Patent ID: 12251891

DETAILED DESCRIPTION

A fiber feeding device, a method of laminating fibers, and a method of molding a composite material according to implementations of the present invention will be described with reference to the accompanying drawings.

(First Implementation)

(Structure and Function of a Fiber Feeding Device)

FIG.1is a front view showing structure of a fiber feeding device according to the first implementation of the present invention, andFIG.2is a perspective view of main elements of the fiber feeding device shown inFIG.1.

The fiber feeding device1selects at least one desired tape T from previously arrayed tapes T without overlapping the tapes T with each other in the width direction of the tapes T, and then feeds out only the selected at least one desired tape T. Each tape T to be fed out by the fiber feeding device1is made of fibers or prepreg, which is material of an FRP. That is, the tapes T are prepreg tapes or dry tapes. A prepreg tape is prepreg, consisting of fibers impregnated with resin, in the form of a tape. A dry tape is fibers, which have not been impregnated with resin, in the form of a tape.

An FRP can be molded by laminating prepreg tapes to produce a laminated body of the prepreg tapes, and subsequently, curing resin included in the laminated body of the prepreg tapes. Alternatively, an FRP can also be molded by an RTM method in which dry tapes are laminated into a laminated body of the dry tapes, and subsequently, the laminated body of the dry tapes is impregnated with resin and the resin is cured.

Therefore, the fiber feeding device1can be built in a lamination head of an AFP apparatus2which automatically laminates the tapes T. In other words, the fiber feeding device1can be attached to the lamination head of the AFP apparatus2as an attachment.

The AFP apparatus2includes a table3for laminating the tapes T, a compaction roller4for pushing the tapes T towards the table3, and a moving mechanism5for moving the compaction roller4relatively to the table3. When the lower surface of the tapes T is not flat, a jig J, such as a lower mold, may be placed on the table3so that the tapes T can be laminated on the jig J, as exemplified byFIG.1.

When the compaction roller4is moved relatively to the table3in a state where the tape T or the tapes T selected by the fiber feeding device1have been pushed on the table3side by the compaction roller4, the tape T or the tapes T can be fed out in a direction opposite to the moving direction of the compaction roller4while giving tension to the tape T or the tapes T. Therefore, the moving mechanism5of the AFP apparatus2is configured to move at least one of the table3and the compaction roller4. When the compaction roller4is moved by the moving mechanism5, the whole lamination head including the compaction roller4may be moved relatively to the table5.

In order to feed out the tapes T from the compaction roller4toward the table3, it is necessary to move the compaction roller4relatively to the table3in direction opposite to a feeding direction of the tapes T. In order to feed out the tapes T from the compaction roller4along a curved line, it is necessary to rotate the compaction roller4relatively to the table3. It is also necessary to move the compaction roller4relatively to the table3in the thickness direction of the tapes T since the thickness of the laminated body of the tapes T increases during the lamination as the tapes T are laminated on the table3.

Therefore, the moving mechanism5is configured to not only linearly move the compaction roller4relatively to the table3in three axis directions orthogonal to each other but rotate the compaction roller4relatively to the table3. In order to move the compaction roller4relatively to the table3in the thickness direction of the tapes T, the whole lamination head may be moved, or only the compaction roller4may be moved without moving the lamination head.

In order to laminate the tape T or the tapes T by the AFP apparatus2as described above, the tape T or the tapes T to be laminated have to be fed out to the compaction roller4. Therefore, the tape T or the tapes T selected from the arrayed tapes T by the fiber feeding device1are fed out towards the compaction roller4included in the lamination head of the AFP apparatus2.

The tapes T supplied to the fiber feeding device1have been arrayed so that the tapes T may not be overlapped with each other in the width direction. Therefore, when at least two tapes T are selected to be fed out, the selected tapes T are also fed out in a state where the selected tapes T are arrayed so that the selected tapes T may not be overlapped with each other in the width direction. Accordingly, the tapes T fed out from the fiber feeding device1are simultaneously pushed by the common and single compaction roller4. In other words, the AFP apparatus2includes the single lamination head having the compaction roller4.

Note that, when the tapes T are allowed to be laminated with a clearance gap or clearance gaps, i.e., when the width of an area in which the tapes T should be laminated is wider than the sum total of the widths of the tapes T fed out towards the table3from the AFP apparatus2including the fiber feeding device1, the tapes T may be fed out with a clearance gap or clearance gaps from the fiber feeding device1towards the compaction roller4. Henceforth, explanation will be given for an example of case where the tapes T are fed out without any clearance gap and overlap unless extents of the clearance gap and overlap are negligible errors when the tapes T are simultaneously fed out from the fiber feeding device1.

FIG.3andFIG.4each shows an example of the partial tapes T selected from the arrayed tapes T supplied to the fiber feeding device1shown inFIG.1.

The tapes T having desired widths can be supplied to the fiber feeding device1. Accordingly, when the wide tapes T are supplied to the fiber feeding device1as exemplified byFIG.3, the total width of the selected tapes T becomes wide even when the number of the tapes T selected and fed out by the fiber feeding device1is not changed. Meanwhile, when the narrow tapes T are supplied to the fiber feeding device1as exemplified byFIG.4, the total width of the selected tapes T becomes narrow even when the number of the tapes T selected and fed out by the fiber feeding device1is not changed.

On the other hand, when the number of the tapes T selected by the fiber feeding device1is changed, the total width of the selected tapes T changes even when the width of each tape T supplied to the fiber feeding device1is not changed. Accordingly, the tape T or the tapes T of a wide variety of total widths can be fed out from the fiber feeding device1to the compaction roller4by changing both of the width of each tape T supplied to the fiber feeding device1and the number of the tapes T selected by the fiber feeding device1. As a result, the tape T or the tapes T whose total width changes can be laminated, and thereby an FRP having a more complicated form can be mold.

The arrayed tapes T supplied to the fiber feeding device1can be produced by the fiber arranging device6having desired configuration. For example, interchangeable bobbins7of the tapes T each having a specific width may be set as exemplified byFIG.1while the tapes T supplied from the bobbins7can be disposed in the width direction by the fiber arranging device6. In this case, the width of each tape T supplied to the fiber feeding device1can be changed by exchanging a bobbin7for another bobbin7of the tape T having a different width.

