CN107107540A - 具有数个层的成型件 - Google Patents

具有数个层的成型件 Download PDF

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CN107107540A
CN107107540A CN201580068735.0A CN201580068735A CN107107540A CN 107107540 A CN107107540 A CN 107107540A CN 201580068735 A CN201580068735 A CN 201580068735A CN 107107540 A CN107107540 A CN 107107540A
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molding part
layer
host material
fiber
reinforcing fiber
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E·里斯
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Mercedes Benz Group AG
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DaimlerChrysler AG
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Abstract

本发明涉及一种具有数个层的成型件(1),所述层分别具有纤维增强塑料,其特征在于,至少两个层在至少一个表征所述层的参数方面有所区别。

Description

具有数个层的成型件
技术领域
本发明涉及一种根据权利要求1所述的成型件。
背景技术
由德国公开文献DE 10 2011 018 422 A1已知一种编织拉挤工艺,以该编织拉挤工艺借助编织装置在编织芯轴上制成多分层空心型材编织物,该空心型材编织物由多个包含增强纤维和热塑性基质材料的混合粗纱或纤维带构成。将空心型材编织物从编织芯轴上引出,并借助布置在编织拉挤设备的加固工具下游的引出装置通过引入矩阵/引入阴模(Einzugsmatrize)引入加固工具中。用热塑性基质材料制成围绕空心型材编织物的滑动护套,其中滑动护套的热塑性基质材料以至少被加热至该热塑性基质材料的玻璃化转变温度的状态存在。最后在加固工具中用基质材料浸渍并加固空心型材编织物,其中加固工具具有调温装置。以这种方法制造的空心型材编织物仅能有限地进行进一步加工。特别是存在空心型材编织物可能在随后的内高压成形中爆裂或断裂的危险。
发明内容
本发明的目的是提供一种不具有前述缺点的成型件。特别要提供一种成型件,其一方面可热变形,另一方面,所述成型件在内高压成形期间在加热状态下不会发生爆裂。
本发明用以达成上述目的的解决方案为,提供一种具有权利要求1的特征的成型件。本发明的有利设计方案请参阅从属权利要求。
所述成型件具有数个层,其中,这些层分别具有纤维增强塑料。所述成型件的特征在于,至少两个层在至少一个表征所述层的参数方面有所区别。通过这种方式就能专门针对不同的用途和/或加工方法来对成型件进行调整和定制。其中,不同的层可承担不同的功能。
优选地,在所述至少一个表征所述层的参数方面有所区别的所述两个层在其功能方面有所区别。这样就能使得成型件与其用途和/或进一步的成形步骤理想地相协调。例如第一层可以为成型件提供刚度和/或强度,其中第二层被构造为不透气的,使得第二层特别能耐受内高压成形中作用的压力和温度。
