WO2002094565A1 - Method for producing a shaped laminate - Google Patents

Method for producing a shaped laminate Download PDF

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Publication number
WO2002094565A1
WO2002094565A1 PCT/NL2002/000251 NL0200251W WO02094565A1 WO 2002094565 A1 WO2002094565 A1 WO 2002094565A1 NL 0200251 W NL0200251 W NL 0200251W WO 02094565 A1 WO02094565 A1 WO 02094565A1
Authority
WO
WIPO (PCT)
Prior art keywords
laminate
laminates
shaped part
another
heating
Prior art date
Application number
PCT/NL2002/000251
Other languages
French (fr)
Inventor
Erik Kroon
Geert Roebroeks
Original Assignee
Fokker Aerostructures B.V.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fokker Aerostructures B.V. filed Critical Fokker Aerostructures B.V.
Publication of WO2002094565A1 publication Critical patent/WO2002094565A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/02—Bending or folding
    • B29C53/04—Bending or folding of plates or sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
    • B29C65/4835—Heat curing adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B29C66/7232—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a non-plastics layer
    • B29C66/72321—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a non-plastics layer consisting of metals or their alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/088—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of non-plastics material or non-specified material, e.g. supports
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/092—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising epoxy resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/38—Layered products comprising a layer of synthetic resin comprising epoxy resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B43/00—Operations specially adapted for layered products and not otherwise provided for, e.g. repairing; Apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C1/00—Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
    • B64C1/06—Frames; Stringers; Longerons ; Fuselage sections
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5057—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like positioned between the surfaces to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7394—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/10—Thermosetting resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B29L2009/003—Layered products comprising a metal layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Definitions

  • the invention relates to the production of laminated parts which comprise alternating layers of a metal and layers of a plastic.
  • the plastic layers may contain a bonding agent and may be reinforced with fibre material.
  • Laminated parts of this type are used, for example, in the aviation and aerospace industry. Examples which may be mentioned are the material Glare® (glass reinforced) and the material ARALL® (aramid aluminate laminate). They have relatively low weight and a relatively high strength and rigidity. These properties are related to the rigid joins between the metal layers, which are obtained by the bonding produced via the plastic layers.
  • WO-A-9853989 has disclosed a method for producing laminate parts of this type.
  • the metal plates with a layer of adhesive between them, optionally provided with a reinforcement, are placed in a mould, with the result that a defined, desired shape is obtained.
  • the assembly is then exposed to an elevated temperature and pressure in order to effect adhesive bonding. After the layers have cooled, the result is a cohesive, shaped part which has the desired mechanical properties with regard to rigidity, strength and the like.
  • one or more metal layers may have sections which overlap one another.
  • a section of a specific, outermost metal-layer piece may be flanged, in such a manner that it comes to lie beneath the adjoining section of another outermost metal-layer piece. The sections can then be joined to one another in the manner described above.
  • the flanged area disrupts the surface of the shaped part. This surface has to be on the inside when used in an aircraft structure, since otherwise the aerodynamically shaped external surface would be disturbed.
  • the shaped part may be reinforced, optionally locally.
  • additional layers have to be secured to the part which has already been shaped.
  • a problem then arises at the flanged areas.
  • the layers which are to be applied to the part which has already been shaped do not fit correctly, since the layers are planar. In practice, this problem is solved by adding filler layers which are supposed to compensate for the difference in height caused by the flange.
  • a laminate of this type has a rigidity which is so great that it is difficult to adapt the laminate to the contour of the non-planar structure.
  • a part which has already been shaped, comprising various metal layers which are joined to one another by a bonding plastic layer can still be made into a specific, desired shape by the use of heat and pressure.
  • the finished laminate has a considerable rigidity, it can nevertheless be deformed successfully under these conditions.
  • the plastic layer has been found to be deformable at elevated temperatures, possibly as a result of its molecules stretching.
