WO2008078161A2 - Computerized plant for producing structures made of resin, composites, or the like - Google Patents

Computerized plant for producing structures made of resin, composites, or the like Download PDF

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Publication number
WO2008078161A2
WO2008078161A2 PCT/IB2007/004057 IB2007004057W WO2008078161A2 WO 2008078161 A2 WO2008078161 A2 WO 2008078161A2 IB 2007004057 W IB2007004057 W IB 2007004057W WO 2008078161 A2 WO2008078161 A2 WO 2008078161A2
Authority
WO
WIPO (PCT)
Prior art keywords
computerized
resin
composites
flexible
plant according
Prior art date
Application number
PCT/IB2007/004057
Other languages
French (fr)
Other versions
WO2008078161A3 (en
Inventor
Gianfranco Cirri
Maria Prudenziati
Original Assignee
Inglass S.P.A.
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 Inglass S.P.A. filed Critical Inglass S.P.A.
Publication of WO2008078161A2 publication Critical patent/WO2008078161A2/en
Publication of WO2008078161A3 publication Critical patent/WO2008078161A3/en

Links

Classifications

    • 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
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
    • 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
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0866—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using particle radiation
    • 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
    • B29C53/56—Winding and joining, e.g. winding spirally
    • B29C53/58—Winding and joining, e.g. winding spirally helically
    • B29C53/60—Winding and joining, e.g. winding spirally helically using internal forming surfaces, e.g. mandrels
    • B29C53/62—Winding and joining, e.g. winding spirally helically using internal forming surfaces, e.g. mandrels rotatable about the winding axis
    • B29C53/64—Winding and joining, e.g. winding spirally helically using internal forming surfaces, e.g. mandrels rotatable about the winding axis and moving axially
    • 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
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0866—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using particle radiation
    • B29C2035/0877—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using particle radiation using electron radiation, e.g. beta-rays
    • 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
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C2037/90—Measuring, controlling or regulating
    • B29C2037/903—Measuring, controlling or regulating by means of a computer
    • 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
    • B29C53/80—Component parts, details or accessories; Auxiliary operations
    • B29C53/8008—Component parts, details or accessories; Auxiliary operations specially adapted for winding and joining
    • B29C53/8066—Impregnating
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J2237/00—Discharge tubes exposing object to beam, e.g. for analysis treatment, etching, imaging
    • H01J2237/30—Electron or ion beam tubes for processing objects
    • H01J2237/31—Processing objects on a macro-scale
    • H01J2237/3156—Curing

Definitions

  • the present invention relates to a system for producing structures made of resin, composites, and the like, for example, pipes, bottles or cylinders, and containers for transporting compressed gases and liquids, tanks, helicopter blades, structural parts for use in nautical, avionic, or space applications, electronics, etc., polymerized in real time.
  • structures made of resin, composites, and the like for example, pipes, bottles or cylinders, and containers for transporting compressed gases and liquids, tanks, helicopter blades, structural parts for use in nautical, avionic, or space applications, electronics, etc., polymerized in real time.
  • the cost is not a significantly important variable and the thickness of the structure is considerable, such as for the launching motors for launching rockets such as Atlas, Ariane, Proton, etc.
  • the polymerization is performed with the end structure, using beams of electrons accelerated up to 20-100 MeV inside bunkers made of reinforced concrete of a thickness of various metres, which have a cost that is not sustainable by industry.
  • the thickness is particularly large even for electrons having the values of energy mentioned above, these electron beams have to be converted into X-rays, which have a higher power of penetration than electrons.
  • the purpose of the invention is to provide an efficient solution to the aforesaid problems, and said purpose is achieved thanks to a computerized flexible innovative plant as defined in the ensuing claims. Thanks to the invention, not only are the problems set forth above overcome or eliminated easily, but there is also achieved a significant improvement in the quality of the product, and a substantial reduction in the times and costs, in so far as the product is polymerized step-by-step during the manufacturing process so that, for example, when a cylinder exits from the winder, it is already polymerized and finished.
  • FIG. 1 is a schematic perspective view of a computerized flexible plant according to the invention
  • FIG. 2 is a view identical to that of Figure 1, at a reduced scale, highlighted in which is the detail illustrated in Figure 3 and
  • Figure 3 is a partial cross-sectional view, at a larger scale, of the detail highlighted in Figure 2.
  • the computerized innovative flexible plant according to the invention for producing structures made of resin, composites, and the like, envisages the availability of all the degrees of freedom necessary for producing structures from the simplest ones to the most complex ones.
  • the plant is characterized by the insertion in an appropriate position of at least one electron gun of low energy (100-300 keV) capable of obtaining step-by-step polymerization, in real time, of the structure during growth by supply of an appropriate resin or composite, etc., fed by the dispenser for dispensing resin, pre-impregnated fibre, etc., which can be polymerized by e-beams ( Figure 1).
  • the plant may have the configuration of a portal, of a filament-winding machine, of an automatic-tape-placement machine, of a robot, etc., but will in any case be characterized by:
  • programmable motors such as for example, stepper motors or d.c. linear motors and encoders;

