CN101925450A - 多层的柔性的平面材料 - Google Patents
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Abstract
一种在制造由纤维复合半成品(1)构成的纤维增强的塑料构件时用于限定基质输入腔的多层的柔性的平面材料,其中此平面材料由多功能层压体(40)构成,此多功能层压体(40)具有薄膜(41)、层压在薄膜(41)上的纺织层(42)以及设置在纺织层(42)上的间隔保持层(43)。
Description
技术领域
本发明涉及一种在借助于用于注入基质材料(matrix material)的注入方法制造由纤维复合半成品构成的纤维增强的塑料构件时用于限定基质输入腔的多层的柔性的平面材料,其中平面材料具有透气的然而不透基质的薄膜、不透气的箔和高度透气的间隔保持层,此间隔保持层设置在薄膜和箔之间并且在薄膜和箔之间产生低压时使箔与薄膜保持一定距离。
背景技术
在制造纤维增强的塑料构件时,已知的是,首先使干燥的纤维复合半成品(所谓的预制件),它们吸收了可流动的、可硬化的基质材料(形式是树脂)。此干燥的纤维复合半成品在此可以是织物、多维铺放物(Gelege)或链增强的单向的半成品,并尤其由碳纤维、玻璃纤维、尼龙纤维、硼纤维或混合物质构成。
已知的是,用来制造纤维增强的塑料构件的方法是所谓的树脂膜熔渗(RFI)方法。在此,干燥的碳纤维-织物或铺放物存放在硬化装置中,并从外面覆上规定量的树脂膜。紧接着,由碳纤维和树脂构成的塑料构件在高压锅或其它的压力容器中在压力和温度下硬化。但是,使用压力容器和为此所需的复杂工具都是很麻烦的。此外,这种方法在温度和压力方面很难操控。此外,提供的高压锅限制了待制造的塑料构件的大小。
为了避免这些缺点,已经研发出了一种在DE 10013409C1中描述的方法,它被称为“VAP”(真空辅助工艺)。在这种方法中,使用了按权利要求1前序部分所述的多层的柔性的平面材料,借助它限定基质输入腔,半成品设置在此基质输入腔内。平面材料在该处由多个相互隔开、相互独立操作的材料层构成,即透气但不透基质的薄膜、高度透气的间隔保持层和不透气的箔。这些材料层依次单个地摆放在流动辅助层上,此流动辅助层铺放在半成品上。如果现在箔和薄膜之间区域被抽成了真空,并因此产生了低压,则穿过薄膜,在位于内部的基质输入腔中压力相应地被降低,由此可流动的树脂从外部的树脂容器中吸入基质输入腔中。在此,薄膜虽然使气体从基质输入腔中流到间隔保持层中,并从该处往向泄露,但同时把树脂拦在基质输入腔中,因此树脂可渗入半成品中。
尽管与使用高压锅的方法相比,这种VAP方法具有明显的优势,但还存在一定的问题,平面材料的每个单个层,即薄膜、间隔保持层以及不透气的箔,必须依次非常精确且无应力地摆放在半成品上方。这一点是相当耗费时间的,并且这一点如果进行得不是非常精确,就会对过程安全性产生负面影响,并且会导致基质材料的不均匀积聚。
发明内容
因此本发明的目的是,提供一种前述类型的多层的柔性的平面材料,借助它能以尽量简单、快速、成本划算且精确的方式执行VAP方法。
按本发明,此目的借助具有权利要求1特征的多层的柔性的平面材料得以实现。在其它的权利要求中描述了本发明的有利实施方式。
在按本发明的平面材料中,薄膜、被层压在薄膜上的纺织层(Textillage)以及设置在纺织层上的间隔保持层一起构成多功能层压体,并因此彼此牢固地连接在一起。“多功能层压体”在此意味着,产生由多个专门的材料层制成的层压体,它同时满足多个功能,即一方面满足薄膜的功能,它是透气的并且对基质材料是密封的;另一方面满足间隔保持层的功能,当在薄膜和箔之间产生低压时,此间隔保持层使不透气的箔与薄膜保持一定距离,因此使薄膜和箔之间的空间保持敞开。
通过单个材料层牢固连接成层压体,不再需要把这些材料层单个地依次铺放。这一点可以在唯一的加工过程中实施。这明显地缩短了把平面材料设置在半成品上方的工作时间。此外还排除了各种危险,即平面材料的单个材料层不能有秩序地和无应力地上下叠置。因此能提高过程安全性和精确性。并减少制造成本和材料成本。
按有利的实施方式,箔与间隔保持层牢固地连接,因此箔也是多功能层压体的一部分。在这种情况下,多功能层压体承担着附加的功能,使基质输入腔(包括多功能层压体的相邻材料层)朝外气密地封闭,因此由箔包围的空间可有效地抽成真空。这种多功能层压体还可再次缩短把平面材料设置在半成品上方的时间,并额外地确保箔有秩序地且无应力地设置在间隔保持层上方。
