CN107073839B - 用于制造纤维增强塑料构件的方法 - Google Patents

用于制造纤维增强塑料构件的方法 Download PDF

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CN107073839B
CN107073839B CN201680003653.2A CN201680003653A CN107073839B CN 107073839 B CN107073839 B CN 107073839B CN 201680003653 A CN201680003653 A CN 201680003653A CN 107073839 B CN107073839 B CN 107073839B
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consolidation
semifinished
products
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semifinished products
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CN107073839A (zh
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J·贝克
D·黑姆
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Bayerische Motoren Werke AG
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Bayerische Motoren Werke AG
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    • 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
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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
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/386—Automated tape laying [ATL]
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Abstract

本发明涉及一种用于由热塑性纤维增强塑料制造构件的方法。在此，制造多个半成品(1)，所述半成品分别具有多个浸渍的纺织层(2)，所述纺织层仅局部彼此连接，以及所述半成品具有带有至少一个缺口(4)的框架形状(3)。借助固结装置(5)固结所述半成品(1)，在固结所述半成品(1)之前分别在缺口(4)中设置内置元件(6)。

Description

用于制造纤维增强塑料构件的方法
技术领域
本发明涉及一种用于制造纤维增强塑料构件的方法、尤其是用于以多个浸渍的纺织层为起点由热塑性纤维增强塑料制造构件的方法。
背景技术
纤维增强塑料构件具有嵌入塑料基质材料中的由增强纤维制成的结构。对于较复杂且较高质量的构件常常需要具有尽可能根据负荷设置的纤维方向的多层纤维结构。浸渍的热塑性纤维带用作用于上述制造的初始材料。这种纤维带通常由单层带状纤维基本结构制成，该纤维基本结构已经借助所需的基质材料浸渍。这种纤维带例如作为辊材料被提供。在DE 4218434 A1中例如描述了一种用于制造这种浸渍的纤维带的可能性。
已知由这种浸渍的纤维带制造多层矩形板，这些多层矩形板用作半成品用于进一步加工。在文献US 2011/0111168 A1中描述了如何由这种纤维带制造多轴平板，所述多轴平板具有尽可能与方向无关的强度并且可被存储并且在晚些时候被进一步加工。
此外，现有技术中公开了所谓的有机板材，其具有嵌入塑料基质中的纤维纺织物、纤维稀松布或纤维针织物。
根据现有技术，当半成品具有一个或多个缺口时，所述半成品不能在一个连续的工艺中被固结。因此，在现有技术中，半成品作为板被固结并且在固结工艺之后从板中冲裁掉内部区域。由此，产生了有价值材料的较多废料。
发明内容
因此，至少一些实施方式的待解决的任务在于，给出一种用于由热塑性纤维增强塑料制造构件的方法，借助该方法可减少材料使用并且因此节约成本。
所述任务通过一种如下的方法来解决，用于由热塑性纤维增强塑料制造构件的方法包括下述步骤：制造多个半成品，所述半成品分别具有多个浸渍的纺织层，所述纺织层仅局部地彼此连接，其中，所述半成品分别具有带有至少一个缺口的框架形状；借助固结装置固结所述半成品，其中，使所述半成品在固结期间在一个连续的工艺中穿过固结装置内的多个加热区；在固结所述半成品之前，分别在缺口中设置内置元件。
根据一种实施方式，在用于由热塑性纤维增强塑料制造构件的方法中，制造多个半成品，它们分别具有多个浸渍的纺织层，所述纺织层仅局部地彼此连接。换言之，所述层在厚度方向上并非全表面地彼此连接。例如，所述半成品分别具有多个纤维带层，在每个层中设有多个并排设置的纤维带，一个层内的纤维带可相同或不同地定向。纤维带优选具有由纤维制成的单层带状纤维基本结构，所述纤维基本结构借助基质材料浸渍。所述纤维带也可称为UD带。替代或附加地，半成品可具有多个浸渍的纺织层，它们分别具有嵌入基质材料中的纤维纺织物、纤维稀松布或纤维针织物。