在成型件的内高压成形中,将流体或热气体例如空气、氮气、惰性气体或其他合适的流体输入成型件并在压力下张紧,使得成型件膨胀直至贴靠在成形工具上。通常在成形后将成形介质移除。通常在内高压成形中,压力最高为大约600巴,温度为大约150℃至大约210℃。
特别也提出一种优选成型件,其中针对所述层的不同功能选出所述至少一个表征所述层的参数。以这种方式就能使得成型件与其进一步的处理或加工以及/或者使用时的条件理想地相协调。
成型件优选被构造为管状半成品,特别是空心型材。管状半成品特别用于制造用于车辆车身的、特别是汽车车身的、特别优选载重汽车车身的结构部件。特定而言,管状半成品优选用于制造载重汽车的白车身盖的支架。
所述成型件的一个优选实施例的特征在于,所述层中的至少一个由纤维增强塑料构成。特别优选地,所述层中的每一个均由纤维增强塑料构成。
纤维增强塑料一般是指具有基质材料以及嵌入基质材料中的纤维的材料。特别优选地,所述层中的至少一个具有连续纤维或连续纤维束、即所谓的粗纱,作为增强纤维。在另一优选实施例中,所述层中的每一个均具有连续纤维或连续纤维束作为增强纤维。此外提出一种优选成型件,其中所述层中的至少一个具有热塑性塑料作为基质材料。与热固性塑料相比,热塑性塑料的优点特别在于,其可以被回收为高品质的纤维增强塑料颗粒,随后特别是可以在注塑法中再利用这些塑料颗粒。成型件的所有层优选均具有热塑性塑料作为基质材料。其中,在将热塑性塑料用作成型件的基质材料的情况下,可以在实现与使用铝时相似的有利机械特性的同时,达到明显更低的密度。
优选将所谓的混合纤维粗纱用于所述层中的至少一个,优选用于每个层。混合纤维粗纱是纤维束,该纤维束由增强纤维和由基质材料构成的纤维、特别是热塑性纤维构成,和/或由用基质材料涂布的增强纤维、特别是经热塑性涂布的增强纤维构成,或者由用基质材料涂布的增强纤维和额外的由基质材料构成的纤维、特别是热塑性纤维构成。其中,所使用的混合纤维粗纱所具有的热塑性材料优选与成型件的所制成的层的基质材料相同,或者可以仅通过混合纤维粗纱来引入该层的全部基质材料。也可以特别在加固成型件期间加入额外的基质材料。无论如何,热塑性的纤维组分会在拉挤工艺中熔化并直接作为基质材料而进入。由此,在需要的情况下视情况减少还要额外加入的基质材料的量。此外,缩短基质材料的流径,以便产生品质更好的基质。也可以将纤维带用于至少一个层。
所述成型件的一个优选实施例的特征在于,所述至少一个表征所述层的参数选自包含所述纤维增强塑料所具有的增强纤维的类型、所述纤维增强塑料的基质材料、所述增强纤维的布置方式和所述增强纤维的布置图案的群组。其中,增强纤维的类型特别是指增强纤维的材料、增强纤维的厚度,以及增强纤维作为单纤维或纤维束或特别是混合粗纱的特性。成型件可以具有玻璃纤维、碳纤维、陶瓷纤维、金属纤维、天然纤维、芳族聚酰胺纤维、玄武岩纤维或其他合适的纤维作为增强纤维。这些纤维也可以毫无困难地彼此组合在一起。
纤维增强塑料的基质材料是指其中嵌入有增强纤维的塑料。如前文所述,塑料在此优选是热塑性塑料。特定而言,所述基质材料可以选自包含聚酰胺6(PA 6)、聚酰胺6.6(PA 6.6)、聚邻苯二甲酰胺(PPA)、聚醚醚酮(PEEK)、聚酰胺12(PA 12)、聚酰亚胺、液晶聚合物(LCP)、聚醚酰亚胺(PEI)、聚苯硫醚(PPS)、聚砜(PSU)、聚对苯二甲酸丁二醇酯(PPT)、聚碳酸酯(PC)、聚甲醛(POM)、聚四氟乙烯(PTFE)、聚甲基丙烯酸甲酯(PMMA)、丙烯腈-丁二烯-苯乙烯(ABS)、聚苯醚(PPE)、聚乙烯(PE)、聚丙烯(PP)、聚氯乙烯(PVC)、聚苯乙烯(PS)和聚对苯二甲酸乙二醇酯(PET)或者由ABS、PPE或另一种合适的材料组成的共混物的群组。
