CN109070496A - 用于制造由金属和纤维复合物构成的半成品或构件的方法 - Google Patents

用于制造由金属和纤维复合物构成的半成品或构件的方法 Download PDF

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CN109070496A
CN109070496A CN201680081048.7A CN201680081048A CN109070496A CN 109070496 A CN109070496 A CN 109070496A CN 201680081048 A CN201680081048 A CN 201680081048A CN 109070496 A CN109070496 A CN 109070496A
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prepreg
metallic carrier
matrix
heat cured
remodeling
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CN109070496B (zh
Inventor
卡罗拉·艾塞尔
吕迪格·海因里茨
赖纳·克尔施
格哈德·迈尔霍费尔
克里斯蒂安·鲁埃
约翰尼斯·里格勒尔
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Austria Iron & Steel United Metal Forming Co Ltd
Voestalpine Stahl GmbH
Voestalpine Metal Forming GmbH
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Austria Iron & Steel United Metal Forming Co Ltd
Voestalpine Stahl GmbH
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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
    • 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
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
    • B29C70/525—Component parts, details or accessories; Auxiliary operations
    • B29C70/528—Heating or cooling
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    • B21D22/022—Stamping using rigid devices or tools by heating the blank or stamping associated with heat treatment
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    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Textile Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Moulding By Coating Moulds (AREA)
  • Reinforced Plastic Materials (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)

Abstract

本发明涉及用于制造半成品或构件(102)的方法，其中，构造为纵切带材(104)的金属载体(103)铺覆有至少一个预浸料(6)，预浸料具备带有连续纤维的能热交联的热固性的基质，预浸料(6)的热固性的基质通过加热预交联，并且铺覆有预交联的预浸料(6)的金属载体(103)通过辊轧成形改型成半成品或构件(102)。为了能够实现金属载体(103)的纤维强化的区域上的塑性的形状改变而提出的是，在预浸料(6)的热固性的基质的预交联时，预浸料的基质转移到跟在基质的粘度最小值(ηmin)之后的粘度状态(η)中，并且在达到其胶凝化点(Pc)之前，预浸料(6)与金属载体(103)共同地改型。

