EP2715742B1 - Semi-finished product in the form of a conductive strip that can be embedded in a composite material, and method for manufacturing such a strip - Google Patents

Description

The invention relates to a semifinished product in the form of an integrated conductive strip in a laminated composite material. The invention is more particularly, but not exclusively, applicable in the aeronautical field for producing elements made of composite materials reinforced by a fibrous reinforcement in a matrix made of a polymer, in order to confer on these structural elements capabilities electrical conduction.

Structural elements made of a laminated composite material with fiber reinforcement and having, moreover, electrical conduction properties are described in the prior art and in particular in the document FR-A-2924894 . This document discloses a laminated structural part comprising, between two fibrous reinforcement plies, a layer comprising a network of conductive cables. Said document also describes a method for obtaining such a structural element, wherein layers of conductive cables are inserted between one or more pairs of structural folds, so as to constitute a dry preform, the assembly then being impregnated with a resin by a resin transfer process to form the matrix and to provide the cohesion of the composite material. This method of obtaining by resin transfer is however not suitable, or proves to be unproductive, for certain parts, particularly thin and large parts, such as fuselage panels, where such a method can not be used. to compete, in terms of productivity, especially with processes implementing draping pre-impregnated folds.

The document US 2006/169481 A1 discloses a flat wire rope 10 having in its cross-section: a first conductive layer 12 made of an electrically conductive material; two electrically insulating layers 14, 16 made of a dielectric material; two connecting layers 28 extending in thickness on either side of the insulating layers outside the semi-product.

The document US 2001/011603 A1 discloses a flat wire rope 11 having in its cross-section: a first conductive layer 11c made of an electrically conductive material; two electrically insulating layers 11b made of a dielectric material completely enclosing the conductive layer and whose width in section is greater than the width of the conductive layer.

1. a. une première couche conductrice constituée d'un matériau électriquement conducteur ;
2. b. deux couches isolantes électriquement constituées d'un matériau diélectrique enserrant complètement la bande conductrice et dont la largeur en section est supérieure à la largeur de la bande conductrice ;
3. c. deux couches de liaison s'étendant en épaisseur de part et d'autre des couches isolantes à l'extérieur du semi-produit.

In order to overcome the drawbacks of the prior art, the invention proposes a semi-finished product according to claim 1, in the form of a strip, capable of being deposited by draping for the constitution of a laminated composite material which semi-product comprises in a cross section and over its entire length:

1. at. a first conductive layer made of a material electrically conductive;
2. b. two electrically insulating layers consisting of a dielectric material completely enclosing the conductive strip and whose section width is greater than the width of the conductive strip;
3. c. two connecting layers extending in thickness on either side of the insulating layers outside the semi-finished product.

Thus, the semi-finished product according to the invention comprises connecting layers making it possible, on the one hand, to ensure the connection of said semi-product with a preform at the time of draping, and on the other hand, the cohesion of the layer. conductive with all the stratification of the composite material, during the cooking or consolidation of the stack constituting the part in which is integrated said conductive layer. Thus, such a part, incorporating a conductive layer, can be achieved by manual or automated draping techniques, implementing pre-impregnated folds.

The invention can be implemented according to the advantageous embodiments, described below, which can be considered individually or in any technically operative combination.

Advantageously, the insulating layers consist of a partially vulcanized elastomer. In addition to ensuring the electrical insulation of the conductive layer, this elastomer layer gives the laminated piece having a conductive layer integrated in said part via a semi-finished product according to the invention, vibroacoustic absorption capabilities and ability to mechanically protect said conductive layer. The partial vulcanization of the insulating layers makes it possible to perfect this vulcanization during the firing of the laminated part incorporating the semi-finished product according to the invention, and thus to ensure a strong cohesion of the conductive layer with the rest of the part.

For example, the insulating layers consist of a partially vulcanized elastomer with a vulcanization rate of the order of 60%. Such partial vulcanization is achieved by heating for a short time. AT As information, the heating temperature is generally of the order of 110 ° C.

Advantageously, the bonding layers consist of a thermosetting glue. Thus, the semifinished product has adequate tackiness for its deposition by draping on a preform.

According to a particular embodiment, the tie layers consist of a thermoplastic polymer. This feature improves the resistance to impact and thermal stresses of the entire laminate in which such a semi-product is integrated.

