HEDGES, Andrew (Monks BrookSt. Cross Business Park, Newport PO30 5WZ, GB)
HANCOCK, Mark (Monks BrookSt. Cross Business Park, Newport PO30 5WZ, GB)
HOLLOWAY, Gary (Monks BrookSt. Cross Business Park, Newport PO30 5WZ, GB)
HEDGES, Andrew (Monks BrookSt. Cross Business Park, Newport PO30 5WZ, GB)
HANCOCK, Mark (Monks BrookSt. Cross Business Park, Newport PO30 5WZ, GB)
| CLAIMS 1. A method of tapering an edge of a fibrous reinforcement sheet or strip for a composite structure, the method comprising compacting an edge region of the sheet or strip to define a taper in cross-section, the edge region having been shaped before compaction to define a series of projections alternating with recesses in plan view, wherein the projections, in plan view, spread when compacted to narrow the recesses between the projections. 2. The method of Claim 1, wherein compaction is performed by squeezing the edge region between a roller and an anvil. 3. The method of Claim 2, wherein relative movement between the roller and the sheet or strip moves the roller along the edge region. 4. The method of Claim 2 or Claim 3, wherein the roller turns about an axis inclined relative to the sheet or strip. 5. The method of Claim 2 or Claim 3, wherein the roller has a frusto-conical surface inclined relative to the sheet or strip. 6. The method of Claim 4 or Claim 5, wherein said axis or said surface of the roller is inclined relative to the sheet or strip at an angle corresponding to a taper angle of the edge region. 7. The method of Claim 1, wherein compaction is performed by squeezing the edge region between a press member and an anvil. 8. The method of Claim 7, wherein the press member has a press surface inclined relative to an opposed press surface of the anvil. 9. The method of Claim 8, wherein the press surfaces of the press member and the anvil are inclined relative to each other at an angle corresponding to a taper angle of the edge region. 10. The method of any of Claims 7 to 9, wherein relative movement between the press member and the anvil moves the press member in a direction extending through the sheet or strip. 11. The method of any preceding claim, preceded by shaping the edge region of the sheet or strip to define the series of recesses alternating with projections in plan view. 12. The method of Claim 11, wherein the edge region is shaped upon cutting the sheet or strip from a larger fibrous reinforcement sheet or strip. 13. The method of Claim 11 or Claim 12, wherein shaping is performed by squeezing the edge region between a cutting roller and a cutting anvil, the cutting roller and/or the cutting anvil having cutting formations to impart the shape of recesses alternating with projections to the edge region. 14. The method of Claim 13, wherein relative movement between the cutting roller and the sheet or strip moves the cutting roller along the edge region. 15. The method of Claim 11 or Claim 12, wherein shaping is performed by squeezing the edge region between a cutting press member and a cutting anvil, the cutting press member and/or the cutting anvil having cutting formations to impart the shape of recesses alternating with projections to the edge region. 16. The method of Claim 15, wherein relative movement between the cutting press member and the cutting anvil moves the cutting press member in a direction extending through the sheet or strip. 17. The method of any preceding claim, wherein the projections each taper in plan toward their extremity. 18. The method of any preceding claim, wherein the projections and recesses define a zigzag edge shape. 19. The method of any preceding claim, wherein the projections and recesses define a sinuous edge shape. 20. A method of making a composite structure, comprising: tapering an edge of a fibrous sheet or strip in accordance with any preceding claim; and incorporating the sheet or strip into a composite structure with the tapered edge lying against or beside at least one other fibrous reinforcement sheet or strip. 21. The method of Claim 20, wherein the cooperating fibrous reinforcement sheets or strips each have a tapered edge and the tapered edges abut one another. 22. Apparatus for tapering an edge of a fibrous reinforcement sheet or strip for a composite structure, the apparatus comprising: a support for supporting the sheet or strip; and a compaction device for compacting an edge region of the sheet or strip to define a taper in cross-section, wherein the compaction device comprises a roller and an anvil arranged to squeeze the edge region between them. 23. The apparatus of Claim 22, wherein relative movement between the roller and the sheet or strip moves the roller along the edge region. 24. The apparatus of Claim 22 or Claim 23, wherein the roller turns about an axis inclined relative to the supported sheet or strip. 25. The apparatus of Claim 22 or Claim 23, wherein the roller has a frusto-conical surface inclined relative to the supported sheet or strip. 26. The apparatus of Claim 24 or Claim 25, wherein said axis or said surface of the roller is inclined relative to the sheet or strip at an angle corresponding to a taper angle of the edge region. 