在半成品内，各相邻层的纤维带的纤维例如可不同地定向。优选地，纤维带首先彼此仅通过点状连接点、如点状焊点连接。因此半成品优选作为未固结半成品存在。半成品在此并且在下面也可称为叠层。此外，各个未固结半成品优选以分开的形式存在、即半成品彼此不连接。
浸渍纤维带的纤维优选是单向连续纤维。所述纤维例如可以是碳纤维、玻璃纤维、芳纶纤维、玄武岩纤维或天然纤维。基质材料优选是热塑性塑料、如PEEK(聚醚醚酮)、PEKK(聚醚酮酮)、PP(聚丙烯)、PE(聚乙烯)、PPS(聚苯硫醚)、TPE(热塑性弹性体)或聚酰胺。
此外，半成品分别具有带有至少一个缺口的框架形状。缺口优选从半成品的一个表面延伸至半成品的相对置表面。相应缺口在横向上优选在所有侧面被半成品的未固结纤维带界定。
优选地，在借助固结装置固结半成品之前分别在半成品的缺口中设置至少一个内置元件。由此可有利地实现：带有缺口的半成品也可被固结，这是因为在固结过程期间不再存在在固结时产生的压力由工艺引起地下降的危险。此外，通过制造具有缺口的固结半成品可节约材料，这是因为可在不必在固结过程之后从半成品中冲裁掉内部区域的情况下制造框架状半成品。
根据另一种实施方式，内置元件全自动地设置在缺口中。例如内置元件可借助一个或多个机械手设置在缺口中。机械手例如可具有真空吸收器或针式抓持器或其它抓持元件，借助它们可抓持内置元件并定位于缺口中。有利的是，可通过借助一个或多个机械手的自动化操作来实现内置元件精确且准确重复的置入。
根据另一种实施方式，半成品借助固结装置固结。在固结后，半成品的各层优选全表面地在厚度方向上彼此连接。优选半成品在固结期间在一个连续的工艺中穿过固结装置内的多个加热区。例如固结装置可构造为组合的压紧和加热装置、尤其是构造为双带压力机。固结装置优选具有两个环形带，半成品在固结时在这两个环形带之间穿过各个加热区。优选环形带由钢制成。作为替代方案，环形带也可含有聚四氟乙烯或由聚四氟乙烯制成。优选固结装置具有多个加热区。这些加热区在此优选具有不同温度。例如固结装置可包括具有约100℃温度的第一加热区、具有约380℃温度的第二加热区和具有60℃温度的第三加热区。优选第一、第二和第三加热区直接相继设置，第二加热区设置在第一和第三加热区之间。
根据另一种实施方式，半成品在固结装置中的设置全自动化地进行。例如一个或多个机械手可抓持半成品并将其设置在固结装置中。固结装置例如可具有(例如可构造为输送带的)供应单元并且该供应单元可将半成品供应给本来的压紧和加热装置。机械手例如可借助真空吸收器或针式抓持器来抓持半成品并且将其放入固结装置或固结装置的供应单元中。借助自动化操作可精确并且准确重复地设置半成品。
根据另一种实施方式，在固结半成品之后从缺口中移除内置元件。内置元件的移除例如可在将通过固结过程彼此连接的半成品分离之前或之后进行。优选借助一个或多个机械手在一个全自动化工艺中从缺口中移除内置元件。
根据另一种实施方式，内置元件与固结装置的一个带固定连接。例如内置元件可与固结装置的一个环形带或与双带压力机的一个环形带固定连接。内置元件例如可与固结装置的带焊接。在该实施方式中，半成品在固结过程后可这样从固结装置中取出，即，例如在一个全自动化工艺中借助一个或多个机械手从环形带上拿起半成品，以致半成品的缺口不含有内置元件并且内置元件固定地保留在固结装置的环形带上。
根据另一种实施方式，内置元件在它们的形状和/或尺寸方面适配于相应缺口。优选内置元件在设置在缺口中之后在所有侧面与半成品具有最大5mm距离。优选内置元件的厚度与半成品的厚度最大偏差1.5mm。
根据另一种实施方式，内置元件构造为置入板或置入板材。例如内置元件可含有聚四氟乙烯或其它耐高温的热塑性材料或由其制成。作为替代方案，内置元件可含有例如铝、橡胶或硅或由铝、橡胶或硅制成。
根据另一种实施方式，至少一个半成品具有多个内部缺口，在固结之前在每个缺口中分别设置至少一个内置元件。
根据另一种实施方式，半成品这样设置在固结装置中，使得半成品直接相互接触。换言之，半成品在设置于固结装置中之后至少部分地相互接触。尤其是，每个半成品应在设置于固结装置中之后与至少另一半成品直接接触。优选除了第一个和最后一个设置在固结装置中的半成品之外，所有其它半成品均与两个另外的半成品直接接触，所述两个另外的半成品与相应半成品在两个相对置的侧面上接触。
根据另一种实施方式，将半成品在设置于固结装置中之后借助固结装置固结，半成品在固结期间至少部分地相互连接。例如半成品可基于熔化(其例如基于通过固结装置的热量输入导致)而相互连接。
根据另一种实施方式，在固结过程之后借助分离装置将相互连接的半成品分离。因此，半成品在分离之后再次以分开的形式存在。分离装置例如可构造为刀、旋转刀、剪刀、激光、超声刀或振荡刀。
根据另一种实施方式，在固结之前在两个直接相邻的半成品之间分别设置一个或多个外置元件。优选外置元件分别在其形状方面适配于直接相邻的半成品。例如，两个直接相互接触设置的半成品可能形成有空隙，在该空隙中可设置一个或多个外置元件。尤其是，相互设置的半成品可能具有局部弯曲的侧向表面，从而半成品不能直接相互接触以致在半成品之间不能避免空隙。通过设置一个或多个外置元件，可避免在固结时出现的问题、如基于半成品之间的空隙的压力下降。外置元件优选与半成品具有最大5mm距离。或者外置元件可直接接触半成品。优选外置元件的厚度与半成品的厚度最大偏差1.5mm，半成品的厚度理解为半成品垂直于各个纤维带层布置方向的延伸尺寸。