Description

用于制造由金属和纤维复合物构成的半成品或构件的方法
技术领域
本发明涉及用于制造半成品或构件的方法，其中，构造为纵切带材的金属载体铺覆有至少一个预浸料，预浸料具有可热交联的热固性的具有连续纤维的基质，预浸料的热固性的基质通过加热预交联，并且铺覆有预交联的预浸料的金属载体通过辊轧成形改型成半成品或构件。
背景技术
为了使以具备带有连续纤维的热固性的基质的预浸料强化的金属载体，即板材下料或板材坯，可以尽可能不受损害地经受改型工艺，尤其是深拉，由现有技术(WO2013/153229A1)公知的是，使金属载体上的塑性变形转移至金属载体的无涂层的区域中。因此，在半成品或构件上存在无涂层的区域，这在其轻质结构潜力并且因而在其应用可能性方面限制这种纤维复合塑料(FVK)强化的半成品或构件。此外，通过该区域限制也限制了预浸料的纤维长度，这可能导致刚性和强度的减小。此外，在半成品或构件(其由具有无压力直至挤压不粘贴地时效硬化的预浸料的板材下料深冲制成)中表现出层离和/或最终交联的纤维复合材料中的孔隙率增加的趋势，这尤其损害了该方法的可再现性。
发明内容
因此，本发明提出如下任务：在其简单性、应用可能性和在其可再现性方面改进开头描绘的类型的方法。此外应该能够实现具有很小周期时间的方法。
本发明以如下方式解决所提出的任务：在预浸料的热固性的基质的预交联时，预浸料的基质转移到跟在其粘度最小值之后的粘度状态中，并且在达到其胶凝化点之前，预浸料与金属载体共同地改型。
如果在预浸料的热固性的基质的预交联时，预浸料的基质转移到跟在其粘度最小值之后的粘度状态中，并且在达到其胶凝化点之前，预浸料与金属载体共同地改型，那么由此可以不仅允许在金属载体上在其纤维强化的区域中的塑性的形状改变，而且可以明显改进该方法的可再现性。于是，在该状态中的预浸料可以允许在其连续纤维和金属载体之间的相应于改型半径的相对运动。因此，在板材下料上甚至可以遵循很小的弯曲半径，而不必考虑到断裂或层离。根据本发明的方法因此可特别多样性地应用。此外可以意外地实现的是，通过共同的改型，带有连续纤维的纤维结构的基质材料的紧凑性可以明显得到改进。在改型时的比较短时间的力加载，尤其是压力加载可以用于减小纤维复合物中的孔隙率，因此，层压质量可以提高，并且在板材下料上的纤维强化部的层离的危险可以进一步减小。因此根据本发明，通过基质转移到跟在其粘度最小值之后的粘度状态，并且在达到基质的胶凝化点之前将预浸料和金属载体共同地改型，使得该方法的可再现性可以明显得到改进。此外可能的是，通过预浸料和金属载体的共同改型提供特别快速的具有很小的周期时间的方法流程。此外，与其他的公知的用于制造纤维复合半成品或构件的方法相比，根据本发明的方法能够实现无需要耗费的和/或可复杂操作的设施安装技术，这除了减小针对根据本发明的方法的成本以外还意味着改进其可再现性。
通常提到的是，金属载体可以由具有铁、铝或镁物质的板材、由轻金属或类似物或由这些材料构成的合金组成。作为金属载体，具有或不具有保护层(例如基于锌)的钢板材可以是突出的。通常进一步提到的是，热固性的塑料基质可以具备带有无机或有机的强化纤维，如玻璃、玄武岩、碳或芳纶的组合物。此外，除了给金属载体依次铺覆多个预浸料，也能想到将预浸料(单层或多层地)堆叠在金属载体上。在预浸料中包含的纤维可以作为纯单向的层。因此，利用多层的预浸料可以提供在金属载体上的单向的或多向的层压体。
此外通常确定的是，热固性的塑料基质也可以具有改性的热固性的聚合物共混物，其优选由环氧化物相和聚氨酯相构成的不强制彼此交联的相组成。PU-环氧树脂共混物的公知的按百分比的组分例如是环境的环氧树脂基质中的初级的聚氨酯相的5至25份额。
通常进一步提到的是，基质的粘度利用流变仪，即在振荡的情况下的Anton Paar公司的MCR 301粘度计(例如板-板配置，直径25mm；间隙1000μm；振幅0.5％；角频率10弧度/秒)，根据ASTM D 4473:08/2016评估确定。
为了减少在改型时在粘度最小值之上经加热的热固性的基质的预浸料被不期望挤出的危险，可以设置的是，在改型前，热固性的基质的交联度设定在4％至15％(例如：通过温度和/或时间)。
可以特别有利的是，在改型时，热固性的基质的交联度设定在20％至45％(例如：通过温度和/或时间)。由此，能附加地减少在改型时热固性的基质被不期望地挤出的危险。在这种交联度中，在改型时作用到预浸料上的压力负荷也可以负责实现用于达到预浸料的提高的层压质量的最佳的条件。此外，这也可以有助于原料配对体之间的附着强度。
可以特别有利的是，在改型时，热固性的基质的交联度设定在25％至40％(例如：通过温度和/或时间)。
如果在改型时，热固性的基质加热到120℃至220℃，那么就可以加速交联，因此，改型可以更快地进行，或者该方法的周期时间降低。
可以特别有利的是，在改型时，热固性的基质被加热至150℃至180℃。
当改型工具被加热并且金属载体利用加热的改型工具改型时，可以防止经加热的预浸料的不期望的冷却和因此是不利于根据本发明的方法的温度改变。以该方式，该方法的可再现性可以进一步提高。规定的是，针对该目的，改型工具的温度可以与预浸料或其基质的温度不同。此外可想到的是，改型工具的工具具有不同的温度，以便适宜地视区域而定地调温金属载体，或者设定层压中的温度梯度。
当预浸料在与金属载体共同改型之后无压力地硬化时，用于改型的周期时间可以减小。
通过在给金属载体铺覆预浸料之前或在给金属载体铺覆预浸料时将中间层(预浸料经由该中间层接至金属载体上)施加到金属载体上，一方面可以改进附着强度，另一方面也起均衡作用地影响热应力。中间层应该至少在金属载体的也铺覆有预浸料的区域中整个面地施加。
中间层的层厚度可以优选是50μm至1000μm，层厚度优选是80μm至700μm。较厚的层，优选500μm至1000μm的层厚的出众之处在于，这些层此外提供保护以防腐蚀(阻挡层)。在具有高刚性要求的应用中，薄膜是优选的(优选＜150μm)。此外，处理时间，即反应时间是关系重大的——对于缩短周期时间尤为重要。在此证实的是，基于聚乙烯、聚丙烯的和/或具有聚酰胺芯的中间层或基于共聚酰胺的中间层可以是特别适当的。这例如可以是Nolax公司的系统(即产品Cox 391，Cox 422，Cox435)、Evonik公司的系统(即产品VestameltX1333-P1)或Hexcel公司的系统(即产品TGA25.01A或DLS 1857)。
