CN105848857B - 具有用来连接热塑性塑料构件的功能层的纤维增强的热固性塑料构件 - Google Patents

具有用来连接热塑性塑料构件的功能层的纤维增强的热固性塑料构件 Download PDF

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CN105848857B
CN105848857B CN201480070007.9A CN201480070007A CN105848857B CN 105848857 B CN105848857 B CN 105848857B CN 201480070007 A CN201480070007 A CN 201480070007A CN 105848857 B CN105848857 B CN 105848857B
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component
functional layer
thermosetting
thermoplastic
thermosetting plastic
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CN105848857A (zh
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弗洛里安·胡贝尔
马丁·米特雷尔
汉斯·洛克纳
彼得·马丁
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KTM Technologies 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/002—Joining methods not otherwise provided for
    • B29C65/006—Diffusion joining
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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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
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
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    • 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
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    • B29C66/474—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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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
    • B29C66/739—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 material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—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 material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
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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
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    • B29C66/7394—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 material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
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    • B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
    • B29C70/026—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers and with one or more layers of pure plastics material, e.g. foam layers
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Abstract

用来通过材料锁合将热固性塑料构件（1）与热塑性塑料构件（9）接合的方法，在此方法中这两个构件借助热固性塑料构件（1）的功能层（3）相互连接，将所述热塑性塑料构件（9）直接设置在硬化的热固性塑料构件（1）的功能层（3）上，因此在热塑性塑料构件（9）和热固性塑料构件（1）的功能层（3）之间设置有渗出区（11）。

Description

具有用来连接热塑性塑料构件的功能层的纤维增强的热固性 塑料构件
技术领域
本发明涉及一种用于纤维增强的热固性塑料构件的制造方法，所述热固性塑料构件能够与热塑性塑料构件材料锁合地连接、尤其是焊接，在所述方法中为了形成基体将具有粘的热固性的基质的增强纤维放入硬化装置中并且使热固性的基质在压力和/或热量下淬火和/或硬化，其中在此硬化工艺之前或之时为了涂覆该基体至少在为连接热塑性塑料构件而设置的接合区域中将功能层设置在粘的热固性的基质和/或增强纤维上，该功能层在硬化工艺期间与热固性的基质和/或增强纤维固定相连。
本发明还涉及一种这样制成的热固性塑料构件，所述热固性塑料部件能够与热塑性塑料构件材料锁合地连接、尤其是焊接，其中所述热固性塑料构件具有基体，所述基体包括置于硬化的热固性的基质中的增强纤维，并且至少在为连接热塑性塑料构件而设置的接合区域中涂敷有功能层。
本发明还涉及一种借助材料锁合的连接、尤其是焊接将这种热固性塑料构件与热塑性塑料构件接合的方法，在此方法中这两个构件借助热固性塑料构件的功能层相互连接，并且还涉及一种通过这种接合方式制成的复合构件。
背景技术
复合纤维构件由于其坚固性以及低的重量尤其在航空、宇宙航行以及汽车技术中变得越来越重要。在此尤其应用了玻璃纤维增强的塑料（GFK），并且越来越应用碳纤维增强的塑料（CFK）。
纤维增强的构件具有增强纤维、尤其是碳纤维、玻璃纤维和/或尼龙纤维，它们埋入或置入尤其热塑性和/或热固性的基质中。该增强纤维在此尤其使该构件具有必要的坚固性或刚性。相反，该基质的主要效果是保持增强纤维的期望形状。因此，这些增强纤维通过基质来定向、支撑以及保护。
由于尤其在坚固性和刚性方面具有更好机械特性，具有热固性基质的纤维增强的构件在许多应用情况下都是优选的。热固性塑料的交联称为硬化。它在此可指交联的聚合或例如加聚或缩聚。因为热固性塑料或热固性的基质在硬化工艺之后不能再熔化，所以纤维增强的热固性塑料构件必须在此硬化工艺之前或之时定型。此外由此该特性，硬化的热固性塑料构件不能与其它构件、尤其是热塑性塑料构件直接焊接。
在应用粘合剂和/或增附剂、尤其是点燃剂的情况下，由现有技术已知的接合方法例如是热固性塑料构件与热塑性塑料构件的粘合。在此的缺点是，由于额外的工艺步骤使工艺持续时间长，并且由此提高了成本。
此外已知的接合方法还包括，这种构件以形锁合和/或力锁合的方式连接。因此，它们能够借螺钉和/或铆钉相互连接。但在此不利的是，在固定器件插入和/或插穿时会纤维增强的热固性塑料构件的纤维状组织。因此会降低该构件的坚固性。备选地或附加地，当然也能够在硬化之后例如借助热塑性塑料构件形状配合地对热固性塑料构件进行挤压包封。但以这种方式也不能在这两个构件之间形成足够牢固的连接。此外所有上面提到的连接方法的缺点都是复杂且昂贵。
由DE 10 2010 007 824 A1还已知一种用于热固性的碳纤维复合构件的制造和接合方法，其借助电阻焊方法提供技术上可靠的复合。对于该电阻焊来说，应用了具有网状结构的碳纤维织物作为加热元件，其设置在这两个待连接的构件之间。这些碳纤维织物在其表面上用热塑性塑料浸渍或连续地弄湿。借助这种浸渍的碳纤维织物，在压力和提高的温度下将两个热固性的构件或热固性的构件通过连接到热固性构件上的热塑性薄膜与热塑性的构件焊接。
但应用薄膜的缺点是，尤其在构件结构复杂时无法确保，该连接薄膜在整个表面上抵靠在热固性塑料构件上。这些所谓的干燥位置削弱了热固性塑料构件和与之相连的构件之间的连接区域。此外在应用这种薄膜的情况下，该制造方法配置得非常复杂且昂贵。
