CN104943325B - 复合构件和制造该复合构件的方法 - Google Patents

复合构件和制造该复合构件的方法 Download PDF

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CN104943325B
CN104943325B CN201510038524.4A CN201510038524A CN104943325B CN 104943325 B CN104943325 B CN 104943325B CN 201510038524 A CN201510038524 A CN 201510038524A CN 104943325 B CN104943325 B CN 104943325B
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layer
thermoplastic elastomer
resin
method described
supporting
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CN104943325A (zh
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T.雅各布
D.伦格肖森
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GM Global Technology Operations LLC
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Abstract

本发明一种用于制造复合构件的方法，所述方法具有以下步骤：a)在由热塑性弹性体制成的、具有空隙(10)的层(6)的两侧制备具有至少两个支承层‑前体层的层结构；b)加热所述层结构，以便使由热塑性弹性体制成的层(6)变为塑性的；c)挤压位于支承层‑前体层之间的由热塑性弹性体制成的层(6)。

Description

复合构件和制造该复合构件的方法
技术领域
本发明涉及一种具有至少两个支承层和布置在所述支承层之间的由热塑性弹性体制成的层的复合构件。从文献DE 10 2011 114 362 A1中已知这种复合构件。
背景技术
复合构件、尤其这种带有由纤维增强塑料制成的复合构件的已知的问题在于，在过载时急剧断裂的趋势，并且在此形成边缘尖锐的碎片。当这种复合构件被应用在机动车制造中时必须确保的是，当复合构件在事故中破裂时，驾乘人员不会由于在此形成的碎片而受到威胁。由此所产生的要对复合构件进行包覆的必要性敏感地制约了复合构件尤其在车辆内部结构中的应用性。
当复合构件取代由纤维增强塑料制成的实心模制件被应用时，就会明显制约通过形成碎片所造成的危险，在所述复合构件中，由纤维增强塑料制成的支承层通过弹性体层相互连接。这种通过对由纤维增强塑料制成的板进行层压和对由此得到的层压件进行切割和成型来制造复合构件带来了显著升高的费用和成本。通过将纤维衬层和在所述纤维衬层之间延伸的弹性体层放置在模子中并且随后将树脂注入模子中来实现对复合构件的直接制造，以至于弹性体层阻碍了、至少明显使树脂的扩散变得困难。相较而言，在三层层压件的情况下(其中热塑性弹性体层位于两个支承层之间)至少还提供给了这样的可能性，即为了构成支承层，将树脂从模子的不同侧面分别注入各个纤维衬层中，这种方法在具有大量层的层压件中已经不再实用。
发明内容
由此本发明所要解决的技术问题在于，提供一种复合构件和用于制造这种复合构件的方法，所述复合构件能够成本低廉地实现，然而同时还有效降低了形成碎片所带来的危险。
根据本发明的设计方式，所述技术问题是通过用于制造具有多个层的复合构件的方法解决的，所述方法具有以下步骤：
a)在由热塑性弹性体制成的、具有空隙的层的两侧制备具有至少两个支承层-前体层的层结构；
b)加热所述层结构，以便使由热塑性弹性体制成的层变为塑性的；
c)挤压位于支承层-前体层之间的由热塑性弹性体制成的层。
由热塑性弹性体制成的层的空隙首先在多个位置允许支承层之间的接触，并且尤其还允许材料从由热塑性弹性体制成的层的一个侧面过渡到另一个侧面，在此情况下，在随后的加热过程和挤压过程中，弹性体层的颗粒在支承层之间被压平，从而在这三个层之间实现紧密的、大面积的连接。
