Patent ID: 12194692

DETAILED DESCRIPTION

A fiber arranging device, a method of arranging 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 Arranging Device)

FIG.1is a front view showing the structure of a fiber arranging device according to the first implementation of the present invention, andFIG.2is a left side view of the fiber arranging device shown inFIG.1.

A fiber arranging device1feeds out tapes T, which are material of an FRP, in a same direction in a state where the tapes T have been arrayed without overlapping the tapes T with each other so that the tapes T can be laminated simultaneously. In other words, the fiber arranging device1arrays tapes T supplied from different directions so that the length directions of the tapes T may become almost parallel, and sends out the arrayed tapes T without overlapping the tapes T with each other.

When a clearance gap may be formed between adjacent laminated tapes T, i.e., the width of an area in which the tapes T are laminated is wider than the sum total of the widths of the tapes T to be arrayed, the fiber arranging device1may array the tapes T with a clearance gap between adjacent tapes T. Hereinafter, a case of arraying the tapes T without a clearance gap and overlap unless extents of the clearance gap and overlap are negligible errors will be described as an example.

Each tape T to be arrayed is a prepreg tape or a dry tape. 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.

FIG.3andFIG.4each shows an example of the arrayed tapes T fed out from the fiber arranging device1shown inFIG.1.

The tapes T having different widths can be supplied to the fiber arranging device1. Therefore, when the tapes T having wide widths are supplied to the fiber arranging device1, the width of the arrayed tapes T fed out from the fiber arranging device1also becomes wide as exemplified byFIG.3. Meanwhile, when the tapes T having narrow widths are supplied to the fiber arranging device1, the width of the arrayed tapes T fed out from the fiber arranging device1also becomes narrow as exemplified byFIG.4.

When the width of each tape T is made large as exemplified byFIG.3, an area of the tapes T which can be laminated per unit time can be enlarged. Conversely, when the width of each tape T is made small as exemplified byFIG.4, each tape T can be laminated along a curved line whose curvature is large. Therefore, according to a form of an FRP to be mold, the tapes T having appropriate widths can be supplied to the fiber arranging device1while the tapes T can be disposed so that the sum of the widths of the tapes T may become appropriate.

Supplying devices of the tapes T each disposed in the fore stage of the fiber arranging device1may be bobbins2themselves of the tapes T each having a constant width. Alternatively, a width adjusting device3for changing the width of the tape T may be disposed between each of the bobbins2of the tapes T and the fiber arranging device1, as needed, as exemplified byFIG.1. The width adjusting device3may have desired structure as long as the width of the tape T can be changed.

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 device3.

When the width adjusting devices3are disposed, the widths of the tapes T supplied from the bobbins2can be changed into desired widths respectively to be supplied to the fiber arranging device1. Conversely, also when the width adjusting devices3are not disposed, the tapes T having different widths can be supplied to the fiber arranging device1by exchanging the bobbins2for other bobbins2of the tapes having the different widths.

An AFP apparatus4is disposed in the rear stage of the fiber arranging device1. In other words, the fiber arranging device1may be an attachment of the AFP apparatus4or a part of components included in the AFP apparatus4, for supplying the arrayed tapes T to the AFP apparatus4. The typical AFP apparatus4includes a table5for laminating the tapes T, a compaction roller6for pushing the tapes T towards the table5, and a moving mechanism7for moving the compaction roller6relatively to the table5. When the lower surface of the tapes T is not flat, a jig J, such as a lower mold, may be placed on the table5so that the tapes T can be laminated on the jig J, as exemplified byFIG.1.

When the compaction roller6is moved relatively to the table5in a state where the arrayed tapes T have been pushed on the table5side by the compaction roller6, the arrayed tapes T can be fed out in a direction opposite to the moving direction of the compaction roller6while giving tension to the tapes T. That is, once the ends of the tapes T have reached the compaction roller6, the tapes T can be fed out without giving tension to the arrayed tapes T or the tapes, which have not been arrayed, by a roller or rollers having power. Therefore, it is not essential to include a power source for feeding out the tapes T in the fiber arranging device1disposed in the fore stage of the AFP apparatus4.

On the contrary, the compaction roller6cannot give tension to the tapes T until the ends of the tapes T reach the compaction roller6. Accordingly, at least one roller which rotates by power of a motor may be disposed at a desired position so that the tapes T can be fed out while applying tension to the tapes T. The typical AFP apparatus4includes at least one roller, which is called a feed roller and has power, for feeding out the tapes T while giving tension to the tapes T as well as at least one brake for stopping the feeding of the tapes T and a cutter for cutting the tapes T.

Also when sufficient tension cannot be given to the tapes T only by the compaction roller6, at least one roller which rotates by power of a motor may be disposed at a desired position so that additional tension can be given to the tapes T. Therefore, a power source, such as a motor, and at least one roller rotating by power of the power source for feeding out the tapes T may be included also in the fiber arranging device1disposed in the fore stage of the AFP apparatus4, as needed.

When the AFP apparatus4having configuration as described above is used, the tapes T arrayed by the fiber arranging device1as exemplified byFIG.3orFIG.4can be laminated on the table5. AlthoughFIG.1shows an example of configuration that the table5is moved along desired driving axes by the moving mechanism7, a gantry holding the compaction roller6may be moved by the moving mechanism7. Moreover, it is practical to allow not only linear movement in orthogonal three axis directions but rotational movement from a viewpoint of allowing molding an FRP having a more complicated form.

