CN105324232A - 由碳纤维废料制备用于加工成cfk-构件的半成品的方法 - Google Patents

由碳纤维废料制备用于加工成cfk-构件的半成品的方法 Download PDF

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CN105324232A
CN105324232A CN201480035251.1A CN201480035251A CN105324232A CN 105324232 A CN105324232 A CN 105324232A CN 201480035251 A CN201480035251 A CN 201480035251A CN 105324232 A CN105324232 A CN 105324232A
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extruder
reclaimed materials
carbon fiber
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W·道纳
S·胡贝尔
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Bayerische Motoren Werke AG
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    • B29C48/001—Combinations of extrusion moulding with other shaping operations
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
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Abstract

本发明涉及一种方法，其中将合适的碳纤维废料(3)连同塑料聚合物(5)引入粉碎机和挤出机(4)，从而由此产生碳纤维聚合物物料并且将其浸渍在树脂中。由此获得回收料预浸料(6)，所述回收料预浸料被赋予合适的形状和/或长度。由此获得的回收料预浸料(6)然后可以在另一个子步骤中通过流动挤压方法被赋予接近最终轮廓的形状(1)。

Description

由碳纤维废料制备用于加工成CFK-构件的半成品的方法
背景技术
本发明涉及根据权利要求1所述的制备用于加工成CFK-构件(碳纤维增强的构件)的半成品的方法。本发明尤其涉及制备CFK-构件的连续方法，其中中间步骤是回收料半成品的制备。
在现有技术中已知，将塑料引入回收料过程从而在之后的再加工过程中再次使用所述塑料。例如在DE19710098A1中公开了由薄片制造聚对苯二甲酸乙二醇酯(PET)-回收料的方法，以及根据所述方法生产的PET-产品。PET-产品具有多种用途，例如作为瓶、高品质薄膜和纤维、医用仪器，尤其是医用注射器和医用容器。人们致力于对所述产品尽可能完全地进行物质循环。但是一个重要问题在于，随着PET-回收料的含量增加，产品的品质发生变化。
尤其用于车辆内部的聚合物材料的模制件必须满足高的机械要求和环境要求，主要是关于其机械性能、其表面性能、其老化行为及其气味行为和排放行为必须符合要求。已知的是，使用各种聚合物材料制备用于车辆内部区域的构件和模制件。典型地使用的材料是玻璃纤维增强的ABS/PC-材料(丙烯腈-丁二烯/苯乙烯共聚物与聚碳酸酯的聚合物共混物)。然而所述材料具有不足的耐紫外线性、差的流动能力、差的热老化行为(热储存之后的韧性和断裂伸长)和不利的表面性能以及差的稳泡性以及尤其差的气味行为。塑料的气味行为被理解为在气候储存和尤其是温度加载一定时间和一定温度之后，部件释放出人可以察觉的挥发性成分的倾向。
在现有技术中还已知使用纤维增强的模制塑料用于机械稳定的构件和模制件。在建筑部件的制备中例如使用玻璃纤维、天然纤维或碳纤维或填料作为增强纤维。然而例如玻璃纤维的纤维材料较为昂贵。玻璃纤维的另一个缺点在于其相对较重。
在例如车辆部件以及车辆内部件的构件的制备中，尤其是在轮廓件的制备中，在现有技术中使用挤出方法、共挤出方法和拉挤方法。然而高的成本始终是限制性因素。因此，用所述方法制备碳纤维增强的构件受材料成本和纤维用量的显著影响。还已知的是，在制备中尤其是在非织造织物的制备中使用碳纤维废料，从而降低成本。然而现有技术中已知的加工方法受到不连续方法的限制。因此分别在不连续的过程中加工一定的批量。
发明内容
因此希望提供一种制备方法，所述制备方法连续加工并且可以加工更大量的热固性塑料和热塑性塑料。
