023) according to the invention, the strips (421, 422) of the two layers are assembled so as not to be butt-jointed but so that each strip is joined to two others by at least half the surface of its side. In that example, the assembly interface is placed on the same side of a strip at its two ends. That alternative embodiment offers a compromise between the flexibility of the ribbon and its mechanical properties.
(34) The method for assembling the two strip layers (421, 422) is selected depending on the intended application of the reinforcement. Assembly methods using gluing, spunlace or compression are, for example and without limitation, suitable for making such an assembly.
(35) In FIG. 11, in a second embodiment of the ribbon (1120) according to the invention, the strips (421, 422) that make up said ribbon are assembled by their ends. That embodiment makes it possible to obtain a very flexible and fine ribbon, with thickness that is substantially constant over the entire length of said ribbon (1120). That assembly is preferably made by gluing.
(36) In FIG. 12, in another exemplary embodiment of the ribbon (1220) according to the invention, the strips (421, 422) are assembled by their ends in a compression zone (1230), which makes it possible to increase the density of fibers in said compressed zone (1230) and obtain a ribbon with a uniform thickness.
(37) Regardless of the embodiment, the ribbon resulting from the assembly of strips can be wound into a reel.
(38) In the case of the extraction of reinforcements in the form of fibers, the fibers are spun after sizing with greasy products, in order to constitute a continuous reinforcing fiber.
(39) The reinforcing fibers and the ribbons can then be used to constitute reinforcements, for example in the form of fabric, suitable for making a composite material with a thermosetting or thermoplastic matrix. The flexibility of the fibers is sufficient for using the techniques for implementing these materials, particularly by automatic laying up and stratification of pre-impregnated plies, thermoforming or injection or infusion of resin in preforms known as dry preforms.
