CN102762360B - 用于制造由热塑性塑料制成的环状纤维增强的成型件的方法以及机动运输工具成型件 - Google Patents
用于制造由热塑性塑料制成的环状纤维增强的成型件的方法以及机动运输工具成型件 Download PDFInfo
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Abstract
本发明涉及一种用于制造由热塑性塑料制成的环状纤维增强的成型件(1)的方法,其包括下述步骤:-提供已裁剪的、基本上平面地构造的、单向纤维增强的垫(2),该垫具有至少部分地包围所述纤维的热塑性基质;-将所述垫(2)转移到预先确定所述成型件(1)的粗糙轮廓(4)工件支架(5);-将在所述工件支架(5)上的所述垫(2)放置并且持续地构造为三维的预型件(6),使得所述垫(2)的所述纤维定向与在稍后使用所述成型件(1)时作用的力和在所述成型件(1)内由此产生的负载路径相协调;-在结束制造所述预型件(6)期间或结束制造所述预型件(6)后将所述垫(2)彼此位置固定;-加热所述预型件(6)直至或者超出所述预型件(6)的所述热塑性基质的熔化温度;-将三维的所述预型件(6)装入到形成所述成型件(1)的最终轮廓的所述成型模具(10)中;-调节均匀的成型模具内压,以用于在维持所述预型件(6)内的所述纤维定向的同时确保所述预型件(6)的加固;-将已加固的所述成型件(1)从所述成型模具(10)中取出。
Description
技术领域
本发明涉及一种用于制造由热塑性塑料制成的环状纤维增强的成型件的方法以及一种机动运输工具成型件。
背景技术
文献US 7235149B2说明了一种用于制造由环状纤维增强的热塑性塑料制成的机动运输工具成型件的方法。在这种情况下,这些带环状纤维增强的预成型件在平坦的面上彼此以不同的角度放置。在此形成的平的纤维织物接着被预热,并且通过热成型变形。根据构件的壁厚实现在分开的或在相同的热成型模具中的加固。
在现有技术上不利的是,压制过程由于必要的材料盈余导致材料废料的增多。此外,在压制过程中才产生的3D结构和环状纤维在变形过程中与所述3D结构相关联的强制定向仅代表在第三维中的纤维定向和材料的需要的流动路径之间的折衷。此外不利的是,为了获得高的变形度,对可流动的材料,也就是说,对热塑性基质的提高的需求是必要的,这强制地导致构件重量的提高。此外,不能实现很高的变形度,因为否则会导致在环状纤维增强的成型件内的纤维断裂。
发明内容
因此,本发明基于的目的在于,提出一种用于制造由热塑性塑料制成的环状纤维增强的成型件的方法,所述目的克服了现有技术的缺点。
根据本发明,所述目的通过一种如下所述用于制造由热塑性塑料制成的环状纤维增强的成型件的方法得以实现。
根据本发明的方法包括下述步骤:
-提供已裁剪的、基本上平面地构成的、单向纤维增强的垫,所述垫具有至少部分地包围所述纤维的热塑性基质;
-将所述垫转送到预先确定成型件的粗糙轮廓的工件支架;
-将在工件支架上的所述垫放置并且持续地构造成三维的预型件,使得所述垫的纤维定向与在稍后使用成型件时作用的力和在成型件内由此产生的负载路径相协调;
-在结束构造预型件期间或者在结束构造预型件后使所述垫彼此位置固定;
-加热所述预型件直至预型件的热塑性基质的熔化温度或者超过预型件的热塑性基质的熔化温度;
-将三维的预型件装入形成成型件的最终轮廓的成型模具中;
-调节均匀的成型模具内压,以用于在维持预型件内的纤维定向的同时确保预型件的加固;
-将加固的成型件从成型模具中取出。
根据本发明,以有利的方式通过将单向纤维增强的垫预先成型成三维的预型件实现了,在随后的加固步骤中成型件基本上不必经历变形过程或流动过程。因此,相比于在现有技术中的情况,以有利的方式需要更少的可流动的材料,也就是说,需要更少的热塑性基质。此外,由于根据本发明的也实现在第三维中的纤维定向的可能,作用在借助于根据本发明的方法制成的成型件上的力和在成型件内由此产生的负载路径能够通过单向纤维增强最优地吸收。