The fiber arranging device1includes tape feeders8and an assembling roller9. Each of the tape feeders8adjusts intervals between the tapes T, and feeds out the tapes T in a same feeding direction, i.e, feeds out the tapes T so that the length directions of the tapes T may become almost parallel to each other. In order to avoid interference among the tape feeders8, the feeding directions of the tapes T differ from each other among the tape feeders8. The assembling roller9is a cylindrical or columnar roller for alternately arraying the tapes T respectively fed out from the tape feeders8in the different directions, and feeding out the arrayed tapes T in a same feeding direction.

The number of the tape feeders8and the number of the tapes T to be fed out from each tape feeder8are determined according to the number of the tapes T to be arrayed by the fiber arranging device1. That is, the number of the tape feeders8and the number of the tapes T to be fed out from each tape feeder8are determined so that the total number of the tapes T fed out from all the tape feeders8may be same as the number of the tapes T to be fed out from the fiber arranging device1to the AFP apparatus4.

Note that, the total number of the tapes T to be fed out from the fiber arranging device1to the AFP apparatus4may be made alterable by stopping a part of the tape feeders8or reducing the number of the tapes T to be fed out from the same tape feeder8. In that case, the number of the tape feeders8and the number of the tapes T to be fed out from each tape feeder8are determined according to the maximum of the total number of the tapes T which may be fed out from the fiber arranging device1to the AFP apparatus4. At least one of the number of the tape feeders8and the number of the tapes T to be fed out from each tape feeder8may be also variable in the fiber arranging device1. In that case, the maximum itself of the total number of the tapes T which can be fed out from the fiber arranging device1to the AFP apparatus4can be changed.

Each of the tape feeders8has tape feeding guides10and a guide moving mechanism11. Each of the tape feeding guides10is a device for guiding the feeding of the tape T, made of fibers or prepreg, in the feeding direction. Accordingly, the number of the tape feeding guides10is equal to the number of the tapes T to be fed out from each tape feeder8.

For example, the tape feeding guide10can be composed of a pedestal12and rollers13fixed to the pedestal12as exemplified byFIG.1so that the travelling direction of the tape T can be restricted while keeping the tension of the tape T. In that case, the number of the rollers13is determined to be appropriate for keeping the tension of the tape T. As a matter of course, the tape feeding guide10can be composed of desired elements, such as a belt conveyor of which a belt is supported and moved with the pulleys, as long as the travelling direction of the tape T can be restricted while keeping the tension of the tape T.

The tapes T which should be adjacently disposed without overlapping the tapes T with each other are fed out from the different tape feeders8. Accordingly, the tapes T fed out from each tape feeder8have to have intervals for disposing the tapes T fed out from the other tape feeders8.

Conversely, when the tapes T which should be adjacently disposed without overlapping the tapes T with each other are fed out from the different tape feeders8while intervals are formed among the tapes T fed out from each tape feeder8, interference among the tape feeding guides10can be avoided without complicating the structure of each tape feeding guide10. Accordingly, the tape feeding guides10for feeding out the tapes T adjacently disposed with intervals in the same tape feeder8can be adjacently disposed with intervals corresponding to the intervals of the tapes T.

When the tape T to be guided by each tape feeding guide10does not have a specific width, i.e., when the tapes T having different widths have to be guided by each tape feeding guide10, the intervals of the tapes T fed out from the same tape feeder8have to be changed according to the width of each tape T. Therefore, the intervals of the tape feeding guides10adjacently disposed in the same tape feeder8also have to be changed according to the width of each tape T.

Even when the width of the tape T to be guided by each tape feeding guide10is constant, a part of the tape feeders8may be stopped, or conversely, the number of the tape feeders8may be increased. Therefore, the number of the alternately disposed tapes T may be changed. Thus, the intervals of the tapes T fed out from the same tape feeder8and the intervals of the tape feeding guides10included in the same tape feeder8have to be changed according to the number of the tape feeders8and the tapes T.

Accordingly, the intervals of the tape feeding guides10adjacently disposed in the same tape feeder8can be changed by the guide moving mechanism11. That is, the guide moving mechanism11adjusts the intervals of the tape feeding guides10adjacently disposed in the same tape feeder8to appropriate intervals according to at least one of the widths of the tapes T and the number of the tapes T.

More specifically, the interval between each two tape feeding guides10adjacently disposed in the same tape feeder8is adjusted by the guide moving mechanism11so that an interval necessary to dispose at least one tape T fed out from the different tape feeder8or the different tape feeders8without overlapping the at least one tape T in the width direction may arise between each two tapes T to be adjacently fed out from the same tape feeder8.

In the illustrated example, the fiber arranging device1includes the three tape feeders8consisting of the first to the third tape feeders8A,8B, and8C so that the three tapes TA, TB, or TC can be fed out from each of the tape feeders8A,8B, and8C. Therefore, the total of the nine tapes TA, TB, and TC can be arrayed and fed out.

More specifically, the feeding of the first tapes TA in the first feeding direction is guided by the first tape feeding guides10A included in the first tape feeder8A. Meanwhile, the first guide moving mechanism11A included in the first tape feeder8A is configured to change the intervals of the first tape feeding guides10A so that the first tapes TA may be fed out with the first intervals in the first feeding direction.

Similarly, the feeding of the second tapes TB in the second feeding direction different from the first feeding direction is guided by the second tape feeding guides10B included in the second tape feeder8B. Meanwhile, the second guide moving mechanism11B included in the second tape feeder8B is configured to change the intervals of the second tape feeding guides10B so that the second tapes TB may be fed out with the second intervals in the second feeding direction.