  • the metal layers can slide along one another more easily when a bending load is applied, which explains the ready deformability.
  • the laminate cools, its original rigidity is restored. Obviously, the deformations must not be so great that separation or delamination occurs.
  • thermosets and thermoplastics may be used.
  • the method according to the invention can be used in various ways.
  • the method is used to reinforce a laminated part which has already been shaped.
  • the invention therefore also relates to the production of a shaped part from at least two prefabricated, hardened laminates which rest partly or completely on top of one another, which laminates have different contours on their surfaces which face towards one another, comprising the steps of: providing at least two laminates which have different surface contours, placing the said laminates at least partly on top of one another, so as to enclose a layer of adhesive which is to be set, heating the said laminates, deforming at least one of the said laminates in order to match their surface contours to one another, bonding the laminates, which have matching surface contours, to one another in order to create the shaped part, cooling the shaped part.
  • the first laminate may comprise a joining structure which has at least one metal layer with overlapping sections, in such a manner that, at the location of these overlapping sections, one of the surfaces of the said laminate has a jump in thickness which forms a deviation from the flat surface of the said laminate, and the other surface thereof is planar, comprising the steps of: placing the two laminates on top of one another, placing the planar surface of the first laminate onto a mould with a corresponding planar surface, heating the said laminates, deforming the second laminate in order to match it to the surface of the first laminate having the jump in thickness in order to create the shaped part, cooling the shaped part.
  • the jump in thickness mentioned above may also be caused, for example, by a connecting strip ("doubler") which is adhesively bonded over the edges of two layers which have been placed end to end.
  • the size of the jump in thickness may amount to approximately 2 mm.
  • the method according to the invention can be used both for smooth, planar part and for curved parts. Even double-curved parts can be processed using the method according to the invention.
  • An advantage of in particular the latter variant is that the reinforcing laminate which is applied to a prefabricated, other laminate does not have to be accurately matched to the shape of the said other laminate. As a result of the heating, the reinforcing laminate can be "fitted" relatively easily, with the result that production of double-curved parts becomes considerably easier and less expensive.
  • Figure 1 shows a first step involved in carrying out the method according to the invention.
  • Figure 2 shows the second step of the method.
  • the method according to the invention relates to the production of shaped parts from a number of metal layers which are joined to one another by a bonding plastic layer.
  • the method steps illustrated in Figures 1 and 2 relate to the reinforcing of the first laminated part, which is denoted overall by 21, by means of the second laminated part, which is denoted by 22.
  • the first laminated part 21 comprises three metal layers 1 to 3, each comprising two sections 4', 5' and 4", 5", and 4'", 5'", respectively.
  • the layers of plastic material 6, 7, which comprise, for example, a matrix of glass fibres embedded in a resin, are arranged between the metal layers 1, 2 and 3, respectively.
  • Section 4', 5' and 4", 5" and 4'", 5'" overlap one another at the locations of the overlaps 8 and 9 and 10, respectively.
  • Section 4' of the outermost metal layer 1 for this purpose has a flanged part 11'
  • section 4" of the metal layer 2 has a flanged part 11"
  • section 4'" of the metal layer has a flanged part 11'".
  • These flanged parts 11', 11" and 11'" extend as far as below the other associated section 5', 5" and 5'", respectively.
  • These flanged parts and sections are adhesively bonded to one another by means of layers of adhesive 12', 12" and 12'", respectively.
  • the plastic layer 6, 7 continue through these overlaps 8, 9 and 10.
  • the laminated part 21 may be reinforced by applying one or more additional layers.
  • additional layers may, for example, be assembled to form a second laminated part 22, which in the exemplary embodiment illustrated comprises the layers 13, 14 and 15. These layers are secured to one another by the plastic layers 16 and 17, respectively. Since the second laminated part 22 is planar, it is not immediately possible for it to be joined to the first laminated part 21 by adhesive bonding. In practice, therefore, hitherto filler panels have been used, and these panels had to fill up the relatively great distance between the layers 3 and 13 outside the flanged part 11'". However, such a procedure is labour-intensive and also leads to an increase in weight as a result of the presence of the filler panels.