也可想到的是，将压力负荷施加到预浸料上，其方法是，将构造为纵切带材的金属载体辊轧成形。这种金属载体可以例如通过金属带材的纵向切分产生，也构造为扁平的纵切带材，以便避免起皱。
当在金属载体辊轧成形后预浸料再次挤压到金属载体上时，可以有效地防止预浸料上的褶皱形成和/或气泡形成(其可能在辊轧成形期间构成)。优选地，该挤压直接跟随在辊轧成形后面。这例如可以借助辊子对进行。
为了使辊轧成形变得容易可以设置的是，金属载体局部铺覆有至少一个预浸料。这可以进一步提高该方法的可再现性。
当金属载体的其中一个扁平侧的40％至70％被铺覆有预浸料时，尤其是可以形成上述的优点。
根据本发明的方法尤其是可以适用于制造结构构件。通常提到的是，结构构件可以是具有承载结构的构件。结构构件尤其是可以适用于载运工具，尤其是机动车、公路车辆、运输车辆、轨道车辆、飞机或宇宙飞行器。结构构件例如可以构造为侧包围、A柱、B柱、C柱、横向载体或纵向载体。
附图说明
在附图中例如详细示出了根据本发明的用于制造半成品或构件的方法。其中：
图1示出根据本发明的方法的流程，其中，辊轧成形设施的构架用于改型与预浸料连接的金属载体；和
图2示出针对在根据图1的方法中使用的预浸料的基质的粘度和交联度的相关于时间的图示。
具体实施方式
根据图1的根据本发明的方法101的流程，为了制造构件102示出辊轧成形设施的作为改型工具112的构架115。
在载体121上设置的预浸料6(其在大小方面不按比例地示出并且已经被预调理)施加到实施为纵切带材104的金属载体103上，即施加在两个扁平侧103.1、103.2中的扁平侧103.1上。金属载体103因此仅局部铺覆有预浸料6。纵切带材104由未详细示出的卷材通过纵切/纵分产生。
金属载体103与载体121和预浸料6一起引导通过挤压辊子对122，随后，载体121保留在金属载体103上。预浸料6可以在上方的和/或下方的侧上铺覆有保护薄膜123。在施加预浸料6之前，至少预浸料6的面对载体121的侧所在的保护薄膜123被取下且开卷。随后，金属载体103被铺覆有预浸料6。
因此被铺覆的金属载体103随后引导通过贯通炉111——加热导致预浸料6的热固性的基质的预交联。因此，交联度α在改型前被设定在4％至15％上。
根据本发明，在该预交联中，热固性的基质转移到跟在其粘度最小值ηmin之后的粘度状态η中，并且预浸料6在达到其基质的胶凝化点Pc之前与金属载体103一起通过辊轧成形设施的构架115的协同作用的辊子124改型。根据本发明，该改型与预浸料6的热固性的基质的预交联相协调地实现，如从图2能看到的那样。由此，可以以短的周期时间可再现地制造铺覆有预浸料6的半成品或构件102。
热固性的基质和金属载体103的有利的共同改型根据本发明是可行的，这是因为在所描述的根据本发明的状态中使用的预浸料6可以通过改型遵循塑性的形状改变。也就是说，预浸料6的连续纤维还相对于金属载体103在预浸料6中可相对地运动。预浸料6的基质位于跟在其粘度最小值ηmin之后的粘度状态η中，由此，连续纤维的断裂或金属载体103上的纤维强化部的层离在改型时没有出现。
根据图2的示图涉及如下的纤维复合材料：
金属载体：钢板材：板材厚度0.81mm
层压部：单向，四个预浸料子层
预浸料：在基质中具有57％纤维份额的连续纤维，厚度：0.22mm
基质：热固性的基体(SGL类型E201：改性的环氧树脂系统)
ηmin＝0.9Pa*s
Pc＝45％
中间层：100μm聚丙烯
基质的交联度α借助差示扫描量热法(DSC)根据ISO 11357-5:2013测量确定。
替代钢板材地，例如6xxx系列的由铝合金构成的板材也是可想到的。通常提到的是，为了借助差示扫描量热法(DSC)测量交联度，根据ISO 11357-5:2013的等温法可以是特别适用的。
在优选被加热的改型工具112中，基质的交联度α从在改型前的4％至15％设定到在改型时的20％至45％，优选25％至40％，边界20％至45％在图2中以虚线画出。这种设定例如可以通过温度和/或时间来实现。
利用优选被加热的改型工具112此外可以确保的是，在改型时，热固性的基质保持在120℃至220℃的温度上，以便可以将构件102通过更快的交联较早地从改型工具112取出，并且因此可以缩短该方法。在许多情况下，温度也可以在150℃至180℃。
此外，待铺覆的金属载体103可以也具有保护涂层21，例如锌层或锌合金层，如可以根据图2看到的那样。在整个面铺覆有预浸料6的区域中，中间层22施加到该保护涂层21上或金属载体103的扁平侧103.1上。中间层22通过将基于聚酰胺的增附剂施布到金属载体103上产生，如在图1中示出的那样。经由该中间层22，预浸料6可以非常牢固地且低应力地连到金属载体103上。
根据图1进一步看到的是，利用跟随构架115的在空中运动的分离装置125，已改型的金属载体103被切割为构件102。
被切割的构件102还可以经受另外的无压力的交联，这没有详细示出。构件102作为结构构件102.1例如可以特别适用于车辆。
在贯通炉111后，为了改进预浸料6上的层压质量还可以设置压紧辊子对126，其使预浸料6受压力负荷。
辊轧成形设施根据常见的带材供应(其借助带材焊接设施127和拉直机128执行)还具有进给冲具129，利用进给冲具，金属载体103被打孔和/或冲压。随后，带材驶入带材清洁部130中，设有预浸料6的面在那里优选被预清洁。在活套坑(Schlingengrube)131后，预浸料6例如以条带形式被施加。此外在图1中看到的是，在改型后进行校准132，并且随后执行可选的去褶皱133。去褶皱133例如可以借助对置的辊子实现，辊轧成形的金属载体103在辊子之间引导，预浸料6再次被挤压到金属载体103上。随后，交联可以通过另外的热源134引发。
如在图1中看到的那样，金属载体103仅局部铺覆有预浸料6，即在扁平侧103.1上铺覆40％至70％，这使共同的改型明显变得容易。扁平侧103.1的铺覆有预浸料6的区域14因此在面积上小于扁平侧103.1的整个面积。