Similarly, the feeding of the third tapes TC in the third feeding direction different from any of the first feeding direction and the second feeding direction is guided by the third tape feeding guides10C included in the third tape feeder8C. Meanwhile, the third guide moving mechanism11C included in the third tape feeder8C is configured to change the intervals of the third tape feeding guides10C so that the third tapes TC may be fed out with the third intervals in the third feeding direction.

When the tapes TA, TB, and TC fed out from the three tape feeders8A,8B, and8C respectively are disposed alternately by the assembling roller9, the interval between each two tapes T fed out from each of the first to third tape feeders8is used for disposing two tapes T respectively fed out from the other two tape feeders8. Therefore, the intervals of the tape feeding guides10included in each of the tape feeders8are adjusted by the guide moving mechanism11so that the interval between each two tapes T fed out from the tape feeding guides10may become the sum total of the widths of the two tapes T respectively fed out from the other two tape feeders8.

The widths of the tapes supplied to the tape feeders8and fed out from the tape feeders8respectively may not necessarily be the same among the tape feeders8. Therefore, when the widths of the tapes T fed out differ among the tape feeders8, the intervals of the tape feeding guides10are adjusted to intervals different among the tape feeders8.

For example, when the tapes TA, TB, and TC are fed out by the first to third tape feeders8A,8B, and8C respectively as illustrated, the first intervals of the first tapes TA fed out in the first feeding direction, the second intervals of the second tapes TB fed out in the second feeding direction, and the third intervals of the third tapes TC fed out in the third feeding direction are not necessarily the same.

On the other hand, when the widths of the tapes T fed out from the tape feeders8are the same, the intervals among the tape feeding guides10are also adjusted to be the same among the tape feeders8. For example, when the tapes TA, TB, and TC are fed out by the first to third tape feeders8A,8B, and8C respectively as illustrated, the first intervals of the first tapes TA fed out in the first feeding direction, the second intervals of the second tapes TB fed out in the second feeding direction, and the third intervals of the third tapes TC fed out in the third feeding direction are adjusted to be the same.

Note that, each figure shows a case where the widths of the tapes T fed out from the tape feeders8are the same. Hereinafter, a case where the widths of the tapes T fed out from the tape feeders8are the same among the tape feeders8will be described as an example, for simplifying explanation.

As mentioned above, the number of the tape feeders8and the number of the tapes T to be fed out from each tape feeder8can be determined freely according to the total number of the tapes T which could be fed out from the fiber arranging device1to the AFP apparatus4. Therefore, the fiber arranging device1has at least two tape feeders8, and more than three tape feeders8may be disposed so that the tapes T may not interfere with each other, regardless of the illustrated example.

Moreover, each tape feeder8is configured to feed out at least two tapes, and more than three tapes T may be fed out from each tape feeder8regardless of the illustrated example. When each tape feeder8is configured to feed out three tapes T as illustrated, the structure of the guide moving mechanism11can be simplified as an example described later.

The tape feeders8and the assembling roller9disposed in the rear stage of the tape feeders8are relatively disposed so that the tapes T fed out from the tape feeding guides10included in the different tape feeders8, with predetermined intervals in different feeding directions may reach the assembling roller9without interference, and may be arrayed alternately on the assembling roller9without overlapping the tapes T with each other. For that purpose, it is necessary to relatively dispose the tape feeders8and the assembling roller9so that the thickness directions of the tapes T fed out from the different tape feeders8may lie on a same plane and become almost perpendicular to the rotating shaft of the assembling roller9at least just before the assembling roller9.

For example, the thickness directions of the tapes TA, TB, and TC respectively fed out from the first to the third tape feeders8A,8B, and8C lie on a same plane and are perpendicular to the rotating shaft of the assembling roller9, in the example shown inFIG.1. In order to avoid interference among the tape feeders8, the thickness directions of the tapes T fed out from a part or all of the tape feeders8may be changed by rollers whose directions of the rotating shafts are different, or the like so that the thickness directions of the tapes T fed out from all the tape feeders8may eventually become almost perpendicular to the rotating shaft of the assembling roller9just before the assembling roller9. At least one of the thickness directions of the tapes T may not be made strictly perpendicular to the rotating shaft of the assembling roller9but be slightly slanted to the rotating shaft of the assembling roller9. In this case, the feeding directions of the arrayed tapes T may be finely adjusted.

As long as all the tapes T can be fed out from the tape feeders8to appropriate positions on the assembling roller9in appropriate directions, the alternately arrayed tapes T can be fed out in a same feeding direction. That is, the tapes T arrayed so that each tapes T adjacent to each other in the width direction may not overlap with each other in the width direction can be produced by the fiber arranging device1and supplied to the AFP apparatus4, as material of an FRP.

Next, an example of concrete structure of the guide moving mechanism11included in each of the tape feeders8will be described.

FIG.5is a top view showing an example of concrete structure of each tape feeder8shown inFIG.1, andFIG.6is a sectional view at the position A-A of the tape feeder8shown inFIG.5.

Since the guide moving mechanism11is a mechanism for adjusting the intervals of the tape feeding guides10, the guide moving mechanism11is composed of a device for relatively moving the tape feeding guides10in parallel. When the three tapes T are fed out by each tape feeder8, the guide moving mechanism11can be composed of a simple power transmission mechanism as shown inFIG.5andFIG.6. That is, the three tape feeding guides10can be relatively moved in parallel by a simple power transmission mechanism.

