CN110312614B - 用于生产复合产品的方法和半成品以及由此获得的产品 - Google Patents

用于生产复合产品的方法和半成品以及由此获得的产品 Download PDF

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CN110312614B
CN110312614B CN201880012943.2A CN201880012943A CN110312614B CN 110312614 B CN110312614 B CN 110312614B CN 201880012943 A CN201880012943 A CN 201880012943A CN 110312614 B CN110312614 B CN 110312614B
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layer
mould
resin
fabric layer
fabric
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CN110312614A (zh
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法比奥·马尔切利
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Lamborghini Motors Co ltd
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    • 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
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
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    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
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Abstract

一种用于生产复合材料制成的产品的方法，包括以下操作步骤：在第一模具(12)和至少一个第二模具(23)之间放置至少一个复合材料纤维织物层(1)和至少一个复合材料纤维的第一层(16)，其中在织物层(1)和第一模具(12)之间放置基本上不含固化剂的非聚合的复合材料树脂层(3)；将树脂和固化剂注入第一模具(12)和第二模具(23)之间，以用注入的树脂浸渍层(1)和第一纤维层(16)，并用注入的固化剂使注入的树脂和树脂层(3)聚合。本说明书还涉及一种可用于该方法的半成品以及一种使用该方法和/或用该半成品制成的产品。

