CN101379237B - 由高抗拉纱线构成的三维织物部件结构及其制造方法 - Google Patents

由高抗拉纱线构成的三维织物部件结构及其制造方法 Download PDF

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CN101379237B
CN101379237B CN2007800050437A CN200780005043A CN101379237B CN 101379237 B CN101379237 B CN 101379237B CN 2007800050437 A CN2007800050437 A CN 2007800050437A CN 200780005043 A CN200780005043 A CN 200780005043A CN 101379237 B CN101379237 B CN 101379237B
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弗伦茨-于尔根·金佩尔斯
格雷戈尔·鲍姆加特
卡尔-约瑟夫·布洛克曼尼斯
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Abstract

本发明涉及一种部件结构，该部件结构包括：通过将由高抗拉纱线制成的纱线片(3，4)叠置布置而形成的缠绕层、以及至少一个沿该部件结构的纵向延伸的、由高抗拉纱线构成的纱线片(2)，其中，纵向延伸的纱线片中的纱线的位置利用由交叉纱线系统构成的织物结构(5)固定。通过防止承载纱线层交叉，不仅角度可以按照几乎无限的并且适应于载荷的方式取向，而且还限制了为此所需的纱线数量。

Description

由高抗拉纱线构成的三维织物部件结构及其制造方法
技术领域
本发明涉及一种三维织物部件结构以及一种制造该三维织物部件结构的方法。
背景技术
越来越多地使用高抗拉织物线(例如碳纤维)生产沿部件长度具有恒定乃至不恒定的横截面轮廓的部件的三维结构。这些高抗拉纱线可以接纳沿它们纵向方向的很大的力而不会发生永久变形。这些织物结构或者形成这些部件的加强件，或者本身是该部件的主要组成部分。在后一种情况下，该织物结构尤其利用弹性粘合装置(例如合成树脂)而稳定形状。这种部件用于汽车或航空领域，以及用于一般机器制造和工厂设备制造的高性能部件的领域。这些织物结构的主要优点是在高强度值的同时重量特别小，当它们用于运动部件、尤其是加速部件时这尤其可减小惯性。
一个经常性应用是以基本具有期望部件形状的成形体用作织物部件结构的芯部。
在这方面，已知通过围绕预成形芯部进行编织而形成织物部件结构。在此情况下，可利用线轴系统以相对于部件芯部的纵向轴线呈0°到+/-45°的角度将纱线织入该编织物中。对于部件内的90°载荷的情况，由于载荷方向与编织物的所有纱线的纱线纵向方向都不同，所以需要使用大量材料。此外，45°纱线和0°纱线的同时处理由于脱纱和捻接而会在编织过程中产生问题，该问题是由来自两个纱线系统的碳丝的经纱部分产生的。如果出于这个原因而将0°碳纱线织入45°的玻璃丝，则该结构在90°载荷下非常不稳定。沿纵向方向的玻璃丝又会导致沿纵向方向不稳定。
因此，本发明的任务是提出一种三维织物部件结构，该结构更好地适合于预期的载荷，并且还提出一种相应的生产该三维织物部件结构的方法。
发明内容
上述目的通过本发明的第一方面来实现，在该第一方面中提供了一种由高抗拉纱线制成的三维织物部件结构，在预期使用中该结构承受沿限定方向的载荷，其特征在于，该织物部件结构包括：通过将由高抗拉纱线制成的纱线片叠置布置而形成的缠绕层；以及至少一个沿该部件结构的纵向延伸的、由高抗拉纱线制成的纱线片，并且每个纵向延伸的纱线片的纱线的位置利用由交叉纱线系统制成的织物结构而被固定。这一目的也通过用于生产根据所述第一方面的所述三维织物部件结构的方法来实现。通过其它方面有利地改进了本发明。
根据第一方面，根据本发明的三维织物部件结构包括：由高抗拉纱线制成的纱线片的叠置的缠绕层以及沿该部件结构延伸的至少一个由高抗拉纱线制成的纱线片，其中，由高抗拉纱线制成的纵向延伸的每个纱线片的纱线通过由交叉纱线系统制成的织物结构而相对于它们的位置被固定。
该三维织物部件结构的支承部分由分层叠置地设置的纱线片形成，这些纱线片彼此不具有相交点或粘合点，具有相交点或粘合点会产生经线部分并损坏纤维结构。这些纱线片几乎可以以任何角度放置。类似于叠放纱线片的角度，纱线片的各自的密度也可匹配于各自方向的载荷状况。
由交叉纱线系统制成的织物结构仅具有固定纵向延伸的纱线片的纱线层的作用，即使部件结构的横截面改变，这些纱线仍保持均匀地分布在周边上，换句话说，这些纱线在周边上相对于彼此具有基本相同的间隔。在非常大的纵向力下，根据本发明的层结构也可具有均通过一个织物结构固定的并沿纵向延伸的多个纱线片。