More specifically, the guide moving mechanism11can be composed of a driving roller20, a motor21, wires22, pulleys23, and a sliding mechanism24, as exemplified byFIG.5andFIG.6. The driving roller20rotates by the power from the motor21. The torque output from the motor21can be transmitted to the rotating shaft of the driving roller20directly as illustrated but may be transmitted to the rotating shaft of the driving roller20indirectly through gears or a power transmission belt.

The driving roller20has outside diameters different from each other. The driving roller20has such structure that the driving roller20rotates around a common rotation axis. For example, the driving roller20may be a single roller rotating by a single rotation shaft and having portions whose outside diameters are different from each other. Alternatively, the driving roller20may include coaxially coupled sub rollers whose outside diameters are different from each other. The outside diameters of the driving roller20correspond to amounts of parallel movement of the tape feeding guides10, respectively.

The number of the wires22is same as that of the tape feeding guides10which should be moved in parallel. Therefore, when the three tape feeding guides10are moved in parallel, the guide moving mechanism11has the three wires22. Each wire22is in the form of a closed curved line. That is, each wire22forms a ring-shaped track having no ends.

Parts of the wires22are fixed to the portions of the driving roller20whose outside diameters are different from each other, respectively so that the wires22may be powered by the portions of the driving roller20whose outside diameters are different from each other, and moved in the length directions, respectively. Other parts of the wires22are coupled to the tape feeding guides10, respectively. In the illustrated example, each wire22is fixed to one of the tape feeding guides10, which is the coupling target, with a coupling tool while each wire22passes through holes formed in the other tape feeding guides10, which are not coupling targets, in order to avoid interference of each wire22with the other tape feeding guides10, which are not coupling targets.

The pulleys23are rollers for moving the wires22in the length directions while supporting the wires22coupled to the driving roller20and the tape feeding guides10. In order to keep the tension of the wires22appropriately, tensioners26for adjusting the tension of the wires22may be included in the guide moving mechanism11, as illustrated.

The sliding mechanism24slides the tape feeding guides10in the moving directions, respectively. In the illustrated example, the sliding mechanism24has two shafts27slidably inserted into through holes formed in the tape feeding guides10.

The guide moving mechanism11having the structure as described above allows moving the tape feeding guides10in parallel by distances different from each other, respectively since the wires22supported with the pulleys23moves in the length directions by distances corresponding to the outside diameters of the driving roller20rotated by the motor21.

FIG.7is a view for explaining the principle for moving the wires22by different distances respectively by the stepped driving roller20shown inFIG.5andFIG.6.

As shown inFIG.7, the outer circumferential lengths of the portions of the driving roller20having the different outside diameters differ from each other even when the rotation angle θ of the driving roller20is the same. Therefore, the tape feeding guides10can be moved in parallel together with the wires22by distances equivalent to the different lengths of the arcs respectively only by powering and rotating the single driving roller20. The distances by which the wires22move per one rotation of the driving roller20can be adjusted by adjusting the outside diameters of the driving roller20respectively.

The rotation angle of the driving roller20is controlled as the rotation quantity including a rotating direction of the motor21. Accordingly, the rotation quantity of the motor21can be preset or numerically input to a control circuit of the motor21by a user. Thereby, the driving roller20can be rotated by a rotation angle specified by a user so that the tape feeding guides10may be moved in parallel by distances specified by the user respectively.

Note that, a handle or a lever may be attached to the driving roller20instead of the motor21so that a user can manually rotate the driving roller20. In that case, a handle or a lever may be configured to be locked when the driving roller20rotated by specific rotation angles so that the driving roller20can be rotated by the rotation angles specified by a user.

Each ofFIG.8andFIG.9is a view for explaining how to wind each wire22shown inFIG.5andFIG.6to the driving roller20.

Each wire22is twisted around the driving roller20, and a part of each wire22is fixed to the driving roller20. Accordingly, the moving direction of each wire22can be determined by selecting a way to twist each wire22around the driving roller20.

Specifically, when the wire22is twisted around the driving roller20so that the wire22may not intersect at any position where the wire22is away from the driving roller20, as shown inFIG.8, the moving direction of the ring wire22can be made counterclockwise in case of rotating the driving roller20counterclockwise. Conversely, when the wire22is twisted around the driving roller20so that the wire22may intersect at a position where the wire22is away from the driving roller20, as shown inFIG.9, the moving direction of the ring wire22can be made clockwise in case of rotating the driving roller20counterclockwise.

In the example shown inFIG.5andFIG.6, the tape feeding guides10are disposed above the driving roller20. Therefore, when the wire22is fed out on the lower side of the rotation axis of the driving roller20as shown inFIG.8, the tape feeding guide10coupled to the wire22moves leftward in case of rotating the driving roller20counterclockwise. Conversely, when the wire22is fed out on the upper side of the rotation axis of the driving roller20as shown inFIG.9, the tape feeding guide10coupled to the wire22moves rightward in case of rotating the driving roller20counterclockwise.

Thus, the sliding direction of each tape feeding guide10can be determined by the way to twist the wire22around the driving roller20while the distance by which each tape feeding guide10moves can be adjusted by adjusting the outside diameter of the driving roller20. Accordingly, the intervals of the tape feeding guides10can be adjusted by rotation of the driving roller20.

