CN104742384A - Method used for manufacturing whole fiber composite and corresponding fiber composite - Google Patents

Method used for manufacturing whole fiber composite and corresponding fiber composite Download PDF

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Publication number
CN104742384A
CN104742384A CN201410611968.8A CN201410611968A CN104742384A CN 104742384 A CN104742384 A CN 104742384A CN 201410611968 A CN201410611968 A CN 201410611968A CN 104742384 A CN104742384 A CN 104742384A
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China
Prior art keywords
fibrage
covering
fibre
composite component
matrix
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Granted
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CN201410611968.8A
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Chinese (zh)
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CN104742384B (en
Inventor
F·埃伯特
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Bayerische Motoren Werke AG
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Bayerische Motoren Werke AG
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/30Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/345Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using matched moulds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/40Shaping or impregnating by compression not applied
    • B29C70/42Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46Shaping 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
    • B29C70/462Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/685Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks by laminating inserts between two plastic films or plates

Abstract

The invention relates to a method used for manufacturing a whole fiber composite and a corresponding fiber composite. The method comprises the steps of: providing a first fiber layer; placing an embedded element on a surface of the first fiber layer; placing at least one first section of a covering fiber layer on a free surface of the embedded element and at least one second section on the surface of the first fiber layer, wherein the covering fiber layer is composed of at least two adjacent partial covering fiber layers; fixing the at least two adjacent partial covering fiber layers on the free surface of the embedded element to generate a stacked setting structure to be squeezed; and squeezing the stacked setting structure to generate a whole fiber composite.

Description

For the manufacture of method and the corresponding fibre-composite component of overall fibre-composite component
Technical field
The present invention relates to for the manufacture of having the method for the overall fibre-composite component of setting element and corresponding fibre-composite component.
Background technology
In the scope produced in enormous quantities, often the fibre-composite component be made up of fibre reinforced plastics is manufactured the large-area component with unified material thickness and even laminating structure.The component with this spline structure can manufacture fast and economically, such as by so-called " wetpressing ", greatly simplifiedly, in this wetpressing on weaving semi-finished product coated substrate in compacting tool set, these semi-finished product are squeezed into the shape desired by later component, wherein, described matrix is permeated semi-finished product and is flooded its fiber.
It is known that in order to the three-dimensional structure of obtained complexity or in order to improve component stability, utilize the enhancement Layer fortifying fibre composite component of local coating.Also can arrange in its framework additional, for local strengthening or the lining forming hollow.But this measure is only at present known for so-called " Resin Transfer Moulding (resin transfer molding practice) " (abbreviation: " RTM ").To this, equally greatly simplifiedly, first weaving semi-finished product are squeezed into preform (performing member) or performing member of weaving in preliminary forming step and make foam core by woollen yarn knitting method (Flechverfahren).Then, this foam core is inserted in compacting tool set and also utilize the matrix injected in mould to flood.Based on preformed element, can without problems together with setting element and being stitched to other preforms.In addition, when injecting matrix, compacting tool set closes, thus farthest prevents the slip of element to be connected.
But RTM method is obviously more complicated and more expensive than wetpressing.In addition, the cycle time for working of RTM method will exceed several times, and thus wetpressing is considered to much economical.
But, by using fibre-composite component that is that obviously faster and more worthwhile wetpressing manufactures the three-dimensional of similar complexity or that strengthen up to now due to many factors or impossible.Belong to this situation particularly: during matrix being coated on each fibrage and then just passing through the extrusion molding in compacting tool set, the element of setting that there will be multiple fibrage of overlaping or insertion is uncontrollably shifted, thus component that is made, that have labyrinth usually becomes waste product and therefore can not use.
Summary of the invention
Therefore the object of the invention is, realizing a kind of as far as possible simply manufacture method of economy, with reproducibly manufacturing, there is the overall fibre-composite component of setting element for process.
This object is achieved by method as described below and by fibre-composite component as described below.
Specifically, propose a kind of method for the manufacture of overall fibre-composite component at this, it comprises the steps:
-the first fibrage is provided,
-element will be set be arranged on a first fibrolaminar surface,
-by cover fibrage to be arranged on at least one first section set element Free Surface on and be arranged on the first fibrolaminar described surface with at least one second section, wherein, described covering fibrage covers fibrage by least two parts be disposed adjacent to each other and forms, and
-at least two parts are covered fibrages be fixed on and set on the Free Surface of element, a kind ofly to be extruded stacking structure is set to produce,
-the stacking structure that arranges is extruded, to produce described overall fibre-composite component.
