CN104379325A - 用于制造包括金属载体和具有纤维增强的合成材料的能固化的涂层的半成品或构件的方法 - Google Patents

用于制造包括金属载体和具有纤维增强的合成材料的能固化的涂层的半成品或构件的方法 Download PDF

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CN104379325A
CN104379325A CN201380029826.4A CN201380029826A CN104379325A CN 104379325 A CN104379325 A CN 104379325A CN 201380029826 A CN201380029826 A CN 201380029826A CN 104379325 A CN104379325 A CN 104379325A
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metallic carrier
coating
fibre
synthetic material
described metallic
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CN104379325B (zh
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弗兰兹·安德勒施
卡罗拉·艾塞尔
伯恩哈特·施特劳斯
克里斯蒂安·瓦尔施
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Voestalpine Stahl GmbH
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/12—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by mechanical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/14—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
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    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/02—Stamping using rigid devices or tools
    • B21D22/022—Stamping using rigid devices or tools by heating the blank or stamping associated with heat treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D35/00—Combined processes according to or processes combined with methods covered by groups B21D1/00 - B21D31/00
    • B21D35/002—Processes combined with methods covered by groups B21D1/00 - B21D31/00
    • B21D35/005—Processes combined with methods covered by groups B21D1/00 - B21D31/00 characterized by the material of the blank or the workpiece
    • B21D35/006—Blanks having varying thickness, e.g. tailored blanks
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/088—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of non-plastics material or non-specified material, e.g. supports