  • a second laminated part 2 can be adhesively bonded direct to the non-planar surface caused by the flange 11'" if the prefabricated laminated parts 21, 22 are heated. This causes the shear strength in the plastic layers 16, 17 to decrease. This decrease is such that, if the laminated parts 21, 22 are pressed together under a sufficiently high pressure, in the exemplary embodiment illustrated the layers 13, 14 and 15 of these parts can be shaped to match the contour of the laminated part 1, in particular the contour at the location and in the vicinity of the flanged part 11'".
  • the layer of adhesive 18 which has previously been applied to the first laminated part 21 is activated, and after cooling this layer of adhesive 18 forms the join between the two laminated parts 21, 22.
  • An advantage of the method according to the mvention is that, for the laminated parts 21, 22 to be bonded to one another, their shapes do not have to be precisely matched to one another. This simplifies and accelerates the production process considerably.
  • the end product which is illustrated in Figure 2 is obtained as a result of the first laminated part 21 being supported on its free surface in a flat mould.
  • the second laminated part 22 when it is pressed on, is forced to adopt the shape which is illustrated.
  • the method according to the invention can even be used to produce double-curved shapes.
  • a corresponding double-curved part 2 can be placed in a prefabricated, double-curved part 1.
  • the desired positioning can be obtained by the application of heat and pressure. If the first curved part 1 is supported in a double-curved mould, the heat and pressure forces the second double-curved part 2 to adjust its shape to match the curvatures of the first double-curved part 1. This once again results in considerable simplification to the method, since in this case too the second double-curved part does not have to be accurately matched to the first curved part.
  • metals and plastics All kinds of different products can be selected for the metals and plastics.
  • suitable metals are aluminium alloys, steel alloys, titanium alloys, copper alloys, magnesium alloys.
  • aluminium copper alloys AA 2000
  • aluminium-manganese alloys AA 3000
  • aluminium-magnesium alloy AA 5000
  • aluminium-zinc alloys AA 7000
  • aluminium-magnesium-silicon alloys AA 6000.
  • the aluminium-copper alloy (AA 2224), the aluminium-zinc alloy (AA 7075) and the alumim ' um-magnesium-silicon alloy (AA 6013) are particularly preferred. The same is true of AA 2X24-23 and AA 7X75-26. If a high resistance to erosion is desired, an AA 50525 alloy may be incorporated in the laminate. Examples of suitable thermosets are epoxy resins, unsaturated polyesters, vinyl esters and phenolic esters.
  • thermoplastics examples include polyarylates (PAR), polysulphones (PSO), polyethersulphones (PES), polyetherimides (PEI), polyphenylene ethers (PEE), polyphenylene sulphide (PPS), polyamide-4,6, polyketone sulphide (PKS), polyether ketones (PEK), polyether ether ketone (PEEK) and polyether ketone ketone (PEKK).
  • PAR polyarylates
  • PSO polysulphones
  • PES polyethersulphones
  • PEI polyetherimides
  • PEE polyphenylene ethers
  • PPS polyphenylene sulphide
  • PPS polyamide-4,6, polyketone sulphide
  • PES polyether ketones
  • PEEK polyether ether ketone
  • PEKK polyether ketone ketone
  • the bonding plastic layer may be provided with a reinforcement in the form of continuous fibres, as is the case, for example, in the abovementioned materials Glare® and ARALL®.
  • S-2 glass or R-glass fibres which each comprise approximately 58- 69% by weight of SiO 2 , 18-29% by weight of Al 2 O 3 and 7-19% by weight of MgO are preferred.
  • E-glass fibres comprising approximately 55% by weight of SiO , 15% by weight of Al 2 O 3 , 19% by weight of CaO, 7% by weight of B 2 O 3 and 3% by weight of MgO are also suitable.