Therefore, can first will set on the first fibrage that element is positioned at as basal layer.Covering fibrage can be placed in sets on the Free Surface of element, on the surface namely do not contacted with the first fibrage.Described covering fibrage as flood be multi-piece type cover fibrage structure with at least two or more part, and whole covering fibrage (as unit) can be made in this wise to be formed by multiple one-piece unit, in this way, particularly for the three-D profile of complexity, at least can reduce gauffer and be formed.This combination can be realized by the overlap placement of loose placement arranged side by side or part.Certainly, various piece covering fibrage also can just be interconnected in advance.
Cover fibrage for making described part continuing to be shifted from their assigned address between processing period, this method specifies: be fixed on by these parts covering fibrage and set on element.This point particularly can ensure during the conveying to compacting tool set or during follow-up pressing steps that realizing stable location keeps, prevent various piece from covering fibrolaminar slip or displacement, otherwise these parts covering fibrage is especially easily shifted relative to integrally unified covering fibrage.
Therefore fibre-composite component can be manufactured the global formation component with complex geometric shapes by this method, but abandons known, component intensity (bauteilintensiv) shell type structure.Except cost saving and lower manufacturing expense, produce new and can the designability of simple realization while component quality is high.
According to another kind of embodiment, at least two parts cover fibrage and are disposed adjacent to each other in this wise: at least two that part is covered in fibrage mutually overlap in overlapping regions.This means: the part covering fibrage be disposed adjacent to each other respectively and the respectively direct adjacent part arranged cover fibrage and arrange with overlapping in each several part section.Preferably determine size and the configuration of the common overlapping regions formed in this wise: the transmission making the power reliably ensured in whole covering fibrage.
Preferably, fixing described part cover fibrolaminar step can comprise with set element local material with engaging ground and/or positive and/or force closure be connected, particularly undertaken adhering to by the matrix of the amount of specifying at least partly and/or jointing material and/or by cutting ferrule or the clamping at least partly of some connectors.That is, such as, matrix can be applied to partly or in large area in the position determined and set on element, set on element one or more part covering fibrage is fixed on and prevents displacement.
As an alternative or supplement, can insert and set connector standing part in element and cover fibrage by such as covering fibrage through appropriate section.Such as clip, pin or nail etc. are suitable for this.These connectors preferably remain among later component.
In addition, at least one covering in fibrage of part can form extensible.According to mathematical definition (geometry), the face of bidimensional is called as extensible, and the expansion in this face can convert Euclidean plane to without internal modification, thus described face is positioned in plane glossily.The feature of this is especially the 3D shape that one does not have " bending formation ".(shape using bidimensional substantially) is delivered to part and covers on fibrage and mean: fibrage will be set element (as said three-dimensional body) and be covered in this wise: make various piece covering fibrage lie against and set on the surface of element glossily and without bending formation.Fibrage can be covered to described part in this wise and carry out cutting, namely, the potential position that may form bending of element surface is set described in vacating, and these placement configurations are become to lead to new part cover fibrolaminar transition by arranging overlapping regions definitely, partly, thus avoid to cover in fibrage in corresponding part and form bending.
According to a kind of embodiment, first fibrage and/or at least two parts can be covered fibrages be provided as non-impregnated fibrage or non-impregnated preform, and the method can comprise one or more matrix is applied to step on each corresponding fibrage.
This means: corresponding each fibrage is prepared to dry that is non-impregnated fibre semi-finished products, and, between their preparatory stage or after this but the latest before pressing steps, in one or more intermediate steps, apply matrix.
Each in principle in fibrage, namely the first fibrage and/or at least two parts cover yarn fabric that is that fibrage can be configured to such as individual layer or multilayer, scrim (Gelege) or knitted fabric, or unidirectional or multidirectional.As fiber, particularly glass fibre, carbon fibre or aramid fibre can be used, but other also can be used to be suitable for the fibrous material of reinforcing fibre composite component.
Preferably, first the semi-finished product of the first fibrage as drying are provided, then (at least partly) coated substrate.Then by set component positioning in the matrix of coating after, then first part can be covered fibrage equally and be fixed on this as the semi-finished product of drying and set on element.Then also coated substrate on fibrage is covered in part.Extrusion process mesostroma afterwards just permeates each fibrage and floods these fibrages.Alternatively, matrix can be applied to set on element and by this matrix, part is covered fibrage and be fixed on and set on element.