When width adjusting devices8for changing the widths of the tapes T respectively are disposed in the fore stage of the fiber arranging device6as exemplified byFIG.1, not only the widths of the tapes T supplied from the bobbins7can be changed to desired widths respectively to be supplied to the fiber feeding device1, but the widths of the tapes T can be changed during feeding of the tapes T. That is, the tapes T whose widths are not constant can be supplied to the fiber feeding device1.

As an example of a device for expanding the width of a dry tape, an opening apparatus disclosed by the pamphlet of the international publication No. 2010/137525 is known. In addition, a device, which can narrow the width of not only a dry tape but a prepreg tape, disclosed by Japanese Patent Application Publication JP2020-93454A may be used as the width adjusting device8.

Therefore, the tapes T having widths different from each other may be arrayed without overlapping the tapes T with each other in the width direction to be supplied to the fiber feeding device1although the examples shown inFIG.3andFIG.4each shows a case where the widths of the tapes T simultaneously supplied to the fiber feeding device1are almost same as each other. The tapes T whose widths are not constant may also be supplied to the fiber feeding device1.

When the total width of the tapes T is narrowed by reducing the number of the tapes T fed out from the fiber feeding device1, it is necessary to exclude the tape T from the target to be fed out as non-selected tape T in order from the tape T on a lateral side or the tapes T on both lateral sides in order to prevent any non-negligible gap from arising between the tapes T fed out. For example, in each of the examples shown inFIG.3andFIG.4, the sixteen tapes T are selectable while the twelve tapes T on both lateral sides are made non-selected, and thereby the four tapes T closer to the center are selectively fed out. As a matter of course, the total width of the tapes T may be narrowed by making the tape T non-selected in order from one side instead of making the tapes T non-selected in order from both sides.

Not only one tape T is made selectable but a set of tapes T may be made selectable. That is, the tapes T supplied from the fiber arranging device6to the fiber feeding device1can be divided into groups so that a group including tapes T can be selected.

Henceforth, explanation will often be given for an example of case where the sixteen tapes T supplied from the fiber arranging device6to the fiber feeding device1are classified into four groups, consisting of the first group having the two tapes TA, the second group having the two tapes TB, the third group having the four tapes TC and the fourth group having the eight tapes TD, from the side close to the center towards both lateral sides, as exemplified byFIG.2, so that the groups can be selected or non-selected. As a matter of course, a group to which only a single tape T belongs may be made. That is, groups each having at least one tape T can be selected or non-selected, besides the example described below.

The above-mentioned fiber feeding device1which feeds out the tapes T selectively can be composed of brakes9, guide rollers10, a belt conveyor11, a roller moving mechanism12, a cutter13, an auxiliary roller14and a controller15. The brake9and the guide roller10are disposed for each selectable group. Therefore, when the tapes T are classified into the four groups of the tapes TA, TB, TC and TD, the four brakes9A,9B,9C and9D, and the four guide rollers10A,10B,10C and10D are included in the fiber feeding device1.

The brake unit consisting of the brakes9is configured to stop feeding out of tapes T, belonging to at least one group, whose feeding out should be stopped, if any, out of the arrayed tapes T supplied to the fiber feeding device1. In the illustrated example, each brake9is configured to stop the feeding out of the corresponding tape T by pinching the corresponding tape T between a brake roller16and a columnar pressing member17. Meanwhile, each brake9is configured to release the stopping of feeding out of the corresponding tape T by pulling apart the pressing member17from the brake roller16relatively.

The pressing member17may have not only a circular columnar form but a desired form, such as a prismatic columnar form. When the pressing member17is composed of a rotatable roller, sudden stopping of the tape T can be avoided.

The pressing member17can be moved relatively to the brake roller16using a desired driving mechanism. For example, at least one of the pressing member17and the brake roller16may be reciprocated linearly using a machine element for reciprocating an object linearly like a ball screw, gears, such as a rack-and-pinion, or a cylinder mechanism, such as an air cylinder, a hydraulic cylinder, or an electric cylinder, having a cylinder tube and a piston reciprocated inside the cylinder tube. Alternatively, at least one of the pressing member17and the brake roller16may be reciprocated along an arc like a pendulum by fixing at least one of the pressing member17and the brake roller16to one end of a shaft rotated by a gear or a motor, or fixing the columnar pressing member17, of which the cross section is not circular, to a rotation shaft of a gear or a motor.

The guide roller unit consisting of the guide rollers10functions as a guide mechanism which guides feeding out of the arrayed tapes T supplied to the fiber feeding device1. Each guide roller10is configured to approach toward the belt conveyor11and to retract from the belt conveyor11by driving of the roller moving mechanism12. Accordingly, each tape T guided by the guide roller10which approached the belt conveyor11is fed out in a state that the tape T is pinched between the belt conveyor11and the guide roller10while each tape T guided by the guide roller10which retracted from the belt conveyor11is not contact with the belt conveyor11.

Therefore, each guide roller10need not have power. Specifically, as long as the guide roller10is brought close to the belt conveyor11so that the distance between the guide roller10and the belt conveyor11may become not more than the thickness of the tape T, the tape T is pinched between the belt conveyor11and the guide roller10with sufficient pressure. Thereby, the power of the belt conveyor11is transmitted to the guide roller10through the tape T by the frictional force between the tape T and each of the belt conveyor11and the guide roller10. Accordingly, each guide roller10can be rotated even when the guide roller10is not powered by a motor or the like. Therefore, all the guide rollers10can be rotated only by the power of the belt conveyor11. As a result, the number of power sources, such as motors, required for the fiber feeding device1can be reduced.

Nevertheless, each of the guide rollers10may be powered by a motor or the like so that each tape T can be fed out by both the guide roller10and the belt conveyor11. That is, each guide roller10may be a power roller similar to a feed roller included in the conventional typical AFP apparatus. In that case, each tape T can be fed out with sufficient power, and thereby each tape T can be fed out without any difficulty even under conditions under which large power is required for pulling out the tape T from the fiber arranging device6.