  • a suitable aramid fibre is produced from polyparaphenylene terephthalamide.

Abstract

A method for producing a shaped part from at least one prefabricated laminate which has at least two metal layers and at least one plastic layer between them comprises the steps of; - providing at least one prefabricated, hardened laminate, - heating the said laminate, - deforming the heated laminate in order to create a shaped part, - cooling the shaped part.

Description

Method for producing a shaped laminate
The invention relates to the production of laminated parts which comprise alternating layers of a metal and layers of a plastic. The plastic layers may contain a bonding agent and may be reinforced with fibre material. Laminated parts of this type are used, for example, in the aviation and aerospace industry. Examples which may be mentioned are the material Glare® (glass reinforced) and the material ARALL® (aramid aluminate laminate). They have relatively low weight and a relatively high strength and rigidity. These properties are related to the rigid joins between the metal layers, which are obtained by the bonding produced via the plastic layers.
WO-A-9853989 has disclosed a method for producing laminate parts of this type. The metal plates with a layer of adhesive between them, optionally provided with a reinforcement, are placed in a mould, with the result that a defined, desired shape is obtained. The assembly is then exposed to an elevated temperature and pressure in order to effect adhesive bonding. After the layers have cooled, the result is a cohesive, shaped part which has the desired mechanical properties with regard to rigidity, strength and the like.
In the same way, it is possible to produce joins in laminated parts of this type. For this purpose, one or more metal layers may have sections which overlap one another. For example, in a part which is to form the skin of an aircraft, a section of a specific, outermost metal-layer piece may be flanged, in such a manner that it comes to lie beneath the adjoining section of another outermost metal-layer piece. The sections can then be joined to one another in the manner described above.
The flanged area disrupts the surface of the shaped part. This surface has to be on the inside when used in an aircraft structure, since otherwise the aerodynamically shaped external surface would be disturbed.
In certain cases, it may be desirable for the shaped part to be reinforced, optionally locally. For this purpose, additional layers have to be secured to the part which has already been shaped. A problem then arises at the flanged areas. The layers which are to be applied to the part which has already been shaped do not fit correctly, since the layers are planar. In practice, this problem is solved by adding filler layers which are supposed to compensate for the difference in height caused by the flange.
However, a solution of this type has drawbacks. Firstly, it is labour-intensive, since the filler layers have to be produced to size separately and then have to be fitted in a separate working step. Moreover, they have the effect of increasing the weight, which represents a considerable drawback in particular for use in the aviation and aerospace industry.
In particular, the application of a prefabricated laminate as an additional reinforcing element to a non-planar structure of this type has proven problematical. A laminate of this type has a rigidity which is so great that it is difficult to adapt the laminate to the contour of the non-planar structure.
Consequently, the application of an additional reinforcement in the form of additional layers of metal is laborious and expensive. It is an object of the invention to provide a method in which these problems do not occur or occur to a lesser extent. This object is achieved by means of a method for producing a shaped part from at least one prefabricated laminate which comprises at least two metal layers and at least one plastic layer located between them, which method comprises the steps of: providing at least one prefabricated, hardened laminate, heating the said laminate, deforming the heated laminate in order to create a shaped part, - cooling the shaped part.
According to the invention, a part which has already been shaped, comprising various metal layers which are joined to one another by a bonding plastic layer can still be made into a specific, desired shape by the use of heat and pressure. Despite the fact that the finished laminate has a considerable rigidity, it can nevertheless be deformed successfully under these conditions. This is possible because the plastic layer has been found to be deformable at elevated temperatures, possibly as a result of its molecules stretching. As a result, the metal layers can slide along one another more easily when a bending load is applied, which explains the ready deformability. When the laminate cools, its original rigidity is restored. Obviously, the deformations must not be so great that separation or delamination occurs. Depending on the materials used, when carrying out the method according to the invention it is possible to select an optimum temperature range of, for example, from 100°C-250°C, preferably between 100°C-180°C. For specific plastics, such as PEEK, the temperature may rise to 350°C. The pressure which is to be employed may, for example, be between 1 and 10 bar, preferably between 2 and 6 bar. Such temperatures and pressures can be obtained by carrying out the method with the aid of an autoclave. Both thermosets and thermoplastics may be used.