Therefore can when utilizing so-called wetpressing by simple, fast and the mode of economy manufacture a kind of corresponding complexity, there is the three-dimensional fiber composite component of setting element.
As selection, the first fibrage and/or part cover fibrage and as preform, can use in a similar manner equally in non-impregnated state for described method.
Alternatively, the first fibrage and/or at least two parts cover fibrage comprise respectively one with matrix prepregs stain, the fiber stack of single or multiple lift.This way allows to abandon the independent step for coated substrate.The substitute is, corresponding each fibrage by matrix impregnation and can be set up according to described process, fixing and extruding.
In each case, set that element such as can comprise a kind of dimensionally stable and/or that functions is integrated (funktionsintegriert) described in and set element.That is, set element to be set to, for determining a corresponding space, although this space is through pressing steps, still should at least substantially remain unchanged.Therefore, the element that all respective shapes are stable in principle is all suitable for setting, and wherein, the volume very little compared with total measurement (volume) caused due to extruding reduces that also should to can be regarded as be dimensionally stable.
The such as thermal insulation of other function, reinforcement, sound insulation and/or noise reduction can also be realized and receive any element of setting of other components all can be considered as being that functions is integrated except shape stability.
Particularly, set the core body that element can comprise foam core, reel, plastic core, metal-cored, wax core and/or be made up of solid material, expanded material for this reason, there is hollow structure, alveolate texture, and/or by sound insulation and/or core body that the material of noise reduction is formed.
Particularly preferably be, set element and be configured to closing direction along compacting tool set about compacting tool set self-centering (automatic centring).For this reason, set element and there is a kind of geometry along closing direction expansion/expansion.What described closing direction should be considered as relating to compacting tool set receives the half module of setting element relative to the direction of relative movement of setting element to carry out extruding.State conversely, geometry is configured to be in reverse to closing direction reduce gradually.In other words, set the direction that element is configured to along remotely pointing to from the first fibrage to reduce gradually.This then provides following possibility: set when mould closes element according to the moulding of compacting tool set that is there is the inclined-plane being configured to respective complementary moulding cavity (former) automatically laterally (transverse to closing direction) shift to predetermined position exactly.
This means: particularly when mould closes can to by set the position determined when element is arranged on the first fibrage to a certain extent-if necessary-revise.Therefore, that is, precision process afterwards can be carried out coarse setting of setting element and therefore reduce waste product.
That has set forth covers fibrage by part and is fixed on to set on element and provides additional advantage: when mould closes, part covers fibrage in a certain degree/scope, also follows the side direction correction motion of setting element.
In addition, the present invention also proposes a kind of fibre-composite component, and it comprises: the first fibrage; Be arranged on and this first fibrolaminar surface sets element; And the Free Surface of this being set element is at least with the covering fibrage that the first section covers at least in part.Cover fibrage to be at least connected to planar each other in the second section with the first fibrage.Cover fibrage to be made up of multiple part covering fibrage, these parts cover fibrage and arrange adjacent to each other, and wherein, at least two in described part covering fibrage mutually overlap respectively in an overlapping regions.
Preferably this fibre-composite component makes by such as the method as described in illustrating.
Described fibre-composite component can be such as the body structural member of motor vehicle, particularly has the body structural member of large or undersized complex geometric shapes or complicated cross section, such as side frame or end wall, and base member, door, top or caudal components.
Accompanying drawing explanation
Hereafter set forth the present invention in further detail by embodiment with reference to the accompanying drawings.Shown in accompanying drawing:
Fig. 1 to 9 for as described in illustrating for the manufacture of each step of method with the overall fibre-composite component of setting element, and
Figure 10 is the schematic cross sectional views of the overall fibre-composite component that the method utilizing to go out as shown in Figure 1 to 9 manufactures.
Detailed description of the invention
Fig. 1 to 9 shows the schematic diagram of the exemplary series of each step for the manufacture of the method with the overall fibre-composite component of setting element.
In the first step shown in Fig. 1, that first implements is to provide the first fibrage 11.This fibrage can be set to non-impregnated textile fibre layer (particularly yarn fabric, scrim or knitted fabric), that this fibrage can be configured to individual layer or multilayer and unidirectional or multidirectional, and therefore form a basis stacking (Grund-Stack), other parts of fibre-composite component to be made be implemented in this basis stacking on.