根据另一种实施方式，外置元件构造为置入板或置入板材。例如外置元件可含有聚四氟乙烯或由其制成。作为替代方案，外置元件可含有例如铝、橡胶或硅或由铝、橡胶或硅制成。
附图说明
下面结合附图1至6所描述的实施方式给出本文所描述方法的其它优点和有利实施方式。附图如下：
图1至图5为根据不同实施例的本文所描述方法的所选方法步骤的示意图，本文所描述方法用于以纤维带为起点由热塑性纤维增强塑料制造构件；
图6为根据另一种实施例的以双带压力机形式的固结装置。
具体实施方式
在实施例和附图中相同或作用相同的部件分别设有同一附图标记。所显示的元件及其相互间的尺寸比例原则上不应视为按照比例的。更多地，为了更好地说明和/或更好地理解，一些元件可能会被夸大地加粗或大尺寸地示出。
图1至2B示出在此所描述的用于制造纤维增强塑料构件的方法的不同方法步骤，其中，图2A和2B示出两种替代的方法步骤，它们可分别连接结合图1所示的方法步骤。
在图1中示出两个半成品1，它们分别具有多个未固结的纤维带2层。每个半成品1包括多个纤维带2层，每个层中的多个纤维带2彼此并排设置，一个层内的纤维带可相同或不同地定向。半成品1在垂直于各个纤维带2层的俯视图中示出。生产出的半成品1不相互连接，而是以分离的方式存在。此外，生产出的未固结半成品1具有框架形状。半成品1具有缺口4，该缺口从相应半成品1的一个表面延伸至相对置的表面。如图1所示，在借助如图6所示的固结装置5固结半成品1之前，分别在缺口4内设置一个内置元件6。内置元件6在缺口4中的设置例如可借助一个或多个机械手进行。借助内置元件6可有利地实现：框架状半成品1可被固结且在固结时产生的由工艺引起的压力在固结过程期间不会下降。
在所示实施例中，内置元件6由特氟隆制成。作为替代方案，内置元件6例如也可由铝、橡胶或硅制成。优选地，内置元件6适配于相应缺口4。尤其是优选，内置元件6在其形状、尺寸和/或数量方面适配于半成品1的缺口4。例如，内置元件6在横向方向上与半成品1具有最大5mm距离。
根据一种如图2A所示的方案，半成品1这样设置在固结装置5中，使得在两个半成品1之间分别设有一个外置元件8。相互邻接的半成品1在此不相互接触，从而半成品在固结过程中不会熔合在一起。外置元件8为此优选在其宽度和厚度方面适配于半成品1。半成品1和/或外置元件8例如可借助一个或多个机械手被设置在固结装置5中或固结装置5的供应单元上。
根据一种在图2B中所示的替代实施例，半成品1这样设置在固结装置5中，使得半成品1直接相互接触。例如，半成品1可借助一个或多个机械手被这样设置在固结装置5中或固结装置5的供应单元上，使得半成品1相互接触。为了抓持半成品1，机械手例如可设有一个或多个抓持单元、如真空吸收器或针式抓持器。
在紧接着方法步骤1B之后的方法步骤1C中，借助固结装置5固结半成品1，半成品1在固结过程期间至少部分彼此连接。固结装置例如可构造为组合的压紧和加热装置。在固结过程期间，在并排设置的半成品之间例如可基于半成品1源于热量输入的至少部分熔化而产生连接。
接着，借助分离装置7分离相互连接的半成品1，所述分离装置可连接于固结装置5之后。在分离半成品1之后，半成品1再次以分开的形式存在，即，半成品1在借助分离装置7的分离过程之后不再彼此连接。分离装置7例如可构造为刀、旋转刀、剪刀、激光、超声刀或振荡刀。
图3示出根据另一种实施例的本文所描述方法的方法步骤，在此与图1所述方法不同，生产出的未固结半成品1具有多个缺口4，所述缺口分别从半成品1的一个表面延伸至相对置的表面。在固结半成品1之前，分别在缺口4中设置至少一个内置元件6。例如，多个待固结半成品可以如结合图3所示的半成品1那样来构造。借助本文所描述的方法可有利地固结具有多个缺口的半成品1。
图4示出根据另一种实施例的本文所描述方法的方法步骤。与结合图1和2B所示实施例不同，生产出的未固结半成品1具有这样的外部形状，其不允许半成品1并排设置为，使得在两个并排设置的半成品之间不存在空隙。在所示实施例中半成品1具有多次弯曲的侧面。
在借助固结装置5固结半成品1之前，使半成品1直接相互接触并且将外置元件8设置在两个直接相邻的半成品1之间。外置元件8优选在它们的形状和尺寸方面适配于直接相邻的半成品。借助外置元件8可有利地在连续的固结工艺中固结具有任何外部轮廓的半成品。
结合图5所示的方法步骤与图4所示实施例的区别在于，两个所提供的未固结半成品1这样相互设置，使得它们的不规则外部轮廓相互对置。半成品1仍这样相互设置，使得它们直接相互接触。在半成品1之间设置一个外置元件8。图5所示方法的优点在于，在连续的固结工艺中并非必须在所有相邻的半成品1之间设置外置元件8，这是因为半成品1定位为，使得它们的不规则外部轮廓在一侧相互对置并且它们的规则外部轮廓在另一侧也相互对置。
图6示出固结装置5，其构造为集成有加热和压紧功能的双带压力机。该双带压力机包括两个构造为环形带的带54、55，并且半成品1可借助这两个带在一个连续的工艺中被压紧并且可运动穿过多个加热区51、52、53。优选地，加热区51、52、53分别具有不同温度。例如第一加热区51可具有100℃的温度，第二加热区可具有380℃的温度并且第三加热区53可具有60℃的温度。在借助固结装置5固结之后，被固结并且相互连接的半成品1可借助分离装置7分离。
在所示实施例中描述的特征也可根据其它实施例相互组合。替代或附加地，附图中所示实施例也可具有根据一般性说明的实施方式的其它特征。
附图标记列表
1 半成品
2 纤维带
4 缺口
5 固结装置
51、52、53 加热区
54、55 带
6 内置元件
7 分离装置
8 外置元件