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B62D—MOTOR VEHICLES; TRAILERS
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    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
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    • B62D29/004—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material the metal being over-moulded by the synthetic material, e.g. in a mould
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/472—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7375—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured
    • B29C66/73751—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being uncured, i.e. non cross-linked, non vulcanized
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7375—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured
    • B29C66/73753—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being partially cured, i.e. partially cross-linked, partially vulcanized
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Abstract

本发明提出了一种用于制造半成品或构件(2)的方法，在该方法中，将具有纤维增强的合成材料的能固化涂层(6、17)施加到金属载体(3)尤其是板(4)上，并且在接下来的步骤中将经涂覆的金属载体(3)变形，尤其是深冲压或弯曲成半成品或构件(2)。针对改进的且低成本的方法提出，对金属载体(3)至多区域性地进行涂覆，并且只有当金属载体的涂层(6、17)在其固化中形成至少一个抗粘着的表面(12)时，才经受变形，其中，经涂覆的金属载体(3)以如下方式进行变形，即，其伴随着变形半径(21)的塑性的形状变化基本上，优选仅在金属载体的无涂层的区域(15)中形成。

Description

用于制造包括金属载体和具有纤维增强的合成材料的能固化的涂层的半成品或构件的方法
技术领域
本发明涉及一种用于制造半成品或构件的方法，在该方法中，将具有纤维增强的合成材料的能固化的涂层施加到金属载体尤其是板上，并且在接下来的步骤中，将经涂覆的金属载体变形、尤其深冲压或弯曲成半成品或构件。
背景技术
由现有技术公知了混合材料(DE19956394B4)，其具有多个上下叠置的金属层，它们分别利用在整个面上纤维增强的单向预浸料层进行涂覆，预浸料层在混合材料变形之后固化成型材。然而不利的是，在混合材料通过其变形获得其最终的形状之前，此类方法对预浸料层的过早固化比较敏感。这尤其可以在如下中得到证实，即，已变形的混合材料降低了形状精度，并连同地损伤了纤维增强的合成材料(FVK)或者预浸渍的碳纤维(CFK预浸料)。因此，以该方式并不能够确保一种可重复的方法。此外，执行使用未固化的预浸料层的方法相对来说是比较昂贵的。此外，这类混合材料相对纤维增强的合成材料而言提出了较高的材料需求。低成本的半成品或构件不能通过这样的方法来制造。
此外，对于纤维增强的半成品或构件的制造而言所公知的是，钢板首先被变形，并且在接下来的步骤中不完全地配设有固化的FVK部分或者利用其进行涂覆。彼此分开的方法步骤，也就是金属载体的成形和FVK部分的成形，连同它们的最后的连接(例如利用螺栓(DE102009009112A1))执行得相对来说比较昂贵，并且此外还要求成本高昂的半成品或者构件，尤其是该方法需要比较高的自动化耗费。