因此,由于纤维定向的优化和可流动的材料的份额减少获得具有轻的重量和相比于现有技术的成型件更小的壁厚的成型件,这特别也在运输工具中受限的结构空间方面提供了大的优点。此外,由于可流动的材料的减少提高了纤维含量,这同样有助于重量降低和力吸收的优化。单向纤维增强的垫优选由单向薄膜裁剪而成。与仅公开了带形结构的现有技术相比,能够通过目的明确地裁剪所述垫使再加工和在此产生的材料部段减少到最少。所述垫的纤维增强优选通过矿物纤维、特别是玻璃纤维、和/或碳纤维、和/或聚酰胺纤维、和/或聚合物纤维、和/或合成纤维和/或由可再生原料的纤维制成。
能够有利的是,借助于焊接方法实施所述垫彼此间的位置固定。在此,所述垫的位置固定优选通过超声波焊接方法和/或加热元件焊接方法和/或激光焊接方法。所述垫的下料在预型件构造结束期间或预型件构造结束后的彼此间的位置固定提供了优点,即预型件具有明显改善的可操作性。
此外,为了所述垫彼此间的位置固定,纺织技术方法优选使用针织和/或缝纫。
所述垫优选在放置在工件支架上之前至少局部预加热,以用于提高所述垫的柔性。通过所述垫的提高的柔性有利地实现,所述垫在放置到工件支架上时能够更好地与三维的粗糙轮廓相匹配。优选的是设置为工件支架加热,以便能够维持所述垫的柔性。
预型件加热或垫的预热优选通过对流加热和/或红外辐射实现。此外,优选在对流连续加热炉和/或红外连续加热炉内。对于已经具有三维的粗糙轮廓的构件,通过红外辐射的或通过对流加热的加热是用于均匀地加热整个预型件的最优方法。
为了转移所述垫和/或为了装入预型件,能够使用机器人系统。在此,特别是能够使用具有可替代的软件支持的摄像监控单元和控制单元(图像识别)的四脚结构系统(例如ABB公司的所谓的FlexPickerTM)。通过使用机器人系统实现了使方法时长相对于手动方法有利地缩短。附加的是,通过使用机器人可实现高的可重复性。这特别是在所述垫彼此间可重复定向和在成型件内与此相关联的纤维定向方面是非常有利的。
均匀的成型模具内压的调节优选通过在成型模具内以注塑法在边缘侧上注射环绕的塑料防水条实现。此外,均匀的成型模具内压的调节能够通过附加地插入GMT块(玻璃垫增强的热塑性塑料),进一步优选通过注射料槽式技术或者通过将密封绳插入到成型模具中或者通过将密封膜插入成型模具中实现。此外,在本发明的范围中,上述可能性能够以任意的组合使用。由于通过上述可能性调节均匀的成型模具内压实现了,在成型模具内不发生所述垫的热塑性材料的不受控的流动过程,所述不受控的流动过程会导致嵌入热塑性基质中的纤维材料的不希望的位移。此外,通过均匀的成型模具内压实现了预型件或成型件的均匀加固。此外,特别是通过以注塑法在边缘侧上注射环绕的塑料防水条以有利的方式将边缘区域封闭,使得没有纤维材料能够从边缘区域出来,或者不会发生所使用的纤维材料的散开。
此外,由于边缘侧注射仅需要少的附加材料,这特别不明显提高成型件的重量。此外,在使用注塑法时能够在成型件上成形有例如夹紧部、容纳部或固定部位的补充的功能部。
工件支架优选在输送路段上运动,其中,沿着所述输送路段进行各个方法步骤。工件支架能够以有利的方式沿着多个工作站,特别是多个机器人工作站运动,以便将直至制成成型件的方法时间进一步最小化。
成型件的制造优选在从20秒至120秒的时间间隔内进行,进一步优选在从40秒至90秒的时间间隔内进行,并且更进一步优选在从55秒至65秒的时间间隔内进行。所说明的时间间隔是用于汽车工业的成型件的通常的生产时间,使得根据本发明的方法也能够集成在机动运输工具的生产线内。
所述垫的放置优选在通过成型件的有限元计算测定的、在构件内的负载路径的基础上进行。成型件的有限元计算允许将纤维定向与所述负载路径目的明确地相匹配。在此,所述匹配能够通过根据本发明的方法以有利的方式也在构件的空间定向上进行。
此外,本发明的部件是机动运输工具成型件,其中,所述成型件由至少两个单向纤维增强的垫逐层地三维构造,使得纤维定向与在稍后使用成型件时作用的力和在此在成型件内产生的负载路径相协调。
