CN104968484A - 金属插件与复合材料层构成的组件、用于将这种插件集成在这种复合材料层中的方法以及这种复合材料层模制获得的部件 - Google Patents

金属插件与复合材料层构成的组件、用于将这种插件集成在这种复合材料层中的方法以及这种复合材料层模制获得的部件 Download PDF

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Publication number
CN104968484A
CN104968484A CN201380060252.7A CN201380060252A CN104968484A CN 104968484 A CN104968484 A CN 104968484A CN 201380060252 A CN201380060252 A CN 201380060252A CN 104968484 A CN104968484 A CN 104968484A
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China
Prior art keywords
assembly
projection
enhancement layer
layer
sheet
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CN201380060252.7A
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English (en)
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大卫·特雷斯
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Plastic Omnium SE
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Plastic Omnium SE
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    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
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    • 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
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Abstract

本发明涉及一种组件(10)，该组件由至少一个金属插件(14A、14B、14C)和增强层(12)构成。该增强层(12)包含长度大于或等于1厘米的增强纤维。金属插件(14A、14B、14C)包括凸起(22)，这些凸起被成型为通过在增强纤维之间通过来穿过所述层(12)，并在所述凸起受到纵向压力时通过塑性变形弯折并挤紧增强纤维。

Description

金属插件与复合材料层构成的组件、用于将这种插件集成在这种复合材料层中的方法以及这种复合材料层模制获得的部件
技术领域
本发明涉及由复合材料制成的部件的技术领域。
背景技术
一般地，复合材料包括增强物和热塑性或热固性树脂基质。增强物可以呈短纤维、长纤维或纤维织物的形式。有涂抹树脂的干增强物层，也有可以直接铺设的预浸渍层。特别地，可以通过注射、压缩或渗透工艺来实现复合材料的成型。
例如涉及由复合材料制成的组件，该复合材料包括热固性聚酯树脂，该热固性聚酯树脂浸渍了玻璃纤维(占该增强物重量的20至30％)，并特别地具有填料和催化剂(固化剂)。该组件可以在每个表面上包括聚乙烯防护膜。
毛坯例如在模具中受压而热压缩成型，该模具一般通过模具的一个活动部分相对于模具的一个固定部分移动来闭合。
这些基于由复合材料制成的组件实现的部件的困难之处在于其组装，以及机动车结构的其他构件的添加或固定。
特别地，可能会需要焊接、螺固或粘接该部件到所述构件上。
发明内容
本发明的目的在于提出一种解决该问题的方案。
本发明的主题在于一种由金属插件和复合材料增强层构成的组件，其特征在于：
增强层包括长度大于或等于1cm的增强纤维；
金属插件包括凸起，这些凸起被成型为：
通过在纤维之间经过来在增强层厚度中穿过增强层；
通过塑性变形弯折，挤紧(enserrer)增强纤维。
根据第一个实施例，凸起为具有一般呈三角形的渐尖端部的齿。
该组件还可以包括柱身以产生“通道”，该柱身可以例如也带有螺纹，以允许进行部件的螺固或添加螺固构件，该柱身通过分开纤维而穿过增强层，因此不损坏纤维。
如前述权利要求中任一项所述的组件包括凸起或柱身，该凸起或柱身穿过增强层，并且不损坏增强层。“不损坏”指的是凸起或柱身不切割、扯破、剪切增强层。
增强层可以包括树脂，该树脂的形式为大致覆盖所有纤维的粉末或预浸物。
根据第二实施例，增强纤维呈长纤维单向层的形式。
根据第三实施例，纤维呈长纤维织物的形式。
根据第四实施例，纤维呈无序地分布在材料中的短切纤维的形式。在该情况下，纤维的长度大于5mm，优选地大于10mm，理想地大于20mm。
有利地，纤维为碳、玻璃或植物纤维。
本发明的主题还在于一种用于将如上所述的插件集成到增强层中的方法，该增强层具有厚度、上壁和下壁，该方法的特征在于，该方法在于：
将插件放置在增强层的上壁上；