发明内容
因此本发明的任务是，基于先前所叙述的现有技术，不仅要简化用于加强的半成品或构件的制造方法，而且还要进行耐用的设计，以便因此还要获得该方法的高的可重复性。此外，该方法应适用于自动化的方法过程。
本发明以如下方式实现所提出的任务，即，对金属载体至多区域性地涂覆，并且只有当金属载体的涂层在其固化下形成至少一个抗粘着的表面时，才经受变形，其中，经涂覆的金属载体如下地进行变形，即，其伴随着变形半径的塑性的形状变化基本上，优选仅在金属载体的无涂层的区域中形成。
如果金属载体只有当其涂层在涂层固化下形成至少一个抗粘着的表面时才经受变形，那么该方法就可以相对FVK涂层的不可避免的固化反应更耐用地构建，这是因为在该方法中本身就允许涂层的固化反应。相对现有技术而言，根据本发明也不必太严格地关注金属载体的储存时间，以便因此必须考虑聚合物基体由于超出处理时间段的性能损失。由此，也可以在方法过程中实现消除应力，尤其是因为方法步骤可以将涂层和变形彼此在时间上不相关地实现，这恰恰对于深冲压或弯曲金属载体用以其成形来说是有利的。涂层的表面的抗粘着的状态同样也可以在变形之后确保经涂覆的金属载体和工具的完全分离，由此，该方法的高的可重复性和相对来说比较简单的自动化能够成为可能。特别地，此外，根据本发明的方法的特征在于，金属载体在其至少一个载体侧上至多是区域性地进行涂覆，以便因此基本上获得金属载体的塑性的可变形性。此外，当金属载体如下地进行变形时，即，其伴随着变形半径的塑性的形状变化基本上在其无涂层的区域中形成，那么就可以实现比较高的变形度。这些无涂层的载体区域能够尽可能无损于FVK涂层地产生塑性的形状变化。当塑性的形状变化仅发生在这些无涂层的区域中时，这就更高了。甚至高要求的轮廓(例如机动车的门槛或纵梁)可以因此被形状精确地引入到金属载体中。此外，虽然抗粘着地然而却并不完全地固化的或者至多是部分固化的FVK涂层甚至可以允许一定的固有的塑性的可变形性，并且因此对金属载体的变形特性产生积极的影响，由此甚至可以无故障地实现窄短的半径。同时，经涂覆的载体区域的特征在于特别高的强度值，并且金属载体在变形期间并且也在变形之后可以机械地稳定化。根据本发明，高度的塑性的形状变化能力因此可以与高的机械强度值相结合，并且同时可以得到一种用于纤维增强的金属载体优选钢板的相对来说比较简单的制造规程。
显而易见地，金属载体可以由具有铁材料、铝材料或镁材料的或类似物的或者由它们组成的合金的板构成。一般来说被提及的是，纤维增强的合成材料(FVK)可以具有与无机或有机的增强纤维(像例如玻璃、玄武岩、碳或作为连续纤维、长纤维或短纤维的芳纶)组合起来的热塑性或热固性的合成材料基体或者可以由其构成。当使用可以给纤维增强的合成材料用作为基体的、化学交联的中间层时，可以改进附着。另外，一般来说被提及的是，抗粘着被理解为涂层的表面不再是粘性的。当涂层的表面在压力下例如被变形工具压紧到另一表面上时，这也会是这种情况。换而言之：能固化的涂层在变形之前至少被部分固化并且不再是粘性的。
于是，根据本发明的方法的特征尤其也在于，将碳纤维增强的合成材料(CFK)作为具有尤其是热固性的基体的纤维增强的合成材料(FVK)施加到金属载体上。
当施加预浸渍的碳纤维时，可以提供低成本的且仍然是高强度的半成品或成品。因此可以在相对较小地提高其重量的情况下制造根据要求被优化的且高强度的半成品或者成品。可设想到其它预浸渍的纤维(例如玻璃纤维、芳纶纤维)，然而施加到钢板上的、具有热固性的基体的碳纤维对于机动车尤其门槛或纵梁的结构构件而言被证明是在当可接受的制造成本的情况下可达到的强度值方面是特别有利的。
如果将具有化学交联的中间层的纤维增强的合成材料施加到金属载体上，那么就已经可以将部分固化的纤维增强的合成材料施加成相对来说被限定的固化状态，并且因此提高了该方法的可重复性。此外，因此可以改进附着，尤其当该中间层可以给纤维增强的合成材料用作为基体时。
如果将具有长纤维的纤维增强的合成材料(FVK)施加到金属载体上，那么就可以相对来说比较快速地执行金属载体的涂覆。因此，由于较短的生产时间而可以降低制造成本。长纤维涂层的此类施加能想到的是借助于挤出成型、拉挤成型、喷涂涂覆或模板涂覆。
作为长纤维的替选，当将纤维增强的合成材料(FVK)的织物或非织物以裁剪的形状施加到金属载体上时，则也可以迅速地执行涂覆。此外，利用具有与无涂层的载体区域相应的留空部的这样的基体可以实现用于制造低成本的半成品或成品的连续的方法。