增强纤维的布置方式在此特别是指制造成型件时布置增强纤维的方式,其中可以通过编织、成网、织造、针织、编结、卷绕或其他合适的方式来布置。在一个特别优选的实施例中,成型件的增强纤维为经编织或卷绕的。
增强纤维的布置图案特别是指纤维以选出的布置方式布置时所用的图案/花样,例如编织图案、成网图案、织造图案、针织图案、编结图案、卷绕图案或另一个相应的图案。特定而言,增强纤维在一个层中的布置图案与在另一个层中的布置图案相比可以更紧或更密。其中“更紧”和“更密”的概念具体是指图案中的每个单位面积设有更多数目的增强纤维或更大份额的增强纤维材料。
成型件优选被构造为空心部件,特别是管状的空心部件。沿周向观察,成型件优选具有闭合的横截面。成型件可以采用不同的横截面,例如圆形横截面、矩形横截面、方形横截面、椭圆形横截面、多边形横截面或其他合适的且特别是与成型件的进一步用途相协调的横截面轮廓。
成型件的周向在此是指同心包围在制造优选为连续型材的成型件时指向进给方向的纵向的方向。径向是垂直于纵向的方向。
所述成型件的一个优选实施例的特征在于,所述成型件的沿径向观察的最内层、即朝向所述成型件的空心的内部空间的层所具有的基质材料与所述成型件的外部的层、特别是最外层的基质材料在化学上和/或物理上相似。由此,在这两个层彼此紧邻的情况下,这两个层特别形成对成型件的稳定性特别有利的材料结合的连接。另一优点在于,成型件沿径向具有相对均匀的材料特性。化学上和物理上非常相似的基质材料的一个实例是PA6和PA 6.6。
作为替代或补充方案,所述最内层的基质材料与所述外部的层的基质材料相比优选具有更高的熔点、更高的玻璃化转变温度、更强的耐热变形能力、更强的耐介质性、特别是更强的化学品耐受性和/或更强的气密性。这些特性中的每一项本身均有助于,使得最内层的基质材料特别适于以特别有利的方式适应在成型件内高压成形时的条件并保持无损,或者无论如何使得材料特性不发生重大改变。
作为替代或补充方案,所述最内层的基质材料与所述外部的层的基质材料相比优选具有更弱的吸湿性、更大的强度和/或更强的阻尼特性。这些特性中的每一项也特别使得内部的层特别能耐受在内高压成形时被加入成型件中的介质。
所述成型件的另一优选实施例的特征在于,所述最内层的基质材料的玻璃化转变温度为至少115℃。作为替代或补充方案,所述最内层的基质材料的熔点优选为至少260℃。这些特性中的每一项也使得内部的层的基质材料特别适用于成型件的内高压成形。
所述成型件的另一优选实施例的特征在于,所述成型件具有三个层,特别优选仅具有刚好三个层,即内层、中间层和外层。这些层优选特别通过相应地选择至少一个表征这些层的参数而专门与成型件的不同功能相协调。
内层所具有的基质材料的熔点优选高于外层所具有的基质材料的熔点。内层的基质材料的熔点优选也高于中间层的基质材料的熔点。在一个优选实施例中,外层与中间层具有相同的基质材料。因此,刚好可以将内层特别设计为用于成型件的内高压成形的材料结合的阻隔件,其中两个外部的层,即中间层和外层则不必具有相应的特性。确切地说,这些外部的层可以在成型件中承担其他功能,例如为成型件提供特殊的强度或刚度。此外,可以为外层或中间层特别选择成本低于内层的基质材料的基质材料,因为通常仅内层的基质材料暴露在成型件的内高压成形条件下,其中其他层则不需要承受相应条件。
所述成型件的一个优选实施例的特征在于,所述中间层具有玻璃纤维作为增强纤维。这样就能制成稳定性特别高的中间层,并为成型件提供大的强度和刚度。作为替代或补充方案,所述内层和/或所述外层优选具有增强纤维,所述增强纤维选自包含碳纤维、玄武岩纤维和芳族聚酰胺纤维的群组。
其中,可以在中间层的玻璃纤维之间或者中间层的玻璃纤维分层之间额外地加入由碳纤维、芳族聚酰胺纤维或玄武岩纤维构成的纤维束、纤维分层或单纤维。优选将这些纤维作为混合纤维粗纱加入。这样就能制成可高度变化且最佳满足要求的成型件。