该已知的连接方法的另一缺点是，在这两个相互待连接的构件之间总是必须放入浸渍的碳纤维织物。因此，热固性塑料构件和热塑性塑料构件的连接配置得非常复杂且昂贵。此外尤其在构件结构复杂时还存在着这样的危险，即设置在连接区域中的浸渍碳纤维织物会起褶皱，因此在碳纤维织物和两个相互待连接的构件之至少一个之间形成干燥位置，这又会削弱此连接区域。
发明内容
因此本发明的目的是，提供一种具有功能层的纤维增强的热固性塑料构件的制造方法，创造这种纤维增强的热固性塑料构件，提供一种将这种纤维增强的热固性塑料构件与热塑性塑料构件接合的方法，并且创造一种这样制成的复合构件，借助该复合构件能够解决上面提到的缺点。
此目的通过一种具有独立权利要求1的特征的纤维增强的热固性塑料构件的制造方法得以实现，并且借助一种具有独立权利要求6的特征的、能够材料锁合地与热塑性塑料构件连接的热固性塑料构件得以实现，并且通过一种具有独立权利要求14的特征的、经由材料锁合来接合热固性塑料构件和热塑性塑料构件的方法得以实现，以及通过一种具有独立权利要求18的特征的复合构件得以实现。
提出了一种用于至少淬火的、尤其完全硬化的纤维增强的热固性塑料构件的制造方法，该热固性塑料构件能够与为此设置的热塑性塑料构件材料锁合地连接。在此制造方法中，在硬化工艺之前或之时在还未变硬的热固性的基体上，将热塑性的或热塑性/热固性的功能层至少涂布在为连接热塑性塑料构件而设置的接合区域中。该热固性的基体在此包括增强纤维、尤其是碳纤维和有粘性的热固性基质。所述至少局部涂布的基体在硬化装置中在压力和/或热量下淬火和/或硬化。此外，在此优选将它带到期望的最终形状。在此硬化工艺中，热塑性的或热塑性/热固性的功能层材料锁合地与热固性的基质和/或基体的增强纤维相连。借助该热塑性的或热塑性/热固性的功能层，该淬火的或完全硬化的热固性的基体在结束其制造方法之后在随后的接合方法中与为此设置的热塑性塑料构件连接。
因此主要提出了一种用于纤维增强的热固性塑料构件的制造方法，所述热固性塑料部件能够与热塑性塑料构件材料锁合地连接、尤其是焊接，在按本发明的制造方法中，为了形成基体，将增强纤维、尤其是碳纤维、玻璃纤维和/或尼龙纤维借助粘性的热固性基质带到硬化装置中。该增强纤维能够以切短的纤维、切短的线、带子、织物垫子、网状物和/或预浸料（Prepreg）的形式提供。在此，概念预浸料指带子或织物垫子或织物网状物，它们借助树脂、优选借助热固性的矩阵材料预浸渍，和/或必要时预硬化。用于热固性基质的材料尤其是环氧树脂或聚氨基甲酸脂类，尤其是一种成份、两种成份或三个成份的树脂。这种硬化装置能够是炉子、高压锅或真空挤压器。但也可考虑其它装置，只要适合对热固性的基质进行淬火和/或硬化。
同样完全不同的方式和方法放入增强纤维和热固性的基质。例如可考虑的是，将增强纤维单独地作为织物和/或作为网状物放入硬化装置中，并且随后通过喷入有粘性的热固性基质借助该基质包围和/或润滑。但备选地或附加的是，由增强纤维和热固性基质构成的组合物也能够作为预浸料放入硬化装置中。当然，也能够将多个这种层放入硬化装置中，尤其是放在模具上。
在将增强纤维和有粘性的热固性基质放入此硬化装置中之后，在压力和/或热量下使热固性的基质淬火和/或硬化。在此硬化工艺之前或之时，为了涂敷基体，至少在为连接热塑性塑料构件而设置的接合区域中将功能层设置在尤其有粘性的热固性基质上和/或增强纤维上。但还备选地，整个基体也能够借助这种功能层覆盖。该功能层在硬化工艺时材料锁合地与热固性的基质和/或增强纤维相连。
按本发明，在硬化工艺之前或之时在尤其有粘性的热固性基质和/或增强纤维上，至少在接合区域中或在增强纤维-基质-复合物的构成此接合区域的区域中涂敷、优选喷射有该功能层。但备选地或附加的是，该功能层尤其在硬化装置闭合之后在硬化装置的模具上，至少喷射在硬化工艺期间抵靠在基体或热固性塑料构件的接合区域上的区域上。通过功能层的喷射，能够有利地避免干燥位置，在此干燥位置的区域中该功能层未在整个表面上抵靠在基体上。如果使用薄膜作为功能层，则这种干燥位置尤其在构件结构复杂时出现。通过该功能层的喷射，能够在功能层和基体之间在接合区域中确保全面积的并因此非常牢固的连接。此外，该纤维增强的热固性塑料构件（其适合与热塑性塑料构件焊接）能够通过功能层的喷射非常成本低廉且快速地制出。
有利的是，该功能层作为流体、膏、粉末和/或颗粒涂敷、尤其是喷射。因此能够尤其良好地调节功能层的厚度。
同样有利的是，该功能层构成为多层的，尤其具有基本上热固性的第一涂层、基村上热塑性的第二涂层和/或设置在这两个涂层之间的热塑性/热固性的混合涂层。尤其优选的是，第一涂层借助基体构成粘附边界面，而第二涂层构成连接面，用来与为此设置的热塑性塑料构件连接、尤其是焊接。有利的是，这些涂层依次涂敷、尤其是喷射在模具和/或基体上。