According to this particular embodiment, the thermoplastic polymer comprises polyetherimide or PEI. Since this polymer is at least partially miscible in many thermosetting and thermoplastic resins, this characteristic makes it possible to ensure a strong cohesion of the conductive layer with the rest of the laminated composite part.

According to another advantageous embodiment, the insulating layers and the bonding layers consist of a partially polymerized thermosetting resin. Thus, the semi-product object of the invention fits perfectly by draping in a lamination of pre-impregnated plies of such a thermosetting resin. The partial polymerization makes it possible at one and the same time to preserve the cohesion of the semifin object of the invention during draping, but also to preserve the flexibility required for this draping operation.

For example, the insulating layers and the bonding layers consist of a partially polymerized thermosetting resin, with a resin polymerization rate of 60 to 80%. Such a partial polymerization is carried out by heating for a short time. By way of information, the heating temperature is of the order of generally around 80 ° C. to 110 ° C., depending on the resins used.

According to one embodiment, alternative to the previous one, the insulating layers and the tie layers consist of a thermoplastic elastomer comprising polyetherimide (PEI). So the semi-product The subject of the invention is capable of being integrated in a stratification constituting a thermoplastic or thermosetting matrix composite.

According to a first variant of the semi-product object of the invention, compatible with all the previous embodiments, the conductive layer consists of a metal foil, a braid or a metal cable. The finesse of such a foil allows the band to marry any type of shape including shapes double curvature.

Advantageously, said metal foil is made of an aluminum alloy which can be obtained by rolling in extremely thin thickness and has a low density. The metal foil may also be made of a copper alloy.

According to a second variant, which is also compatible with the previous embodiments, the conductive layer consists of a plurality of metallic conductors electrically insulated from one another. Thus, on the one hand, several different electrical signals can be transmitted in each of the conductors and the lateral separation of the conductors from one another makes it possible to use thicker conductors without impairing the shaping capacity of the semi-finished product.

1. a recouvrir par une opération de calandrage une bande de matériau électriquement conducteur par deux couches d'élastomère cru ;
2. b vulcaniser l'ensemble constitué lors de l'étape précédente ;
3. c conditionner l'ensemble sous la forme d'un rouleau apte à être utilisé dans une machine à draper.

The invention also relates to a process for manufacturing such a semi-product according to the different embodiments, which semi-product comprises elastomer insulating layers, said method comprising the steps of:

1. covering, by a calendering operation, a strip of electrically conductive material with two layers of raw elastomer;
2. vulcanizing the assembly formed in the previous step;
3. c conditioning the assembly in the form of a roll suitable for use in a draper machine.

Thus, the method which is the subject of the invention makes it possible to manufacture automatically large quantities of semi-finished products, in the form of strips or coils, which coils can be stored and integrated as much as necessary into laminates constituting parts in material composite.

• la figure 1 est une vue en éclaté et en section selon une coupe A-A, définie figure 2, de deux exemples de réalisation d'un semi-produit selon l'invention, figure 1A, selon une variante de réalisation comprenant un clinquant comme couche conductrice et figure 1B selon une variante de réalisation où cette couche conductrice comprend une pluralité de conducteurs ;
• la figure 2 représente selon une vue en élévation, un semi-produit selon une variante de réalisation de l'invention comportant une pluralité de conducteurs dans la couche conductrice ;
• et la figure 3 est un synoptique d'un exemple de procédé de réalisation en continu d'un semi-produit selon l'invention.

The invention is explained below according to its preferred embodiments, which are in no way limiting, and with reference to Figures 1 to 3 , in which :

• the figure 1 is an exploded and sectional view in AA section, defined figure 2 of two embodiments of a semi-finished product according to the invention, Figure 1A according to an embodiment variant comprising a foil as conductive layer and Figure 1B according to an alternative embodiment wherein said conductive layer comprises a plurality of conductors;
• the figure 2 represents in elevational view, a semi-product according to an alternative embodiment of the invention comprising a plurality of conductors in the conductive layer;
• and the figure 3 is a block diagram of an exemplary method for continuously producing a semi-finished product according to the invention.