挤压可以在模具中在整个层结构上进行，以便同时将支承层-前体层压紧或密封成支承层。
优选地，支承层-前体层具有由纤维材料制成的层。这种由纤维材料制成的层一方面用于提高制成后的复合构件的负载强度，另一方面可以在制备过程中被用作位置保持件，由纤维制成的层的纤维间隙通过另一个浸渍的方法步骤d)被树脂填充。
当预浸料坯(Prepreg)被用作纤维材料衬层时，可以省去浸渍步骤d)。
纤维在支承层中的体积比或质量比可以大于一半。
通过浸渍步骤d)可以符合目的地在挤压步骤c)之前开始，以便确保至少在浸渍的开始阶段时由热塑性弹性体制成的层的空隙还很大，并且允许树脂良好地穿过。
浸渍步骤和挤压步骤的时间上的交集是符合期望的，由此不会使在浸渍时输入的树脂填充由热塑性弹性体制成的层的所有空隙，因为否则的话将会很困难地实施对由热塑性弹性体制成的层的压缩。
当树脂通过由热塑性弹性体制成的层输入支承层-前体层中的至少一个时，实现了具有多于三个层的复合构件的制备。然而在仅具有三个层的复合构件中，这种方法也是符合目的的，因为该方法允许树脂仅从层结构的一个侧面输入，并且于此允许使用简单的工具。
由热塑性弹性体制成的层(其通过步骤a)导入支承层-前体层之间)可以被预先制备，尤其呈织物、层状物的形式或由纤维制成的无纺织物的形式、打孔薄膜或由或多或少的紧凑的颗粒制成的组织的形式，所述颗粒通过软化和部分熔融而相互连接成连续的层。
无纺织物或颗粒组织尤其还可以直接通过步骤a)构成在支承层-前体层中的一个上，例如通过将颗粒或丝线的集束撒向无纺织物；因为这样得到的层在挤压之前不必再进行移动，所以层的颗粒或丝线的相互间的加固是不必要的。
根据本发明的另一设计方式，所述技术问题还通过具有至少两个支承层和在支承层之间布置的由热塑性弹性体制成的层的复合构件解决，所述复合构件具有空隙，支承层通过所述空隙材料接合地相互组合。
支承层可以具有由纤维材料制成的衬层，然而其中，支承层之间的材料接合的组合优选不是通过纤维材料而是通过基质完成的，纤维材料从由热塑性弹性体制成的层的两侧嵌入所述基质中。
附图说明
本发明的其他特征和优点由以下结合附图对实施例的描述给出。在附图中：
图1示出剖切用于实施方法的模具的示意性剖视图；
图2示出剖切在注入树脂之前布置在模具中的层的示意性剖视细节图；
图3示出树脂注入的开始阶段；
图4示出继续阶段，其中，树脂开始穿过由热塑性弹性体制成的层的空隙；
图5示出支承层上的树脂越过由热塑性弹性体制成的层的扩散；
图6示出伴随着树脂的扩散的挤压；和
图7示出在挤压结束之后所得的工件的结构。
具体实施方式
图1以示意性剖视图方式示出了模具1，它具有凹模2和与凹模2相适配地成型且朝凹模2运动的压模3。在凹模2与压模3之间的空腔4中放置了三个由松散的纤维材料制成的、分别被由热塑性弹性体制成的层6隔离开的层5。层5的纤维可以是任何在复合材料技术中常用的纤维，例如玻璃纤维、碳纤维、芳族聚酸胺纤维或天然纤维、尤其是植物性来源的纤维、例如麻纤维。优选地，这些纤维以完全卷绕的连续带的形式存在，所述连续带为了置入凹模2中而只得必须被切割成匹配的形状。
由热塑性弹性体制成的层6明显比由纤维材料制成的层5更薄。由纤维材料制成的层5通常包含大量相互层叠的纤维或丝线，相比较而言，在层6中的纤维或丝线的数量则被限制为用于使层牢固所需的最小值。这样，层6尤其具有松散的织物的形式，或者层6也可以被设计为无纺织物，该无纺织物的纤维为了确保无纺织物的牢固而相互粘附在其交叉点上。这种层6还可以作为成卷的材料被输送，并且为了在模具1中的进一步加工而被切割成相应所需的形状。
原则上可以考虑的是，制造图1所示的对层5和层6的布置，这是通过以下方式实现的：分别在将由纤维材料制成的层5放置在凹模2中之后、将由热塑性弹性体制成的颗粒撒在凹模2中，以便构成层6，在层6上又可以放置下一个由纤维材料制成的层5。
模具1包括抽吸管道7，抽吸管道与(未示出的)真空泵相连，以便当压模3与最上方的由纤维材料制成的层5接触定位并且气密地封闭模子时，在模子闭合之后对空腔4抽真空。设有注入通道8，以便将构成基质的树脂注入被抽真空的空腔4中。