通过使各个纱线片的叠放角与部件轴线相匹配可以使得在加载期间的分力基本沿高抗拉纱线的纵向延伸。这导致最佳地利用了高抗拉纱线的材料。继而，这导致对于特定载荷状况而言可经济地使用纤维材料。纱线的叠放方向和数量相应地适合于该载荷状况。纱线片的相对于部件的纵向轴线的叠放角的范围包括从0°到大约90°。因此，覆盖了所有可想到的载荷变化。因此，针对所需的力的接收，本发明给出了一种措施得当的构造。
另选的是，纱线片可以以保持相同或变化的叠放角铺设。保持相同的角度确保纱线层具有均匀紧密的结构，而对于变化的角度，可以以最优的方式考虑局部荷载状态。因此，必须根据使用该部件时已知载荷结构相应地预先确定叠放结构。
固定纵向纱线的织物结构可用这样的纱线形成，对该纱线的抗拉强度的要求比不上高强度纱线，并且该纱线本身在相交点处不会受到任何损坏。为此，例如可使用玻璃丝，玻璃丝比例如碳纤维制成的纱线经济得多。
在本发明的一改进中，织物结构的交叉纱线系统被按照有利于高抗拉纱线的拉伸位置的方式强烈地变形(所述交叉纱线系统的纱线有利地具有比高抗拉纱线更小的横截面)，从而使通过交叉形成的纹理几乎完全由交叉纱线接纳。这确保了接收载荷的纱线的拉伸位置沿着力加载的方向。纵向纱线有利地作为所谓的地经(Stehfaden)而被织入织物结构。
该织物结构可以可选地构造成编织或针织织物。该部件结构例如被树脂三维地稳定。
就该方法来说，围绕预成形芯部以不同角度相继地设置由纱线片制成的纱线层，换句话说，铺设机构和部件彼此相对地运动，其中，该铺设机构被顺序布置。结果，这些层围绕部件芯部相继以不同角度形成。沿该部件结构延伸的纱线片的位置利用交叉纱线系统的织物结构而被固定。关于各个纱线层的设置的顺序没有强制规定，即使纵向设置的纱线片形成最内部层也是有利的。但是，可以形成由纵向延伸的纱线制成的另一个的层。
该不同铺设角度一方面由引导纱线片的铺设装置的圆周速度确定，而另一方面由部件和铺设装置之间的相对速度确定。例如，在铺设装置和部件之间具有相同的相对速度的情况下，如果铺设装置的圆周速度增加，则相对于部件的纵向轴线或部件的芯部的角度也增加。在用于纱线片的铺设装置具有非常高的圆周速度，而部件具有供给速度较低的情况下，则可实现几乎90°的叠放角。如果铺设装置不参与旋转，则叠放所谓的0°纱线，该纱线与该部件轴线同轴地延伸。这些纱线然后作为所谓的地经织入织物结构。根据铺设装置的不同的旋转方向，可实现相对于纵向轴线正的或负的叠放角。
通过改变相应的速度，铺设角可适应局部要求。
用于固定纵向定向的纱线层的交叉纱线系统的织物结构实际上对于部件结构的后续使用特性并不重要。因此，应强调，材料的使用被选择为尽可能地少或必要地少，并且该方法确保高生产率。换句话说，该结构还可被设计成相对地开放，从而提高该过程的效率。尤其有利的是，以相对低的纱线张力供给交叉纱线，以便利用这些纱线几乎完全接纳通过交叉产生的纹理，而接收力的纵向纱线几乎被完全拉伸地嵌入该织物结构。
由于纵向纱线的铺设过程和固定过程可同步进行，换句话说，可以在部件结构的运行过程中分级地进行，从而可确保高生产率。
通过随后用树脂凝固，该结构在空间上还被如此固定，即：使得在生产织物部件结构时必要的芯部可以在随后被去除。这样将得到中空体部，该中空体部具有良好的弹性特性以及非常好的支承特性。其低重量还确保具有优异的使用特性。
芯部的除去可通过芯部材料的溶解(可溶沙)或收缩(例如，膨胀结构)而实现。
附图说明
下文将借助于一个实施方式进一步说明本发明。唯一的附图示出了处于生产过程中的包含芯部的织物部件结构。
具体实施方式
芯部1例如被形成为汽车的保险杠。借助用于纱线片2至4的相应的供给元件以及用于生成编织物5的编织工具将该芯部1沿箭头方向推动。
首先，供给纱线片2，该纱线片的供给元件被设置为固定不动，从而该纱线片相对于芯部1的纵向轴线平行地放置。该纱线片2借助编织物5而被织成一片的所谓的地经，并且其位置被固定，从而即使芯部的形状和横截面改变，纱线片2的纱线在芯部1的周边上也彼此相隔相同的间隔。
纱线片3被沿顺时针方向围绕芯部1以较高圆周速度放置，从而产生大约70°的叠放角。纱线片4被沿反方向围绕芯部1以较低圆周速度放置。这产生-60°的叠放角。
作为芯部1的运动的另选方案，对应的放置机构和编织机构也可沿该部件运动。在每种情况下，这依赖于相应的相对速度。
为了简化起见，附图仅示出各个纱线片3、4的一股纱线。实际上，术语“纱线片”是指相互平行地放置的一片纱线。在此情况下，纱线片的宽度应被调整为，在缠绕期间，层被相互紧邻地搁置，使得不仅在该纱线片内，而且在螺旋延伸的层之间都可确保保持恒定的纱线间隔。