In the second step shown in Fig. 2, two component matrix that matrix 12 is such as made up of a kind of resin-hardener-mixture are coated on a surface of the first fibrage 11.Preferably coating can being limited on a regional area, being arranged on setting element 13 on the described surface of the first fibrage 11 in third step (Fig. 3) below in this region.Certainly matrix can be coated in one of the first fibrage 11 equally more in large regions or in the part of multiple regions.
The element 13 of setting arranged in third step is configured to supporting-core in shown embodiment, such as, be made up of the material of expanded material or other dimensionally stables.Certainly, described set element 13 also can comprise other alternative materials and/or functions integrate set element 13, particularly reel, plastic core, metal-cored, wax core and/or the core body that is made up of solid material, expanded material, there is hollow structure, alveolate texture, and/or by sound insulation and/or core body that the material of noise reduction is formed.
Next other matrix 14 being coated in the 4th step (Fig. 4) sets on the Free Surface 15 of element 13, be not namely connected with the first fibrage 11 that on the surface.In addition, matrix 16 to be coated on the described surface of the first fibrage 11 (as long as in the step after Fig. 1 also unenforced words), after this matrix, to become the part of the fibre-composite component 30 that will manufacture.This means: unnecessary fringe region then can keep in contrast without matrix coating state.
Fig. 5 to Fig. 9 shows by the overall covering fibrage 17 of three parts of being disposed adjacent to each other, of covering that fibrage 17a to c form.Three first (part) section 18a altogether (namely each part covers fibrage first section 18a) of whole covering fibrage 17 be arranged on set element 13 Free Surface 15 on and altogether four second (part) section 18b be arranged on the surface of the first fibrage 11.Every part covering fibrage all can be used as non-impregnated fibrage or non-impregnated preform provides.At this, three each covering in fibrage 17a to c of part are configured to extensible in mathematical meaning respectively.
First, in the 5th step shown in Fig. 5, the Part I of whole covering fibrage 17 covering fibrage 17a is arranged on and sets on the Free Surface 15 of element 13.Set on the Free Surface 15 of element 13 owing to being coated according to Fig. 4 matrix coating, therefore cause Part I cover fibrage 17a be fixed on together with one of first section 18a simultaneously set element 13 Free Surface on.Thus, by with set element 13 local, connection that material engages achieves the fixing step that Part I covers fibrage 17a.Certainly, as a supplement or alternative, can carry out force closure and/or positive is fixing, is particularly undertaken adhering to by jointing material and/or by connector (not shown) cutting ferrule or the clamping at least partly of some.
In ensuing 6th step (Fig. 6), be coated with the other matrix 19 being applied to second and Part III covering fibrage 17b or 17c.Matrix 19 is particularly coated in Part I and covers fibrage 17a back on described surface of setting element 13 in respective edges region, to obtain one covering with second and Part III the region that fibrage 17b and c (reference Fig. 7) overlap.In addition, cover corresponding second (part) section 18b of fibrage 17b and 17c for second and Part III, also matrix is applied on the surface of the first fibrage 11.
As shown in Figure 7, then second and Part III covered fibrage 17b and 17c and to be arranged on corresponding ready position and to be fixed by coated matrix.Part covers fibrage 17a to c and is disposed adjacent to each other in this wise: part each two 17a and 17b or 17a and 17c covered in fibrage (particularly can be seen in fig .9) respectively in an overlapping regions 20 and mutually overlap.
Just can produce that one is stacking accordingly arranges structure 25 thus.
After this, in the 8th step, the stacking structure 25 that arranges is extruded, with the overall fibre-composite component 30 shown in producing in fig. 8, and implement one after a while, selectable, shear the 9th step of fibre-composite component 30 that produces for edge cutting being opened and obtaining the Member Lip determined.
Alternatively, the first such fibrage and/or part can be utilized to cover fibrage and perform described method, described fibrage comprises a fiber stack with the single or multiple lift of matrix prepregs stain respectively.Therefore can omit the intermediate steps for coated substrate, particularly set forth in Fig. 2,4 and 6, for the step of coated substrate.