还有利的是，喷射的材料（其构成功能层）的粘度这样进行选择，即尤其在构件几何形状复杂时该材料均匀地润湿模具和/或基体，和/或基本上不会流走，因此功能层在硬化工艺之前或之时不会裂开。
如果功能层与热固性的基质和/或增强纤维在硬化工艺期间通过粘附相连，则能够确保功能层和热固性基质和/或增强纤维之间的足够牢固的连接。热固性的基质和/或增强纤维因此与功能层直接地连接、尤其是粘合，而未应用附加介质如粘合剂和/或点燃剂。因此在功能层和热固性基质和/或增强纤维之间形成有粘附边界面。功能层因此与热固性基质和/或增强纤维具有非常牢固的连接，因此基本上可以避免功能层从基体上松脱。
有利的是，在形成粘附边界面时热塑性/热固性的功能层的热固性成份在此硬化工艺期间沿粘附边界面的方向迁移，并且热塑性的成份背向该方向迁移。因此能够在功能层和基体以及为此设置的热塑性塑料构件之间实现更强的结合。
有利的是，热固性的基质在湿式浸渍方法中尤其在喷射功能层之前喷射到增强纤维上，并且在注射方法中尤其在喷射功能层之后喷到硬化装置中和/或与增强纤维一起作为预浸料放到硬化装置中。
同样有利的是，硬化装置的模具在喷射功能层之前预加热，和/或在硬化工艺期间保持优选恒定不变的温度。优选的是，该温度高于或等于热固性基质和/或用在功能层中的热固性塑料的硬化温度，即优选在100°C和200°C之间，尤其优选是120°C，并且低于用在功能层中的热塑性材料的熔化温度，即优选在100°C和300°C之间，尤其优选是200°C。由于热塑性材料的熔化温度高于热固性塑料的硬化温度，所以热固性塑料硬化，而不会完全熔化该热塑性塑料。因此能够有利地避免功能层局部地撕裂，因为加热到熔化温度之上的热塑性塑料由于期由此上升的粘度可能会流走。上面提到的温度范围的另一优点在于，尤其在热塑性/热固性的功能层中加热到硬化温度的热固性塑料沿基体的方向（即沿待形的粘附边界面的方向）加快迁移，而功能层的热塑性成份沿接合面的方向加快迁移，在该接合面的区域中纤维增强的热固性塑料构件随后能够与为此设置的热塑性塑料构件连接、尤其是焊接。因此有利的是，在功能层和纤维增强的热固性塑料构件之间，该粘合连接在粘附边界面的区域中变得更牢固。同时，通过功能层的接合区域中的更高热塑性浓度，还改善了纤维增强的热固性塑料构件与为此设置的热塑性塑料构件之间的连接质量。
按本发明，热固性塑料构件（其能够与热塑性塑料构件连接、尤其是焊接）具有基体，该基体包括置入硬化的热固性基质中的增强纤维、尤其是碳纤维、玻璃纤维和/或尼龙纤维，并且至少设置得用来连接热塑性塑料构件的接合区域设置有（尤其是涂敷有）功能层。该功能层是热塑性的或热塑性/热固性的功能层。因此有利的是，热固性塑料构件能够快速且不复杂地在焊接方法或浇铸方法的范畴与热塑性塑料构件连接。
借助热塑性/热固性的功能层，能够确保基体和功能层之间的以及功能层和热塑性塑料构件之间的尤其牢固的连接，所述热塑性塑料构件设置得用来连接、尤其是焊接热固性塑料构件。因此，功能层的热固性塑料尤其在基本上热固性的基体和功能层之间形成了尤其牢固的连接、尤其是粘合连接。同时在形成尤其牢固的材料锁合（尤其是焊接连接）的情况下，功能层的热塑性塑料还实现了与为此设置的热塑性塑料构件的连接、尤其是焊接。
有利的是，功能层是喷射层或薄膜。构成为喷射层的功能层的特征尤其在于，在功能层和基体之间基本上未形成干燥位置。因此，功能层和喷射层在整个表面上抵靠在基体上。喷射层优选根据前面所述的制造方式构成，其中提到的特征能够单个地或以任意的组合方式存在。
如果在功能层和基体之间构成了粘附边界面，则能够确保它们两者之间的尤其可靠的连接。因此，该功能层与基体、尤其与热固性的基质和/或增强纤维直接地连接、尤其是粘合，
还有利的是，热塑性/热固性的功能层的热固性塑料与热固性的基质相同或至少在最大程度上类似。因此能够在功能层和基体、尤其热固性的基质和/或增强纤维之间之间确保非常牢固的结合。
用在功能层中的热塑性塑料优选是丙烯腈-丁二烯-苯乙烯共聚物（ABS）或聚酰胺、尤其是聚酰胺11或12。但备选地，同样也可考虑其它技术上可能的热塑性塑料。作为热固性塑料，尤其一种成份、两种成份或三个成份的环氧树脂或聚氨基甲酸脂类是优选的。
