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Composite materials

Inactive Publication Date: 2013-05-16
HEXCEL COMPOSITES LTD (GB)
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The patent text describes a way of making sure that there are no gaps between strips of material, which can help improve the quality and efficiency of the manufacturing process. This is done by ensuring that the width of the strips is very precise, so that they can automatically be placed next to each other without overlapping. This results in a more uniform and efficient manufacturing process.

Problems solved by technology

However, it does impose additional constraints on the dimensions of the prepreg, if it is to automatically lay down the prepreg at an acceptable quality standard.
However, it is known that passing prepreg with its backing paper through the slitting unit comprising slitting blades produces paper debris which produces an unacceptable result.
This is because variation in the width of the strips of prepreg has been observed in practice, and overlapping strips are more problematic than a gap between strips.

Method used

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  • Composite materials
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Examples

Experimental program
Comparison scheme
Effect test

embodiment 1

[0075]In embodiment 1, there is provided a strip of curable prepreg comprising unidirectional fibres aligned with the length of the strip, the fibres being at least partially impregnated with curable thermosetting resin and comprising a flexible polymeric sheet on an outer face of the strip, wherein the strip has a substantially rectangular cross-section defining a width and a thickness of the strip.

[0076]In embodiment 2, there is provided a strip according to embodiment 1, having a length of at least 500 m, preferably at least 1,000 m, more preferably at least 2,000 m, most preferably of least 4,000 m.

[0077]In embodiment 3, there is provided a strip according to embodiment 1 or 2, having a width of from 2.0 to 50 mm, preferably from 3.0 to 25 mm.

[0078]In embodiment 4, there is provided a strip according to embodiment 1 to 3, having a thickness in the range of from 0.05 to 1.0 mm.

[0079]In embodiment 5, there is provided a strip according to embodiment 1 to 4, comprising a second pol...

embodiment 8

[0082]In embodiment 8, there is provided a strip of curable prepreg according to embodiments 1 to 7, wherein the thickness of the polymeric sheet is in the range of from 10 to 150 micrometres, preferably from 10 to 100 micrometres.

[0083]In embodiment 9 there is provided a strip of curable prepreg according to any one of embodiments 1 to 8, wherein this polymeric sheet is made from polyethylene, polyethylene terephthalate, polypropylene, or mixtures thereof.

[0084]In embodiment 10, there is provided a strip of curable prepreg according to any one of embodiments 1 to 9 which is way-wound onto a bobbin.

embodiment 11

[0085]In embodiment 11, there is provided a process for forming a plurality of strips of prepreg according to any one of claims 1 to 10 from a sheet of prepreg, wherein the sheet of prepreg comprises unidirectional fibres at least partially impregnated with curable thermosetting resin and comprising a flexible polymeric sheet on an outer face of the sheet of prepreg, the process comprising the step of slitting the prepreg into a plurality of strips, the slits being substantially parallel to the direction of alignment of the fibres.

[0086]In embodiment 12, there is provided a process according to embodiment 11 which is a continuous process.

[0087]In embodiment 13, there is provided a process according to embodiment 11 or 12, wherein one or more rotary blades are positioned as the sheet of prepreg is brought into contact with the blade or blades.

[0088]In embodiment 14, there is provided a process according to any one of embodiments 11 to 13, wherein any blades are evenly spaced apart.

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Abstract

A strip of curable prepreg comprising unidirectional fibres aligned with the length of the strip, the fibres being at least partially impregnated with curable thermosetting resin and comprising a flexible polymeric sheet on an outer face of the strip, wherein the strip has a substantially rectangular cross-section defining a width and a thickness of the strip.

Description

TECHNICAL FIELD[0001]The present invention relates to strips of prepreg, particularly for application by an automated lay-up apparatus.BACKGROUND[0002]Composite materials have well-documented advantages over traditional construction materials, particularly in providing excellent mechanical properties at very low material densities. As a result, the use of such materials is becoming increasingly widespread and their fields of application range from “industrial” and “sports and leisure” to high performance aerospace components.[0003]Prepregs, comprising a fibre arrangement impregnated with resin such as epoxy resin, are widely used in the generation of such composite materials. Typically a number of plies of such prepregs are “laid-up” as desired and the resulting laminate is cured, typically by exposure to elevated temperatures, to produce a cured composite laminate.[0004]In a typical lay-up procedure, the prepreg is provided as a roll of material to provide length (e.g. of the order...

Claims

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Application Information

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IPC IPC(8): B32B5/00B32B3/08
CPCB26D1/245B29C70/086B29C70/386B29C2793/0036B29C2793/0081B29K2023/06Y10T156/1052B29K2067/00B29K2105/243B29K2995/0094B32B3/08B32B5/00Y10T428/24B29K2023/12B32B5/022B32B5/08B32B7/06B32B27/12B32B27/32B32B27/36B32B3/266B32B2260/021B32B2260/046B32B2262/0269B32B2262/101B32B2262/106B32B2262/14B32B2270/00B32B2307/546B32B2307/58B32B2307/748B32B2605/18Y10T156/10B32B2037/1253B65H2301/4148B32B37/12B32B37/16
Inventor ELLIS, JOHNFISSET, EMILIE
Owner HEXCEL COMPOSITES LTD (GB)