Patent Application
20070251641
a and 1b show perspective schematic views of the device object of the present invention showing different positions of the laying and cutting heads and of the tool with the forming membrane.
a and 2b show schematic views of the tables of the device with their modules forming an upper planar surface and an upper surface with the shape of the piece.
a shows a schematic view of the heating means used in the forming tool and
a and 4b show perspective schematic views of the pieces manufactured with the device and process of the present invention.
In the preferred embodiment illustrated in the drawings, the device object of the present invention comprises two tables 11, 13, a laying head 15 and a cutting head 17 supported by means 19 allowing its displacement over said tables 11, 13, and a tool 21 including a forming membrane 25 and means 27 for providing heat to a space provided it, which is supported by means 23 allowing its displacement in order to be placed on each of the tables 11, 13 and to position the forming membrane 25 on it.
This device results particularly advantageous for manufacturing long pieces with a U-shaped section as shown in
The cutting head 17 is located in the rear part of the laying head 15, being able to move downwards to a lower position at the moment when cutting is necessary.
Tables 11, 13 are the same and have a modular structure, including an outer module 31 and an inner module 33 in order to be initially configured with an upper planar surface 41 in order to carry out the laying and cutting operations on it by offering a surface the function of which is to support the stratified material and regenerate the vertical force which the laying head 15 produces and to allow the cutting operations to be carried out without damaging the cutting blade.
Tables 11, 13 can also be configured with an upper surface 43 with the shape of the piece to be manufactured in order to carry out the forming operation of the same.
Tables 11, 13 include means (not illustrated) for generating a vacuum in a closed space on it and, optionally, means (not illustrated) for providing heat to their upper surface.
In the event that the piece to be manufactured has curved parts on its surface (for example, radios) and/or different thicknesses, the inner module 33 of the tables 11, 13 should also have them. In any case, the inner module 33 copying the inner surface of the piece to be manufactured must always be totally retractable inside the table 11, 13 itself using to that effect auxiliary means, if necessary.
The device includes two tables 11, 13 such that when a forming operation is being carried out on one of these, laying and cutting operations can be carried out on the other. In this way the use of the laying head 15, cutting head 17 and of the tool 21 with the forming membrane is optimized.
The process object of the present invention will be described below.
In the first step, the laminating process on a table with a planar surface is carried out by means of an automatic laying head.
If the thickness of the laminate should require it, compacting by vacuum may be necessary, which requires that the table is airtight. To that effect, it would be necessary to cover the area to be laid, before carrying out the laying, with a film of plastic material, or of any other type, which is non-porous. In order to keep the film in place, and so that it does not move due to the loads of all types produced in the laying process, it is fastened to the surface by vacuum, the latter being transmitted through drills carried out on the table itself, and/or on the hot forming tool.
In the second step, the excess parts of the laminate are cut on the table itself by means of a cutting head. To carry out this operation, the laminate must be fastened to the table by means of vacuum. This is produced and transmitted through drills in said table, as described in the previous section. Furthermore, a film of plastic or other material is positioned on the laminated material, and covers the whole table, in order to reduce the loss of vacuum. The upper part of the table is covered with a material which allows cutting of that which has been laid without damaging the cutting blade.
In the third step, the piece is formed with the desired shape by arranging a forming membrane on it, elevating a module with the shape of the piece and applying heat and vacuum.
In a preferred embodiment of the invention this step is carried out by means of the following steps:
Arranging a forming membrane on the piece
Applying an initial heating cycle until a predetermined temperature, depending on the carbon fiber material used, is reached. In this way the production of large creases in the curved areas is facilitated in the later stage.
Applying a first vacuum cycle until a predetermined inner pressure (about 1 bar) is reached.
Displacing a module of the device with the shape of the piece upwards at a predetermined speed.
Applying a second cycle of vacuum and heat until a predetermined pressure and temperature are reached, maintaining its application for the time necessary to form the piece.
In the preferred embodiment which has just been described, those modifications that are comprised within the scope defined by the following claims can be introduced.
| Number | Date | Country | Kind |
|---|---|---|---|
| PCT/ES06/70052 | Apr 2006 | ES | national |