可以将织物或非织物要么利用合成材料基体预浸渍地施加到金属载体上，要么在施加到金属载体上之后利用合成材料基体浸渍。对于制造方法的自动化而言，在此的特征尤其在于利用合成材料基体浸渍的、用于铺放到金属载体上的织物。
如果在可能利用增附物进行预处理的情况下将涂层施加到金属地和/或有机地预涂覆的金属载体上，那么在金属载体与涂层之间的材料锁合(kraftschlüssig)的连接失效的危险就会在变形时明显降低。因此可以提高该方法的可重复性和其参数。此外，利用此类预处理可以提供对水、化学物质和气候影响的抗性，并且额外地也提供了改进了的防腐蚀性。
如果多层织物或非织物针对纤维增强的合成材料(FVK)的尤其是多向的层构造上下叠置，那么就可以明显改进半成品或成品的机械强度。
为了拓宽抗粘着的区域并且为了避免在变形工具处的可能的粘着，可以在变形之前在涂层上施加分隔层。例如，对于这样的分隔层而言，特征在于经涂覆的纸，例如烘焙纸。
如果将能固化的涂层无压力地预凝胶化并且在接下来的步骤中按压到金属载体上，以便将该涂层施加到金属载体上，出于纤维增强的原因而能够降低合成材料的排出，并且因此可以避免该合成材料在金属载体的弯曲区域中不受控制地向前推挤。通过在预凝胶化的过程中所获得的较高的粘性，可以相对强烈地减少合成材料的排出。因此，无须考虑纤维增强的合成材料在金属载体的变形的过程中的损坏。此外，如此无压力地预凝胶化的涂层不会具有降低了的附着特性，这就可以实现能受机械负载的半成品或构件。
特别有利地，根据本发明的方法也可以用于制造承载的结构构件，其中，其特征尤其也在于针对机动车的门槛或纵梁。
附图说明
在附图中例如详细地示出了根据本发明的方法。其中：
图1示出方法过程，该方法过程具有铺设在金属载体上的纤维增强的合成材料(FVK)，
图2示出具有金属载体的方法过程，该金属载体具有施加的纤维增强的合成材料(FVK)，并且
图3示出根据图1和2所示的构件的中断的截面视图。
具体实施方式
根据按照图1所示的用于制造构件2的方法过程1，在第一步骤中，将具有纤维增强的合成材料(FVK)的能固化的涂层6施加到从由钢板5构成的卷4分离下来的金属载体3上。金属载体3在该待涂覆的侧上事先也许还被清洁或者被化学预处理，然而不对此进行详细阐释。为了施加涂层6而设置有机械手7，其接收机械手9的下料8。为了该目的，机械手9根据金属载体3的待涂覆的区域面积对利用合成材料基体预浸渍的织物10进行裁剪。经涂覆的金属载体3随后借助于烘干或固化装置11经受部分固化，据此涂层6形成至少一个抗粘着的表面12。由此，金属载体3也可以很容易地铺设成堆垛13，进而例如被临时存储或准备进一步传输。但是尤其地可以因此实现，经涂覆的金属载体3在接下来步骤中可以变形成构件2，这是因为金属载体的涂层6在其固化中形成至少一个抗粘着的表面12。因此，将经涂覆的金属载体3引入到深冲压工具14中并且进行变形。因为对金属载体3至多是区域性地在它的其中一个金属载体侧上进行涂覆(如这由图1获知的那样)，所以也可以确保金属载体3的比较高的塑性的可变形性。因此，能够无问题地实现较高的变形度，如这例如在机动车的门槛或纵梁的情况下会是必要的。
如在图1中同样能看到，在金属载体3通过其深冲压而承受弹性变形的部位都设置有无涂层的区域15。但是，也可以根据要求在金属载体3上存在有另外的无涂层的区域。
为了区别于根据图1示出的方法1，根据图2的方法16具有将涂层17施加到金属载体3上的另一类型。树脂18和固化物19以预先给定的比例与纤维20优选长纤维进行混合并被涂到金属载体3上。紧接着，如同在图1的情况下地实现借助于烘干或固化装置11对涂层17进行抗粘着的固化。经涂覆的金属载体3然后又可以铺设成堆垛13，或者也可以立即借助于深冲压工具14经受深冲压，这未进行详细阐释。
根据图3能看到，金属载体3具有无涂层的区域15，无涂层的区域在变形的情况下经受金属载体3的塑性的形状变化，该形状变化伴随着变形半径12，尤其是弯曲半径。因此，确保了经涂覆的金属载体3的比较高的塑性的可变形性。此外，金属载体还具有金属的和/或有机的保护涂层22，例如锌层。此外，在涂层6与保护涂层22之间设置有增附物23。在涂层6或者7上还施加有分隔层24。有利地，根据本发明的方法可以用于优化在压缩或弯曲性能方面的碰撞性能中的机械特性。
在表格1中示例性地将未经涂覆和经涂覆的罩形型材的机械特性进行对比。
表格1
针对不同的负载选择下面的测试构造：
针对准静态轴向压缩：具有FVK加强的表面的大约50％；
针对3点弯曲：具有FVK加强的表面的大约15％；