图2示出在注入树脂之前，在两个相互邻接的由纤维材料制成的层5之间的由热塑性弹性体制成的层6的横截面。在层6中示出了由热塑性弹性体制成的单个颗粒或丝线9的剖视图。在层5中为简明起见未示出纤维，尽管层5中的纤维的强度可以和纤维9的强度处于相近的数量级。由热塑性弹性体制成的纤维9分别被空隙10相互间隔开。在所示的实施例中，纤维9不规则地布置，并且空隙10的尺寸也发生变化。也可以使用具有大小均匀、规则布置的空隙10的层6、例如织物或打孔薄膜。
图3示出在树脂11注入一开始时图2所示的层5、6的示意图。树脂11到目前为止浸透了上方的由纤维材料制成的层5的部分，然而还未达到由热塑性弹性体制成的层6。
在图4中，在上部的层5中的树脂11的扩散已经沿侧向的方向明显继续推进了，此外，树脂还穿过层6的空隙10，并且刚好开始浸透下部的层5。
在图5中，下部的层5也已经大部分被树脂11浸透，层6的空隙10中除个别例外都还没有树脂。
这种扩散特性尤其可通过使用触变性的树脂11实现。尤其是具有这种流动特性的环氧树脂可以从市场购得并应用在此处。触变性的液体的特征在于，该液体在流动状态下的粘度小于在静止状态下的粘度。由此，触变性液体不是通过液体以宽阔的前端的推进而浸透基材，而是倾向于在推进时构成树状的结构。当液体在其前端位置上的推进放缓时，则粘度增加，这进一步阻滞了扩散，并导致后续的液体向那些已经被前端顺利地推进过的位置流出。因此，当树脂11仅穿过层6的零散的空隙10时，就足以浸透位于层6的另一侧的由纤维材料制成的层5。
当被注入的树脂11的量达到了与层5的纤维的质量或体积成正比的预设数值(该数值优选不大于纤维的质量或体积)时，可以由此开始挤压压模3与凹模2之间的层5、6。该数值应该如此大，从而使得单个的由纤维材料制成的层5不足以容纳树脂11，并且在树脂穿过一个(或多个)层6的空隙之后必须到达其他由纤维材料制成的层5。所述挤压在能使层6的热塑性弹性体发生塑性变形的温度下进行。如图6所示，挤压迫使树脂11在宽阔的前端上被推进到层5、6的尚未被浸透的区域。因为由热塑性材料制成的纤维9在层6的尚未被浸透的区域中处于真空环境中，所以纤维可以经受层5的自上和自下作用在纤维上的压力而导致横截面压扁。由此使得纤维之间的空隙10变窄。
当层5、6中的真空间隙都被排除时，挤压过程结束。纤维层5这样由挤进纤维层中的树脂11压紧成支承层13。如图7所示，由热塑性弹性体制成的层6的纤维9熔融成几乎封闭的层6'，在该层6'中仅存在使树脂11从一个层5流向另一个层5的空隙10。根据支承层13的局部的不均一性、例如在支承层中的单个凸起的纤维或纤维层或纤维密度的弯曲，层6'可能会具有局部的凹陷和隆起12。因为所述凹陷和隆起12使层5相互间的剪切运动变得困难，因此凹陷和隆起有利于制成后的复合工件的硬度和负载强度。
显然可以得出，取代了由纯纤维材料制成的层5，还可以使用被树脂预先浸透的层、所谓的“预浸料坯”。预浸料坯的使用降低了要注入的树脂的量；因为提前的压紧不会使得纤维层保持无树脂，所以在使用预浸料坯的情况下可以在树脂注入之前就已经开始压紧。在极端情况下，预浸料坯可以使注入树脂11变得完全是多余的；通过在抽真空的空腔4中加热并挤压层5、6，还可以实现嵌入到层5之间的由热塑性弹性体制成的层的颗粒的横截面被压平，从而使位于该层之间的空隙10大体上被封闭，并且所形成的层6'与邻接的层5的轮廓相适配。
显然，以上详细的描述和附图示出了本发明的示例性的设计方式，然而所设计方式仅被用于阐述，而不能以任何方式对本发明的范围构成限制。所述设计方式的多种变型都是可行的，只要不脱离以下权利要求的范围和权利要求的等同内容范围即可。尤其可以从所述描述和附图得到实施例的在权利要求中未被提及的技术特征。所述技术特征还可以以不同于此处特别公开的组合的方式出现。多个所述技术特征以同一语句或与其他行文方式被相互提及，然而不能以这一事实得出结论，认为所述技术特征仅能以特别公开的方式出现，相反，原则上可以得出，从多个所述技术特征中可以去掉或改变其中某个技术特征，只要不影响本发明的功能性即可。
附图标记清单
1 模具
2 凹模
3 压模
4 空腔
5 由纤维材料制成的层
6 由热塑性弹性体制成的层
7 抽吸管道
8 注入通道
9 纤维
10 空隙
11 树脂
12 凹陷/隆起
13 支承层