成型件可以具有三个以上的层。特别优选地,成型件具有三个在功能方面且优选也在材料设计方面不同的层,其中,这些彼此不同的层中的至少一个、特别是这些层中的每一个又可以具有数个在相应的功能和/或材料设计方面相同的层。也就是说,成型件可以采用多分层结构,其中特定而言,该成型件可以具有各包含数个分层的三个功能层。
在一个优选实施例中,外层和/或中间层所具有的基质材料选自包含PA6、PE、PP、PVC、PS、PA和PET的群组。内层的基质材料优选选自包含PA6.6、PPA、PEEK、PA12、聚酰亚胺、LCP、PEI、PPS、PSU、PBT、PC、POM、PTFE、PMMA、ABS、PPE和由ABS、PPE组成的共混物的群组。在特别优选的实施例中,外层和/或中间层具有基质材料,该基质材料为PA或PA6。此外,一个优选实施例的特征在于,内层具有基质材料,该基质材料选自包含PA6.6、PA12、PPA、PEEK、聚酰亚胺、LCP、PEI、PPS和PSU的群组。
所述成型件的另一优选实施例的特征在于,所述外层和所述中间层具有PA 6作为基质材料,其中,所述内层具有PA 6.6或PPA作为基质材料。这样就以特别合适的方式确保,与外层和中间层的基质材料相比,内层具有更好的机械特性、更弱的吸湿性、更强的耐介质性,更高的熔点和更高的玻璃化转变温度。这样就能以特别合适的方式使得内层特别是在成型件的内高压成形时与其作为支撑层的用途相协调。
所述成型件的另一优选实施例的特征在于,所述层中的至少一个层的增强纤维为经编织的。特定而言,成型件的所有层的增强纤维优选均为经编织的。其中,在所述成型件的一个特别优选的设计方案中,所述内层的编织图案与所述外层的编织图案相比更密或更紧。内层的编织图案与中间层的编织图案相比优选也更密或更紧。这样就能为内层选择尽可能密的特殊编织图案,使得该内层特别适于成型件的内高压成形。
所述成型件的另一优选实施例的特征在于,所述成型件以编织拉挤法制成。其中,特别优选用下述方法来制造成型件,即:将作为连续纤维的增强纤维编织在静止的编织芯轴上,该编织芯轴并非用作消失型编织芯轴,而是保留在编织单元中。也就是说,将增强纤维编织在固定不动的编织芯轴或编织芯部上,其中成型件在随后的加固步骤中制成为空心型材。可以在编织拉挤过程中实施浸渍和加固。
特别优选采用如德国公开文献DE 10 2011 018 422 A1中所描述的方法来制造成型件。
特定而言,优选在编织拉挤法(编织、UD编织、卷绕)的范围内,在编织拉挤设备中以以下步骤连续制造热塑性的FVK空心型材作为成型件:用多个混合粗纱或纤维带制成多分层的空心型材编织物,其中混合粗纱或纤维带包括增强纤维和热塑性基质材料。借助具有至少两个编织轮的编织装置在编织芯轴上制成多分层的空心型材编织物。将空心型材编织物从编织芯轴上引出,并借助布置在编织拉挤设备的加固工具下游的引出装置通过引入矩阵/引入阴模引入加固工具中。用热塑性基质材料围绕空心型材编织物制成滑动护套,其中滑动护套的热塑性基质材料以至少被加热至该热塑性基质材料的玻璃化转变温度的状态存在。在加固工具中用基质材料浸渍并加固空心型材编织物,其中加固工具具有调温装置。
本发明也包括一种制造所述成型件的相应制造方法,特别是编织拉挤法。
可以将为制成滑动护套而在加固工具的入口处熔化的基质材料,特别是紧接在引入矩阵后直接输送到空心型材编织物。
所述成型件的另一优选实施例的特征在于,用塑料、特别是热塑性塑料对成型件至少部分地进行挤压包封和/或后注射。其中,优选至少一个连接元件通过挤压包封或后注射与成型件连接。特别优选用纤维增强塑料、特别是短纤维增强塑料、尤其是短纤维增强的热塑性塑料至少部分地对成型件进行挤压包封或后注射。如此制成的连接元件用于在组装时、例如组装汽车车身时将成型件与相邻的部件连接在一起。其中,优选通过塑料后注射将成型件与相邻的、优选由有机板和/或注塑件形成的覆板部件以材料结合的方式连接在一起,其中,成型件承受该结构所产生的负荷。