为了在基体上确保功能层的高牢固的连接，同时优化此功能层的特性以便与为此设置的热塑性塑料构件连接，使得功能层在热塑性塑料构件和纤维增强的热固性塑料构件之间形成尤其牢固的连接，有利的是，在粘附边界面的范围内热塑性/热固性的功能层的热固性成份大于为与热塑性塑料构件接合而设置的连接面的范围内的热固性成份。因此，热塑性/热固性的功能层的热固性塑料部分（其在与基体连接的连接区域中以较高的浓度存在）的作用是，功能层尤其牢固地与纤维增强的基体的热固性基质连接、尤其是粘合。同时，在功能层的连接面中以更高浓度存在的热固性塑料部分的作用是，使功能层更好地与为此设置的热塑性塑料构件尤其牢固地连接。
有利的是，热塑性/热固性的功能层的热塑性成份高于或等于所述热固性成份。因此，热塑性/热固性的功能层的热塑性成份尤其能够使硬化的纤维增强的热固性塑料构件与为此设置的热塑性塑料构件连接、尤其是焊接。在相互基本上平衡热塑性塑料与热固性塑料的比例时，有利的是，在功能层和纤维增强的热固性塑料构件之间确保了尤其牢固的粘合连接，并且确保了功能层与为此设置的热塑性塑料构件的尤其牢固的连接、尤其是焊接连接。
在本发明的有利的改进方案，所述功能层尤其在其整个表面上具有10μm至1000μm、尤其150μm至750μm的厚度。功能层尤其优选基本上在其整个表面上具有均匀的厚度。因此能够确保，在焊接为此设置的热塑性塑料构件时功能层不是完全熔化，因此热塑性塑料构件直接地抵靠在热固性塑料构件上。这可能会削弱这两个尤其相互焊接的构件之间的连接区域。尤其通过喷射方法能够形成尤其薄的功能层。通过非常薄的功能层，能够降低纤维增强的热固性塑料构件的制造成本。
此外通过上面提到的喷射方法，能够避免功能层和基体之间的干燥位置。有利的是，功能层因此在整个表面上贴靠在基体上，因此功能层尤其通过其整个接触区域非常牢固地与基体粘合。
有利的是，热固性塑料构件或基体在多个相互隔开的或至少局部地重叠的区域中用功能层进行涂敷。因此有利的是，该热固性塑料构件在多个位置与一个或多个热塑性塑料构件连接、尤其是焊接。还有利的是，功能层相互具有相同的和/或不同的厚度。
在按本发明的方法中，为了通过材料锁合的连接、尤其是焊接将热固性塑料构件与热塑性塑料构件接合，在此方法中这两个构件借助热固性塑料构件的功能层相互连接，并且还涉及一种通过这种接合方式制成的。在此，热塑性塑料构件直接地结合、尤其是焊接在热固性塑料构件的功能层上，其中在热塑性塑料构件和热固性塑料构件的功能层之间形成了渗出区。渗出区的特征在于热塑性塑料构件朝热固性塑料构件的功能层的均匀的材料过渡。渗出区优选具有约20μm至40μm的厚度。渗出区确保了尤其焊接的热塑性塑料构件和尤其纤维增强的热固性塑料构件之间的非常牢固的连接。此外，该接合方法是一种纤维增强的热固性塑料构件与热塑性塑料构件的成本非常低廉且快速的连接。
有利的是，热固性塑料构件根据前面所述的制造方式制成和/或构成，其中提到的方法步骤以及特征能够单个地或以任意的组合方式存在。
如果热塑性塑料构件和/或热固性塑料构件的功能层尤其局部地预加热和/或熔化，并且优选局部熔化的热塑性塑料构件压在热固性塑料构件的功能层上，则能够尤其快速且不复杂地使热固性塑料构件与热塑性塑料构件连接。
但备选地，热固性塑料构件也能够尤其在浇铸方法中作为预硬化的或硬化的插入件插入压铸模中，并且随后在模具闭合时借助构成热塑性塑料构件的热塑性塑料熔化物进行喷射。在此，热塑性塑料构件作为热塑性塑料熔化物直接喷射在热固性塑料构件的功能层上。此制造方法尤其适用于复杂的复合构件，其具有通过纤维增强的热固性塑料构件构成的外部轮廓和/或罩、通过热塑性塑料构件构成的功能元件（尤其是柱）、止动元件和/或固定器件，其优选喷射在热固性塑料构件的内侧上。合适的浇铸模具包括两个或多个铸造模具部件。这些铸造模具部件中的一个或多个具有一个或多个喷射通道，有粘性的热塑性材料通过这些喷射通道喷射。
按本发明，该复合构件具有至少一个热固性塑料构件和至少一个热塑性塑料构件，它们借助至少一个功能层相互连接。所述热塑性塑料构件直接与热固性塑料构件的功能层连接、尤其是焊接。因此，能够非常快速且成本低廉制造出这种复合构件。在热塑性塑料构件和功能层之间设置有渗出区。因此确保了热塑性塑料构件和热固性塑料构件之间的尤其牢固的连接。
尤其有利的是，热固性塑料构件根据前面的描述制成、构成和/或与热塑性塑料构件连接，其中提到的方法特征能够单个地或以任意的组合方式存在。
为了确保热固性塑料构件和热塑性塑料构件之间的尤其牢固的连接，热塑性塑料构件在与热固性塑料构件连接的连接区域中通过功能层与热固性的基体间隔开来。该功能层因此在热塑性塑料构件涂敷、尤其是焊接时不会完全透过。换而言之，在其整个接触区域上借助功能层确保了热塑性塑料构件和热固性塑料构件之间的非常牢固的连接，因为它们通过与基体的粘合形成了粘附边界面，并且通过与热塑性塑料构件的连接、尤其是焊接形成了渗出区。