Claims (14)

1.一种用于制造复合构件的方法，包括:
制备具有至少第一和第二支承层-前体层和置于第一和第二支承层-前体层之间的热塑性弹性体层的层结构，所述层结构中的热塑性弹性体层由至少部分通过空隙彼此分开的丝线构成；
用树脂浸渍所述层结构，使得树脂流动经过第一支承层-前体层，经过热塑性弹性体层中的第一分组空隙，并且流入到第二支承层-前体层中，由此导致热塑性弹性体层中的在加热前保持不含树脂的第二分组空隙；
加热所述层结构，以便使热塑性弹性体层变为塑性状态；并且
将位于第一和第二支承层-前体层之间的热塑性弹性体层的丝线挤压到热塑性弹性体层中的第二分组空隙内，以形成复合构件。
2.根据权利要求1所述的方法，其中，所述挤压包括对在模具中的层结构进行挤压，以便将第一和第二支承层-前体层压紧成支承层。
3.根据权利要求1所述的方法，其中，所述支承层-前体层包括由纤维材料制成的层。
4.根据权利要求2所述的方法，其中，所述支承层-前体层包括由纤维材料制成的层。
5.根据权利要求4所述的方法，其中，所述纤维材料在所述支承层中的体积比大于一半。
6.根据权利要求4所述的方法，其中，所述纤维材料在所述支承层中的质量比大于一半。
7.根据权利要求1所述的方法，其中，所述层结构的浸渍在所述热塑性弹性体层的挤压之前开始。
8.根据权利要求1所述的方法，其中，所述热塑性弹性体层的挤压和所述层结构的浸渍至少部分地在时间上交叠。
9.根据权利要求1所述的方法，其中，所述热塑性弹性体层被预先制备，随后被放置到第一和第二支承层-前体层之间。
10.根据权利要求1所述的方法，其中，将所述热塑性弹性体层构造在第一和第二支承层-前体层之一上。
11.根据权利要求1所述的方法，其特征在于，所述热塑性弹性体层选自织物、层状物、无纺织物、打孔薄膜或颗粒组织。
12.根据权利要求1所述的方法，其特征在于，所述树脂是触变性的树脂。
13.根据权利要求6所述的方法，其特征在于，所述树脂的质量小于所述纤维材料的质量。
14.根据权利要求1所述的方法，其特征在于，所述加热和所述挤压将热塑性弹性体层的丝线熔融以封闭所述第二分组空隙。
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