准静态轴向压缩在30mm/min的成形速度的情况下执行直至60％的成形。3点弯曲测试在30mm/min的成形速度的情况下执行250mm的最大行程。
尽管部分地对罩形型件进行涂覆，但是在可负载性下相对未经涂覆的罩形型件仍显现了明显的改进，从而因此无须考虑在可达到的变形度的情况下的限制。
在表格2中相对常规的钢板比较了具有不同FVK涂层的平面式的半成品的强度。FVK涂层在拉伸测试或者弯曲测试之前具有至少一个抗粘着的表面。
表格2
FVK涂层的固化在20℃与130℃之间进行120分钟至500分钟。优选地，在预浸渍的非织物的情况下，在90℃与130℃之间进行90分钟至180分钟，而在后浸渍的非织物的情况下以及在使用长纤维的情况下，在20℃与60℃之间在至少480分钟的情况下进行。
在示例中，金属载体厚度相对涂层厚度的比例具有从1:2直至1:0.4的范围被证实是有利的。相应的金属载体材料的钢板厚度或者板厚度也可以进行改变，本发明特别是以金属载体厚度在从0.6mm至5mm，尤其是从1mm至2.5mm的范围中为特征。
总的来说因此指出，可以将强度提升10％至20％，并且令人惊奇的是具有已相对较薄的在0.2mm至3mm，尤其0.4mm至2mm涂层厚度的范围中的FVK层也是如此。因此，绝对能够对例如门槛或纵梁实现在超出10％的范围内的总重量节省。这就有利地造成车身总重量小，并因此车辆总重量小，这同样反映在较低的燃料消耗上。

Claims (14)

1.一种用于制造半成品或构件(2)的方法，在所述方法中，将具有纤维增强的合成材料的能固化的涂层(6、17)施加到金属载体(3)，特别是板(4)上，并且在接下来的步骤中将经涂覆的金属载体(3)变形，特别是深冲压或弯曲成半成品或构件(2)，其特征在于，对所述金属载体(3)至多区域性地进行涂覆，并且只有当所述金属载体的涂层(6、17)在其固化中形成至少一个抗粘着的表面(12)时，才经受变形，其中，所述经涂覆的金属载体(3)以如下方式进行变形，即，其伴随着变形半径(21)的塑性的形状变化基本上，优选仅在所述金属载体的无涂层的区域(15)中形成。
2.根据权利要求1所述的方法，其特征在于，将碳纤维增强的合成材料作为具有特别是热固性基体的纤维增强的合成材料施加到所述金属载体(3)上。
3.根据权利要求2所述的方法，其特征在于，施加预浸渍的碳纤维。
4.根据权利要求1、2或3所述的方法，其特征在于，将具有化学交联的中间层的纤维增强的合成材料施加到所述金属载体(3)上。
5.根据权利要求1至4中任一项所述的方法，其特征在于，将具有长纤维的纤维增强的合成材料施加到所述金属载体(3)上。
6.根据权利要求1至5中任一项所述的方法，其特征在于，将所述纤维增强的合成材料的织物或非织物以裁剪的形状(8)施加到所述金属载体(3)上。
7.根据权利要求6所述的方法，其特征在于，将所述织物或非织物要么利用合成材料基体预浸渍地施加到所述金属载体(3)上，要么在施加到所述金属载体(3)上之后利用所述合成材料基体浸渍。
8.根据权利要求1至7中任一项所述的方法，其特征在于，将所述涂层(6、17)在可能利用增附物进行预处理的情况下施加到金属地和/或有机地预涂覆的金属载体(3)上。
9.根据权利要求1至8中任一项所述的方法，其特征在于，多层织物或非织物针对纤维增强的合成材料的特别是多向的层结构上下叠置。
10.根据权利要求1至9中任一项所述的方法，其特征在于，在所述变形之前将分隔层施加到所述涂层(6、17)上。
11.根据权利要求1至10中任一项所述的方法，其特征在于，所述金属载体(3)，特别是钢板(4)具有0.6mm至5mm，特别是1mm至2.5mm的板厚度。
12.根据权利要求1至11中任一项所述的方法，其特征在于，所述涂层(6、17)具有0.2mm至3mm，特别是0.4mm至2mm的厚度。
13.根据权利要求1至12中任一项所述的方法，其特征在于，将所述能固化的涂层(6、17)无压力地预凝胶化，并且在接下来的步骤中按压到所述金属载体(3)上，以便将其施加到所述金属载体(3)上。
14.利用根据权利要求1至13中任一项所述的方法来制造机动车的承载的结构构件特别是门槛或纵梁的应用。
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EP2836354B1 (de) 2016-06-08
WO2013153229A1 (de) 2013-10-17
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