Abstract

A computerized flexible innovative system for producing structures made of resin, composites, and the like, characterized by the presence of a self-shielded electron gun and by a movement that enables the availability of all those degrees of freedom necessary for positioning the product in every point thereof under the electron beam in order to obtain step-by-step, in real time, polymerization of the product as this is assuming its definitive configuration, which will be completely and uniformly polymerized and hence completely defined. The system is provided with a variety of modalities of feed of the composite material, e.g. dispensers of thin layers of resin, of impregnated fibres and tapes of different types that with their arrangement in a programmed way, which is no longer constrained by the geodetics, opens an innovative capacity of design of tanks, products, and structures that are more resistant and less expensive.

Description

Computerized plant for producing structures made of resin, composites, or the like
Field of the invention The present invention relates to a system for producing structures made of resin, composites, and the like, for example, pipes, bottles or cylinders, and containers for transporting compressed gases and liquids, tanks, helicopter blades, structural parts for use in nautical, avionic, or space applications, electronics, etc., polymerized in real time. State of the prior art
Currently, all the above structures are obtained with different types of machines and plants for producing the desired shape and structure, such as, for example, with filament- winding machines, automatic-tape-placement machines, etc., but all have in common the «curing» technique, i.e., the step of polymerization of the resin matrix that impregnates tapes, and fibres of various types and compositions. Said common technique consists in the use of heat for polymerization of the matrix, said heat being supplied by ovens, or autoclaves, where associated to the heat is, in succession, vacuum for expelling occluded gases during manufacture and pressure for better compacting of the structure. In the case, as in space applications, the cost is not a significantly important variable and the thickness of the structure is considerable, such as for the launching motors for launching rockets such as Atlas, Ariane, Proton, etc., the polymerization is performed with the end structure, using beams of electrons accelerated up to 20-100 MeV inside bunkers made of reinforced concrete of a thickness of various metres, which have a cost that is not sustainable by industry. Sometimes, when the thickness is particularly large even for electrons having the values of energy mentioned above, these electron beams have to be converted into X-rays, which have a higher power of penetration than electrons. As may be readily understood, this method is not suited for the industrial production of the composite structures mentioned above, and for this reason today it is customary to resort to thermal polymerization with all the drawbacks that this involves and that may be readily understood from the extremely low energy efficiency and the long times for polymerizing the entire structure, and in addition, since obviously the heat reaches the external surface, this surface polymerizes (i.e., becomes rigid) before the inside, thus giving rise to significant strains and stresses. Summary of the invention
The purpose of the invention is to provide an efficient solution to the aforesaid problems, and said purpose is achieved thanks to a computerized flexible innovative plant as defined in the ensuing claims. Thanks to the invention, not only are the problems set forth above overcome or eliminated easily, but there is also achieved a significant improvement in the quality of the product, and a substantial reduction in the times and costs, in so far as the product is polymerized step-by-step during the manufacturing process so that, for example, when a cylinder exits from the winder, it is already polymerized and finished. All this is obtained with further advantages, as will be better pointed out and clarified hereinafter, resorting to the computerized flexible plant according to the present invention, characterized in particular by the use of a self- shielded electron gun for generating electrons accelerated at a voltage of between 100 and 300 kV such as to polymerize the resin matrix, which impregnates the fibre or the tape, during manufacture of the product.
Consequently, the structure being produced is polymerized step-by-step during the manufacturing process as may be understood more fully from the ensuing description of the computerized flexible plant as a whole. Brief description of the drawings The invention will now be described in detail with reference to the annexed drawings, which are provided purely by way of non-limiting example and in which:
- Figure 1 is a schematic perspective view of a computerized flexible plant according to the invention; - Figure 2 is a view identical to that of Figure 1, at a reduced scale, highlighted in which is the detail illustrated in Figure 3 and