使插件的凸起穿过增强层的厚度而穿入；
通过塑性变形弯折凸起，使得凸起向下壁弯折，并挤紧增强纤维。
有利地，在一个具体的实施例中，凸起通过轴向或侧向力来弯折。
在一个具体的实施例中，弯折凸起的步骤在用于制造由复合材料制成的部件的模具中实现。“树脂”指的是属于热塑性或热固性聚合物一族的有机材料。
在另一具体实施例中，在将组件引入到用于制造由复合材料制成的部件的模具中之前预先实现弯折凸起的步骤。
本发明的一个特别有意义的应用在于实现如上所述的组件或由树脂制成的部件边缘处和/或该层或部件中间处的界面。这可以是平的界面，或带有贯穿螺固柱身(该柱身穿过部件，但不损坏纤维)的界面。
特别地，包括这种插件的组件或部件可以更容易地由机器人通过磁化或吸附来夹持。这是特别有利的，因为磁化和吸附一般不能用于纤维层。插件还可以用于实现与另一金属构件的焊接。
插件还可以包括与另一部件接口的平的或鼓起的表面，该表面可以是用于焊接、磁化或吸附的平的表面，或者是构成用于实现最终部件固定的鼓起(excroissance)。
最后，本发明的主题还在于一种由复合材料制成的部件，该部件通过如上所述的组件的成型和聚合获得。
在一个特别有利的实施例中，该由复合材料制成的部件为机动车构件。
附图说明
阅读示例性地而非限制性地提供的附图，本发明将变得更易理解。在这些附图中：
图1为符合本发明的组件的一部分的透视立面图；
图2为符合本发明的组件的一部分的透视仰视图；
图3a、图3b、图3c和图3d以剖视图示出了图1的组件的集成方法的步骤；
图4示出了用于符合本发明的组件的螺固柱身的实施例。
具体实施方式
参照图1和图2，只示出了组件10的一小部分，该组件设有复合材料增强层12和三个金属插件14A、14B、14C。
为了简化说明，该组件部分在下文中称为“组件”。组件由沿着对称轴线L的纵向方向、沿着轴线T的横向方向和沿着轴线Z的贯穿方向限定。
在该示例中，复合材料增强层12具有矩形形状和4mm的厚度。该增强层包括下壁16A和上壁16B，金属插件布置在该上壁的表面上。
复合材料层包括树脂和长度大于或等于1cm的增强纤维。增强纤维为玻璃纤维，并构成相互交错和叠置的层。
在该示例中，金属插件具有矩形形状和1mm的厚度，但也可以具有任意形状和包括在0.5至1.5mm之间的厚度。
金属插件14A、14B、14C限定尺寸比其上布置这些金属插件的层更小的矩形。在这里，金属插件具有与组件10的纵向对称轴线L重合的纵向对称轴线。
在所考虑的用于机动车的应用中，组件的尺寸最经常比插件的尺寸大得多。在该示例中，布置在增强层表面上的三个插件中的两个14A、14B限定包括在由复合材料层限定的矩形形状内部的表面。第三插件14C构成长度比另外两个插件14A、14B更大的矩形，并包括端部20，该端部超出到由复合材料层构成的矩形形状的外部。
金属插件设有凸起22，这些凸起按照规则的间隔(即在该示例中按5mm的间隔)分布在插件边缘附近和插件14B的中央部分上。这些凸起22构成小的矩形齿和三角形尖齿，其起点位于插件边缘附近。这些凸起能够在插入插件时分开纤维，并通过在纤维之间通过来穿过复合材料增强层，这些凸起的端部以大致平行于复合材料层的下壁16A的方式弯曲。可替代地，这些凸起可以大致弯曲到自身，其端部指向上壁。
组件也可以包括穿过复合材料层并分开纤维(因此不损坏纤维)的螺固柱身。要注意的是，这些柱身一般位于插件的中间而不是插件的边缘处。
凸起被成型为通过分开增强纤维穿过复合材料层而不显著地损坏增强纤维。凸起通过塑性变形(例如像办公订书钉那样)弯折。由此，当受到沿着其纵向方向的压力时，凸起挤紧增强纤维。凸起还可以通过侧向变形来弯折，并且在凸起位于组件边缘处时，凸起可以向组件的外部或内部弯折。
根据第二实施例，增强纤维为长纤维单向层。
根据第三实施例，纤维为长纤维织物，即纤维是连续的。由此，纤维呈单向纤维的形式，其长度等于部件的长度。
根据第四实施例，纤维为短切纤维，并无序地分布在材料中。在该情况下，纤维必须具有大于或等于2cm的长度。
现在描述一种用于将如上所述的插件集成在增强层12中的方法。如图3a所示，第一步骤在于将插件放置在增强层上。根据图3b，使插件的凸起穿过层12穿入，凸起22通过分开纤维在纤维之间通过。然后，通过沿轴线Z施加的力或侧向的力使凸起通过塑性变形来弯折到层上，这允许如示例的图3d所示地实现凸起向着层弯折。可替代地，凸起可以如图3c所示地以大致平行于层的方式弯折。
在一个具体的实施例中，在用于制造复合材料部件的模具中实现凸起弯折步骤。为此，在模具中引入至少一个带有插件的增强层，关闭模具，然后注入树脂。
在另一具体的实施例中，在将组件引入用于制造复合材料部件的模具中之前预先实现凸起弯折步骤。
最后，本发明的一个主题在于通过成型和交联如上所述组件所获得的复合材料部件。
本发明不限于所述实施例，其他实施例对于本领域的技术人员是明显的。特别地，增强纤维可以是碳纤维、植物纤维、或其他材料的纤维。同样地，可以在复合材料边缘或中间处实现界面。这些界面可以是平界面，或如图4所示的带有贯穿螺固柱身24的界面。复合材料层可以包含长度大于或等于1cm的增强纤维。所述层的厚度可以是不同的，其厚度可以包括在0.5至10mm之间，优选地在1至7mm之间，并在某些配置中包括在1至4mm之间。插件的齿可以位于插件的中间，以增加锚固点和改善抗拔扯强度。最后，插件还可以包括用于与另一部件接口的鼓起，该鼓起可以例如被螺固、焊接或包覆成型。
特别地，可以考虑将该组件应用于制造底板、纵梁、前柱、中柱、后柱、门窗件面板、车顶横梁、或车辆结构性梁或增强件。