Claims (13)

1.用于制造半成品或构件(102)的方法，其中，
给构造为纵切带材(104)的金属载体(103)铺覆至少一个预浸料(6)，所述预浸料具备带有连续纤维的能热交联的热固性的基质，
将所述预浸料(6)的热固性的基质通过加热预交联，并且使铺覆有预交联的预浸料(6)的金属载体(103)通过辊轧成形改型成半成品或构件(102)，
其特征在于，
在所述预浸料(6)的热固性的基质的预交联时，使所述预浸料的基质转移到跟在所述基质的粘度最小值(ηmin)之后的粘度状态(η)中，并且在达到所述基质的胶凝化点(Pc)之前，使所述预浸料(6)与所述金属载体(103)共同地改型。
2.根据权利要求1所述的方法，其特征在于，在改型之前，将热固性的基质的交联度(α)设定在4％至15％。
3.根据权利要求1或2所述的方法，其特征在于，在改型时，将热固性的基质的交联度(α)设定在20％至45％。
4.根据权利要求3所述的方法，其特征在于，在改型时，将热固性的基质的交联度(α)设定在25％至40％。
5.根据权利要求1至4中任一项所述的方法，其特征在于，在改型时，将热固性的基质加热至120℃至220℃。
6.根据权利要求5所述的方法，其特征在于，在改型时，将热固性的基质加热至150℃至180℃。
7.根据权利要求1至6中任一项所述的方法，其特征在于，加热改型工具(112)，并且使所述金属载体(103)利用经加热的改型工具(112)来改型。
8.根据权利要求1至7中任一项所述的方法，其特征在于，使所述预浸料(6)在与所述金属载体(103)共同改型后无压力地硬化。
9.根据权利要求1至8中任一项所述的方法，其特征在于，在给金属载体(103)铺覆预浸料(6)之前或在给金属载体(103)铺覆预浸料(6)时，将中间层(22)施加到金属载体(103)上，所述预浸料(6)经由所述中间层接至所述金属载体(103)上。
10.根据权利要求1至9中任一项所述的方法，其特征在于，在金属载体(103)的辊轧成形后，将预浸料(6)再次挤压到金属载体(103)上。
11.根据权利要求1至10中任一项所述的方法，其特征在于，给金属载体(103)局部地铺覆至少一个预浸料(6)。
12.根据权利要求11所述的方法，其特征在于，金属载体(103)的其中一个扁平侧(103.1、103.2)的40％至70％被铺覆有预浸料(6)。
13.根据权利要求1至12中任一项所述的方法，其用于制造结构构件(102.1)。
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