按有利的实施方式,间隔保持层具有多个单独的、构成为隆起的间隔保持部件。这些间隔保持部件在此按目的地这样进行设置,即优化气体在各间隔保持部件之间与薄膜或箔平行的穿透性。但对此还可备选的是,为间隔保持层使用高度透气的织物、针织品、网状物和其它材料。
附图说明
下面借助附图示例性地详细阐述了本发明。其中:
图1在剖面图中示出了用来制造纤维增强的塑料构件的装置,用来说明按现有技术的VAP方法;
图2在示意图中示出了按本发明的平面材料的第一实施例,其中只是为了清晰起见各单层是相互隔开的;以及
图3在示意图中示出了按本发明的平面材料的第二实施例,其中只是为了清晰起见各单层是相互隔开的。
具体实施方式
首先借助图1的装置详细阐述了按现有技术的VAP技术。
图1所示的装置示出了待制造的构件或干燥的纤维复合半成品1,它例如借助结构5设置在工具3上。此构件或层压体(Laminat)在此可以是指由碳纤维(CFK)、玻璃纤维(GFK)、尼龙纤维(AFK)、硼纤维(BFK)或混合材料构成的塑料制品,并尤其用来制造未加固的和加固的、大面积的装饰板、塑料工具或用来修复损坏的FVW构件的杆柄。工具3具有适当的形状,用来容纳半成品1或(必要时)上层结构,并且可由不同的合适材料(例如木材、钢材、金属片、玻璃和类似材料)构成。
此构件用半渗透的薄膜7覆盖,此薄膜7是透气的,但能阻止基质材料的穿透。此薄膜7位于周边表面8的外部,但借助密封件9尽量紧密地密封在构件1上,此密封件9用来封闭由薄膜7和覆盖层5或工具表面3构成的内腔25。备选的是,薄膜7也可围绕着整个构件1进行引导。在构件1和薄膜7之间,在构件1的整个面向薄膜7的表面上设置撕开织物13(Abreiβengewebe)(可选的)和流动辅助件15,撕开织物13或流动辅助件15的功能是,使薄膜7与构件1的表面保持一定的距离。此流动辅助件15可以是指格栅或栅栏亦或坚固的织物或针织品或网状物,它在真空下不能被强烈地压缩,并例如由金属、塑料或纺织的半成品构成。
由结构5、纤维复合半成品1和薄膜7与密封件9、撕开织物13和流动辅助件15构成的结构利用不透气的箔19覆盖。此箔19围绕着薄膜7的周边借助密封件21密封在工具3上,因此由工具3的表面23和箔19的内壁构成的空间27朝周围环境是密封的。在箔19和薄膜7之间嵌入了形式为通风织物32的间隔保持层,它例如可以是玻璃织物、无纺布或类似物体。此通风织物32的功能是,将此外穿透薄膜7从空间27中被抽出的空气和气体沿着薄膜表面引导,并且如果此空间借助真空泵29和插入内腔27中的相应气体导管31抽真空,则在此使箔19与薄膜7保持一定距离。
为了把基质材料导入构件1中,软管或导管13(它们接在未示出的树脂贮存器上)导向流动辅助件15。内腔25因此是基质输入腔。
在已知的方法中,通过以下方法来制造纤维增强的塑料构件,即干燥的纤维复合半成品首先按构造上的规定进行定位并且因此层压体结构由多个半成品单层构成。工具3是分开的(eingetrennt),即借助分离介质或分隔箔和撕开织物(一起在构件1的构件下侧上构成结构5)来做预先处理,以避免基质材料与工具3粘合在一起并且使得可以将构件从工具表面上再次分开(脱模)。构件1的干燥半成品优选设有撕开织物13。此外,流动辅助件15在该结构5的上方通过简单的铺放就被加设。只能渗透空气、但不能渗透液体的薄膜7铺放在此流动辅助件15上,并借助密封件21进行密封。紧接着,通风织物32平放在薄膜7上,并借助箔19和密封件21朝周围环境是密封的。在此过程中,基质输入导管33和真空导管29借助常规的实施方法和按图1的密封进行设置。
在加设所述的材料和不透气的箔19之后,空间27借助真空泵29抽成真空。同时,基质材料-贮存器连接到系统上。以便把基质材料导入内腔25中。通过真空产生压差,此压差把基质材料从贮存器中吸到抽成真空的内腔25中。此基质材料从现在开始通过流动辅助件15和导管33被分布在构件表面上。存在的空气在此通过内腔25的长期抽吸透过薄膜7被清除。在此,基质材料从构件表面垂直地朝下地渗透到层压体中。一旦完全浸透结束后,则在保留相同真空的情况下通过适当的温度实现硬化。在此通过化学工艺产生的气泡通过薄膜7排出。
构件在硬化后脱模,其中此方法的所有辅助物质都手动去除,并且构件最终也从工具3上去除。