Claims (13)

1.一种由至少一个金属插件(14A、14B、14C)和至少一个复合材料增强层(12)构成的组件(10)，其特征在于：
所述增强层(12)包含长度大于或等于1厘米的增强纤维；
所述至少一个金属插件(14A、14B、14C)包括凸起(22)，这些凸起被成型为：
通过在所述增强纤维之间通过来穿过所述层(12)；
通过塑性变形而弯折，并挤紧所述增强纤维。
2.如权利要求1所述的组件(10)，其中，所述凸起(22)具有渐尖的端部。
3.如上述权利要求中任一项所述的组件(10)，包括螺固柱身(24)，该螺固柱身通过分开所述纤维而穿过所述复合材料增强层(12)。
4.如上述权利要求中任一项所述的组件(10)，包括穿过所述增强层但不损坏该增强层的凸起或柱身(24)。
5.如上述权利要求中任一项所述的组件，其中，所述纤维为长纤维单向层。
6.如权利要求1至3中任一项所述的组件(10)，其中，所述纤维的形式为无序地分布在材料中的短切纤维。
7.如上述权利要求中任一项所述的组件(10)，其中，所述纤维为碳纤维、玻璃纤维或植物纤维。
8.一种用于将插件(14A、14B、14C)集成在增强层(12)中的方法，其特征在于，该方法在于：
将插件(14A、14B、14C)放置在所述层(12)上；
使所述插件的凸起(22)穿过所述层；
使所述凸起通过塑性变形弯折到所述层上。
9.如权利要求8所述的方法，其中，在用于制造复合材料部件的模具中实现所述凸起的弯折步骤。
10.如权利要求8或9所述的用于制造组件(10)的方法，其中，通过轴向力或侧向力使所述凸起(22)弯折。
11.如权利要求7所述的方法，其中，在将所述组件引入用于制造复合材料部件的模具中之前预先实现所述凸起的弯折步骤。
12.一种复合材料部件，其特征在于，该部件通过如权利要求1至6中任一项所述的组件的成型和聚合来获得。
13.如权利要求12所述的复合材料部件，所述部件为机动车构件。
CN201380060252.7A 2012-11-20 2013-11-19 金属插件与复合材料层构成的组件、用于将这种插件集成在这种复合材料层中的方法以及这种复合材料层模制获得的部件 Pending CN104968484A (zh)

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