CN108349128B - 用于由纤维复合材料制造成形杆件的方法 - Google Patents

用于由纤维复合材料制造成形杆件的方法 Download PDF

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CN108349128B
CN108349128B CN201780003776.0A CN201780003776A CN108349128B CN 108349128 B CN108349128 B CN 108349128B CN 201780003776 A CN201780003776 A CN 201780003776A CN 108349128 B CN108349128 B CN 108349128B
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T·霍格尔
O·康拉德
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Bayerische Motoren Werke AG
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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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14008—Inserting articles into the mould
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • 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
    • B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
    • B29C70/386—Automated tape laying [ATL]
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0005—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor using fibre reinforcements
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B29C45/14221—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure by tools, e.g. cutting means
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • 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
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • B29C70/205—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres the structure being shaped to form a three-dimensional configuration
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2307/00—Use of elements other than metals as reinforcement
    • B29K2307/04—Carbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2313/00—Use of textile products or fabrics as reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2905/00—Use of metals, their alloys or their compounds, as mould material
    • B29K2905/02—Aluminium

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  • Composite Materials (AREA)
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  • Moulding By Coating Moulds (AREA)
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Abstract

本发明涉及一种使用连接工具由纤维复合材料制造成形杆件的方法，所述连接工具具有加热区段，该方法至少包括如下步骤：将多个配置有热塑性基质的纤维带并行地供应给连接工具，使这些纤维带组合在一起以及在所述加热区段中受到加热并连接成纤维绳，其中，该纤维绳接着从所述连接工具直接码放到加工模具或者码放设备中，该码放设备构造为用于将纤维绳放入加工模具中，所述连接工具由多轴的工业机器人构成或者由该工业机器人所携带，并且使所述连接工具在码放纤维绳期间运动，所述加工模具是注塑模具，将多根纤维绳以格栅结构并且以其相应的最终形状码放到注塑模具中，所述多根纤维绳共同构成待制作之构件的构件结构并且直接利用塑料进行注塑包封。