As has already been mentioned, the method according to the invention can be used in various ways. According to a first possibility, the method is used to reinforce a laminated part which has already been shaped. The invention therefore also relates to the production of a shaped part from at least two prefabricated, hardened laminates which rest partly or completely on top of one another, which laminates have different contours on their surfaces which face towards one another, comprising the steps of: providing at least two laminates which have different surface contours, placing the said laminates at least partly on top of one another, so as to enclose a layer of adhesive which is to be set, heating the said laminates, deforming at least one of the said laminates in order to match their surface contours to one another, bonding the laminates, which have matching surface contours, to one another in order to create the shaped part, cooling the shaped part.
In particular, the first laminate may comprise a joining structure which has at least one metal layer with overlapping sections, in such a manner that, at the location of these overlapping sections, one of the surfaces of the said laminate has a jump in thickness which forms a deviation from the flat surface of the said laminate, and the other surface thereof is planar, comprising the steps of: placing the two laminates on top of one another, placing the planar surface of the first laminate onto a mould with a corresponding planar surface, heating the said laminates, deforming the second laminate in order to match it to the surface of the first laminate having the jump in thickness in order to create the shaped part, cooling the shaped part.
The jump in thickness mentioned above may also be caused, for example, by a connecting strip ("doubler") which is adhesively bonded over the edges of two layers which have been placed end to end. The size of the jump in thickness may amount to approximately 2 mm.
The method according to the invention can be used both for smooth, planar part and for curved parts. Even double-curved parts can be processed using the method according to the invention. An advantage of in particular the latter variant is that the reinforcing laminate which is applied to a prefabricated, other laminate does not have to be accurately matched to the shape of the said other laminate. As a result of the heating, the reinforcing laminate can be "fitted" relatively easily, with the result that production of double-curved parts becomes considerably easier and less expensive.
The invention will be explained in more detail below with reference to the figures.
Figure 1 shows a first step involved in carrying out the method according to the invention.
Figure 2 shows the second step of the method.
The method according to the invention relates to the production of shaped parts from a number of metal layers which are joined to one another by a bonding plastic layer. The method steps illustrated in Figures 1 and 2 relate to the reinforcing of the first laminated part, which is denoted overall by 21, by means of the second laminated part, which is denoted by 22. The first laminated part 21 comprises three metal layers 1 to 3, each comprising two sections 4', 5' and 4", 5", and 4'", 5'", respectively. The layers of plastic material 6, 7, which comprise, for example, a matrix of glass fibres embedded in a resin, are arranged between the metal layers 1, 2 and 3, respectively.
The sections 4', 5' and 4", 5" and 4'", 5'" overlap one another at the locations of the overlaps 8 and 9 and 10, respectively. Section 4' of the outermost metal layer 1 for this purpose has a flanged part 11', section 4" of the metal layer 2 has a flanged part 11" and section 4'" of the metal layer has a flanged part 11'". These flanged parts 11', 11" and 11'" extend as far as below the other associated section 5', 5" and 5'", respectively. These flanged parts and sections are adhesively bonded to one another by means of layers of adhesive 12', 12" and 12'", respectively. The plastic layer 6, 7 continue through these overlaps 8, 9 and 10.
In certain cases, it may be desirable for the laminated part 21 to be reinforced by applying one or more additional layers. These additional layers may, for example, be assembled to form a second laminated part 22, which in the exemplary embodiment illustrated comprises the layers 13, 14 and 15. These layers are secured to one another by the plastic layers 16 and 17, respectively. Since the second laminated part 22 is planar, it is not immediately possible for it to be joined to the first laminated part 21 by adhesive bonding. In practice, therefore, hitherto filler panels have been used, and these panels had to fill up the relatively great distance between the layers 3 and 13 outside the flanged part 11'". However, such a procedure is labour-intensive and also leads to an increase in weight as a result of the presence of the filler panels.