还有利的是，热塑性塑料构件的热塑性塑料与热塑性的或热塑性/热固性的功能层相同或至少在最大程度上类似。因此能够形成渗出区，它确保了热塑性塑料构件与热固性塑料构件的非常牢固的连接。
尤其对于热塑性/热固性的功能层来说，该连接面与构成粘附边界面的区域相比具有更高的热塑性成份，热塑性塑料构件设置、尤其是焊接在该连接面上。因此，该功能层与焊接在上面的热塑性塑料构件构成了非常牢固的连接，该功能层在与热塑性塑料构件或与功能层的连接面接合的接合区域中配备有更高的热塑性成份或更高的热塑性浓度。所有工业可用的热塑性塑料、尤其是ABS和/或聚酰胺、尤其是聚酰胺11和/或12都适合当作热塑性塑料来用。
附图说明
在下面的实施例中说明了本发明的其它优点。其中：
图1在横截面中示出了纤维增强的热固性塑料构件具有功能层的区域；
图2在横截面中分别示出了纤维增强的热固性塑料构件和热塑性塑料构件在接合、尤其是烛接之前的区域；以及
图3在横截面中示出了复合构件与热塑性塑料构件的连接区域，该热塑性塑料构件连接、尤其是焊接到热固性塑料构件的功能层上。
具体实施方式
图1示出了热固性塑料构件1的横截面，其包括基体2和功能层3。该热固性塑料构件1在此构成为纤维增强的热固性塑料构件。因此，该基体2包括增强纤维4，其埋入塑料基质5中。该增强纤维能够是玻璃、碳和/或尼龙纤维。在此实施例中，该增强纤维4构成为碳纤维。该碳纤维能够作为切短的纤维、切短的线、带子或如此处所示的一样作为织物垫布置在该基体2中。同样还可考虑的是，引入增强纤维作为编织物（即至少两个相叠放置的织物垫）。该基质5在此是热固性的塑料，尤其是环氧树脂或聚氨基甲酸脂类。该热固性的基质5在此硬化并且使增强纤维4具有形状稳定性。该增强纤维4首先使基体2或热固性塑料构件1具有必要时的坚固性。
该热固性的基体2能够具有各种任意的形状。因此该基体2能够例如是车辆的车射构件亦或也可以是这种车辆的内护板。这种热固性的基体或热固性塑料构件具有复杂的构件几何形状，尤其具有自由形状表面和/或侧凹。
这种热固性的构件的主要问题在于，它在硬化之后只能以非常昂贵的方法才能与其它构件连接。此外该方法的缺点是，连接质量不是特别好，因此存在着这两个构件在负载时相互松脱的危险。
按本发明，按图1的热固性塑料构件1因此具有功能层3。该功能层3是热塑性塑料或者由热塑性塑料和热固性塑料构成的混合体。在热塑性/热固性的功能层3中，热固性塑料与热塑性塑料的成份比优选是1/4、1/3、1/2或优选是1/1。
功能层3借助粘性直接地与基体2相连、尤其是粘合。因此在功能层3和基体2之间形成有粘附边界面6。该功能层3在此如图1所示的一样只与基体的热固性的基质5相连，亦或也额外地或附加地与增强纤维4相连。该粘附边界面6是热固性的基质5朝热塑性的或热塑性/热固性的功能层的清晰过渡部位。在它们之间未布置渗出区。也未设置连接介质，尤其是粘合剂和/或点燃剂。
该功能层3设置在热固性塑料构件1的接合区域7a中。功能层3在其背向基体2的侧面上具有连接面8，热固性塑料构件1能够在该连接面上与为此设置的热塑性塑料构件9连接、尤其是焊接（参照图2和3）。该热固性塑料构件1也能够具有多个这样构成的接合区域7a，它在此接合区域中与一个或多个热塑性塑料构件9连接、尤其是焊接。
与基体2相比，该功能层3构造得非常薄。它优选具有10μm至1.000μm、尤其150μm至750μm的厚度。但非常薄的功能层3是尤其优选的，即厚度为10μm至250μm、尤其至200μm，尤其优选至150μm。
这种薄的功能层也能够通过喷射方法构成。为此为了形成基体2，将具有粘的热固性的基质5的增强纤维4、尤其是碳纤维装入此处未示出的硬化装置中。这种硬化装置能够例如是炉子、高压锅或真空挤压器。在此硬化装置中，在压力和/或热量下使热固性的基质5淬火和/或硬化。但在此硬化工艺之前将功能层3设置在接合区域7a中，在该接合区域中热固性塑料构件1与为此设置的热塑性塑料构件9连接。
为了构成这种相比于薄膜非常薄的功能层3，将该功能层在硬化工艺之前或之时喷射在粘的热固性的基质5和/或增强纤维4上。备选地或附加地，能够将构成功能层3的热塑性塑料或热塑性/热固性的混合物喷射在硬化装置的此处未示出的模具上。在此尤其有利的是，将热塑性塑料和/或热固性塑料（借助它形成功能层3）喷射到该模具的在硬化工艺期间抵靠在基体2的接合区域7a上的区域中。在将功能层3喷射到模具上之后，通过增强纤维4与粘的热固性的基质5（尤其作为预浸料）一起的插入，功能层3和基体2之间的接触能够在模具中实现。备选地，也能够在模具闭合和/或将粘的热固性的基质5喷入闭合模具中时，实现接触。在随后的硬化工艺期间构成该非常牢固的粘附边界面6（功能层3与基体2借助它相连），其中没有应用额外的粘合剂和/或点燃剂。