27. The apparatus of any of Claims 22 to 26, further comprising a shaping device arranged to shape the edge region of the sheet or strip, before compaction, to define a series of recesses alternating with projections in plan view. 28. The apparatus of Claim 27, wherein the shaping device comprises a cutting roller and a cutting anvil arranged to squeeze the edge region between them, the cutting roller and/or the cutting anvil having cutting formations to impart the shape of recesses alternating with projections to the edge region. 29. The apparatus of Claim 28, wherein relative movement between the cutting roller and the sheet or strip moves the cutting roller along the edge region. 30. The apparatus of Claim 27, wherein the shaping device comprises a cutting press member and a cutting anvil arranged to squeeze the edge region between them, the cutting press member and/or the cutting anvil having cutting formations to impart the shape of recesses alternating with projections to the edge region. 31. The apparatus of Claim 30, wherein relative movement between the cutting press member and the cutting anvil moves the cutting press member in a direction extending through the sheet or strip. 32. A composite structure such as a wind turbine blade, produced by the method of any of Claims 1 to 21 or by use of the apparatus of any of Claims 22 to 31. 33. A method for composite manufacturing, comprising the steps of feeding a fibre strip along a path, cutting the strip, bringing a first and a second strip end compaction part of a strip end compaction device towards each other with the strip between them, the first and second strip end compaction parts having strip contact surfaces, so that the strip is given a wedge shape with an increasing thickness in the direction away from a strip end. 34. The method of Claim 33, wherein the strip contact surfaces are oriented so as to give the strip said wedge shape. 35. The method of Claim 33 or Claim 34, comprising rotating the first and second strip end compaction parts in opposite directions so that the strip contact surfaces move, due to their rotation, along with the strip and contact the strip so that the strip is given said wedge shape. 36. The method of any of Claims 33 to 35, wherein the step of cutting the strip comprises rotating a cutting part, with a cutting edge, and a support part, with a support surface, in opposite directions, and forcing the cutting part and the support part towards each other with the strip between them, so that the cutting edge and the support surface move, due to their rotation, along with the strip, and so that the strip is cut by the cutting edge, wherein the cutting edge extends across the strip and is oriented, at least along a section of the lateral extension of the strip, in a non-zero angle to a direction perpendicular to the strip feeding direction. 37. The method of Claim 36, wherein the cutting edge is oriented, at a first section of the lateral extension of the strip, in a first non-zero angle to the direction perpendicular to the strip feeding direction, and, at a second section of the lateral extension of the strip, in a second non-zero angle to the direction perpendicular to the strip feeding direction. 38. A cutting device, comprising a strip end compaction device with a first and a second strip end compaction part, adapted for the method of any of Claim 33 to 37. 39. A method for composite manufacturing, comprising the steps of feeding a fibre strip along a path, rotating a cutting part, with a cutting edge, and a support part, with a support surface, in opposite directions, and forcing the cutting part and the support part towards each other with the strip between them, so that the cutting edge and the support surface move, due to their rotation, along with the strip, and so that the strip is cut by the cutting edge, wherein the cutting edge extends across the strip and is oriented, at least along a section of the lateral extension of the strip, in a non-zero angle to a direction perpendicular to the strip feeding direction. 40. The method of Claim 39, wherein the cutting edge is oriented, at a first section of the lateral extension of the strip, in a first non-zero angle to the direction perpendicular to the strip feeding direction, and, at a second section of the lateral extension of the strip, in a second non-zero angle to the direction perpendicular to the strip feeding direction. 41. The method of Claim 39 or Claim 40, comprising bringing a first and a second strip end compaction part of a first strip end compaction device towards each other with the strip between them, the first and second strip end compaction parts having strip contact surfaces oriented so that, when in contact with a first strip termination section of the strip extending away from a first strip end, the strip is given a wedge shape with an increasing thickness in the direction away from the first strip end. 42. The method of any of Claims 39 to 41, comprising rotating a first and a second strip end compaction part of a second strip end compaction device in opposite directions, the first and second strip end compaction parts having strip contact surfaces, and bringing the first and second strip end compaction parts towards each other with the strip between them, so that the strip contact surfaces move, due to their rotation, along with the strip and contact a second strip termination section of the strip extending away from a second strip end, so that the strip is given a wedge shape with an increasing thickness in the direction away from the second strip end. 43. A cutting device, comprising a cutting part and a support part, adapted for the method of any of Claims 39 to 42. |