从上述的实施方式中可知,在已知的、借助附图1描述的方法中,薄膜7、起间隔保持层作用的通风织物32和不透气的箔19必须单个地且依次地设置在构件1或流动辅助件15上方,这是很耗时间并会影响过程安全性。
下面借助图2描述了按本发明的平面材料的第一实施形式。
此平面材料是指多功能层压体40,它承担了图1所述的薄膜7和通风织物32的功能。此多功能层压体40包含薄膜41、纺织层42和间隔保持层43。
薄膜41是指半渗透的、多微孔的、憎水的聚脂胺薄膜,它可应用在低温和高温VAP技术中,或是指半渗透的、多微孔的、憎水的膨体聚四氟乙烯(ePTFE)薄膜,它尤其应用在高温VAP方法中。按照图1的构造方案,多功能层压体40这样设置在半成品1或(必要时)流动辅助件15(图1)的上方,即薄膜41位于多功能层压体40的面向半成品1的侧面上。薄膜41一方面对导入内腔25中的基质材料(树脂)是不可渗透的,但对气体是可渗透的,因此内腔25也可透过薄膜41被抽成真空,并且气体可通过薄膜41排出。
被层压在薄膜41上的纺织层42首先用来加强薄膜41。纺织层42可由织物、针织品、无纺布或编织物构成。尤其可使用多元酯、贝纶、尼龙或聚丙烯,作为纺织层42的材料。在任何情况下,纺织层42都构成为不会以不期望的方式影响薄膜41的透气性。薄膜41和纺织层42之间的连接可通过层压工艺实现,在此可使用网有湿气的PU-层压系统或一般的热粘胶剂。此粘胶剂在此也可点状地进行涂敷,以便尽可能小地损害薄膜41的透气性。
间隔保持层43承担着通风织物32(图1)的任务,并这样构成,即当箔44和纺织层42(或薄膜41)之间的空间被抽成真空时,则安放在间隔保持层43上的不透气的箔44与纺织层42保持一定距离。此间隔保持层43在图2的实施例中由各单个的彼此分开的间隔保持部件45构成,它们彼此隔开距离地设置在纺织层42上。间隔保持层43的高度可在170μm和1000μm之间。间隔保持部件45这样进行设置,即在将空间27(图1)抽成真空时,气体能尽量不受阻挡地平行于多功能层压体40的主平面在各间隔保持构件45之间穿流。间隔保持部件45可以例如指泡沫粒结。此外还可能的是,间隔保持层43由高度透气的纺织织物、针织品或编织物构成。间隔保持层43与纺织层42固定相连,其中根据材料可使用一般的粘合技术。
因此,图2所述的多功能层压体40由固定的复合体构成,此复合体包含薄膜41、纺织层42和间隔保持层43。在此实施例中必要的是,将图3所示的不透气的箔44随后还铺放在间隔保持层43上。
图3示出了按本发明的多功能层压体40′的第二实施例,它与图2所示的实施例的不同之处仅在于,不透气的箔44已经是多功能层压体40′的固定组成部分。此箔44在此牢固地固定、尤其是粘合在间隔保持层43或间隔保持部件45的表面上,并因此构成第四层压层。多功能层压体40′的其它构造,即薄膜41、纺织层42和间隔保持层43都与图2的实施例是一致的,因此有关它们可参照那里的描述。
与多功能层压体40相比,多功能层压体40′的优点是,不必事后单独地、手工地安放不透气的箔44,因此可加速待抽真空的空间27相对于周围环境的密封,并确保此箔44最佳地放置在间隔保持层43上。
Claims (4)
1.一种多层的柔性的平面材料,所述平面材料在借助于用于注入基质材料的注入方法制造由纤维复合半成品(1)构成的纤维增强的塑料构件时用于限定基质输入腔,其中平面材料具有透气的然而不透基质的薄膜(41)、不透气的箔(44)和高度透气的间隔保持层(43),此间隔保持层(43)设置在薄膜(41)和箔(44)之间并且当在薄膜(41)和箔(44)之间产生低压时将箔(44)与薄膜(41)保持一定距离,其特征在于,薄膜(41)、被层压在薄膜(41)上的纺织层(42)以及设置在纺织层(42)上的间隔保持层(43)一起构成为多功能层压体(40、40′)并且由此被牢固地彼此连接。
2.按权利要求1所述的平面材料,其特征在于,箔(44)与间隔保持层(43)牢固地连接,从而箔(44)也是多功能层压体(40′)的一部分。
3.按权利要求1或2所述的平面材料,其特征在于,间隔保持层(43)具有多个单独的、以隆起的形式构成的间隔保持部件(45)。
4.按上述权利要求之任一项所述的平面材料,其特征在于,间隔保持层(43)具有170μm至1000μm的厚度。
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