Description

用于生产复合产品的方法和半成品以及由此获得的产品
技术领域
本发明涉及一种生产复合产品的方法，该复合产品包括纤维层，特别是碳纤维织物层。本说明书还涉及一种可用于该方法的半成品以及一种使用该方法和/或用该半成品制成的产品。
背景技术
众所周知，RTM(树脂传递模塑)方法可用于通过包含碳纤维织物的复合材料来生产部件。在这种已知的方法中，在两个匹配的模具之间放置一个或多个叠放的干织物层，即基本上没有被树脂浸渍的织物，在高压下将与固化剂混合的树脂注入模具中，使得树脂在模具中聚合以获得成品。
在该方法的称为RTM-L(RTM-Light，轻型树脂传递模塑)的变型中，在较低压力下注入树脂，以增加模具的工作寿命，并因此降低投资成本。
然而，在注入树脂时，在RTM和RTM-L方法中，织物层、特别是外层的纤维由于浸渍阶段的树脂压力梯度而发生移位，从而导致失去织纹规则性，使最终产品的美观方面恶化。
在另一种现有技术方法中，使用预先用树脂浸渍的织物，称为预浸渍。它们在不注入另外的树脂的情况下在至少一个模具上被再加热和压紧。这种现有技术方法允许获得外层即使在树脂聚合后也保持织纹规则性的复合产品。然而，它比RTM方法更昂贵，并且正是由于层的预浸渍，使得所制造的产品的结构性能不佳。
发明内容
因此，本公开的目的是提供一种没有上述缺点的方法。该目的通过在所附权利要求中规定其主要特征的一种方法和一种半成品来实现。
借助于本公开的方法，可以使用干纤维织物和向其中注入树脂和固化剂的模具制造具有良好美观外观和优异结构性能的复合材料部件。因此，该方法可以至少部分地自动化，这也归功于可以在初始阶段期间制备的本公开的半成品。实际上，由此获得的产品的至少一个外表面包括织物，其织纹基本上是规则的并且其高视觉质量符合汽车工业的高标准，例如“A类”标准。
因此，尽管现有技术的RTM方法由于树脂注入期间外层纤维的变形和移位而不能保证产品具有较高美观特征，但是本公开的方法允许获得的产品的外观与使用预浸渍方法获得的外观相同。因此，该方法将RTM方法的生产时间减少和机械性能优异的典型优点与使用预浸渍方法制造的产品的改善的美观光洁度结合起来。
这些优点首先归功于非聚合的树脂层，其在注入浸渍织物层和叠加在其上的结构层的树脂之前使外部织物层黏附到模具的功能表面上。此外，与树脂一起注入的固化剂的量足以也使施加在织物层上的树脂聚合。
还由于在织物层和与其相邻的结构层之间施加的热塑膜，在树脂注入期间织物层更牢固地保持在正确的位置。
使用包括织物层、基本不含固化剂的树脂层和热塑膜的半成品进一步简化了本方法。半成品可以容易地切割成预定的形状，甚至可以储存以供后面的阶段使用。由于在外部织物层和相邻的结构层之间存在热塑膜，使用该方法或半成品获得的产品可以与由复合材料制成的现有技术产品区分开。
在该方法的某些特定步骤中，织物层和结构层在至少一个模具上被压紧和 /或加热，以在注入树脂之前提高这些层之间的黏合度，从而获得更好的成品。
附图说明
通过下面参照附图对实施方式的详细而非限制性的说明，根据本发明的方法、半成品和产品的其他优点和特征对于熟知本行业的人员将变得更清楚，在附图中：
-图1是该方法的初始操作步骤的示意图；
-图2是从初始操作步骤获得的半成品的放大剖视图；
-图3、图5、图7、图9、图11、图13、图15和图17是该方法的进一步的操作步骤的示意性剖视图；
-图4、图6、图8、图10、图12、图14、图16和图18分别是来自图3、图5、图7、图9、图11、图13、图15和图17的细节IV、VI、VIII、X、XII、 XIV、XVI和XVIII的放大视图。
具体实施方式
图1示出了用于制造半成品的方法的初始操作步骤，其中优选对至少一个纤维织物层1加压，例如使用压延机2，以消除纬纱和经纱之间的所有间隙，并增加纱线张力，从而使织物结构更紧凑。织物层1优选是用于复合材料的纤维织物，特别是具有基本均匀的纬纱和/或厚度在0.1和0.8mm之间、特别是在0.2和0.3mm之间的碳纤维：例如，具有“斜纹”、“平纹”、“缎纹”、“编织”、“单向”或其他类型的均匀和/或规则的织纹图案的碳纤维织物，其特别是具有230和260g/m2之间的克重。优选地，织物层1的织物基本上是干的，即，它含有按重量计小于10％的量的添加剂，例如黏合层或固定剂。在织物层1 的至少一个表面上，特别是通过喷雾器4施加至少一层基本不含固化剂的非聚合的复合材料树脂3，特别是环氧树脂。树脂3例如可以是由亨斯迈公司 (Huntsman Corporation)制造的XB 3518树脂，并且以织物层1的重量的2％和7％之间、特别是5和19g/m2之间并且更特别为约12g/m2的量施加在织物层1上。在织物层1的设置有树脂3的表面上通过压延机6施加保护片5，例如，特别是诸如Mylar的塑料材料的保护片5，其不吸收湿气并因此在环境湿度变化时不会收缩，使得树脂3因此被保护片5覆盖。这防止了在织物层1 中形成褶痕，并且特别是通过防止聚合过程开始而使树脂层3保持其原始状态，基本上不被环境条件改变。因此，由于树脂3未被活化，因此保护片5 可移除地施加在树脂层3上。