Figure 10 shows the schematic cross sectional views of overall fibre-composite component 30 in the compacting tool set 50 with lower mold half 51 and top half module 52 utilizing the method as described in Fig. 1 to 9 to make.
This fibre-composite component 30 comprises the first fibrage 11, the covering fibrage 17 of setting element 13 and utilizing the first section 18a to be covered at least in part by the Free Surface 15 of setting element 13 be arranged on a surface of this first fibrage 11, wherein, this covering fibrage 17 and the first fibrage 11 are at least connected to planar each other in two the second section 18b (this also can be optionally around second section of setting element 13).Cover fibrage 17 (as shown in Fig. 7 to 9) and cover fibrage (17a to c by multiple part, not shown in Fig. 10) form, these parts cover fibrage and arrange adjacent to each other, wherein, at least two in described part covering fibrage mutually overlap (not shown equally) respectively in an overlapping regions.
As selection, set element 13 be configured to along compacting tool set closing direction S about compacting tool set 50 or its top half module 52 self-centering.For this reason, set element 13 and there is a kind of geometry expanded along closing direction S/expand.Described closing direction S should be considered as relating to compacting tool set 50 and receive the top half module 52 of setting element relative to the direction of relative movement of setting element 13 to carry out extruding.In other words, set the direction that element 13 is configured to along remotely pointing to from the first fibrage 11 to reduce gradually.This then provides following possibility: set when mould 50 closes element 13 according to the moulding of compacting tool set that is there is the inclined-plane being configured to respective complementary moulding cavity (former) automatically laterally (transverse to closing direction S) move to predetermined position exactly.

Claims (10)

1., for the manufacture of the method for overall fibre-composite component, comprise the steps:
-the first fibrage is provided,
-element will be set be arranged on a described first fibrolaminar surface,
-by cover fibrage to be arranged on at least one first section described in set element Free Surface on and be arranged on described first fibrolaminar described surface with at least one second section, wherein, described covering fibrage covers fibrage by least two parts be disposed adjacent to each other and forms, and
-described at least two parts are covered fibrages be fixed on described in set on the described Free Surface of element, to be extruded stacking structure is set to produce one,
-the described stacking structure that arranges is extruded, to produce described overall fibre-composite component.
2. the method for claim 1, is characterized in that, described at least two parts is covered fibrage and is disposed adjacent to each other in this wise: at least two that described part is covered in fibrage mutually overlap in an overlapping regions.
3. method as claimed in claim 1 or 2, it is characterized in that, fixing described part cover fibrolaminar step comprise with described set element local material with engaging ground and/or positive and/or force closure be connected, particularly undertaken adhering to by the matrix of the amount of specifying at least partly and/or jointing material and/or by cutting ferrule or the clamping at least partly of some connectors.
4. the method as described in any one of claims 1 to 3, is characterized in that, at least one covering in fibrage of described part forms extensible.
5. the method as described in any one of Claims 1-4, it is characterized in that, described first fibrage and/or described at least two parts are covered fibrages provided as non-impregnated fibrage or as non-impregnated preform, and the method comprises one or more matrix is applied to step on each corresponding fibrage.
6. the method as described in any one of Claims 1-4, is characterized in that, described first fibrage and/or described at least two parts cover fibrages comprise respectively one with matrix prepregs stain, the fiber stack of single or multiple lift.
7. the method as described in any one of claim 1 to 6, it is characterized in that, described set that element comprises dimensionally stable and/or functions integrates set element, particularly foam core, reel, plastic core, metal-cored, wax core and/or the core body that is made up of solid material, expanded material, there is hollow structure, alveolate texture, and/or by sound insulation and/or core body that the material of noise reduction is formed.
8. the method as described in any one of claim 1 to 7, is characterized in that, described in set the closing direction that element is configured to along compacting tool set self-centering about this compacting tool set.
9. fibre-composite component, comprising: the first fibrage; Be arranged on and this first fibrolaminar surface sets element; And the Free Surface of this being set element is at least with the covering fibrage that the first section covers at least in part, wherein, described covering fibrage is at least connected to planar each other with described first fibrage in the second section, it is characterized in that: described covering fibrage covers fibrage by multiple part and forms, these parts cover fibrage and to arrange adjacent to each other and described part at least two of covering in fibrage mutually overlap respectively in an overlapping regions.
10. fibre-composite component as claimed in claim 9, it is characterized in that, this fibre-composite component makes by the method as described in claim 1 to 8.
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