On the other hand, also when the tape T is guided by the guide roller10without bringing the tape T into contact with the belt conveyor11by retracting the guide roller10from the belt conveyor11so that the distance between the guide roller10and the belt conveyor11may become larger than the thickness of the tape T, the tape T pushed towards the table3by the compaction roller4can be fed out by moving the compaction roller4relatively to the table3; as mentioned above.

Specifically, as long as the tape T is pushed by the compaction roller4, the tape T can be fed out since tension acts on the tape T due to the frictional force between the tape T, being fed out and pushed by the compaction roller4, and each of the compaction roller4and the jig J or the tape T laminated on the lower side. In this case, the guide roller10retracted from the belt conveyor11is also rotated due to the frictional force between the guide roller10and the tape T being fed out and pushed by the compaction roller4.

Therefore, the tape T required to be pinched between the guide roller10and the belt conveyor11to be fed out is each tape T whose end has not reached the compaction roller4, out of the tapes T of which feedings are not stopped by the brakes9.

Note that, each tape T having reached the compaction roller4may be pinched between the guide roller10and the belt conveyor11to be fed out. Nevertheless, not only when the feeding speed of the belt conveyor11differs from the relative speed of the compaction roller4to the table3, but when the feeding speeds of the tapes T fed out from the compaction roller4differs from each other, slack and excess tension may arise in the tapes T, having reached the compaction roller4, pinched by the belt conveyor11and at least one of the guide rollers10. Therefore, in such a case, it is appropriate to pinch only tapes T, which have not reached the compaction roller4, by the belt conveyor11and at least one of the guide rollers10to be fed out. Conversely, it is appropriate to pull the tapes T, having reached the compaction roller4, away from the belt conveyor11so as not to be powered by the belt conveyor11.

The roller moving mechanism12is configured to move the guide rollers10so that at least one target guide roller10may approach the belt conveyor11or retract from the belt conveyor11, as mentioned above. The guide roller10which should be brought close to the belt conveyor11is each guide roller10for guiding the tape T whose end has not reached the compaction roller4, among the tapes T of which feedings are not stopped by the brakes9, as mentioned above. On the contrary, the guide roller10which should be retracted from the belt conveyor11is each guide roller10for guiding the tape T of which feeding is stopped by the brake9or each guide roller10for guiding the tape T whose end has reached the compaction roller4, among the tapes T of which feedings are not stopped by the brakes9.

Accordingly, whether the guide rollers10should be brought close to the belt conveyor11or retracted from the belt conveyor11are determined based on the operating conditions of the brakes9and the positions of the ends of the tapes T respectively. This determination is performed by the controller15.

Therefore, the roller moving mechanism12is configured to bring, close to the belt conveyor11, at least one guide roller10which should be brought close to the belt conveyor11, selected by the determination in the controller15, and retract, from the belt conveyor11, the other guide roller10or guide rollers10which are not selected by the controller15. As a matter of course, the determination in the controller15may be selecting at least one guide roller10which should be retracted from the belt conveyor11and making the other guide roller10or guide rollers10non-selected. This determination is equivalent to the determination for selecting at least one guide roller10which should be brought close to the belt conveyor11.

More specifically, the roller moving mechanism12receives control signals from the controller15. Then, when at least one guide roller10which should be brought close to the belt conveyor11has been selected, the roller moving mechanism12pushes the selected guide roller10or guide rollers10to the belt conveyor11so that the tape T or tapes T guided by the selected guide roller10or guide rollers10, out of all the tapes T may be pinched between the belt conveyor11and the selected guide roller10or guide rollers10.

That is, the roller moving mechanism12brings the at least one guide roller10, selected from the guide rollers10, close to the belt conveyor11so that the interval between the at least one selected guide roller10and the belt conveyor11may become not more than the thickness of each tape T. Thereby, each tape T, of which feeding out is not stopped by the corresponding brake9, which has not reached the compaction roller4can be pinched between the corresponding guide roller10and the belt conveyor11to be fed out. As a matter of course, all the guide rollers10may be selected so that all the tapes T may be pinched between the guide rollers10and the belt conveyor11to be fed out.

Meanwhile, the roller moving mechanism12keeps the other non-selected guide roller10or guide rollers10retracted from the belt conveyor11. Specifically, when all the guide rollers10are not selected as guide rollers10which should be brought close to the belt conveyor11, and therefore there is non-selected at least one guide roller10, the roller moving mechanism12positions the non-selected at least one guide roller10away from the belt conveyor11so that at least one tape T guided by the non-selected at least one guide roller10may not be pinched between the non-selected at least one guide roller10and the belt conveyor11.

Thereby, each tape T of which feeding is stopped by the corresponding brake9is positioned away from the belt conveyor11so that power may not be transmitted from the belt conveyor11, and is kept stopped. In addition, each tape T which has reached the compaction roller4is also positioned away from the belt conveyor11, and thereby is not powered by the belt conveyor11. Accordingly, each tape T which has reached the compaction roller4can be fed out toward the table3with a relative speed of the compaction roller4to the table3, which is independent from the conveying speed of the belt conveyor11. Furthermore, the tapes T which have reached the compaction roller4can be fed out with speeds independent from each other.

The roller moving mechanism12can be composed of desired driving mechanisms. In the illustrated example, the roller moving mechanism12is composed of cylinder mechanisms12A, such as air cylinders, hydraulic cylinders, or electric cylinders, each having a cylinder tube and a piston reciprocated inside the cylinder tube. That is, the roller moving mechanism12is configured to reciprocate the rotation shafts of the guide rollers10using the cylinder mechanisms12A respectively. The roller moving mechanism12may also be configured to linearly reciprocate the rotation shafts of the guide rollers10toward the belt conveyor11using machine elements for linearly reciprocating objects like gears, such as rack-and-pinions, or ball screws.

As another example of configuration of the roller moving mechanism12, each of the rotation shafts of the guide rollers10may be hung by a wire, a chain, or a belt so that the rotation shafts of the guide rollers10can be elevated or lowered respectively. Alternatively, each of the rotation shafts of the guide rollers10may be supported by a cam so that the rotation shafts of the guide rollers10can be elevated or lowered by rotations of the cams respectively. That is, the tapes T may be pushed to the belt conveyor11by the weight of the guide rollers10respectively as the above-mentioned examples. As still another example, the roller moving mechanism12may be configured to reciprocate the rotation shafts of the guide rollers10along arcs like pendulums respectively. In that case, the rotation shafts of the guide rollers10may be rotatably coupled to the ends of shafts whose inclination angles are changed by gears or motors, respectively, for example.