- Figure 3 is a partial cross-sectional view, at a larger scale, of the detail highlighted in Figure 2.
Detailed description of the invention The figures illustrate the following elements:
1) Filament winding of cylinder tanks for compressed gases, with degrees of freedom and corresponding feed
2) Possible variants of filament winding
3) Cylinder with the minimum number of degrees of freedom necessary to have different layers of fibres in series and in parallel, and corresponding scars (Kevlar)
4) Cylinder on a robot
5) Structure on a portal (Prima Progetti, Comau)
The computerized innovative flexible plant according to the invention, for producing structures made of resin, composites, and the like, envisages the availability of all the degrees of freedom necessary for producing structures from the simplest ones to the most complex ones. The plant is characterized by the insertion in an appropriate position of at least one electron gun of low energy (100-300 keV) capable of obtaining step-by-step polymerization, in real time, of the structure during growth by supply of an appropriate resin or composite, etc., fed by the dispenser for dispensing resin, pre-impregnated fibre, etc., which can be polymerized by e-beams (Figure 1).
The plant may have the configuration of a portal, of a filament-winding machine, of an automatic-tape-placement machine, of a robot, etc., but will in any case be characterized by:
1) the presence of a self-shielded rasterizable electron gun with acceleration voltage comprised between 100 and 300 kV and in any case sufficient for the polymerization of thin layers of resin, composites, and the like;
2) the availability of all those degrees of freedom necessary for producing structures made of resin, composites or the like from the simplest ones to the most complex ones (Figure 2);
3) the use of programmable motors, such as for example, stepper motors or d.c. linear motors and encoders;
4) the possibility of having available a supply of a number of types of resins, fibres of different composition, impregnated either with the same matrix or with a different, but compatible, matrix, as likewise pre-impregnated tapes (Figure 2);
5) being completely computerized.
There is hence obtained the possibility of producing any type of structure, with the fundamental advantage that the structure thus obtained, for example, a tank for compressed gases, is already polymerized at the end of the winding operation, curing of the resin for impregnation of the fibre having already been obtained as a result of the energy transferred by the electron beam.
With the above type of plant there are thus enhanced all the advantages of electron-beam curing as compared to conventional thermal curing, in so far as it is performed during the manufacturing process; namely: a) the curing time using the e-beam technique is faster by one to three orders of magnitude than thermal curing; b) in the case of e-beam curing, no initiators are used in the resins so that the pot life coincides with the shelf life; the dispensers of pre-impregnated fibres do not have any need for frequent recleaning, and moreover the viscosity of the resin can be reduced by heating; c) the production of volatile elements is basically zero in e-beam polymerization so that problems of environmental pollution are eliminated or at least mitigated; d) e-beam polymerization is performed at room temperature and on a step-by- step basis so that there is elimination of the mechanical strains and stresses induced by oven and autoclave treatments, where the heating, which comes necessarily from outside, hardens the external layers of the structure before the more internal ones; e) there do not exist upper limits to the thickness of a product in so far as this is polymerized step-by-step during its growth; f) with this step-by-step polymerization no migrations or splitting of resin and fibres can occur, as, instead, did occur during winding followed by thermal curing; g) step-by-step polymerization also enables development a new software that will maximize the mechanical resistance (e.g., the maximum pressure in the case of a tank for compressed gas) in so far as it is possible to wind the fibre on appropriate lines that will not necessarily be the geodetic lines; h) the flexible plant proposed is also able to program step-by-step the degree of tensioning of the fibre so as to obtain, for example, matrices precompressed along pre-chosen layers of the pressurized casing; i) furthermore, on account of the availability of a number of dispensers for different types of fibre and/or matrix (but in any case ones that can be polymerized with e-beam), the plant makes possible the production in succession or in parallel of layers having characteristics that differ from one another (Figure 3), but are compatible with one another, thus opening the way to a new design method (and software) aimed at obtaining structures that are less expensive and more resistant than the current ones.

