Method and apparatus for fabricating a fibre reinforced thermoplastic composite structure

Abstract

The invention provides a method of fabricating a fibre reinforced thermoplastic composite structure comprising: placing a first layer of fibre reinforced thermoplastic material on top of a second layer of fibre reinforced thermoplastic material; providing a local heating source and locally heating a portion of at least the upper layer of thermoplastic composite material; and providing an ultrasonic transducer and locally introducing ultrasonic energywaves to the heated portion of the thermoplastic material such that ultrasonic consolidation of the fibre reinforced thermoplastic occurs.

Description

Background technique [0001] Composite materials are now commonly used as structural materials in various industries. One such field is the aerospace industry, where structural composite materials are used to form an increasing proportion of aircraft structures. In this regard, composite materials are considered to be a polymer matrix reinforced with fibers or meshes, most typically carbon fibers but possibly fibers or metal meshes of other materials. Composites tend to fall into one of two main families of materials, those with a thermoplastic matrix and those with a thermoset matrix. Thermoset composites require vulcanization, a process by which the chemical structure of the polymer matrix is ​​irreversibly changed, usually by the application of heat and optionally pressure. Once vulcanized, a thermoset composite possesses its ultimate rigidity, hardness and strength properties and cannot return to its unvulcanized soft state. In contrast, thermoplastic composites do not r...

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Problems solved by technology

However, as mentioned, when used with thermoplastic composites, the ultrasonic tape laying technique must agree that it cannot be achieved in an efficient and rapid manner.

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