机动运输工具成型件优选具有塑料防水条。所述塑料防水条优选在边缘侧上环绕地成形在成型件上。将塑料防水条成形在机动运输工具成型件上以有利的方式通过在注塑法或者注塑过程内的注射过程实现。
有利的是,塑料防水条由纤维增强的、进一步优选由短纤维增强的塑料制成。在此,在边缘侧上环绕的塑料防水条优选形成封闭的结构。因此特别有利地提高了成型件的结构刚性。
在一个有利的实施形式中,成型件具有带有至少一个封闭的横截面的空腔。至少一个封闭的横截面特别是能够通过设置在预型件内的膨胀体制成。在预型件内,膨胀体借助于流体以压力加载,使得所述膨胀体与成型模具的壁联合地形成在机动运输工具成型件内的空腔。作为膨胀体优选使用弹性泡沫,特别是硅树脂泡沫。在这种情况下也可考虑的是利用消失的芯制成,所述芯形成成型件内的空腔。其它替代方案是气体注入方法和/或水注入方法。
被证实为有利的是,垫的或成型件的纤维增强通过矿物纤维、特别是玻璃纤维和/或碳纤维和/或聚酰胺纤维和/或聚合物纤维和/或合成纤维和/或由可再生原料制成的纤维制成。
优选的是,机动运输工具成型件构成为封闭运输工具的开口的盖或门的支承结构,或者构成为车身的结构部件。成型件能够进一步优选地构成为运输工具的底板总成的部件或者构成为电池壳体或者构成为电池支架。此外,在本发明的范围中,成型件在飞机中用作结构型材。根据本发明,机动运输工具包括每一种陆地运输工具、水上运输工具或者空中运输工具。
在在汽车工业领域中,用于工业应用、在机械制造中,用于运动仪器和在建筑领域中制造轻型结构部件和空心体构件时获得根据本发明的技术的其它可能的应用。
附图说明
下面借助于仅示出一个实施例的附图阐述本发明。附图中示意地示出:
图1示出一种用于实施根据本发明的方法的设备;
图2示出根据本发明的具有塑料防水条的机动运输工具成型件的细节视图;
图3示出另一根据本发明的具有空腔的机动运输工具成型件。
在附图中,相同的或相同功能的元件设有相同的附图标记。
具体实施方式
图1示出一种用于实施根据本发明的方法的设备,所述方法用于制造由热塑性塑料制成的环状纤维增强的成型件1。在此,在多个输送单元3上提供已裁剪的、基本上平面地构成的、单向纤维增强的垫2,该垫具有至少部分包围所述纤维的热塑性基质。在该实施例中,垫2被输送单元3从储料槽中取出,并且在预先确定的位置上提供。可替代地,能够通过滚动单元和/或切割单元提供垫2(在此未详细示出)。垫2在放置在工件支架5上之前至少局部预热,以用于提高垫2的柔性。接着,将垫2转移到预先确定所述成型件1的粗糙轮廓4的工件支架5。工件支架5本身在输送路段13上运动。在工件支架5上放置裁剪的垫2,并且持续地构造成三维的预型件6,使得所述垫2的纤维定向与在稍后使用成型件1时作用的力和在成型件1内由此产生的负载路径相协调。沿着输送路段13设置的多个机器人工作站或机器人系统14承担转移、放置和构造预型件6的任务。在结束构造预型件6后,垫2彼此位置固定。在此,借助于激光焊接设备7实现所述位置固定,其中,激光光学系统(未详细示出)设置在另一机器人工作站17上。
可替代地,在构造预型件6期间已经能够通过纺织技术方法实现垫2彼此间的位置固定。随后,预型件6在红外连续加热炉8中加热到超过预型件6的热塑性基质的熔化温度。可替代地,加热也能够在对流连续加热炉内或在成型模具10本身中进行。借助于另一机器人工作站9实现了将三维的预型件6装入在形成所述成型件1的最终轮廓的成型模具10中。通过将环绕的塑料防水条18(参见图2)在边缘侧上注射到预型件6上实现调节均匀的成型模具内压以用于在保持预型件6内的纤维定向的同时确保预型件6的加固。为此,设有注塑单元15,所述注塑单元提供相应塑化的材料,优选为纤维增强的热塑性材料,并且借助压力注射到成型模具10中。将加固的成型件1同样借助于机器人工作站9从成型模具10中取出,并且输送给贮存单元16。