TECHNIQUES
Automatic fibre placement machines are known as making the manufacturing of composite material products more efficient. They involve moving a placement head past a mould and depositing fibres on the mould, see e.g. US6692681B1,
US2007044896A1 or WO2005105641A2, which fibres can be provided in tows, plies, tapes or any other kind of fibre bundle lengths, here commonly referred to as strips. Stress concentrations in carbon fibre and glass fibre tow/ply/tape drop-offs can lead to delamination. This severely reduces the strength of a laminate and could lead to catastrophic failure. Traditional means to minimise these drop-off stresses include minimising the tow or ply thickness to both reduce the abrupt section change and the area of resin rich pockets. Reducing thicknesses of tows or plies, however, also reduces the deposition rate of the material which leads to high component costs.
In accordance with the present invention, there is provided a method of tapering an edge of a fibrous reinforcement sheet or strip for a composite structure, the method comprising compacting an edge region of the sheet or strip to define a taper in cross- section, the edge region having been shaped before compaction to define a series of projections alternating with recesses in plan view, wherein the projections, in plan view, spread when compacted to narrow the recesses between the projections.
The inventive concept encompasses a method of making a composite structure, comprising: tapering an edge of a fibrous sheet or strip in accordance with the above method; and incorporating the sheet or strip into a composite structure with the tapered edge lying against or beside at least one other fibrous reinforcement sheet or strip. The present invention also provides an apparatus for tapering an edge of a fibrous reinforcement sheet or strip for a composite structure, the apparatus comprising: a support for supporting the sheet or strip; and a compaction device for compacting an edge region of the sheet or strip to define a taper in cross-section, wherein the compaction device comprises a roller and an anvil arranged to squeeze the edge region between them.
The inventive concept also encompasses a composite structure such as a wind turbine blade produced by the above methods or apparatus.
The invention also provides a method for composite manufacturing, comprising the steps of feeding a fibre strip along a path, cutting the strip, bringing a first and a second strip end compaction part of a strip end compaction device towards each other with the strip between them, the first and second strip end compaction parts having strip contact surfaces, so that the strip is given a wedge shape with an increasing thickness in the direction away from a strip end.
The invention further provides a cutting device, comprising a strip end compaction device with a first and a second strip end compaction part, adapted for the above method.
The invention also provides a method for composite manufacturing, comprising the steps of feeding a fibre strip along a path, rotating a cutting part, with a cutting edge, and a support part, with a support surface, in opposite directions, and forcing the cutting part and the support part towards each other with the strip between them, so that the cutting edge and the support surface move, due to their rotation, along with the strip, and so that the strip is cut by the cutting edge, wherein the cutting edge extends across the strip and is oriented, at least along a section of the lateral extension of the strip, in a non-zero angle to a direction perpendicular to the strip feeding direction.
The invention further provides a cutting part and a support part, adapted for the above method.
Optional features of the present invention are set out in the sub claims appended hereto. As described further below, the problem described above is solved by shaping tow/ply/tape drop offs which, together with on-part compaction and consolidation, allows much thicker material to be used. In certain embodiments of the invention, shaped cutters form part of the surface of a roller device. The cutter roller may operate with a paired under roller. When a cut is required, both rollers accelerate to match the speed of the tow/ply/tape and move together to clamp and cut the tow. The compaction or forming method consists of two mechanisms; one for the stationary material, and one for the material being deposited. The stationary forming method operates on the stationary material and stamps the desired end condition via an anvil and a former die. The moving forming method operates on the material being deposited and uses an offset cam roller former together with a supporting roller former device. During operation both rollers accelerate to match the speed of the tow/ply/tape. For both methods one or both of the formers can move together to form the material.