Claims (21)

1.一种由高抗拉纱线制成的三维织物部件结构，在预期使用中该结构承受沿限定方向的载荷，其特征在于，该织物部件结构包括：通过将由高抗拉纱线制成的纱线片(3，4)叠置布置而形成的缠绕层；以及至少一个沿该部件结构的纵向延伸的、由高抗拉纱线制成的纱线片(2)，并且每个纵向延伸的纱线片(2)的纱线的位置利用由交叉纱线系统制成的织物结构(5)而被固定。
2.根据权利要求1所述的三维织物部件结构，其特征在于，所述纱线片设置成与所述部件轴线成一定角度，该角度与该限定的主载荷方向相匹配，从而使在加载过程中作用的分力基本沿该高抗拉纱线的纵向延伸。
3.根据权利要求1或2所述的三维织物部件结构，其特征在于，各个纱线片内的高抗拉纱线的数量不同，并且与提供的载荷的大小相匹配。
4.根据权利要求1或2所述的三维织物部件结构，其特征在于，所述叠置布置的纱线片相对于所述三维织物部件结构的纵向轴线被设置在0°到90°的范围内。
5.根据权利要求4所述的三维织物部件结构，其特征在于，每个所述纱线片被以保持恒定的角度铺设。
6.根据权利要求4所述的三维织物部件结构，其特征在于，至少一个纱线片的叠放角根据在该部件的预期使用过程中该部件的局部载荷状态而变化。
7.根据权利要求1或2所述的三维织物部件结构，其特征在于，用于固定纵向延伸的所述纱线片(2)的所述织物结构(5)是由纱线形成的，这些纱线相对于缠绕层的高抗拉纱线来说是廉价的，并且具有较低的抗拉强度。
8.根据权利要求4所述的三维织物部件结构，其特征在于，所述用于固定的织物结构(5)的纱线的横截面小于该高抗拉纱线(2-4)的横截面，并且不会消极影响该高抗拉纱线的基本展开的形式。
9.根据权利要求1或2所述的三维织物部件结构，其特征在于，所述用于固定的织物结构(5)通过编织形成。
10.根据权利要求9所述的三维织物部件结构，其特征在于，将要被固定的纱线片(2)的纱线作为地经织入到该织物结构(5)中。
11.根据权利要求1或2所述的三维织物部件结构，其特征在于，所述用于固定的织物结构(5)是针织结构。
12.根据权利要求11所述的三维织物部件结构，其特征在于，将要被固定的纱线片(2)的纱线作为地经织入到该织物结构(5)中。
13.根据权利要求1或2所述的三维织物部件结构，其特征在于，所述纱线片是借助合成树脂在空间上稳定的。
14.用于生产根据权利要求1所述的三维织物部件结构的方法，所述三维织物部件结构至少在其生产过程期间围绕预成形芯部设置，其特征在于，围绕该预成形芯部(1)将纱线片(2-4)以不同角度相续地铺设成纱线层，以产生由平行的高抗拉纱线制备的独立层，其中，通过由交叉纱线系统制成的织物结构(5)固定沿该部件结构延伸的至少一个纱线片(2)，同时缠绕其余的至少两个纱线片(3、4)。
15.根据权利要求14所述的方法，其特征在于，通过引导所述纱线片的铺设装置的圆周速度并根据部件芯部相对于该铺设装置的位置改变速度的关系来调节不同的铺设角度。
16.根据权利要求15所述的方法，其特征在于，所述织物结构(5)的交叉纱线以这样低的纱线张力供给，即：所述织物结构的交叉纱线不会使它们所固定的由高抗拉纱线制成的纱线片(2)偏离纱线片(2)的铺设方向。
17.根据权利要求14到16中任一项所述的方法，其特征在于，所述纵向延伸的纱线片(2)通过编织而被固定。
18.根据权利要求14到16中任一项所述的方法，其特征在于，所述纵向延伸的纱线片(2)通过针织而被固定。
19.根据权利要求14所述的方法，其特征在于，所述三维织物部件结构在其生产之后被凝固有合成树脂，从而使其形状固定。
20.根据权利要求19所述的方法，其特征在于，在所述织物部件结构的形状固定之后，除去所述预成形芯部(1)。
21.根据权利要求20所述的方法，其特征在于，所述芯部(1)被溶解或被收缩，并且将其在这种状态下从中空的所述部件结构中移除。
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