The belt conveyor11is a conveyance device for feeding out at least one tape T guided by at least one guide roller10, which does not guide the tape T of which feeding should be stopped by the brake9, selected from all the guide rollers10when the at least one guide roller10is selected. The at least one tape T to be fed out by the belt conveyor11is pinched between the selected at least one guide roller10and the belt conveyor11.

The belt conveyor11can be composed of a belt18, a driving roller19, pulleys20, a suction chuck21and backup rollers22. The belt18has regularly-disposed many through holes. The driving roller19powers and moves the belt18. The pulleys20support the belt18so that a track may be formed by the belt18. The suction chuck21sucks air through the holes of the belt18. The backup rollers22support the belt18from the inner side of the belt18. That is, the belt conveyor11can include the suction chuck21of a vacuum type.

FIG.5is a perspective view showing an example of structure of the suction chuck21shown inFIG.1, andFIG.6is a schematic view showing an aspect of feeding out the tapes T while sucking the tapes T by the suction chuck21shown inFIG.5.

As exemplified byFIG.5, a suction box forming negative pressure can be disposed as the suction chuck21behind the belt18having the holes. In the example shown inFIG.5, the suction chuck21has five suction openings23, a hollow housing24and an exhaust hose25. The housing24has concave portions for disposing the backup rollers22and one of the pulleys20while the suction openings23for vacuum chucking open at portions of the housing24other than the concave portions. The exhaust hose25is coupled to the housing24in order to couple the housing24to an ejector.

Accordingly, each tape T pushed on the belt18by the corresponding guide roller10can be sucked to the belt18by the suction chuck21sucking air through the holes of the belt18, as shown inFIG.6. In this case, each tape T sucked to the belt18can be pulled away from the belt18after the tape T has passed the suction area by the suction chuck21. Therefore, it is appropriate to determine the suction area by the suction chuck21so that each tape T may smoothly separate from the belt18just before the compaction roller4.

The portions forming the suction openings23of the housing24have no rigidity except for the edges of the suction openings23. Therefore, when the guide rollers10and the cutter13are pressed to the belt18, the belt18may deform to a non-negligible extent at portions distant from the edges of the suction openings23. Accordingly, when the suction chuck21is included in the belt conveyor11, it is appropriate to dispose the backup rollers22at positions behind the belt18, opposite to the guide rollers10and the cutter13respectively in order to support the belt18.

Namely, it is appropriate to support the belt18by the backup rollers22from the inner side so that the belt18may not be dented in the pressing direction of the guide rollers10and the cutter13even when the guide rollers10and the cutter13are pressed on the belt18, and thereby the pressure applied from the guide rollers10and the cutter13to the belt18and the tapes T may not decrease. In this case, each tape T pressed on the belt18by the corresponding guide roller10is pinched and fed out by the corresponding guide roller10and the corresponding backup roller22together with the belt18. In the illustrated example, the driving roller19for moving the belt18also serves as the backup roller22.

When the suction chuck21having sufficient suction force is included in the belt conveyor11, not only each tape T pressed on the belt18by the guide roller10but each tape T guided by the guide roller10away from the belt conveyor11can be sucked. Accordingly, not only each tape T pressed on the belt18by the guide roller10but each tape T near the belt18can be prevented from deviating in the width direction of the tape T by the suction chuck21sucking each tape T.

That is, when the suction chuck21having sufficient suction force is included in the belt conveyor11, the belt conveyor11can function as not only a feeding device for conveying the tapes T, of which ends have not reached the compaction roller4, while sucking the tapes T, but a guide device for preventing all the tapes T guided by the guide rollers10, including each tape T of which feeding out is stopped by the brake9, from deviating in the width direction.

In other words, the belt conveyor11equipped with the suction chuck21functions as a guide device for keeping the intervals of the tapes T arrayed by the fiber arranging device6. Accordingly, even when the tapes T having various widths are supplied with various intervals from the fiber arranging device6to the fiber feeding device1, a selected part or all of the tapes T can be fed out toward the compaction roller4while keeping the intervals of the tapes T determined by the fiber arranging device6.

Note that, even when the tapes T consist of breathable dry tapes, not only each dry tape pressed on the belt18by the guide roller10can be vacuum-chucked, but dry tapes including each dry tape away from the belt18can be sucked for preventing the dry tapes from deviating in the width direction as long as the suction chuck21has the sufficient suction force.

Meanwhile, when the tapes T consist of prepreg tapes, each prepreg tape pressed on the belt18by the guide roller10adheres to the belt18due to the tack even without the vacuum chucking. Accordingly, when a certain degree of deviation of each prepreg tape in the width direction may be accepted, the suction chuck21may be omitted. In that case, the belt18of the belt conveyor11may have no holes.

The cutter13is a tool for cutting at least one tape T which has been fed out in a certain ply. As mentioned above, when the suction chuck21is included in the belt conveyor11, it is appropriate to dispose the backup roller22, for supporting the belt18, at the position behind the belt18, corresponding to the cutter13so that the belt18may not deform even when the cutter13is pressed on the belt18.

In the illustrated example, the single cutter13is common to all the tapes T. As a matter of course, the cutter13may be disposed for each group. When the cutter13is disposed for each group, the number of the tapes T to be laminated in a same ply can be changed without cutting all the tapes T. The cutting edge formed on the tip of the cutter13may be reciprocated linearly or along an arc.

The auxiliary roller14is disposed in order to change the feeding direction of the tapes T while keeping the tension of the tapes T, as needed. In the illustrated example, the auxiliary roller14is disposed in front of the fiber feeding device1in order to direct the feeding direction of the tapes T supplied from the fiber arranging device6to the brake rollers16of the brakes9.