按本发明的方法的主要优点（在此喷射功能层3）在于，功能层3完全抵靠在基体2上。这一点尤其在构件几何形状复杂时尤其明显，因为在这种情况下构成为薄膜的功能层3可能会形成所谓的干燥位置，它们最终可能削弱功能层3和基体2之间的连接。
如果功能层3既具有热塑性的成份也具有热固性的成份，则能够确保功能层3与基体2的非常良好的粘合，同时还确保与为此设置的热塑性塑料构件9的非常牢固的连接（图3所示）、尤其是焊接连接。这种热塑性/热固性的功能层3的特征尤其在于，功能层3的热固性成份在粘附边界面6的区域中比连接面8的区域中的成份更高，该连接面是为连接为此设置的热塑性塑料构件9而设置的。此外如果热塑性/热固性的功能层3的热固性塑料与热固性的基质5相同或至少在最大程度上类似，则有助于在功能层3和基体2之间实现非常强的粘合。为此，优选环氧树脂或聚氨基甲酸脂类树脂适合当作热固性塑料来用。
图2在横截面中示出了在与热塑性塑料构件9连接、尤其是焊接之前纤维增强的热固性塑料构件1的局部区域。为此，纤维增强的热固性塑料构件1能够作为插入件插入此处未示出的浇铸装置中，并且通过作为热塑性塑料熔化物存在的热塑性塑料构件9在热固性塑料构件1的接合区域7a的范围内的直接喷出，与它接合、尤其是焊接。因此，使该热塑性塑料熔化物与热固性塑料构件1的功能层3连接、尤其是焊接，并同时在与压铸模相互配合时形成热塑性塑料构件9的最终形状。
但备选地，尤其作为功能元件制好的热塑性塑料构件9也能在其接合区域7b中局部地预热和/或熔化，并且在此期间或者在该预热和/或熔化过程之后借助其熔化的接合区域7b在热固性塑料构件1的接合区域7a中按压在其功能层3上。在此，该热塑性塑料构件9与功能层3熔化。附加地或备选地，也可对该功能层3进行预热和/或熔化。该接合工艺能够在为此设置的接合装置中进行。
借助两个上面提到的方法，制造出图3所示的复合构件10。其特征在于，该热塑性塑料构件9与纤维增强的热固性塑料构件1相连、尤其是焊接，其中这两个构件之间的连接通过功能层3来实现。在热塑性塑料构件9与热固性塑料构件1连接、尤其是焊接时，热固性塑料构件1的功能层3和热塑性塑料构件9之间形成渗出区11。如果热塑性塑料构件9的热塑性塑料与热塑性的或热塑性/热固性的功能层3相同或至少在最大程度上类似，则该渗出区11构造得尤其牢固。各种任意的工业上可用的热塑性塑料都适修合。但ABS和/或聚酰胺、尤其是聚酰胺11和/或12是尤其优选的。
如同在图3所示的横截视图中可看到的一样，功能层3未完全熔化。热固性塑料构件1的纤维增强的热固性基体2以及与之相连的热塑性塑料构件9因此通过热塑性的或热塑性/热固性的功能层3的余下部件相互隔开来。这两个构件的这些接合区域7a、7b按图3交错地熔化并因此构成渗出区11，该渗出区确保了热塑性塑料构件9和热固性塑料构件之间的非常牢固的连接。
图1至3分别只示出了热固性塑料构件1和/或热塑性塑料构件9或包围这两个构件的复合构件10的一部分。该热固性塑料构件1能够具有多个这样构成的接合区域7a，它在此接合区域中与一个或多个热塑性塑料构件9可连接或已焊接。热塑性塑料构件9优选是功能元件、尤其是加固柱和/或固定区域（优选夹子、孔眼或类似物体）。但也可考虑的是，热固性塑料构件1在整个表面上涂敷有相应的功能层3。在此，热固性塑料构件1、尤其是其基体2在其硬化之前在整个表面上借助作为流体、软膏、粉末和/或颗粒存在的热塑性材料喷射，以便形成功能层3。
本发明并不局限于这些所示和所述的实施例。即使它们是在不同的实施例中示出和描述的，在专利权利要求框架内的变体与特征的组合同样是可能的。
参考标记清单
1热固性塑料构件
2基体
3功能层
4增强纤维
5热固性的基质
6粘附-边界面
7接合区域
8连接面
9热塑性塑料构件
10复合构件
11 渗出区

Claims (19)

1.一种用于至少硬化的纤维增强的热固性塑料构件(1)的制造方法，所述热固性塑料构件能够与热塑性塑料构件(9)材料锁合地连接，
在此方法中在硬化工艺之前或之时在还未硬化的热固性基体(2)上具有增强纤维(4)和有粘性的热固性基质(5)，将具有热塑性成份和热固性成份的功能层(3)至少涂敷在为连接热塑性塑料构件(9)而设置的接合区域(7a)中，
其特征在于，
所述至少局部涂布的基体(2)在硬化装置中在压力和/或热量下淬火和/或硬化，
其中在此硬化工艺期间具有热塑性成份和热固性成份的功能层(3)材料锁合地与热固性的基质(5)和/或基体(2)的增强纤维(4)相连，
因此所述至少淬火的基体(2)在所述制造方法结束之后借助具有热塑性成份和热固性成份的功能层(3)在随后的接合方法中与为此设置的热塑性塑料构件(9)相连。