FIG.10shows an example of moving directions and moving amounts of the respective tape feeding guides10in case of changing the intervals of the tape feeding guides10, for feeding out the tapes T having wide widths exemplified byFIG.3, to the intervals of the tape feeding guides10, for feeding out the tapes T having narrow widths exemplified byFIG.2.

When the three tapes T are fed out by the tape feeder8as shown inFIG.5andFIG.6, the intervals of the three tape feeding guides10can be adjusted according to the width of the tape T so that the intervals of the three tape feeding guides10may become equal intervals. In this case, the central tape feeding guide10and one of the tape feeding guides10on both sides can be moved with appropriate moving amounts different from each other in a same direction while the other of the tape feeding guides10on both sides can be moved with an appropriate moving amount in the opposite direction. Thereby, the intervals of the three tape feeding guides10can be changed with keeping the intervals equal to each other.

In case of altering the intervals of the tape feeding guides10for feeding out the wide tapes T to the intervals of the tape feeding guides10for feeding out the narrow tapes T as shown inFIG.10, the intervals of the three tape feeding guides10can be narrowed according to the widths of the tapes T with keeping the intervals equal to each other by sliding the central tape feeding guide10and the tape feeding guide10on the left side towardFIG.5andFIG.6, rightward by appropriate distances indicated with the arrows inFIG.10respectively, and sliding the tape feeding guide10on the right side towardFIG.5andFIG.6, leftward by an appropriate distance indicated with the arrow inFIG.10. Meanwhile, the intervals of the three tape feeding guides10can be widened with keeping the intervals of the three tape feeding guides10equal to each other by similar sliding in the opposite direction.

This also applies to a case of altering the number of the tapes T disposed between each two spaced adjacent tapes T fed out from the same tape feeder8, like a case of stopping a part of the tape feeders8, and a case of newly adding the tape feeder8.

Thus, in order to change the intervals of the tape feeding guides10with keeping the intervals of the tape feeding guides10equal to each other by rotating the driving roller20, each of the ways to twist the wires22around the driving roller20can be determined to either one of the two ways shown inFIG.8andFIG.9according to the respective moving directions of the tape feeding guides10while the outside diameters of the driving roller20can be respectively determined according to moving distances of the tape feeding guides10and the wires22necessary for changing the intervals of the tape feeding guides10with keeping the intervals of the tape feeding guides10equal to each other.

As a matter of course, also when the intervals of the tape feeding guides10should be changed with keeping the intervals of the tape feeding guides10unequal to each other, like a case where the widths of the tapes T are different from each other among the tape feeders8or a case where the widths of the tapes T are different from each other in the same tape feeder8, the outside diameters of the driving roller20can be determined according to corresponding moving distances of the tape feeding guides10respectively.

In the example shown inFIG.5, the wire22fixed to the left tape feeding guide10is twisted by the way shown inFIG.9so that rotating the driving roller20counterclockwise can move the left tape feeding guide10rightward. Since the sliding distance of the left tape feeding guide10is the maximum among the three tape feeding guides10, the wire22fixed to the left tape feeding guide10is twisted around the portion having the maximum outside diameter of the driving roller20.

Meanwhile, the wire22fixed to the right tape feeding guide10is twisted by the way shown inFIG.8so that rotating the driving roller20counterclockwise can move the right tape feeding guide10leftward. Since the sliding distance of the right tape feeding guide10is the second longest among the three tape feeding guides10, the wire22fixed to the right tape feeding guide10is twisted around the portion having the second largest outside diameter of the driving roller20.

Further, the wire22fixed to the central tape feeding guide10is twisted by the way shown inFIG.9so that rotating the driving roller20counterclockwise can move the central tape feeding guide10rightward. Since the sliding distance of the central tape feeding guide10is the minimum among the three tape feeding guides10, the wire22fixed to the central tape feeding guide10is twisted around the portion having the minimum outside diameter of the driving roller20.

AlthoughFIG.5andFIG.6show an example that the wires22are twisted around the driving roller20, power transmission members, such as power transmission belts, each forming a track may be used instead of the wires22. Alternatively, the tape feeding guides10may be respectively moved by chains, in the forms of closed curved lines, moved by coaxially disposed sprockets having outside diameters different from each other, instead of the driving roller20.

That is, the structure of the guide moving mechanism11can be simplified by adopting, as the guide moving mechanism11, a mechanism that at least one rotating body, such as the driving roller20or sprockets, having portions whose outside diameters are different from each other and rotation axes lie on a same straight line is rotated to move power transmission members, such as the wires22, power transmission belts or chains, in the forms of closed curved lines by mutually different moving amounts corresponding to the mutually different outside diameters of the at least one rotating body respectively. When power transmission members, such as power transmission belts or chains, whose moving directions cannot be changed easily by selecting twisting ways unlike the wires22are used, at least one rotating direction of a part of rotating bodies may be changed by gears or the like.

As other examples, the guide moving mechanism11may be composed of desired machine elements, such as ball screws, sets of rack-and-pinion, or cylinder mechanisms each having a cylinder tube and a piston reciprocated in the cylinder tube, for moving objects linearly.

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

Next, a method of arranging fibers and a method of molding a composite material using the fiber arranging device1and the AFP apparatus4will be described.

FIG.11is a flow chart showing an example of a flow for molding an FRP with material consisting of prepreg tapes using the fiber arranging device1and the AFP apparatus4shown inFIG.1.