Claims (14)

1.用于由热塑性纤维增强塑料制造构件的方法，包括下述步骤：
－制造多个半成品(1)，所述半成品分别具有多个浸渍的纺织层(2)，所述纺织层仅局部地彼此连接，其中，所述半成品分别具有带有至少一个缺口(4)的框架形状；
－借助固结装置(5)固结所述半成品(1)，其中，使所述半成品(1)在固结期间在一个连续的工艺中运动穿过固结装置(5)内的多个加热区(51、52、53)；
－在固结所述半成品(1)之前，分别在缺口(4)中设置内置元件(6)，并且在两个直接相邻的半成品(1)之间分别设置一个或多个外置元件(8)。
2.根据权利要求1所述的方法，其中，为了固结，将半成品(1)借助全自动化工艺设置在固结装置(5)中。
3.根据权利要求1或2所述的方法，其中，内置元件(6)在缺口(4)中的设置全自动化地进行。
4.根据权利要求1或2所述的方法，其中，所述内置元件(6)与固结装置(5)的一个带固定连接。
5.根据权利要求4所述的方法，其中，所述带是环形带。
6.根据权利要求1或2所述的方法，其中，所述内置元件(6)在它们的形状和/或尺寸方面适配于相应缺口(4)。
7.根据权利要求1或2所述的方法，其中，所述内置元件(6)在设置于缺口(4)中之后在所有侧面与半成品(1)的最大距离为5mm。
8.根据权利要求1或2所述的方法，其中，所述内置元件(6)含有聚四氟乙烯或由聚四氟乙烯制成。
9.根据权利要求1或2所述的方法，其中，为了固结，所述半成品(1)这样设置在固结装置(5)中，使得半成品直接相互接触。
10.根据权利要求1或2所述的方法，其中，使所述半成品(1)在固结过程期间至少部分地相互连接。
11.根据权利要求10所述的方法，其中，在固结之后借助分离装置(7)将相互连接的半成品(1)分离。
12.根据权利要求1或2所述的方法，其中，所述外置元件(8)在它们的形状和/或尺寸方面适配于直接相邻的半成品(1)。
13.根据权利要求1或2所述的方法，其中，所述固结装置(5)构造为组合的压紧和加热装置。
14.根据权利要求1或2所述的方法，其中，所述固结装置(5)构造为双带压力机。
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