Figure 1 according to a first embodiment of a semifinished product (101, 102) according to the invention, the latter comprises, at the core, a conductive layer (105, 106) which, according to a first variant (101) of embodiment, may consist of a metal foil (105), Figure 1A , or, in a second variant (102), consisting of a plurality (106) of conductors, Figure 1B arranged in a sheet, preferably in the form of so-called flat metal cables. This conductive layer (105, 106) is sandwiched between two insulating layers (121, 122) made of a dielectric material, preferably, but not exclusively, an elastomer. Advantageously, the semifinished product (101, 102) according to the invention comprises two layers (111, 112) called connection layers having interface characteristics rendering said semi-finished product (101, 102) capable of being draped on a machine. automatic draper and able to form a cohesive interface with fibrous reinforcement layers pre-impregnated following a cooking or consolidation operation. Said bonding layers (111, 112) may be layers attached to the insulating layers, by impregnation of these layers hot or cold, or be an integral part of said insulating layers.

Said insulating layers (121, 122) must be sufficiently thick to ensure complete electrical insulation of the conductive layer (105, 106) of its environment in the finished product, ie after the semi-finished product ( 101, 102) object of the invention has undergone a form of draping, to insert it in the heart of a laminate, and then a cooking or consolidation operation at high temperature and under pressure. This insulation must be total and effective, especially for high voltages, of the order of 3000 volts. Thus, the insulating layers (121, 122) must also be watertight, but retain sufficient flexibility to allow the semi-finished product (101, 102) to be rolled for installation on an automatic draper machine, and to be able to undergo a peel-press operation on the preform without the integrity of said layers being degraded by these mechanical stresses. Finally, once placed in the finished product within a stack of plies reinforced with high performance fibers, the semifinished product (101, 102) of the invention must ensure the transfer of mechanical loads between the folds located on either side of said semi-product, without constituting a weak zone in the stack and without losing its integrity with respect to its electrical insulation and sealing properties.

The answer to all these specifications leads to contradictory properties. Thus, an effective transfer of forces through the semi-product integrated into the finished product leads to favoring the stiffness of the band, while the vibroacoustic and protective absorption properties of the conductors lead to favor the flexibility. The conditions also depend on the thickness of the semi-product (101, 102) and therefore the section of the conductive layer (105, 106) in the heart of said semi-product.

Thus, according to an exemplary embodiment, Figure 1A the conductive layer (105) consists of a foil. Said foil (105) may consist of a copper foil or an aluminum alloy. Since said foil (105) is thin, it is easily adapted to draping operations. By way of non-limiting example, the foil has a width of 20 mm, which for a conductive section of 1 mm ² leads to a thickness (135) of said foil of 0.05 mm. This foil of thin layer can be inserted in thin resin layers, thus, the insulating layers (121, 122) can consist of a thermosetting resin, partially polymerized, for example with a resin polymerization rate of the order of 60 at 80%. This partial polymerization, placing said resin in a so-called half-cooked state, makes it possible to preserve said resin with a certain tack, so that the bonding layers (111, 112) are constituted by the outside of the insulating layers (121, 122 ). The flexibility of the band is then sufficient to be draped, but of sufficient rigidity to support said foil and prevent it from creasing during these draping operations. The subsequent firing of the lamination corresponding to the finished part makes it possible, by the polymerization of the assembly, to produce a strongly cohesive connection of the semi-finished product (101) with the rest of the part.

According to another embodiment, Figure 1B , the conductive layer (106) consists of a plurality of conductors, for example in the form of so-called flat cables. This configuration makes it possible to transit different signals in each of the conductors. In return, the section of each conductor must be sufficient individually so that, compared to the foil (105), this technical solution leads to a substantially greater thickness (136) of each of the conductors. By way of nonlimiting example, each flat cable having a width (146) of 2 mm, a conductive section of 1 mm ² is obtained for a thickness (136) of conductors of 0.5 mm. Also, this embodiment leads to a substantially higher semi-product thickness (102).

Otherwise, figure 2 each flat cable must be spaced transversely from its neighbor by a distance (246) sufficient, typically of the same order of magnitude as the width (146) of the cable. This distance must also be filled by the insulating layers (121, 122).

Returning to Figure 1B according to this embodiment comprising a conductive layer (106) having a plurality of conductors, the insulating layers (121, 122) are advantageously made of a partially vulcanized elastomer. Thus, the flexibility of the insulating layers (121, 122) is controlled at different stages of manufacture of the semi-product (102) and its implementation for the constitution of a laminated structural part, by the vulcanization rate of said layers (121, 122) insulating.