图2示出根据本发明的具成形的塑料防水条18的机动运输工具成型件1的细节视图。成型件1由至少两个单向纤维增强的垫2逐层地三维构造,使得纤维定向与在稍后使用成型件1时作用的力和在成型件1内由此产生的负载路径相协调。将塑料防水条18在边缘侧上环绕地成形在成型件1上。将塑料防水条18成形在机动运输工具成型件1上通过注塑法内的注射过程在机动运输工具成型件1的成型模具10中实现。塑料防水条1由短纤维增强的塑料形成。
图3示出根据本发明的具有空腔20的机动运输工具成型件1,所述空腔具有至少一个封闭的横截面。该至少一个封闭的横截面通过设置在预型件6内的膨胀体19制成。在预型件6内,膨胀体19借助于流体以压力加载(通过箭头标明),以至于所述膨胀体与成型模具的壁(在此未详细示出)联合地形成机动运输工具成型件1内的空腔20。
作为膨胀体19使用弹性泡沫,特别是硅树脂泡沫。可替代地,能够利用消失的芯制成,所述芯形成成型件1内的空腔20。
Claims (26)
1.用于制造由热塑性塑料制成的环状纤维增强的成型件(1)的方法,包括下述步骤:
-提供已裁剪的、基本上平面地构造的、单向纤维增强的垫(2),所述垫具有至少部分地包围纤维的热塑性基质;
-将所述垫(2)转移到预先确定所述成型件(1)的粗糙轮廓(4)的工件支架(5);
-将在所述工件支架(5)上的所述垫(2)放置并且持续地构造为三维的预型件(6),使得所述垫(2)的纤维定向与在稍后使用所述成型件(1)时作用的力和在所述成型件(1)内由此产生的负载路径相协调;
-在结束制造所述预型件(6)期间或结束制造所述预型件(6)后将所述垫(2)彼此位置固定;
-加热所述预型件(6)直至所述预型件(6)的所述热塑性基质的熔化温度或者超出所述预型件(6)的所述热塑性基质的熔化温度;
-将三维的所述预型件(6)装入到形成所述成型件(1)的最终轮廓的成型模具(10)中;
-调节均匀的成型模具内压,以用于在维持所述预型件(6)内的所述纤维定向的同时确保所述预型件(6)的加固,其中,所述均匀的成型模具内压的调节通过在所述成型模具(10)内以注塑法在边缘侧上注射环绕的塑料防水条(18)和/或通过将GTM块附加地插入所述成型模具(10)中和/或通过注射料槽式技术和/或通过将密封捆扎件插入所述成型模具(10)中和/或通过将密封膜插入所述成型模具(10)中实现;
-将已加固的所述成型件(1)从所述成型模具(10)中取出。
2.如权利要求1所述的方法,其特征在于,所述垫(2)彼此间的位置固定借助于焊接方法实现。
3.如权利要求2所述的方法,其特征在于,所述焊接方法包括超声波焊接方法和/或加热元件焊接方法、和/或激光焊接方法。
4.如权利要求1所述的方法,其特征在于,所述垫(2)彼此间的位置固定通过纺织技术方法实现。
5.如权利要求4所述的方法,其特征在于,所述纺织技术方法包括针织和/或缝纫。
6.如上述权利要求1-5之一所述的方法,其特征在于,所述垫(2)在放置到所述工件支架(5)前至少局部加热,以用于提高所述垫(2)的所述柔性。
7.如上述权利要求1-5之一所述的方法,其特征在于,所述预型件(6)的加热通过对流加热和/或红外辐射实现。
8.如权利要求6所述的方法,其特征在于,所述垫(2)的加热通过对流加热和/或红外辐射实现
9.如上述权利要求7所述的方法,其特征在于,所述对流加热和/或红外辐射在对流连续加热炉内和/或红外连续加热炉内进行。
10.如上述权利要求8所述的方法,其特征在于,所述对流加热和/或红外辐射在对流连续加热炉内和/或红外连续加热炉内进行。
11.如权利要求1-5和8-10之一所述的方法,其特征在于,为了转移所述垫(2)和/或为了装入所述预型件(6)而使用机器人系统(9、14)。
12.如权利要求1-5和8-10之一所述的方法,其特征在于,将所述工件支架(5)在输送路段(3)上运动,并且沿着所述输送路段(3)进行各个方法步骤。
13.如权利要求1-5和8-10之一所述的方法,其特征在于,所述成型件(1)的制造在从20秒至120秒的时间间隔内进行。
