Method and apparatus for fabricating fibre reinforced thermoplastic composite structure

Abstract

An apparatus for fabricating a fibre reinforced thermoplastic composite structure is described. The apparatus comprises a localised heat source arranged to heat a portion of a stack of fibre reinforced thermoplastic material layers and an ultrasonic transducer arranged to locally introduce ultrasonic energy waves to the heated portion of the fibre reinforced thermoplastic material layers. The apparatus makes it possible to achieve ultrasonic consolidation of the layers 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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