Claims

I) A computerized flexible innovative plant for manufacturing products, structures made of resin, composites, and the like, in a configuration that can vary from a portal to a robot, to a filament-winding machine, or to an automatic-tape-placement machine, etc., but always characterized by the presence of at least one electron gun capable of polymerizing thin layers of resin, composites or the like coming from various and different systems for feed of resin, impregnated fibres, and tapes.
2) The computerized flexible innovative plant as per Claim 1), characterized by the availability of all the degrees of freedom necessary for bringing under the electron beam any point of the structure to be polymerized. 3) The computerized flexible innovative plant according to one or more of the preceding claims, characterized by the use of stepper or d.c. linear motors and encoders for programming both the position and the speed in the movement.
4) The computerized flexible innovative plant according to one or more of the preceding claims, characterized by a self-shielded electron gun having an accelerating voltage comprised between 100 and 300 kV and in any case sufficient to polymerize in real time, step-by-step, thin layers of resins, composites, or the like, that can be polymerized via e- beam. 5) The computerized flexible innovative plant according to one or more of the preceding claims, characterized in that the electron beam emitted by the gun provided with extraction window, can be rasterized, i.e., deflected and programmed in voltage and current intensity as in a standard kinescope. 6) The computerized flexible innovative plant according to one or more of the preceding claims, characterized by the availability of different feed systems, which can be programmed in temperature and mechanical winding tension, for various types of pre-impregnated fibres and tapes and resins. 7) The computerized flexible innovative plant according to one or more of the preceding claims, characterized in that the possibility of polymerizing, i.e., hardening immediately the resin matrix with e- beam and of having available a number of types of pre-impregnated fibres, e.g., carbon or Kevlar fibres, or glass or boron fibres, and of being able to regulate the tension of winding thereof enables the production of new and more efficient types of structures and above all enables start of a new and innovative capacity of design.
PCT/IB2007/004057 2006-12-21 2007-12-20 Computerized plant for producing structures made of resin, composites, or the like WO2008078161A2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITMO2006A000414 2006-12-21
ITMO20060414 ITMO20060414A1 (en) 2006-12-21 2006-12-21 COMPUTERIZED INNOVATIVE FLEXIBLE PLANT FOR STEP-BY-STEP POLYMERIZATION IN REAL TIME, DURING THE PROCESS OF REALIZATION, RESIN, COMPOSITE OR SIMILAR STRUCTURES

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WO2008078161A2 true WO2008078161A2 (en) 2008-07-03
WO2008078161A3 WO2008078161A3 (en) 2008-08-21

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8004172B2 (en) 2008-11-18 2011-08-23 Cree, Inc. Semiconductor light emitting apparatus including elongated hollow wavelength conversion tubes and methods of assembling same
WO2013013663A1 (en) * 2011-07-27 2013-01-31 Shubbar Abdul Amir Device for reinforcing tanks with fibres impregnated with synthetic resin

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WO2002017347A1 (en) * 2000-08-21 2002-02-28 Corning Incorporated Electron-beam curing and patterning of sol-gel
US20020145213A1 (en) * 2001-04-10 2002-10-10 Junhai Liu Layer manufacturing of a multi-material or multi-color 3-D object using electrostatic imaging and lamination
EP1674243A2 (en) * 2004-12-27 2006-06-28 Objet Geometries Ltd. Apparatus and method for three dimensional model printing

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US4575330B1 (en) * 1984-08-08 1989-12-19
US5414267A (en) * 1993-05-26 1995-05-09 American International Technologies, Inc. Electron beam array for surface treatment
EP1126502A1 (en) * 2000-02-18 2001-08-22 Shin-Etsu Chemical Co., Ltd. Method and system for shielding secondary X-rays from an electron beam irradiating unit
US20020008213A1 (en) * 2000-07-21 2002-01-24 Nobuo Kawada Electron beam system for treating filamentary workpiece, and method of fabricating optical fibers
WO2002017347A1 (en) * 2000-08-21 2002-02-28 Corning Incorporated Electron-beam curing and patterning of sol-gel
US20020145213A1 (en) * 2001-04-10 2002-10-10 Junhai Liu Layer manufacturing of a multi-material or multi-color 3-D object using electrostatic imaging and lamination
EP1674243A2 (en) * 2004-12-27 2006-06-28 Objet Geometries Ltd. Apparatus and method for three dimensional model printing

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8004172B2 (en) 2008-11-18 2011-08-23 Cree, Inc. Semiconductor light emitting apparatus including elongated hollow wavelength conversion tubes and methods of assembling same
US8362681B2 (en) 2008-11-18 2013-01-29 Cree, Inc. Semiconductor light emitting apparatus including elongated hollow wavelength conversion tubes
US9046248B2 (en) 2008-11-18 2015-06-02 Cree, Inc. Semiconductor light emitting apparatus including bulb and screw-type base
WO2013013663A1 (en) * 2011-07-27 2013-01-31 Shubbar Abdul Amir Device for reinforcing tanks with fibres impregnated with synthetic resin

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Publication number Publication date
ITMO20060414A1 (en) 2008-06-22
WO2008078161A3 (en) 2008-08-21

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