First, in step S1, the tapes T consisting of prepreg tapes supplied from mutually different directions are arrayed by the fiber arranging device1. Specifically, the tape T supplied from the bobbins2are supplied from mutually different directions to the fiber arranging device1as exemplified byFIG.1. The widths of the tapes T to be supplied to the fiber arranging device1may be changed to desired widths by the width adjusting devices3respectively, as needed.

The tapes T fed from mutually different directions into the fiber arranging device1are fed into the corresponding tape feeders8respectively. The tape feeding guides10included in each of the tape feeder8are previously positioned so as to have the intervals according to the widths of the tapes T by driving the guide moving mechanism11. More specifically, the tape feeding guides10are positioned by the guide moving mechanism11so that the tapes T fed out from one of the tape feeders8may have intervals in which the tapes T fed out from the other tape feeders8can be disposed without overlapping the tapes T with each other.

Accordingly, the tapes T of which the intervals are regulated by the tape feeding guides10are fed out from each tape feeder8. The tapes T fed out from the tape feeders8are gathered to the assembling roller9. On the assembling roller9, the tapes T fed out from the different tape feeders8are disposed alternately, and all the tapes T gathered on the assembling roller9are fed out in a same feeding direction. Thereby, the arrayed tapes T can be produced as material of an FRP.

Next, in step S2, the arrayed tapes T are laminated. For that purpose, the tapes T arrayed by the fiber arranging device1are supplied to the AFP apparatus4. Then, the arrayed tapes T are laminated by the AFP apparatus4.

When the AFP apparatus4is configured to move the compaction roller6relatively to the table5by the moving mechanism7as shown inFIG.1, for example, the tapes T supplied to the AFP apparatus4are pushed on the table5side by the compaction roller6moved relatively to the table5by driving the moving mechanism7. Thereby, the tapes T pushed on the table5side by the compaction roller6are fed out in the direction opposite to the moving direction of the compaction roller6.

The tapes T fed out toward the table5first are laid on the table5directly or on a lamination jig J, such as a mold, placed on the table5. The tapes T fed out toward the table5afterward are subsequently laminated on the tapes T adjacent on the lower side. When all the tapes T have been laminated, a laminated body of the tapes T consisting of prepreg tapes is obtained. That is, a laminated body of the arrayed tapes T produced by the fiber arranging device1can be produced by the AFP apparatus4.

Note that, the arrayed tapes T simultaneously fed out from the AFP apparatus4do not overlap with each other in the width direction. Therefore, the tack force of prepreg does not act between each adjacent tapes T. Accordingly, it is possible to feed out each tape T with independent feeding rate and length different from those of another tape T. As a result, even when the compaction roller6is moved along a curved line, the tapes T can be fed out without slack, excess tension, and the like in the tapes T. Thereby, it is possible to produce a laminated body of the tapes T having a complicated form.

Next, in step S3, the resin included in the laminated body of the tapes T is cured. Thereby, an FRP can be molded. That is, an FRP referred to as a composite material can be molded using the laminated body of the tapes T produced by the AFP apparatus4.

In case of thermosetting resin, the resin can be cured by heating the resin with a heater, such as an autoclave apparatus or an oven. Meanwhile, in case of thermoplastic resin, the resin can be cured by air cooling of the resin molten by previously heating the resin, or cooling of the heated molten resin with a cooling system.

When the resin is cured, the laminated body of the tapes T may be transferred from the lamination jig J onto a molding jig, or the common jig J may be used for curing the resin. Usually, curing the resin requires pressurization of the laminated body of the tapes T 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 with vacuuming. A device or devices, such as an upper mold, a vacuum device, a heater or a cooling system, required for molding an FRP may be integrated with the AFP apparatus4.

FIG.12is a flow chart showing an example of a flow for molding an FRP with material consisting of dry tapes using the fiber arranging device1and the AFP apparatus4shown inFIG.1. InFIG.12, the same signs are attached to steps similar to those inFIG.11except for whether the tapes T are dry tapes or prepreg tapes, and detailed explanation thereof is omitted.

Dry tapes may also be arrayed by the fiber arranging device1, and then the arrayed dry tapes may be laminated by the AFP apparatus4or another dedicated lamination apparatus. In that case, a laminated body of the tapes T consisting of the dry tapes is obtained in step S2. 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 sealed by a mold or bagging with vacuuming. After that, an FRP is molded by curing the resin with which the laminated body of the tapes T has been impregnated, in step S3.

(Effects)

As described above, the fiber arranging device1, the method of arranging fibers and the method of molding a composite material array the tapes T consisting of prepreg tapes or dry tapes without overlapping the tapes T with each other by alternately disposing the sets of the tapes T fed out with adjustable intervals.

Therefore, the fiber arranging device1, the method of arranging fibers and the method of molding a composite material allow laminating many tapes simultaneously. In addition, the feeding speeds and feeding lengths of the tapes T may differ from each other among the tapes T. Accordingly, the tapes T can be laminated along a curved line without excess tension and slack of the tapes T. As a result, an FRP having a more complicated form can be molded.

In particular, the intervals of the tapes T to be disposed alternately can be changed. Therefore, even when an FRP is molded using the tapes T having widths different from each other, an excess gap and a non-negligible lap between each tapes T adjacent to each other can be prevented from arising. In other words, the tapes T having unspecified widths can be laminated with high quality.

As a result, the total width of the laminated tapes T can be changed. In addition, in case of feeding out the tapes T along a curved line having a large curvature, the narrow tapes T can be used for securing the quality. Meanwhile, in case of feeding out the tapes T along a straight line or a curved line having a small curvature, the wide tapes T can be used for improving the lamination efficiency. That is, the tapes T having appropriate widths according to the form of an FRP can be used as material.