Fig. 1 shows a side view of a cutting device 1 in an automatic fibre placement machine. A fibre tow 2 is fed through the cutting device, which comprises a cutting part 11 and a support part 12, shown in a perspective view in fig. 2. Although reference is here made to a fibre tow, the invention is applicable to any kind of fibre strips, whether they are fibre tows, fibre tape, UD ply, biax ply, triax ply, or any other length of fibres for composite material manufacturing. Also, the invention is applicable to such fibre strips regardless whether they are dry or impregnated with resin. When the tow 2 is to be cut, the cutting part 11 , provided with a cutting edge 111, and the support part 12, provided with a support surface 121, are brought to rotate in opposite directions as indicated in fig. 2 with the arrows Al 1 and A12, and the cutting part 11 and the support part 12 are moved from opposite sides of the tow 2, towards the tow 2, so that the cutting edge 111 and the support surface 121 moves due to their rotation along with the tow 2. Alternatively, one of the cutting part 11 and the support part 12 can be rotated but not translated. The cutting part 11 and the support part 12 are forced towards each other with the tow 2 between them, so that the tow 2 is cut by the cutting edge 111. The cutting edge extends in a direction parallel to the axis of rotation of the cutting part 11, in a zigzag manner. Thus, during the cutting operation, the cutting edge 111 extends across the tow 2 and is oriented, at a first section 1111 of the lateral extension of the tow, in a first non-zero angle to the direction perpendicular to the tow feeding direction, and, at a second section 1112 of the lateral extension of the tow, in a second non-zero angle to the direction perpendicular to the tow feeding direction.
Fig. 3 shows different alternatives for the shape of the cutting edge 111. Reference is made to fig. 1. The cutting device 1 comprises a first and a second tow end compaction device 3, 4. As can be seen in the side view in fig. 4, the first tow end compaction device 3 comprises a first and a second tow end compaction part 31, 32. In fig. 4 the second tow end compaction part 32 is shown sectioned vertically and parallel to the tow path. Fig. 5 shows the first and second tow end compaction parts 31, 32 in a view along the tow path. The first and second tow end compaction parts 31 , 32 are arranged to move, upon cutting the tow, towards each other from opposite sides of the tow 2, towards the tow. Alternatively, one of the first and second tow end compaction parts 31, 32 can be stationary. The first and second tow end compaction parts 31, 32 have tow contact surfaces 311, 321. A first tow termination section, indicated in fig. 4 with a double arrow 21, is here defined as a section extending from a first tow end 22 and a certain distance along the tow 2. The tow contact surfaces 311, 321 are oriented so that, when in contact with the first tow termination section 21, the tow 2 is given a wedge shape with an increasing thickness in the direction away from the first tow end 22.
Fig. 6 shows a perspective view of the first tow termination section 21 after the cut by the cutting part 11 and the support part 12, and fig. 7 shows a perspective view of the first tow termination section 21 after contact with the first and second tow end compaction parts 31, 32.
As can be seen in the side view in fig. 8, the second tow end compaction device 4 comprises a first and a second tow end compaction part 41, 42, which are
substantially disc shaped. In fig. 8 the first tow end compaction part 41 is shown sectioned vertically and parallel to the tow path. Fig. 9-11 each show a portion of the first tow end compaction part 41 in respective views that are sectioned in a radial direction and perpendicular to the tow path. The first and second tow end compaction parts 41, 42 are arranged to rotate in opposite directions as indicated in fig. 8 with the arrows A41 and A42. Further, the first and second tow end compaction parts 41, 42 have tow contact surfaces 411, 421. A second tow termination section, indicated in fig. 8 with a double arrow 23, is here defined as a section extending from a second tow end 24 and a certain distance along the tow 2. The first and second tow end compaction parts 41, 42 are arranged to move, while rotating, from opposite sides of the tow 2, towards the tow, so that the tow contact surfaces 411, 421 move due to their rotation along with the tow 2. Thereby, the tow contact surfaces 311, 321 contact the second tow termination section 23 so that the tow is given a wedge shape with an increasing thickness in the direction away from the second tow end 24. Alternatively, one of the first and second tow end compaction parts 41, 42 can be rotated but not translated.