最后,一种优选成型件的特征在于,所述成型件被构造为用于车辆的、特别是用于汽车的、特别优选用于载重汽车的支撑管或组装支架。成型件特别优选被构造为用于车辆车身的覆板部件的、特别是载重汽车的车身前盖的支撑管或组装支架。
附图说明
下面结合附图对本发明进行详细说明。其中:
图1为成型件的一种实施例的纵截面的示意图;
图2为根据图1的成型件的横截面示意图,及
图3为根据图1和图2的成型件的制造方法的一种实施方式的示意图。
具体实施方式
图1为成型件1的一种实施例的纵截面的示意图。成型件1优选制造为连续型材并被定尺剪切为特定的长度。成型件1的纵轴线L优选与制造连续型材时成型件1的进给方向或引出方向对应。
如图2所示,成型件1在此为具有圆形横截面的空心的管状型材,该型材具有数个层,在此刚好为三个层,即内层3、中间层5和外层7。这些层中的至少一个、视情况这些层中的一个以上、特别是这些层中的每一个可以具有数个分层,这些分层在其功能和/或材料设计方面在相应的层中相同。而不同的层,即内层3、中间层5和外层7在其对于成型件1的功能方面,特别在表征不同的层的至少一个参数方面有所区别。特定而言,这个参数是在考虑到所述层的不同功能的情况下选出的。
所述层中的每一个,即内层3、中间层5和外层7具有纤维增强塑料或优选由纤维增强塑料构成。该塑料特别是指连续纤维增强塑料,其中增强纤维被编织,特别被编织成混合纤维粗纱。
在此处具体描述的实施例中,外层7具有被构造为碳纤维、玄武岩纤维和/或芳族聚酰胺纤维的增强纤维。前述纤维类型的组合也是可行的。外层优选具有PA 6作为基质材料。
中间层6优选被构造为玻璃纤维增强层,即具有玻璃纤维作为增强纤维。也可以额外地在玻璃纤维层中加入碳纤维、芳族聚酰胺纤维和/或玄武岩纤维,以便灵活地调整玻璃纤维层的特性。中间层5优选具有PA 6作为基质材料。
因此,在此处所示的实施例中,中间层5和外层7优选具有相同的基质材料,特别是PA 6。
在此处所描述的实施例中,内层3具有熔点高于中间层5和外层7的基质材料的基质材料。内层3特别优选具有PA 6.6或PPA作为基质材料。内层的增强纤维可以为碳纤维、玄武岩纤维、芳族聚酰胺纤维和/或玻璃纤维。内层3优选还具有与中间层5和外层7的编织图案不同的编织图案,其中特定而言,内层的编织图案与中间层5和外层7的编织/卷绕图案相比更密或更紧。
其中,内层3特别适合耐受成型件1内高压成形时的条件。
图2为根据图1的成型件1的上述实施例的横截面示意图。相同和功能相同的元件用相同的附图标记表示,以便参阅前文的描述。其中,成型件1被构造为具有圆形横截面的管状成型件。在被成型件1的层包围的内部空间9中用径向朝外的箭头P表示成型件1内高压成形时作用于内层3的压力,为清楚起见,仅其中一个箭头配有附图标记P。其中,这个内层用作支撑层和保护层以对抗内高压成形时施加于成型件1的内压和热量,特定而言,具体方式是:与中间层5和外层7相比,内层在基质材料方面具有更高的熔点和优选更高的玻璃化转变温度。
图3为根据图1和图2的成型件1的制造方法的一种实施方式的示意图。其中,使用编织拉挤装置11制造成型件1,该编织拉挤装置具有包含数个编织轮15的编织单元13,其中将混合纤维粗纱编织在固定不动且静止的编织芯轴19上,为清楚起见,仅其中一个混合纤维粗纱用附图标记17标出。在此过程中制成多分层的空心型材编织物,借助配设给拉挤单元21的引出单元23将空心型材编织物从编织芯轴19引出并引入到加固工具25中。在加固工具25中用热塑性基质材料围绕空心型材编织物制成滑动护套。优选通过检查装置27来检查由引出单元23进一步输送的连续型材,视情况在再成型装置29中对连续型材实施再成型。特定而言,特别是可以通过弯曲来改变连续型材的横截面和/或其走向。