因此本发明的目的在于克服上述缺点并且尤其提供具有短加工时间的连续方法，所述方法能够由具有良好的最终机械性能的聚合物材料低成本地制备半成品和构件。
通过根据权利要求1所述的方法实现所述目的。本发明的基本构思在于，将合适的碳纤维废料连同塑料聚合物引入粉碎机和挤出机，从而由此形成碳纤维聚合物物料并且将其浸渍在树脂中。由此获得回收料预浸料，所述回收料预浸料被赋予合适的形状和/或长度。然后可以在另一个子步骤中通过流动挤压方法，所述回收料预浸料被赋予接近最终轮廓的形状。
为此可以使用挤出方法、共挤出方法或拉挤方法等，从而由此制备模制件例如轮廓件或车辆内部部件。
因此在本发明的一个普通形式中，提供在用于加工成碳纤维增强的构件的连续过程中制备半成品的方法，所述方法具有至少如下步骤：
-将碳纤维废料引入挤出机；
-将塑料聚合物计量加入挤出机；
-粉碎碳纤维废料并且将经粉碎的废料与塑料聚合物混合成聚合物物料；
-用树脂浸渍聚合物物料从而由此形成回收料预浸料，所述回收料预浸料被赋予合适的形状和/或长度。
本发明的一个方面因此在于，在挤出机中机械粉碎碳纤维增强的塑料废料或碳纤维增强的塑料材料，由此制备碳纤维回收料，从而使其与热固性塑料或热塑性塑料以期望的混合比例混合成聚合物物料。混合比例和碳纤维废料尺寸对之后的模制件的期望的机械性能和技术性能产生影响。可以优选通过螺杆几何形状或者通过螺杆长度调节粉碎程度。
优选提出这样的方法：其中使用热塑性塑料或热固性塑料作为塑料聚合物。
在本发明的一个特别优选的实施方案中，引入挤出机的碳纤维废料或碳纤维边角料的粉碎直接在挤出机中进行。通过这种方式可以避免高成本的预粉碎并且因此避免分开的工艺步骤。因此在一个优选的实施方案中，使用具有适应期望的粉碎程度的螺杆几何形状的挤出机用于粉碎碳纤维废料。例如可以通过螺杆长度或者通过螺杆几何形状调节粉碎程度。
替代性地，也可以在挤出机中设置粉碎装置，从而在操作挤出机螺杆时同时通过粉碎装置进行粉碎。
在本发明的一个优选的实施方案中，用树脂浸渍经挤出的聚合物物料，从而由此形成回收料预浸料，可以为所述回收料预浸料赋予合适的形状和/或长度。因此还优选的是挤出之后的子步骤：回收料预浸料在离开挤出机之后以一定间距进行切割，即缩短成适应再加工的预浸料块。替代性地，回收料预浸料在离开挤出机之后也可以被赋予一定形状。
在本发明的另一个优选的实施方案中，经切割的或者被赋予一定形状的回收料预浸料优选通过在工具中压力成型(例如流动挤压)而成型成接近最终轮廓的半成品。
特别有利的是，为了进行压力成型，将回收料预浸料引入挤压工具的赋形腔体并且通过挤压印模挤压。根据本发明，上述子步骤可以在连续的流水线过程或生产线中彼此串联连接。
从属权利要求中表明了本发明的其它有利的实施方案，或者下文参考附图连同本发明的优选实施方案的描述更详细地说明了本发明的其它有利的实施方案。
附图说明
图1显示了根据本发明的制备用于CFK-构件的回收料预浸料的方法的示意图。
图1中显示了根据本发明的通过挤出机(4)在挤出过程中和之后的压力成型过程中制备CFK-构件(2)的方法的步骤的示意性顺序。
具体实施方式
根据实施例，所述方法在具有如下步骤的连续过程中进行：
首先将碳纤维废料(3)引入挤出机(4)。在挤出机(4)中通过挤出机螺杆粉碎碳纤维废料(3)。此外还向挤出机(4)中计量加入塑料聚合物(5)。
分别通过与挤出机螺杆直接连接的供应装置(10)将碳纤维废料(3)和塑料聚合物(5)引入挤出机(4)。
通过粉碎碳纤维废料(3)并且将经粉碎的废料与塑料聚合物混合从而产生聚合物物料。用树脂浸渍聚合物物料从而由此形成回收料预浸料(6)，所述回收料预浸料(6)被赋予合适的形状和/或长度。
如图1中所示，回收料预浸料(6)在离开挤出机(4)之后以一定间距切割成彼此分离的单个回收料预浸料(6)。在生产方向上仅示意性地显示了四个成型的回收料预浸料(6)。在所述方法中可以使用热塑性塑料或热固性塑料作为塑料聚合物(5)。
碳纤维废料(3)的粉碎在挤出机(4)中直接进行。在本实施例中，使用具有适应期望的粉碎程度的螺杆几何形状的挤出机(4)用于粉碎碳纤维废料(3)。
根据本发明也可以设置调节机构和适应机构，使得粉碎装置与螺杆运输机能够可调节地共同作用，从而因此调节期望的粉碎程度。
根据方法的实施例的进一步的形式在于，经切割的并且被赋予一定形状的回收料预浸料(6)通过在工具(8)中流动挤压而成型成接近最终轮廓的半成品，其中将回收料预浸料(6)引入挤压工具(8)的赋形腔体(7)并且通过挤压印模(9)挤压。在流动挤压之后，半成品(1)在工具(8)中固化，并且在固化之后从工具(8)中脱模。
本发明的实施方案不限于上文所述的优选实施方案。可想到多种变体形式，这些变体形式即使在基本不同种类的实施方案中仍然利用所述解决方案。