The controller15integrally controls the fiber feeding device1. Typical control targets in the fiber feeding device1are switching of ON/OFF of each brake9, movement of each guide roller10by driving the roller moving mechanism12, operation of the cutter13, and actuation of the belt conveyor11and the suction chuck21.

Accordingly, the controller15has a function to store an integral control program for integrally controlling these control targets, and to control the respective control targets according to the stored integral control program. That is, the controller15has a function to output control signals to each control target according to the integral control program. As a matter of course, the controller15may be configured to bi-directionally communicate with each control target so that the controller15can recognize the operation mode and the like of each control target.

As mentioned above, whether each guide roller10should be moved in the direction approaching the belt conveyor11or the direction away from the belt conveyor11is determined based on whether the brake9corresponding to the tape T guided by the guide roller10is in the ON state or the OFF state as well as whether the tape T guided by the guide roller10has reached the compaction roller4.

Whether the tape T guided by each guide roller10has reached the compaction roller4can be determined based on an elapsed time from a desired trigger signal, such as an elapsed time after switching the corresponding brake9off or an elapsed time after pinching the tape T by the guide roller10and the belt conveyor11. In that case, the controller15can automatically determine whether the tape T guided by each guide roller10has reached the compaction roller4, with reference to the control program.

Alternatively, the feeding length of each tape T may be measured, and whether the tape T guided by each guide roller10has reached the compaction roller4may be automatically determined base on the feeding length of the corresponding tape T. In that case, a function to acquire the feeding length of each tape T from a controller of the bobbins7, the fiber arranging device6or the width adjusting devices8, or a function to acquire the feeding length of each tape T from the belt conveyor11as a rotation amount of a motor for rotating the driving roller19can be provided with the controller15so that the controller15can determine whether each tape T has reached the compaction roller4, based on the feeding length of the corresponding tape T. Otherwise, sensors including rollers or the like for detecting the feeding lengths of the tapes T respectively may be disposed at desired positions so that the controller15can acquire the feeding lengths of the tapes T from the sensors respectively.

At the time when the end of the tape T guided by each guide roller10reaches the compaction roller4, it is necessary to move the compaction roller4to apply pressure on the tape T. On the contrary, at the time when at least one tape T has been laminated in each ply, and therefore the at least one tape T is cut by the cutter13, it is appropriate to operate the brake9or the brakes9to stop the feeding out of the at least one tape T to be cut.

Accordingly, a function to acquire necessary information from the control unit5A of the moving mechanism5which moves the compaction roller4relatively to the table3can be provided with the controller15so that the fiber feeding device1may interlock with the moving mechanism5. Conversely, the controller15of the fiber feeding device1may be a part of the control unit5A which controls the moving mechanism5so that the controller15can bi-directionally communicate with the control unit5A since the fiber feeding device1itself could be built in the lamination head of the AFP apparatus2.

Next, a concrete example of controlling the fiber feeding device1by the controller15will be described.

FIG.7shows an example of control signals output from the controller15in case of feeding out only the two tapes TA, belonging to the first group shown inFIG.1, from the fiber feeding device1to the compaction roller4.FIG.8is a schematic view showing a state of the fiber feeding device1controlled by the control signals shown inFIG.7.

For example, in case of feeding out only the two tapes TA belonging to the first group shown inFIG.1from the fiber feeding device1to the compaction roller4, the control signals shown inFIG.7can be generated by the controller15, and output to the brakes9and the roller moving mechanism12.

Specifically, as shown inFIG.7, the control signal for switching the operating mode off can be output to each of the brakes9A for stopping the movement of the tapes TA belonging to the first group while the control signal for switching the operating mode on can be output to each of the brakes9B,9C and9D for stopping the movement of the remaining tapes TB, TC and TD belonging to the second to the fourth groups. Thereby, as shown inFIG.8, only the tapes TA belonging to the first group to which the brakes9A do not work are fed out while the tapes TB, TC and TD belonging to the second to the fourth groups stop by the operation of the brakes9B,9C and9D.

In addition, the control signals shown inFIG.7can be output from the controller15to the roller moving mechanism12so that the guide roller10A for guiding the tapes TA belonging to the first group may activate the operation for pushing the tapes TA belonging to the first group on the belt conveyor11while the remaining guide rollers10B,10C and10D for guiding the remaining tapes TB, TC and TD belonging to the second to the fourth groups may not activate the operation for pushing the remaining tapes TB, TC and TD belonging to the second to the fourth groups on the belt conveyor11respectively.

Thereby, the roller moving mechanism12drives, and only the guide roller10A for guiding the tapes TA belonging to the first group is brought close to the belt conveyor11, as shown inFIG.8. Therefore, only the tapes TA belonging to the first group are pinched by the guide roller10A and the belt conveyor11supported by the backup roller22which doubles the driving roller19. As a result, only the tapes TA belonging to the first group before reaching the compaction roller4can be fed out toward the compaction roller4by the power of the belt conveyor11.

Meanwhile, since the guide rollers10B,10C and10D for guiding the tapes TB, TC and TD belonging to the second to the fourth groups do not push the tapes TB, TC and TD belonging to the second to the fourth groups on the belt conveyor11respectively, the tapes TB, TC and TD belonging to the second to the fourth groups are not powered by the belt conveyor11. Therefore, excess tension does not arise in each of the tapes TB, TC and TD, belonging to the second to the fourth groups, of which the movement has been stopped by the brakes9B,9C and9D respectively.

FIG.9shows an example of control signals output from the controller15in case of feeding out only the two tapes TA, belonging to the first group shown inFIG.1, and the two tapes TB, belonging to the second group, from the fiber feeding device1to the compaction roller4.FIG.10is a schematic view showing a state of the fiber feeding device1controlled by the control signals shown inFIG.9.

In case of feeding out only the two tapes TA belonging to the first group and the two tapes TB belonging to the second group as shown inFIG.1from the fiber feeding device1to the compaction roller4, the control signals shown inFIG.9can be generated by the controller15, and output to the brakes9and the roller moving mechanism12.