优选还设有未绘示的分离装置,通过分离装置将以上述方式制成的连续型材定尺剪切成单个成型件。
整体而言,借助所述方法可以制造出一种适于指定的再加工和/或用途的高度专业的成型件1。其中重量特别可以得到减轻,且可以降低与成型件1相关的成本。特定而言,这样就能降低载重汽车的车身前盖的成本并减轻其重量。
可以用成型件1提供可在适合批量生产且高度整合的制造工艺中制造的、具有理想的抗扭刚度和弯曲刚度的闭式空心型材。其中可以实现适于回收利用的材料方案,其中可以在回收利用中制成具有技术可用性的增强塑料颗粒。通过将所有制造工艺整合成所谓的一步法,大幅地节省了成本和能源。就成型件1而言,通过针对所要求的特性将各种材料整合在一起可提高性能,特别提高强度和刚度。
特别通过专门调整成型件1的内部的层,可以将成型件设计为不透气的,由此可对成型件1实施内高压成形,但也可以用塑料挤压包封成型件。成型件1具有耐介质性和耐温性。成型件1的NVH特性(噪声、振动、声振粗糙度)也得到减小及改善。

Claims (10)

1.一种具有数个层的成型件(1),所述层分别具有纤维增强塑料,其特征在于,至少两个层在至少一个表征所述层的参数方面有所区别。
2.根据权利要求1所述的成型件(1),其特征在于,所述至少一个参数选自由所述纤维增强塑料所具有的增强纤维的类型、所述纤维增强塑料的基质材料、增强纤维的布置方式和增强纤维的布置图案组成的群组。
3.根据权利要求1和2中任一项所述的成型件(1),其特征在于,所述成型件(1)的最内层所具有的基质材料与外部的层的基质材料相比,
a)在化学上和/或物理上相似,和/或
b)具有更高的熔点,和/或
c)具有更高的玻璃化转变温度,和/或
d)具有更强的耐热变形能力,和/或
e)具有更强的耐介质性,和/或
f)具有更强的气密性,和/或
g)具有更弱的吸湿性,和/或
h)具有更大的强度,和/或
i)具有更强的阻尼特性。
4.根据上述权利要求中任一项所述的成型件(1),其特征在于,最内层的基质材料的玻璃化转变温度为至少115℃和/或熔点为至少260℃。
5.根据上述权利要求中任一项所述的成型件(1),其特征在于,所述成型件具有三个层,即内层(3)、中间层(5)和外层(7),其中,所述内层(3)所具有的基质材料的熔点优选高于所述外层(7)所具有的基质材料的熔点。
6.根据上述权利要求中任一项所述的成型件(1),其特征在于,所述中间层(5)具有玻璃纤维作为增强纤维,其中,所述内层和/或所述外层具有选自由碳纤维、玄武岩纤维和芳族聚酰胺纤维组成的群组的增强纤维。
7.根据上述权利要求中任一项所述的成型件(1),其特征在于,所述外层(7)和所述中间层(5)具有PA 6作为基质材料,其中,所述内层(3)具有PA 6.6或PPA作为基质材料。
8.根据上述权利要求中任一项所述的成型件(1),其特征在于,所述层的增强纤维为经编织/卷绕的,其中,所述内层(3)的编织/卷绕图案与所述外层(7)的编织图案相比优选更密。
9.根据上述权利要求中任一项所述的成型件(1),其特征在于,所述成型件(1)以编织拉挤法或通过编织/卷绕而制成。
10.根据上述权利要求中任一项所述的成型件(1),其特征在于,所述成型件(1)被构造为用于车辆的、特别是用于机动车的、优选用于载重汽车的支撑管或组装支架。
CN201580068735.0A 2014-12-19 2015-11-27 具有数个层的成型件 Pending CN107107540A (zh)

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