Claims (10)

1.在用于加工成碳纤维增强的构件(2)的连续过程中制备半成品(1)的方法，所述方法具有至少如下步骤：
a.将碳纤维废料(3)引入挤出机(4)；
b.将塑料聚合物(5)计量加入挤出机(4)；
c.粉碎碳纤维废料(3)并且将经粉碎的废料与塑料聚合物混合成聚合物物料；
d.用树脂浸渍聚合物物料从而由此形成回收料预浸料(6)，所述回收料预浸料(6)被赋予合适的形状和/或长度。
2.根据权利要求1所述的方法，其特征在于，使用热塑性塑料作为塑料聚合物(5)。
3.根据权利要求1所述的方法，其特征在于，使用热固性塑料作为塑料聚合物(5)。
4.根据权利要求1至3中任一项所述的方法，其特征在于，碳纤维废料(3)的粉碎在挤出机(4)中直接进行。
5.根据权利要求4所述的方法，其特征在于，使用具有适应期望的粉碎程度的螺杆几何形状的挤出机(4)用于粉碎碳纤维废料(3)。
6.根据前述权利要求1至5中任一项所述的方法，其特征在于，回收料预浸料(6)在离开挤出机(4)之后以一定间距进行切割。
7.根据前述权利要求1至6中任一项所述的方法，其特征在于，回收料预浸料(6)在离开挤出机(4)之后被赋予一定形状。
8.根据前述权利要求1至6任一项所述的方法，其特征在于，经切割的或者被赋予一定形状的回收料预浸料(6)通过在工具(8)中流动挤压而成型成接近最终轮廓的半成品。
9.根据权利要求8所述的方法，其特征在于，为了进行流动挤压，将回收料预浸料(6)引入挤压工具(8)的赋形腔体(7)并且通过挤压印模(9)挤压。
10.根据权利要求8或9所述的方法，其特征在于，半成品(1)在工具(8)中流动挤压之后固化。
CN201480035251.1A 2013-11-05 2014-10-28 由碳纤维废料制备用于加工成cfk-构件的半成品的方法 Pending CN105324232A (zh)

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