Specifically, as shown inFIG.9, the control signal for switching the operating mode off can be output to each of the brakes9A for stopping the movement of the tapes TA belonging to the first group and the brakes9B for stopping the movement of the tapes TB belonging to the second group while the control signal for switching the operating mode on can be output to each of the brakes9C and9D for stopping the movement of the remaining tapes TC and TD belonging to the third and fourth groups. Thereby, as shown inFIG.10, only the tapes TA belonging to the first group and the tapes TB belonging to the second group to which the brakes9A and9B do not work are fed out while the tapes TC and TD belonging to the third and fourth groups stop by the operation of the brakes9C and9D.

In addition, the control signals shown inFIG.9can be output from the controller15to the roller moving mechanism12so that the guide rollers10A and10B for guiding the tapes TA and TB belonging to the first and second groups may activate the operation for pushing the tapes TA and TB belonging to the first and second groups on the belt conveyor11respectively while the remaining guide rollers10C and10D for guiding the remaining tapes TC and TD belonging to the third and fourth groups may not activate the operation for pushing the remaining tapes TC and TD belonging to the third and fourth groups on the belt conveyor11respectively.

Thereby, the roller moving mechanism12drives, and only the guide rollers10A and10B for guiding the tapes TA and TB belonging to the first and second groups respectively are brought close to the belt conveyor11, as shown inFIG.10. Therefore, only the tapes TA and TB belonging to the first and second groups are pinched by the guide rollers10A and10B, and the belt conveyor11supported by the backup rollers22respectively. As a result, only the tapes TA and TB belonging to the first and second groups before reaching the compaction roller4can be fed out toward the compaction roller4by the power of the belt conveyor11respectively.

Meanwhile, since the guide rollers10C and10D for guiding the tapes TC and TD belonging to the third and fourth groups do not push the tapes TC and TD belonging to the third and fourth groups on the belt conveyor11respectively, the tapes TC and TD belonging to the third and fourth groups are not powered by the belt conveyor11. Therefore, excess tension does not arise in each of the tapes TC and TD, belonging to the third and fourth groups, of which the movement has been stopped by the brakes9C and9D respectively.

As the examples shown inFIG.7toFIG.10, tapes T belonging to at least one desired group can be selected from the tapes TA, TB, TC and TD belonging to the groups, to be fed out towards the compaction roller4, by the control of the brakes9A,9B,9C and9D, and the guide rollers10A,10B,10C and10D interlocked with each other by the controller15. In other words, the number of the tapes T simultaneously fed out towards the compaction roller4can be changed.

As mentioned above, once the tapes T fed out from the fiber feeding device1have reached the compaction roller4, it is appropriate to pull apart the tapes T from the belt conveyor11since the feeding speeds of the tapes T are fixed according to the relative speed of the compaction roller4to the table3. Accordingly, it is necessary to control the fiber feeding device1by the controller15in which the control program has been installed also after the tapes T fed out from the fiber feeding device1have reached the compaction roller4.

FIG.11shows an example of control states of the AFP apparatus2including the fiber feeding device1in case of laminating one ply by feeding out only the two tapes TA, belonging to the first group shown inFIG.1, and the two tapes TB, belonging to the second group, from the fiber feeding device1to the compaction roller4.

As shown inFIG.11, in the initial state of the AFP apparatus2including the fiber feeding device1, all the brakes9A,9B,9C and9D are made the ON states so that any of the tapes TA, TB, TC and TD belonging to all the groups may not be fed out. Meanwhile, the pressurization by each of the guide rollers10A,10B,10C and10D, the cutter13, and the compaction roller4is made the OFF state.

When only the tapes TA and TB belonging to the first and second groups are fed out, the brakes9A and9B for stopping the movement of the tapes TA and TB belonging to the first and second groups respectively are switched off under the control by the controller15while the press operation onto the belt conveyor11of the tapes TA and TB belonging to the first and second groups by the guide rollers10A and10B for guiding the tapes TA and TB respectively is switched on under the control by the controller15, as explained with reference toFIG.9andFIG.10. Thereby, the ends of the tapes TA and TB belonging to the first and second groups are powered by the belt conveyor11supported by the backup rollers22, to be fed out to the compaction roller4.

When the ends of the tapes TA and TB belonging to the first and second groups reached the compaction roller4, the press operation onto the belt conveyor11of the tapes TA and TB belonging to the first and second groups by the guide rollers10A and10B for guiding the tapes TA and TB respectively is switched off under the control by the controller15.

Meanwhile, the moving mechanism5of the AFP apparatus2moves the compaction roller4relatively to the table3in the thickness direction of the tapes TA and TB under the control by the control unit5A interlocking with the controller15of the fiber feeding device1. Accordingly, pressure is applied on the tapes TA and TB from the compaction roller4. That is, the pressurization on the tapes TA and TB by the compaction roller4is switched on.

Thereby, the power given from the belt conveyor11to the tapes TA and TB belonging to the first and second groups is intercepted while tension is applied from the compaction roller4to the tapes TA and TB belonging to the first and second groups. Then, the tapes TA and TB can be laminated on the table3by moving the compaction roller4relatively to the table3in the length direction of the tapes TA and TB. Since the tapes TA and TB are fed out from the AFP apparatus2with speeds independent from each other by the tension received from the compaction roller4, the tapes TA and TB can also be fed out along a curved line.

When the tapes TA and TB reach the end of a lamination area, the relative movement of the compaction roller4to the table3by the driving of the moving mechanism5is stopped. Meanwhile, the brakes9A and9B for stopping the movement of the tapes TA and TB belonging to the first and second groups respectively are almost simultaneously switched on under the control by the controller15. Thereby, the movement of the tapes TA and TB belonging to the first and second groups is stopped.

In addition, the control signal for switching the operating state to the ON state is output from the controller15to the cutter13. Thereby, the cutter13is activated, and the tapes TA and TB belonging to the first and second groups are cut.

When the tapes TA and TB have been cut, the control signal for switching the operating state to the OFF state is output from the controller15to the cutter13. Thereby, the cutter13is driven, and the cutting edge of the cutter13is retracted from the tapes TA and TB belonging to the first and second groups.

After that, the moving mechanism5moves the compaction roller4relatively to the table3in the thickness direction of the tapes TA and TB, and thereby the pressurization by the compaction roller4onto the tapes TA and TB is turned off. That is, the compaction roller4is pulled apart from the tapes TA and TB. Thereby, the lamination of the tapes TA and TB for one ply has been completed, and the AFP apparatus2including the fiber feeding device1returns to the initial state.