Furthermore, it is not necessary to feed out the tapes T alternately from the AFP apparatus4since the tapes T fed out from the AFP apparatus4have been already arrayed by the fiber arranging device1, and thereby there is no interference between mechanisms for feeding out the tapes T in the AFP apparatus4. That is, the tapes T can be fed out simultaneously while applying pressure on the tapes T by the common and single compaction roller6without preparing a compaction roller per tape T.

Accordingly, even when many tapes T are fed out, the structure of the lamination head of the AFP apparatus4can be made simple and compact. In other words, more tapes T can be laminated simultaneously without making the structure of the lamination head of the AFP apparatus4complicated and large-scale.

Moreover, even when at least one of the widths and the number of the tapes T is altered, it is not necessary to slide the lamination head of the AFP apparatus4in the width direction of the tapes T since the AFP apparatus4is not required to include lamination heads having compaction rollers corresponding to the tapes T. Accordingly, it is possible to easily change not only the widths of the tapes T to be fed out from the AFP apparatus4but the number of the tapes T. In other words, it is unnecessary to prepare lamination heads, having complicated mechanisms for feeding out the tapes T with changing the widths and the number of the tapes T, in the AFP apparatus4.

(Second Implementation)

FIG.13is a diagram showing configuration of a fiber arranging device according to the second implementation of the present invention.

A fiber arranging device1A in the second implementation shown inFIG.13is different from the fiber arranging device1in the first implementation in the feature that the intervals of the tape feeding guides10can be automatically adjusted in real time based on the widths of the tapes T measured by width sensors30during feeding out the tapes T. Other configuration and actions of the fiber arranging device1A in the second implementation are not substantially different from those of the fiber arranging device1in the first implementation. Accordingly, only the main elements of the fiber arranging device1A are illustrated in a block diagram, and the same signs are attached to the same elements and the corresponding elements while explanation thereof is omitted.

In the fiber arranging device1A in the second implementation, each of the tape feeders8includes the width sensors30for detecting the widths of the tapes T. Therefore, each of the tape feeders8includes the width sensors30whose number is equal to the number of the tapes T, and thereby the fiber arranging device1A includes the width sensors30whose number is equal to the total number of the tapes T to be arrayed. For example, in case of feeding out the three tapes TA, TB, or TC from each of the first to the third tape feeders8A,8B, and8C as exemplified byFIG.1andFIG.2, the number of the width sensors30is nine.

A desired known sensor can be used as each of the width sensors30. Examples of the non-contact width sensor30for measuring the width of the tape T include a sensor using at least one reflective laser displacement sensor and a sensor using at least one transmissive laser displacement sensor. Alternatively, the tape T may be photographed by an image sensor, and the width of the tape T may be detected by image processing.

In case of utilizing at least one reflective laser displacement sensor, the two edges on both sides of the tape T can be detected by measuring displacement in the thickness direction of the tape T using a single reflective laser displacement sensor or a pair of reflective laser displacement sensors, which oscillate a belt-like laser beam or belt-like laser beams crossing the edges on both sides of the tape T. In this case, the distance between the edges can be detected as the width. Meanwhile, in case of utilizing at least one transmissive laser displacement sensor, a single laser oscillator or a pair of laser oscillators, which oscillate a belt-like laser beam or belt-like laser beams crossing the edges on both sides of the tape T, and a single laser photodetector or a pair of laser photodetectors, which detect the laser beam oscillated by the single laser oscillator or the laser beams oscillated by the pair of the laser oscillators can be disposed so that the tape T may be interposed. In this case, a range within which the laser beam or the laser beams are not detected with the single laser photodetector or the pair of the laser photodetectors due to interruption of the laser beam or the laser beams by the tape T can be detected as the width.

The widths of the tapes T measured by the width sensors30included in each tape feeder8are output to each of controllers31of the guide moving mechanisms11included in all the other tape feeders8. Each of the controllers31of the guide moving mechanisms11is configured to control the intervals of the tape feeding guides10controlled by the corresponding guide moving mechanism11, based on the widths of the tapes T measured by the width sensors30included in all the other tape feeders8. Specifically, each controller31controls the guide moving mechanism11so that the intervals of the tape feeding guides10may become appropriate intervals corresponding to the widths of the tapes T fed out from the other tape feeders8.

In case of feeding out the three tapes TA, TB, or TC from each of the first to the third tape feeders8A,8B, and8C as exemplified byFIGS.1and2, andFIG.13, for example, the widths of the first tapes TA measured by the first width sensors30A included in the first tape feeder8A are output to each of the second controller31B of the second guide moving mechanism11B included in the second tape feeder8B and the third controller31C of the third guide moving mechanism11C included in the third tape feeder8C.

Similarly, the widths of the second tapes TB measured by the second width sensors30B included in the second tape feeder8B are output to each of the first controller31A of the first guide moving mechanism11A included in the first tape feeder8A and the third controller31C of the third guide moving mechanism11C included in the third tape feeder8C while the widths of the third tapes TC measured by the third width sensors30C included in the third tape feeder8C are output to each of the first controller31A of the first guide moving mechanism11A included in the first tape feeder8A and the second controller31B of the second guide moving mechanism11B included in the second tape feeder8B.