14.如权利要求1-5和8-10之一所述的方法,其特征在于,所述成型件(1)的制造在从40秒至90秒的时间间隔内进行。
15.如权利要求1-5和8-10之一所述的方法,其特征在于,所述成型件(1)的制造在从55秒至65秒的时间间隔内进行。
16.如权利要求1-15中任一项所述的方法制造的机动运输工具成型件(1),其特征在于,所述成型件(1)由至少两个单向纤维增强的垫(2)逐层地三维构造,使得纤维定向与在稍后使用所述成型件(1)时作用的力和在所述成型件(1)内由此产生的负载路径相协调,其中,塑料防水条(18)在边缘侧上环绕地成形在所述成型件(1)上。
17.如权利要求16所述的机动运输工具成型件,其特征在于,所述塑料防水条(18)在边缘侧注射在所述成型件(1)上。
18.如权利要求16或17所述的机动运输工具成型件,其特征在于,所述塑料防水条(18)由纤维增强的塑料制成。
19.如权利要求16或17所述的机动运输工具成型件(1),其特征在于,所述成型件(1)具有带有至少一个封闭的横截面的空腔(20)。
20.如权利要求16或17所述的机动运输工具成型件(1),其特征在于,纤维增强通过矿物纤维形成。
21.如权利要求20所述的机动运输工具成型件(1),其特征在于,所述矿物纤维包括玻璃纤维、和/或碳纤维。
22.如权利要求16或17所述的机动运输工具成型件(1),其特征在于,纤维增强通过聚酰胺纤维形成。
23.如权利要求16或17所述的机动运输工具成型件(1),其特征在于,纤维增强通过聚合物纤维形成。
24.如权利要求16或17所述的机动运输工具成型件(1),其特征在于,纤维增强通过合成纤维形成。
25.如权利要求16或17所述的机动运输工具成型件(1),其特征在于,纤维增强通过由能再生原料的纤维形成。
26.如权利要求16或17所述的机动运输工具成型件(1),其特征在于,所述成型件(1)构成为封闭所述运输工具的开口的盖或门的支承结构,或者构成为车身的结构部件。
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- 2010-12-21 US US13/515,833 patent/US20120269999A1/en not_active Abandoned
- 2010-12-21 EP EP10803235A patent/EP2516137A1/de not_active Withdrawn
- 2010-12-21 KR KR1020127019132A patent/KR20120123350A/ko not_active Application Discontinuation
- 2010-12-21 WO PCT/EP2010/007827 patent/WO2011085792A1/de active Application Filing
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Also Published As
Publication number | Publication date |
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WO2011085792A1 (de) | 2011-07-21 |
US20120269999A1 (en) | 2012-10-25 |
EP2516137A1 (de) | 2012-10-31 |
DE102010013131A1 (de) | 2011-06-22 |
CN102762360A (zh) | 2012-10-31 |
KR20120123350A (ko) | 2012-11-08 |
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