By installing such a control program as described above in the controller15, selection, feeding out and lamination of the tapes T can be repeated according to the form of an FRP to be produced. Thereby, a laminated body of the tapes T consisting of prepreg tapes or dry tapes can be produced as a material of an FRP.

While all the guide rollers10have been pulled apart from the belt conveyor11, the belt18may be stopped to move. That is, the movement of the belt18may be interlocked with the control of the guide rollers10and the roller moving mechanism12. On the contrary, while at least one tape T is being fed out from the compaction roller4, the belt18of the belt conveyor11may not be stopped to move since unnecessary frictional force between the belt18and the at least one tape T can be reduced as long as the at least one tape T may contact with the belt18near the compaction roller4even when the at least one tape T is being guided by the guide roller10away from the belt conveyor11. Therefore, control signals for switching the operational mode of the belt conveyor11between the ON mode and the OFF mode are output from the controller15to the driving roller19of the belt conveyor11at appropriate timing.

While all the guide rollers10have been pulled apart from the belt conveyor11, the suction chuck21may be turned off by controlling the suction chuck21by the controller15. Nevertheless, while at least one tape T is being fed out from the compaction roller4, the suction chuck21may be kept in the ON state since deviation of the at least one tape T in the width direction can be prevented by sucking the at least one tape T, being fed out, by the suction chuck21, as mentioned above.

(A Method of Laminating Fibers and a Method of Molding a Composite Material)

Next, a method of laminating fibers and a method of molding a composite material using the AFP apparatus2including the fiber feeding device1will be described.

FIG.12is a flow chart showing an example of a flow for molding an FRP with material consisting of prepreg tapes using the AFP apparatus2including the fiber feeding device1shown inFIG.1.

First, in step S1, at least one tape T to be laminated is selected from the tapes T and the selected least one tape T is fed out, in the fiber feeding device1.

Specifically, the tapes T, consisting of prepreg tapes, previously arrayed by the fiber arranging device6are supplied to the fiber feeding device1. Then, the controller15controls the brakes9and the roller moving mechanism12according to a control program so that the movement of the tape T or the tapes T which should not be laminated may be stopped by the brake9or the brakes9while only the tape T or the tapes T to be laminated may be pinched between at least one guide roller10and the belt conveyor11with the suction chuck21, and fed out to the compaction roller4, like the examples shown inFIG.7toFIG.10. Thereby, only the single tape T or the tapes T selected as laminating target or laminating targets from the tapes T arrayed by the fiber arranging device6are fed out towards the compaction roller4.

Next, in step S2, the single tape T or tapes T fed out from the fiber feeding device1to the compaction roller4are laminated.

Specifically, when the end of the tape T or the ends of the tapes T fed out from the fiber feeding device1to the compaction roller4have reached the compaction roller4, the guide roller10or the guide rollers10which guide the tape T or the tapes T fed out to the compaction roller4are retracted from the belt conveyor11under the control by the controller15while the compaction roller4approaches the table3by driving of the moving mechanism5controlled by the control unit5A interlocked with the controller15. As a result, the tape T or the tapes T fed out to the compaction roller4are pressurized from the compaction roller4, and tension arises due to frictional force between the compaction roller4and the tape T or the tapes T.

Then, the compaction roller4is moved relatively to the table3, in the direction opposite to the feeding direction of the tape T or the tapes T, by driving of the moving mechanism5controlled by the control unit5A. Thereby, the tape T or the tapes T pushed onto the table3side by the compaction roller4are fed out in the direction opposite to the moving direction of the compaction roller4.

The compaction roller4can be not only moved linearly but rotated to the table3. When the tapes T are fed out, the tapes T do not overlap with each other in the width direction, and therefore the tack of prepreg does not act between each adjacent tapes T. Accordingly, each tape T can be fed out with a feeding speed and a feeding length independent from those of another tape T. As a result, even when the compaction roller4is moved along a curved line, each tape T can be fed out without slack, excess tension and the like.

When the tape T or the tapes T fed out from the compaction roller4reach the end of a laminating target area, the compaction roller4is stopped to move relatively to the table3, and then the tape T or the tapes T fed out from the compaction roller4are cut by the cutter13. Thereby, the lamination of the tape T or the tapes T for one ply has been completed.

After that, the selection and feeding out of at least one tape T to be laminated in step S1, and the lamination of the selected at least one tape T in step S2are repeated until it is determined that the lamination of the tapes T belonging to all the plies has been completed, in step S3. The determination whether the lamination of the tapes T belonging to all the plies has been completed can be automatically performed by the control unit5A of the moving mechanism5and the controller15of the fiber feeding device1, which interlock with each other through intercommunication, based on control programs.

Note that, the tape T or the tapes T fed out to the table3first are laminated on the table3directly or the jig J, such as a mold, placed on the table3for laminating the tapes T while the tape T or the tapes T fed out to the table3afterward are sequentially laminated on the tape T or the tapes T adjacent downward.

When the lamination of the tapes T belonging to all the plies has been completed, a laminated body of the tapes T consisting of prepreg tapes is obtained. That is, the laminated body of the tapes T can be produced by laminating each tape T or tapes T for one ply, selected by the fiber feeding device1, in the ply direction by the AFP apparatus2.

Next, in step S4, the resin included in the laminated body of the tapes T is cured. Thereby, an FRP can be molded. That is, the FRP which is also referred to as a composite material can be molded using the laminated body of the tapes T produced by the AFP apparatus2.

When the resin is thermosetting, the resin can be cured by heating the resin with a heater, such as an autoclave apparatus or an oven. Meanwhile, when the resin is thermoplastic, the resin previously melted by heating can be cured by air cooling or cooling with a chiller.

When the resin is cured, the laminated body of the tapes T may be transferred from the jig J for lamination to a molding jig. Alternatively, the jig J for lamination may also be used for curing the resin. Generally, it is necessary for curing the resin to pressurize the laminated body of the tapes T also from above. Accordingly, the laminated body of the tapes T may be pressurized by an upper mold. Alternatively, the atmospheric pressure may be applied on the laminated body of the tapes T by bagging including vacuuming. Note that, at least one device, such as an upper mold, a vacuum device, and a heater or a chiller, necessary for molding the FRP may be integrated with the AFP apparatus2.