According to the invention, a second laminated part 2 can be adhesively bonded direct to the non-planar surface caused by the flange 11'" if the prefabricated laminated parts 21, 22 are heated. This causes the shear strength in the plastic layers 16, 17 to decrease. This decrease is such that, if the laminated parts 21, 22 are pressed together under a sufficiently high pressure, in the exemplary embodiment illustrated the layers 13, 14 and 15 of these parts can be shaped to match the contour of the laminated part 1, in particular the contour at the location and in the vicinity of the flanged part 11'". During the heating, the layer of adhesive 18 which has previously been applied to the first laminated part 21 is activated, and after cooling this layer of adhesive 18 forms the join between the two laminated parts 21, 22.
An advantage of the method according to the mvention is that, for the laminated parts 21, 22 to be bonded to one another, their shapes do not have to be precisely matched to one another. This simplifies and accelerates the production process considerably.
The end product which is illustrated in Figure 2 is obtained as a result of the first laminated part 21 being supported on its free surface in a flat mould. As a result, the second laminated part 22, when it is pressed on, is forced to adopt the shape which is illustrated. It should be noted that the method according to the invention can even be used to produce double-curved shapes. For example, a corresponding double-curved part 2 can be placed in a prefabricated, double-curved part 1. Although these parts do not initially rest correctly against one another, the desired positioning can be obtained by the application of heat and pressure. If the first curved part 1 is supported in a double-curved mould, the heat and pressure forces the second double-curved part 2 to adjust its shape to match the curvatures of the first double-curved part 1. This once again results in considerable simplification to the method, since in this case too the second double-curved part does not have to be accurately matched to the first curved part.
All kinds of different products can be selected for the metals and plastics. Examples of suitable metals are aluminium alloys, steel alloys, titanium alloys, copper alloys, magnesium alloys. In particular, mention may be made of aluminium copper alloys (AA 2000), aluminium-manganese alloys (AA 3000), aluminium-magnesium alloy (AA 5000), aluminium-zinc alloys (AA 7000) and aluminium-magnesium-silicon alloys (AA 6000).
The aluminium-copper alloy (AA 2224), the aluminium-zinc alloy (AA 7075) and the alumim'um-magnesium-silicon alloy (AA 6013) are particularly preferred. The same is true of AA 2X24-23 and AA 7X75-26. If a high resistance to erosion is desired, an AA 50525 alloy may be incorporated in the laminate. Examples of suitable thermosets are epoxy resins, unsaturated polyesters, vinyl esters and phenolic esters. Examples of suitable thermoplastics are polyarylates (PAR), polysulphones (PSO), polyethersulphones (PES), polyetherimides (PEI), polyphenylene ethers (PEE), polyphenylene sulphide (PPS), polyamide-4,6, polyketone sulphide (PKS), polyether ketones (PEK), polyether ether ketone (PEEK) and polyether ketone ketone (PEKK).
The bonding plastic layer may be provided with a reinforcement in the form of continuous fibres, as is the case, for example, in the abovementioned materials Glare® and ARALL®. S-2 glass or R-glass fibres, which each comprise approximately 58- 69% by weight of SiO2, 18-29% by weight of Al2O3 and 7-19% by weight of MgO are preferred. E-glass fibres, comprising approximately 55% by weight of SiO , 15% by weight of Al2O3, 19% by weight of CaO, 7% by weight of B2O3 and 3% by weight of MgO are also suitable. A suitable aramid fibre is produced from polyparaphenylene terephthalamide.