Description

用于由纤维复合材料制造成形杆件的方法
本发明涉及一种优选使用工业机器人由纤维复合材料制造成形杆件的方法。
纤维增强塑料具备很高的轻质结构潜力并且与其他材料(诸如金属或者非增强塑料)相比由于添加了纤维而能够吸收/承受大的拉力。其中，在如下情况下，纤维增强塑料在单位重量方面的优点可以得到最佳利用，即纤维在基质材料中是符合负载路径地布设的，这以材料的适合承载的结构设计为前提条件。然而在汽车制造中迄今为止只是初步实现了这一点。
从现有技术已知的是，例如借助热塑性拉挤工艺(Pultrusion)由纤维复合材料制造直的杆件。然而该方法却是难以掌控的。此外，这种系统非常大型、昂贵并且针对可制作的构件形状来说是不灵活(非柔性)的。
因此，本发明的目的是：提供一种方法，借其可以由纤维复合材料更加经济地且在造型方面具有更大可变性地制造杆件。
此目的通过使用连接工具由纤维复合材料制造成形杆件的方法得以实现，所述连接工具具有加热区段，该方法至少包括如下步骤：将多个配置有热塑性基质的纤维带并行地供应给所述连接工具，使这些纤维带组合在一起以及在所述加热区段中受到加热并连接成纤维绳，其中，该纤维绳接着由所述连接工具直接码放到加工模具或者码放设备中，所述码放设备构造为用于将纤维绳放入所述加工模具中。
根据本发明，提出了一种使用连接工具由纤维复合材料制造成形杆件的方法。该方法至少包括如下步骤：将多个配置有热塑性基质的纤维带并行地供应给连接工具，使这些纤维带组合在一起以及在所述连接工具的加热区段中受到加热并连接成纤维绳，其中，纤维绳接着由连接工具直接且不进行冷却地码放到加工模具或者码放设备中，该码放设备构造为用于将纤维绳放入所述加工模具中，所述连接工具由多轴的工业机器人构成或者由该工业机器人所携带，并且使所述连接工具在码放纤维绳期间运动，所述加工模具是注塑模具，将多根纤维绳以格栅结构并且以其相应的最终形状码放到注塑模具中，其中，所述多根纤维绳共同构成待制作之构件的构件结构并且直接利用塑料进行注塑包封。
优选地，所述连接工具由工业机器人构成或者由该工业机器人所携带。
在一种有益的实施方式中，采用多轴机器人作为工业机器人，该多轴机器人可以配备有机器人头部。实施本方法所需的设备部分可以集成在机器人头部中，其中与此相关地特别是包含用于供应和输送具有热塑性基质的纤维带的推进装置(Vortrieb)、用于将纤维带组合在一起并集束的装置、在加热区段中对组合在一起的纤维带进行加热的热力区和用以码放制成的纤维绳的推出装置(Austrieb)。不论是推进装置还是用于将纤维带组合在一起并集束的装置，都可以通过配合作用的辊子或者滚筒提供。经浸渍的纤维带作为原始材料被卷绕在辊子或者筒管上提供给工业机器人使用。
通过使用多轴工业机器人，可以将纤维绳以任意的形状以及在任意的位置上码放。还实现了：可变地调定纤维带和纤维绳的数量并因此调定增强特性。优选并行地供应多个纤维带。
在一种有利的实施方案中，纤维带由碳素纤维构成。它们具有0.1mm至0.3mm的厚度。优选纤维带构造为单向性的。
另外，在按照本发明的方法中可以实现：通过工业机器人依次将多根纤维绳彼此相叠地码放。通过纤维绳的数量可以控制待制造之杆件的材料强度。在此，可以对工业机器人进行编程，将多根相同的纤维绳沿着预定的延伸方式彼此相叠码放，以调定杆件粗细。各纤维绳经由其相应的热塑性基质彼此相靠地附着或者说连接。
此外，作为本方法的另一备选实施方式，有益的是：所供应的纤维带的数量是可变的。通过纤维带的数量可以确定相应纤维绳的横截面。
根据本发明的第一方面规定：所述加工模具是成型模具。纤维绳于是可以以任意形状和以很高的速度码放到成型模具中，其中，纤维绳接着通过该成型模具被置于其所期望的最终形状。这一方案也可以用于对待制造的杆件进行三维造型。继成型加工之后，利用塑料将已成型的纤维绳或者纤维绳堆组进行注塑包封。作为对此备选的方案，可以将由连接工具提供的纤维绳码放到一个码放设备中，其中，该码放设备接着可以放入成型模具中，用于将纤维绳成型为其最终形状。在使用例如由铝模构成的码放设备的情况中，可以通过码放设备在空间中的运动(空间运动)实现纤维绳的弯曲造型，其中纤维绳基本上平直地从所述连接工具中排出。所述在空间中的运动(空间运动)可以通过机器人来实现，因为码放设备与成型模具相比是很轻的。
根据本发明成形的杆件在车辆工程中主要用作支架材料用以稳固塑料构件，例如在车顶弓梁(Dachspriegel，软顶车篷框架)中。
根据本发明的第二方面规定：所述加工模具是注塑模具，并且将一根纤维绳或多根纤维绳直接码放到该注塑模具中或者说其型模中。
根据本发明，通过采用工业机器人而能够实现：将纤维绳弯曲地、特别是三维弯曲地码放。以此方式可制造的构件与传统的拉挤工艺方法相比在造型方面具备增大的可变性并因此具备扩大的应用范围。
在本方法的一种有益的变型实施方案中规定：将纤维绳以待制作的成形杆件的最终形状码放到注塑模具中并且直接利用塑料进行注塑包封。在此，工业机器人直接在注塑机中作业并且将纤维绳码放到注塑机内部预先给定的型模中。纤维绳的码放一结束，就可以将注塑模具闭合并且围绕一个杆件或者多个杆件注射塑料。等待时间和模具停机时间都非常短。制造速度显著提高，并使成本得以下降。
在本方法的一种发展设计中规定：将多根纤维绳以其相应的最终形状码放到注塑模具中，其中，所述多根纤维绳共同形成待制作之构件的构件结构并且直接利用塑料进行注塑包封。
另外，本方法的下述实施方式也是有利的，其中，将纤维绳以格栅结构码放。接着可以通过注塑法对所述格栅结构进行注塑包封。在采用格栅结构的情况中，可以在构件中可变地构造设计多个负载路径。
本发明在其设计上并不局限于前述的优选实施例。更确切地说，可以考虑一些变型设计，它们将所描绘的解决方案同样也应用在原则上不同型式的设计当中。例如，也可以加工不同于碳素纤维的其他纤维材料。作为热塑性基质，例如可以使用聚酰胺基质。

Claims (4)

1.使用连接工具由纤维复合材料制造成形杆件的方法，所述连接工具具有加热区段，该方法至少包括如下步骤：将多个配置有热塑性基质的纤维带并行地供应给所述连接工具，使这些纤维带组合在一起以及在所述加热区段中受到加热并连接成纤维绳，其中，该纤维绳接着由所述连接工具直接码放到加工模具或者码放设备中，所述码放设备构造为用于将纤维绳放入所述加工模具中，所述连接工具由多轴的工业机器人构成或者由该工业机器人所携带，并且使所述连接工具在码放纤维绳期间运动，所述加工模具是注塑模具，将多根纤维绳以格栅结构并且以其相应的最终形状码放到注塑模具中，其中，所述多根纤维绳共同构成待制作之构件的构件结构并且直接利用塑料进行注塑包封。
2.如权利要求1所述的方法，其特征在于：通过所述连接工具或者工业机器人依次将多根纤维绳彼此相叠地码放。
3.如权利要求1或2所述的方法，其特征在于：所供应的纤维带的数量是可变的并且该数量决定所述纤维绳的横截面。
4.如权利要求1或2所述的方法，其特征在于：将所述纤维绳弯曲地码放。
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CN108349128A (zh) 2018-07-31
WO2017140460A1 (de) 2017-08-24
US11045984B2 (en) 2021-06-29

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