FIG.13is a flow chart showing an example of a flow for molding an FRP with material consisting of dry tapes using the AFP apparatus2including the fiber feeding device1shown inFIG.1. Note that, the steps inFIG.13similar to those inFIG.12except for whether the tapes T are dry tapes or prepreg tapes are denoted with the same signs, and detailed explanation thereof is omitted.

Dry tapes may be objects of the selection by the fiber feeding device1and the lamination by the AFP apparatus2or another dedicated lamination apparatus. In that case, when it is determined that the lamination of the tapes T belonging to all the plies has been completed, in step S3, a laminated body of the tapes T consisting of the dry tapes is obtained.

Accordingly, in step S10, resin is injected into the laminated body of the tapes T. For that purpose, the laminated body of the tapes T is seal by a mold, or the laminated body of the tapes T is bagged with vacuuming. Then, in step S4, an FRP is molded by curing the resin with which the laminated tapes T have been impregnated.

Effects

As described above, the fiber feeding device1, the method of laminating the fibers, and the method of molding the composite material select at least one desired tape T from previously arrayed tapes T consisting of prepreg tapes or dry tapes, and laminate the selected tape T or tapes T.

Accordingly, according to the fiber feeding device1, the method of laminating the fibers, and the method of molding the composite material, the number of the tapes T laminated simultaneously can be changed. In addition, the width of each tape T itself can also be changed since the arrayed tapes T can be pushed by the single and common compaction roller4. As a result, the total width of at least one tape T simultaneously fed out from the fiber feeding device1to a same ply can be easily changed.

When the suction chuck21is provided with the belt conveyor11, the intervals (pitches) of the tapes T arrayed by the fiber arranging device6can be kept so that the tapes T can be prevented from overlapping with each other more certainly. Accordingly, a feeding speed and feeding length can be changed between each tapes T adjacent in the width direction in a same ply. Consequently, the tapes T can be laminated curvedly without excess tension, slack and the like in the tapes T. As a result, it becomes possible to mold an FRP having a more complicated form.

Moreover, it is not necessary to prepare a compaction roller for every tape T since the single tape T or the arrayed tapes T are fed out from the fiber feeding device1to the compaction roller4of the AFP apparatus2. Accordingly, there is no interference between parts which conventionally arises due to preparing compaction rollers corresponding to tapes, and thereby it also becomes unnecessary to feed out tapes alternately like a conventional AFP apparatus.

That is, since it is not necessary to provide the AFP apparatus2with lamination heads including compaction rollers corresponding to tapes T, it is unnecessary to prepare a complicated mechanism for sliding lamination heads in the width direction of the tapes T even when the widths and the number of the tapes T are changed. Accordingly, it becomes possible to laminate many tapes T, of which the number and widths could be changed, without making the lamination head of the AFP apparatus2complicated and large-scale.

Moreover, the fiber feeding device1can power the tapes T, which could be fed out, at different positions by the single and common belt conveyor11. Accordingly, it becomes unnecessary to prepare motors for powering the guide rollers10, to which rotation power is transmitted from the belt conveyor11through the tapes T, and thereby the number of necessary power sources can be reduced.

(Second Implementation)

FIG.14is a perspective view showing structure of a suction chuck included in a fiber feeding device according to the second implementation of the present invention.

A fiber feeding device1A in the second implementation shown inFIG.14is different from the fiber feeding device1in the first implementation in the feature that an air blowing port30for discharging air through the holes of the belt18is formed at an end portion of the suction chuck21included in the belt conveyor11. Other configuration and actions of the fiber feeding device1A in the second implementation do not substantially differ from those of the fiber feeding device1in the first implementation. Therefore, only an example of structure of the suction chuck21is illustrated, and the same signs are attached to the same elements and the corresponding elements while explanation thereof is omitted.

As shown inFIG.14, the air blowing port30can be formed in the end portion on the compaction roller4side of the suction chuck21. More specifically, the air blowing port30can be formed at a position at which the tapes T sucked to the belt18by the suction chuck21should be pulled apart from the belt18in order to feed out the tapes T toward the compaction roller4.

In this case, the inside of the housing24included in the suction chuck21is segmented to an area for sucking air through the suction openings23, and an area for discharging air through the air blowing port30. The exhaust hose25for discharging air is coupled to the area for sucking air through the suction openings23while an air supply hose31for supplying air is coupled to the area for discharging air through the air blowing port30.

FIG.15is a schematic view showing an aspect of feeding out the tapes T while sucking the tapes T by the suction chuck21shown inFIG.14.

As exemplified byFIG.14, when air is discharged from the air blowing port30formed on the compaction roller4side of the suction chuck21, air blow can be performed to the tapes T through the holes of the belt18. As a result, as shown inFIG.15, the tapes T suck to the belt18by suction of air from the suction openings23through the holes of the belt18can be pulled apart from the belt18at the position at which the air blowing port30is formed. That is, trouble that the tapes T are not pulled apart from the belt18due to the suction of the tapes T to the belt18can be avoided by the air blow to only the portions of the tapes T passing the end portion on the compaction roller4side of the belt18.

According to the above-mentioned second implementation, an effect that the tapes T can be pulled apart from the belt conveyor11with the suction chuck21at appropriate positions, and thereby the tapes T can be stably fed out to the compaction roller4can be attained in addition to effects similar to those in the first implementation.

In particular, a prepreg tape has tack, and therefore forming the air blowing port30for air blow in the end portion on the compaction roller4side provides a benefit even when the tapes T are fed out by the simple belt conveyor11from which the suction chuck21has been omitted. Nevertheless, the air blow needs the holes of the belt18. Therefore, in case of performing air blow through the holes of the belt18, it is reasonable to also perform vacuum chucking by the suction chuck21.

(Other Implementations)

While certain implementations have been described, these implementations have been presented by way of example only, and are not intended to limit the scope of the invention. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made without departing from the spirit of the invention. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the invention.