Then, the first controller31A of the first guide moving mechanism11A included in the first tape feeder8A controls the intervals of the first tape feeding guides10A based on the widths of the second tapes TB measured by the second width sensors30B included in the second tape feeder8B and the widths of the third tapes TC measured by the third width sensors30C included in the third tape feeder8C so that the intervals of the first tape feeding guides10A may become appropriate intervals corresponding to the widths of the second tapes TB fed out from the second tape feeder8B and the widths of the third tapes TC fed out from the third tape feeder8C, more specifically, so that the intervals of the first tape feeding guides10A may become intervals which allows disposing the second tapes TB fed out from the second tape feeder8B and the third tapes TC fed out from the third tape feeder8C without overlapping the first to third tapes TA, TB and TC with each other.

Similarly, the second controller31B of the second guide moving mechanism11B included in the second tape feeder8B controls the intervals of the second tape feeding guides10B based on the widths of the first tapes TA measured by the first width sensors30A included in the first tape feeder8A and the widths of the third tapes TC measured by the third width sensors30C included in the third tape feeder8C so that the intervals of the second tape feeding guides10B may become appropriate intervals corresponding to the widths of the first tapes TA fed out from the first tape feeder8A and the widths of the third tapes TC fed out from the third tape feeder8C, more specifically, so that the intervals of the second tape feeding guides10B may become intervals which allows disposing the first tapes TA fed out from the first tape feeder8A and the third tapes TC fed out from the third tape feeder8C without overlapping the first to third tapes TA, TB and TC with each other. It is similar for the third controller31C of the third guide moving mechanism11C included in the third tape feeder8C.

When the guide moving mechanism11is driven by the motor21as exemplified byFIG.5andFIG.6, the motor21is the controlled target by the controller31. Therefore, the intervals of the tape feeding guides10are controlled by outputting a control command signal of the rotation amount of the motor21, corresponding to the intervals of the tape feeding guides10, from the controller31to the motor21.

Controlling the intervals of the tape feeding guides10according to the widths of the tapes T actually measured by the width sensors30as described above allows changing the intervals of the tape feeding guides10while following the widths of the tapes T even when the widths of the tapes T change during feeding of the tapes T. Accordingly, the tapes T can be supplied to the fiber arranging device1A while changing the widths of the tapes T during feeding of the tapes T.

FIG.14is a top view showing an example of forms of the tapes T which can be arrayed by the fiber arranging device1A shown inFIG.13.

The tapes T supplied to the fiber arranging device1A while changing the widths with a constant amount of change per unit time has a trapezoidal form overall as shown inFIG.14. That is, the total width of the arrayed tapes T can be changed by arraying the tapes T, each having a non-constant width, by the fiber arranging device1A. As a matter of course, the tapes T may be supplied to the fiber arranging device1A while changing the widths with a non-constant amount of change per unit time. In that case, the overall shape formed by the arrayed tapes T can be made more complicated.

When the tapes T are supplied to the fiber arranging device1A while changing the widths, it is necessary to dispose the width adjusting devices3in the front stage of the fiber arranging device1A as shown inFIG.1. In addition, it is also necessary to control not only the intervals of the tape feeding guides10but the width adjusting devices3in real time during feeding of the tapes T. Accordingly, feedback control may be performed based on the widths of the tapes T measured by the width sensors30so that the widths of the tapes T fed out from the corresponding width adjusting devices3may become target widths respectively.

FIG.15shows an example of a control block diagram for feedback control of the width adjusting devices3based on the widths of the tapes T measured by the width sensors30shown inFIG.13.

As shown inFIG.15, the width of the tape T adjusted by the width adjusting device3is measured by the width sensor30. The width of the tape T measured by the width sensor30is output to the controller31of the corresponding guide moving mechanism11in order to control the intervals of the corresponding tape feeding guides10B.

In addition, the width of the tape T measured by the width sensor30can be also output to the corresponding width adjusting device3. Then, feedback control of the width adjusting device3can be performed so that the differences between target values of the width of the tape T given to the width adjusting device3as time series control-command values and the actual measured values of the width of the tape T measured by the width sensor30may approach zero.

AlthoughFIG.15shows the control block diagram focusing on one width adjusting device3, the width adjusting devices3whose number is the same as the number of the tapes T can be integrally controlled. Therefore, feedback control of the width adjusting devices3can be performed by setting a total width of the arrayed tapes T as a target value.

When the variation in the width among the tapes T fed out by the same tape feeder8is negligible, only the width of one tape T or the widths of a part of tapes T, out of the tapes T fed out by the same tape feeder8, may be measured by at least one width sensor30as representative value or representative values. In this case, each width of the tape T which was not measured by the width sensor30may be considered as the representative value or an estimate value based on the representative values.

According to the above-mentioned second implementation, an effect that the tapes T can be fed out while changing the total width of the arrayed tapes T can be attained in addition to the effects similar to those in the first implementation. Accordingly, it becomes possible to mold an FRP having a more complicated form.

Note that, the tapes T can be fed out while changing the total width of the arrayed tapes T also in the first implementation by controlling the guide moving mechanisms11with a prepared control program, in which the amounts of change of the intervals of the tape feeding guides10have been defined based on the amounts of change of the widths of the tapes T to be supplied, i.e., a control program for defining time series positions of the tape feeding guides10. Nevertheless, controlling the guide moving mechanisms11based on the widths of the tapes T measured by the width sensors30like the second implementation can make it unnecessary not only to create a control program for every form of FRP but to prepare a complicated control program itself.

(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.