The examples described above relate to shaping the ends of strips of fibrous material in the context of automated fibre placement. However, the cutting and compaction techniques can be adapted for shaping the edges of wider sheets of fibrous material, e.g. for use in hand lay-up techniques, as described below with reference to Figures 12 to 15.
Fig. 12 shows a sheet 50 of prepreg material of indeterminate length, having a width of approximately one metre and a thickness of approximately 1.2 mm. The prepreg sheet 50 is laid over an elongate anvil 52. The anvil 52 extends is a direction parallel to a free edge 54 of the sheet 50, across the full width of the sheet 50.
A roller 56 having a cylindrical outer surface 58 is arranged above the anvil 52. The roller 56 is configured to roll across the full width of the prepreg sheet 50 on the anvil 52, i.e. parallel to the free edge 54 of the sheet 50, such that the roller 56 presses the prepreg sheet 50 against the anvil 52 as it rolls. The roller 56 includes a continuous cutting edge 60 that extends in a zigzag manner around the cylindrical outer surface 58 of the roller 56. As the roller 56 is rolled across the prepreg sheet 50, it bears heavily against the sheet 50 on the anvil 52 so that the zigzag cutting edge 60 performs a zigzag cut through the sheet 50, parallel to the free edge 54 of the sheet 50.
Referring to Figure 13, once the roller 56 has cut through the sheet 50, a waste portion 62 of the sheet 50, which includes the free edge 54, is removed and discarded to reveal a new free end portion 64 of the prepreg sheet 50 on the anvil 52. The new free end portion 64 has a zigzag profile defined by the zigzag cut. It will of course be appreciated that the zigzag cut could be performed at any point along the length of the prepreg sheet 50 so that the portions of the sheet 50 on both sides of the cutting roller 56 are usable, thereby eliminating wastage. When viewed in plan, the zigzag profile of the new free end portion 64 of the sheet 50 comprises a series of adjoined triangular projections 66 that taper towards the extremity of the new free end portion 64. When viewed in section, the triangular projections 66 are of substantially uniform thickness moving towards the extremity of the new free end portion 64. A series of inverted triangular spaces 68 are defined between the triangular projections 66.
Referring now to Figure 14, once the new free end portion 64 of zigzag profile has been created, a compaction roller 70 having a smooth cylindrical outer surface 72 is provided above the anvil 52 and rolled along the new zigzag free end portion 64 of the prepreg sheet 50. The compaction roller 70 bears heavily against the sheet 50 on the anvil 52 to compact the new free end portion 64 as it rolls to create a compacted free end portion 73.
The purpose of cutting the zigzag profile is to allow the triangular projections 66 space to spread out laterally, i.e. in plan view, when compacted. Hence, as the new free end portion 64 is compacted by the roller 70, the triangular projections 66 spread laterally into the inverted triangular spaces 68 between projections 66 to create a substantially straight new free edge 74. As shown in Figure 15, the roller 70 is tilted slightly so that its rotational axis 76 is inclined with respect to an upper surface 78 of the sheet 50. Tilting the roller 70 in this way increases the degree of compaction of the new free end portion 64 towards the tips 80 of the triangular projections 66 (Figure 14). This results in a compacted free end portion 73 that tapers towards the new free edge 74 of the sheet 50 when viewed in section.
It should be appreciated that cutting projections 66 that taper in plan view towards the extremity of the new free end portion 64 is advantageous because it results in corresponding spaces 68 between projections 66 that widen towards the extremity of the new free end portion 64. This allows the prepreg material more space to expand laterally when viewed in plan towards the new free edge 74, where compaction is greatest. In other embodiments of the invention, rather than tilting the compaction roller 70, a roller having a frustoconical surface may be used to produce the tapering compacted free end portion 73.
It will be appreciated that the techniques described above with reference to Figures 12-15 are also suitable for cutting strips of fibrous material. Fig. 16 shows a cross-section of a laminate produced without the methods described above. The abrupt section changes at tow or sheet ends lead to stress concentrations which can lead to de-lamination. Fig. 17 shows a cross-section of a laminate produced in accordance with the methods described above, and it can be seen that the abrupt section changes at the tow or sheet ends are removed, and therefore the risk of de- lamination is considerably reduced or removed.