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US 2019/0240934 A1Published application
Fiber-reinforced composites, laminates including the same, and systems and methods for making such laminates
AssigneeFibre Reinforced Thermoplastics B.V.
InventorsRinus Prins, Gerard de Weerd, Nikhil K. E. Verghese
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Abstract
This disclosure includes fiber-reinforced composites, laminates including the same, and systems and methods for making such laminates.
Claims22
A method for forming a laminate from at least first and second fiber-reinforced composites, the method comprising:
- placing the first fiber-reinforced composite onto a substrate using an end effector of a robotic arm at least by translating and/or rotating the end effector relative to the substrate;
- placing the second fiber-reinforced composite onto the substrate using the end effector at least by translating and/or rotating the end effector relative to the substrate, wherein the placing the second fiber-reinforced composite is performed such that the second fiber-reinforced composite overlies or is adjacent to the first fiber-reinforced composite;
- and
- bonding the second fiber-reinforced composite to the first fiber-reinforced composite at least by:
- heating the second fiber-reinforced composite;
- and/or
- applying pressure to the second fiber-reinforced composite;
- wherein at least one of the first and second fiber-reinforced composites comprises:
- a matrix material including a thermoplastic material;
- and
- a non-woven fibrous region comprising a plurality of continuous fibers dispersed in the matrix material;
- wherein the width and the length of the non-woven fibrous region are substantially equal to the width and the length, respectively, of the fiber-reinforced composite;
- and
- wherein the non-woven fibrous region has a mean relative fiber area coverage (RFAC) (%) of from 65 to 90 and a coefficient of variance (COV) (%) of from 3 to 20.
11 more elements
A method for forming a laminate from at least first and second fiber-reinforced composites, the method comprising:
- placing the first fiber-reinforced composite onto a substrate using an end effector of a robotic arm at least by translating and/or rotating the end effector relative to the substrate;
- placing the second fiber-reinforced composite onto the substrate using the end effector at least by translating and/or rotating the end effector relative to the substrate, wherein the placing the second fiber-reinforced composite is performed such that the second fiber-reinforced composite overlies or is adjacent to the first fiber-reinforced composite;
- and
- bonding the second fiber-reinforced composite to the first fiber-reinforced composite at least by:
- heating the second fiber-reinforced composite;
- and/or
- applying pressure to the second fiber-reinforced composite;
- wherein at least one of the first and second fiber-reinforced composites comprises first and second polymeric-rich regions that are disposed on opposing sides of the fiber-reinforced composite, each having less than 10% fibers by volume, wherein:
- the width and the length of each of the polymeric-rich regions are substantially equal to the width and the length, respectively, of the fiber-reinforced composite;
- and
- the sum of the thicknesses of the polymeric-rich regions is from 15% to 25% of the thickness of the fiber-reinforced composite.
8 more elements
A system for forming a laminate from one or more fiber-reinforced composites, each comprising fibers dispersed within a matrix material, the system comprising:
- a heat source configured to provide heat to at least one of the one or more fiber-reinforced composites;
- one or more sensors configured to capture data indicative of at least one of:
- a color of at least one of the one or more fiber-reinforced composites;
- a composition of the matrix material of at least one of the one or more fiber-reinforced composites;
- a composition of the fibers of at least one of the one or more fiber-reinforced composites;
- a thickness of at least one of the one or more fiber-reinforced composites;
- and
- a width of at least one of the one or more fiber-reinforced composites;
- and
- a processor configured to vary a heat provided by the heat source based, at least in part, on data captured by the one or more sensors.
7 more elements
Dependencies are inferred from the claim text.