Figure 3 , according to an example of continuous manufacture of the semi-product of the invention, the conductors or the foil are unwound from a roller (306) of great length. After a continuous surface treatment (310), two strips (321, 322) are attached to said conductors or foil by rolling (330) or calendering. Advantageously, the two strips (321, 322) consist of a raw elastomer.

In this green state, the strips (321, 322) of elastomer are very malleable and plastic and, during the calendering operation (330), they perfectly fit the conductors (306) and in particular fill the spaces between said conductors. The assembly thus produced, is then partially vulcanized by passing through a cooking station (340) for example with a vulcanization rate of the order of 60%.

After this partial vulcanization, the insulating elastomer layers achieve a cohesion and elastic behavior that allows to roll (350) the tape on a roll for installation on an automatic draper and the removal of the said tape by draping on a pegy preform.

After having been integrated in the preform, the partially vulcanized semi-finished product is cooked or consolidated with said preform. During this cooking, according to the vulcanization rate of the layers (121, 122) insulating, the rigidity thereof increases, so that a mechanical transfer of forces can be achieved through said semi-product. The presence of polyetherimide in the elastomer constituting said insulating layers (121, 122) allows a strong chemical cohesion between the semi-finished product of the invention and the rest of the stratification, because of the at least partial miscibility of this polymer in both thermoplastic resins and thermosetting resins. Thus a very rigid laminate, allows an effective transfer of forces on either side of the semi-product (101, 102) object of the invention when it is integrated into the final piece. The elasticity of the semi-product gives the structural part incorporating said semi-product vibroacoustic damping capabilities.

The above description and the exemplary embodiments show that the invention achieves the desired objectives, in particular it allows the continuous and economical manufacture of semifinished products (101, 102) ready to be draped with the aid of an automatic machine and integrable on demand in the lamination of a composite piece with fibrous reinforcement, giving said room capabilities for routing a signal or electrical power.

Claims (11)

1. Semifinished product in the form of a band (101, 102), capable of being deposited by drape forming in order to form a laminated composite material having fibrous reinforcement, the semifinished product comprises, along a cross section and over its entire length:

   a. a first conductive layer (105, 106) formed of an electrically conductive material;

   b. two electrically insulating layers (121, 122) formed of a dielectric material completely enclosing the conductive layer (105, 106), the sectional width of which is greater than the width of the conductive layer;

   c. two bonding layers (111, 112) extending in thickness on either side of the insulating layers (121, 122) on the outside of the semifinished product, the said two bonding layers exhibiting interfacial characteristics such that the semifinished product is capable of forming a cohesive interface with preimpregnated fibrous reinforcing layers subsequent to a curing or consolidation operation.
2. Semifinished product according to Claim 1, characterized in that the insulating layers (121, 122) are formed of a partially vulcanized elastomer.
3. Semifinished product according to Claim 2, characterized in that the bonding layers (111, 112) are formed of a thermosetting adhesive.
4. Semifinished product according to Claim 2, characterized in that the bonding layers (111, 112) are formed of a thermoplastic polymer.
5. Semifinished product according to Claim 4, characterized in that the thermoplastic polymer constituting the bonding layers (111, 112) comprises polyetherimide.
6. Semifinished product according to Claim 1, characterized in that the insulating layers (121, 122) and the bonding layers (111, 112) are formed of a partially polymerized thermosetting resin.
7. Semifinished product according to Claim 1, characterized in that insulating layers (121, 122) and the bonding layers (111, 112) are formed of a thermoplastic elastomer comprising polyetherimide.
8. Semifinished product according to Claim 1, characterized in that the conductive layer (105) is formed of a metal foil.
9. Semifinished product according to Claim 8, characterized in that the foil (105) is formed of an aluminium alloy.
10. Semifinished product according to Claim 1, characterized in that the conductive layer is formed of a plurality (106) of metal conductors electrically insulated from one another.
11. Process for the production of a semifinished product according to Claim 2, characterized in that it comprises stages consisting in:

    a. covering, by a calendering operation (330), a band (306) of electrically conductive material with two layers (321, 322) of raw elastomer;

    b. partially vulcanizing (340) the combination formed during the preceding stage;

    c. packaging (350) the combination in the form of a roll capable of being used in a draping machine.

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