2.根据权利要求1所述的制造方法，其特征在于，所述增强纤维(4)是碳纤维。
3.根据权利要求1所述的制造方法，其特征在于，该功能层(3)尤其作为流体、膏、粉末和/或颗粒涂敷在硬化装置的模具上，至少涂敷在该模具的在硬化工艺期间抵靠在接合区域(7a)上的区域上，和/或在所述模具闭合时转移到未硬化的基体上。
4.根据权利要求1所述的制造方法，其特征在于，所述功能层(3)在硬化工艺期间通过粘附与热固性的基质(5)和/或增强纤维(4)连接，因此在这两个构件之间形成了粘附边界面(6)，
具有热塑性成份和热固性成份的功能层(3)的热固性成份在此硬化工艺期间沿粘附边界面(6)的方向迁移，并且热塑性的成份背向该方向迁移。
5.根据权利要求1所述的制造方法，其特征在于，热固性的基质(5)在湿式浸渍法中喷射到增强纤维(4)上，并且在注射方法中喷到硬化装置中或与增强纤维(4)一起作为预浸料放到硬化装置中。
6.根据权利要求1-5任一项的制造方法，其特征在于，硬化装置的模具在喷射功能层(3)之前预加热，和/或在硬化工艺期间保持恒定不变的温度，
该温度高于或等于热固性基质(5)和/或用在功能层(3)中的热固性塑料的硬化温度，并且低于用在功能层(3)中的热塑性材料的熔化温度。
7.一种用来将热塑性塑料构件(9)与热固性基体(2)焊接的热固性塑料构件(1)，所述基体具有置入热固性基质(5)中的增强纤维(4)并且至少在为连接热塑性塑料构件(9)而设置的接合区域(7a)中具有功能层(3)，其特征在于，
热固性的基体(2)是硬化的并且功能层(3)是具有热塑性成份和热固性成份的功能层(3)。
8.根据权利要求7所述的热固性塑料构件，其特征在于，该功能层(3)是喷射层或薄膜。
9.根据权利要求8所述的热固性塑料构件，其特征在于，该功能层(3)与基体(2)这样直接地连接，即在功能层(3)和基体(2)之间形成有粘附边界面(6)。
10.根据权利要求9所述的热固性塑料构件，其特征在于，该功能层(3)与热固性的基质(5)和/或增强纤维(4)这样直接地连接，即在功能层(3)和基体(2)之间形成有粘附边界面(6)。
11.根据权利要求7所述的热固性塑料构件，其特征在于，具有热塑性成份和热固性成份的功能层(3)的热固性塑料与热固性的基质(5)的热固性塑料相同或至少在最大程度上类似。
12.根据权利要求7所述的热固性塑料构件，其特征在于，在粘附边界面(6)的范围内具有热塑性成份和热固性成份的功能层(3)的热固性成份大于为与热塑性塑料构件(9)接合而设置的连接面(8)的范围内的热固性成份。
13.根据权利要求7所述的热固性塑料构件，其特征在于，具有热塑性成份和热固性成份的功能层(3)的热塑性成份大于或等于所述热固性成份。
14.根据权利要求7-13任一项所述的热固性塑料构件，其特征在于，所述功能层(3)具有基本上均匀的10μm-1000μm的厚度。
15.根据权利要求14所述的热固性塑料构件，其特征在于，所述功能层(3)具有基本上均匀的150μm-750μm的厚度。
16.一种用来接合硬化的热固性塑料构件(1)和热塑性塑料构件(9)的方法，所述热固性塑料构件根据权利要求1-5任一项所述的方法制成，
在此方法中这两个构件借助热固性塑料构件(1)的功能层(3)相互连接，其特征在于，
将所述热塑性塑料构件(9)直接焊接在功能层(3)上硬化的热固性塑料构件(1)上，因此在热塑性塑料构件(9)和热固性塑料构件(1)的功能层(3)之间设置有渗出区(11)。
17.根据权利要求16所述的方法，其特征在于，所述热塑性塑料构件(9)和/或所述功能层(3)在焊接之前至少在其各自的接合区域(7a；7b)中预加热和/或熔化并且相互挤压，或者所述硬化的热固性塑料构件(1)尤其在浇铸方法中作为插入件插入压铸模中，和/或所述热塑性塑料构件(9)作为热塑性塑料熔化物直接喷射在热固性塑料构件(1)的功能层(3)上。
18.一种具有硬化的热固性塑料构件(1)和热塑性塑料构件(9)的复合构件(10)，所述热固性塑料构件根据权利要求1-5任一项所述的方法制成，
它们借助硬化的热固性塑料构件(1)的功能层(3)相互连接，其特征在于，
将所述热塑性塑料构件(9)直接与硬化的热固性塑料构件(1)的功能层(3)焊接，因此在热塑性塑料构件(9)和功能层(3)之间设置有渗出区(11)。
19.根据权利要求18所述的复合构件，其特征在于，热塑性塑料构件(9)的热塑性塑料与具有热塑性成份和热固性成份的功能层(3)相同或至少在最大程度上类似。
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