Claims

Claims
1. Method for producing a shaped part from at least one prefabricated laminate (21, 22) which comprises at least two metal layers (1-3; 13-15) and at least one plastic layer (6, 7; 16, 17) located between them, which method comprises the steps of: providing at least one prefabricated, hardened laminate (21, 22), heating the said laminate (2), deforming the heated laminate (21, 22) in order to create a shaped part, cooling the shaped part.
2. Method according to Claim 1, comprising the step of deforming the heated laminate (21, 22) under an elevated pressure.
3. Method according to Claim 2, comprising the step of applying a pressure of between 1 bar and 10 bar.
4. Method according to Claim 2, comprising the step of applying a pressure of between 2 bar and 6 bar.
5. Method according to Claim 2, 3 or 3, comprising the step of applying the pressure by means of a surface press.
6. Method according to Claim 2 or 3, comprising the steps of heating and deforming the laminate (21, 22) in an autoclave.
7. Method according to one of the preceding claims, comprising the step of heating the laminate (21, 22) to a temperature of between 100°C and 180°C.
8. Method according to one of Claims 1-6, comprising the step of heating the laminate (21, 22) to a temperature of between 100°C and 170°C.
9. Method according to Claim 7 or 8, comprising the step of heating the laminate (21, 22) to a temperature of 120°C.
10. Method according to one of the preceding claims, in which the plastic layer comprises a thermoset.
11. Method according to one of the preceding claims for producing a shaped part from at least two prefabricated, hardened laminates (21, 22) wliich rest partly or completely on top of one another, which laminates (21, 22) have different contours on their surfaces which face towards one another, comprising the steps of: providing at least two laminates (21, 22) which have different surface contours, placing the said laminates (21, 22) at least partly on top of one another, so as to enclose a layer of adhesive (18) which is to be set, heating the said laminates (21, 22), deforming at least one of the said laminates (21, 22) in order to match their surface contours to one another, bonding the laminates (21, 22), which have matching surface contours, to one another in order to create the shaped part, cooling the shaped part.
12. Method according to Claim 11, in which a first laminate (21) comprises a joining structure which has at least one metal layer (1-3) with overlapping sections (4'-5'"), in such a manner that, at the location of these overlapping sections (4'-5'"), one of the surfaces of the said laminate (21) has a jump in thickness (11"') which forms a deviation from the flat surface of the said laminate (21), and the other surface thereof is planar, comprising the steps of: placing the two laminates (21, 22) on top of one another, - placing the planar surface of the first laminate (21) onto a mould with a corresponding planar surface, heating the said laminates (21, 22), deforming the second laminate (22) in order to match it to the surface of the first laminate (21) having the jump in thickness (11 " ') in order to create the shaped part, cooling the shaped part.
13. Method according to Claim 12, in which the laminates (21, 22) have a double- curved shape.
PCT/NL2002/000251 2001-05-21 2002-05-15 Method for producing a shaped laminate WO2002094565A1 (en)

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NL1018120A NL1018120C2 (en) 2001-05-21 2001-05-21 Method for manufacturing a molded laminate.

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NL1025744C2 (en) * 2004-03-16 2005-01-18 Stork Fokker Aesp Bv Laminate with metal layers, used for aerospace applications, contains electrical heating layer
WO2008132050A1 (en) 2007-04-26 2008-11-06 Airbus Operations Gmbh Fibre metal laminate panel
NL2007603C2 (en) * 2011-10-14 2013-04-16 Univ Delft Tech Fiber metal laminate.
EP2857168A1 (en) * 2013-10-02 2015-04-08 BAE Systems PLC Flexible tooling
WO2015049509A1 (en) * 2013-10-02 2015-04-09 Bae Systems Plc Flexible tooling
WO2017139536A1 (en) * 2016-02-11 2017-08-17 Durez Corporation Molded polymer and metal articles
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NL1025744C2 (en) * 2004-03-16 2005-01-18 Stork Fokker Aesp Bv Laminate with metal layers, used for aerospace applications, contains electrical heating layer
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