在织物层1的、与设置有树脂层3的表面相对的表面上通过压延机8施加热塑膜7，优选包括至少一个尼龙、聚丙烯、ABS、PLA、聚碳酸酯或聚对苯二甲酸乙二醇酯的网片。然后，将由此获得的织物层1通过切割机9切割成预定形状，并且可以将所得的半成品10卷起和/或封装在密封袋11中，以在储存期间防止被外部因素(如湿度或挥发性碳)污染。
图2示出了包括织物层1的半成品10，织物层1设置有由保护片5覆盖的树脂层3、连接至热塑膜7并被插在袋11中。
现在参照图3和图4，可以观察到，在方法的第一步骤中，半成品10从袋11中取出、与保护片5分离并放置在第一模具12上，第一模具12的功能表面优选是凸形的和/或由复合材料制成，特别是含有碳纤维，其中树脂层3 位于织物层1和第一模具12之间。因此，热塑膜7位于与第一模具12相对的一侧。
现在参照图5和图6，可以观察到，在方法的下一个步骤中，织物层1被第一真空袋13覆盖并通过抽出空气使得第一真空袋13内的气压减小、特别是低于130毫巴而被压紧到第一模具12上。第一真空袋13包括防止对沉积在织物层1上的树脂3进行抽吸的无孔的剥离膜14，以及尼龙泄放层15，其克重低于预浸渍方法中使用的现有技术的泄放层的克重，特别是克重小于180 g/m2，更特别是约为170g/m2。
现在参照图7和图8，可以观察到，在方法的下一个步骤中，将第一真空袋13从织物层1移除，并且在织物层1上施加至少一个第一内纤维层16，其优选包括用于结构应用的一个或多个干碳纤维织物。特别地，第一内层16具有700和900g/m2之间的克重和/或1和8mm之间的厚度。可以在第一内层 16上放置由塑料材料、优选泡沫塑料材料制成的至少一个隔层17，使得第一内层16被隔层17完全或部分地覆盖。第一内层16的至少一个表面、特别是与织物层1相对的表面可以设置有黏合层18，例如，与碳纤维混合的热塑丝线或黏合膜。
现在参照图9和图10，可以观察到，在方法的下一个步骤中，织物层1 和第一内层16以及隔层17(如果存在)可以被第二真空袋19(例如，与第一真空袋13相同的真空袋)覆盖并通过抽出空气而被压紧到第一模具12上。同时，例如通过红外辐射器将层1和层16加热到70℃和90℃之间的温度，以压缩且至少部分地熔化热塑膜7，从而通过黏合层18将织物层1连接至第一内层16并将第一内层16连接至隔层17。
现在参照图11和图12，可以观察到，在方法的下一个步骤中，将第二真空袋19从第一内层16移除，并且可以在第一内层16和/或隔层17(如果存在) 上施加至少一个第二内层20，其优选包括用于结构应用的一个或多个干碳纤维织物。特别地，第二内层20具有700和900g/m2之间的克重和/或1和8mm 之间的厚度。第二内层20的至少一个表面、特别是面向织物层1的表面可以设置有黏合层21，其例如是与碳纤维混合的热塑丝线或黏合膜。
现在参照图13和图14，可以观察到，在方法的下一个步骤中，织物层1、第一内层16和第二内层20以及隔层17(如果存在)可以被第三真空袋22(例如，与第一真空袋13相同的真空袋)覆盖并通过抽出空气而被压紧到第一模具12上。同时，例如通过红外辐射器将层1、16和20加热到70°和90℃之间的温度，以通过黏合层21将第二内层20连接至隔层17。
现在参照图15和图16，可以观察到，在方法的下一个步骤中，织物层1、第一内层16和第二内层20以及隔层17(如果存在)被至少一个第二模具23 覆盖，使得层1、16和20在第一模具12和第二模具23之间至少位于通过放置在模具之间的至少一个周边密封件气密地封闭的空腔中。优选地，第二模具 23的功能表面是凹形的和/或由复合材料制成，特别是包含碳纤维。然后将模具12、23彼此固定并加热，例如在温度为45和90℃之间的烤炉中加热，之后通过至少一个第一喷嘴24将树脂和固化剂注入模具12、23之间，以浸渍层 1、16、20。同时，例如通过与RTM方法相同的方式，通过至少一个第二喷嘴 25从模具12、23中抽出空气。第一喷嘴24和/或第二喷嘴25优选至少定位在层1、16和/或20的一个边缘处，使得注入和/或抽气发生在与该边缘基本相切的方向上。
与通过第一喷嘴24注入的树脂混合的固化剂包括足以使该树脂聚合的第一数量的固化剂以及足以使施加在织物层1上的树脂3也聚合的第二数量的固化剂。优选地，注入模具12、23中的树脂与施加在织物层1上的树脂3相同，特别是环氧树脂，例如由亨斯迈公司制造的XB 3518树脂。优选地，第一数量和第二数量的固化剂包括与注入的树脂和树脂3相容的固化剂，特别是单胺固化剂，例如亨斯迈公司制造的
Figure GDA0003126581030000061
22962固化剂。
优选地，与注入的树脂混合的第一数量的固化剂按重量计为按重量计的注入的树脂的量的20％和30％之间，而用于树脂3的加入的第二数量的固化剂按重量计为第一数量的1.5％和55％之间。
现在参照图17和图18，可以观察到，在注入的树脂已浸渍层1、16和20 并由于注入的固化剂而进行了聚合且层1上的树脂3也由于注入的固化剂而进行了聚合之后，从模具12、23中取出包括织物层1、热塑膜7、一个或多个内层16、20以及至少一个隔层17(如果需要)的成品部件26，并对其精加工以供使用。
在不脱离所附权利要求的范围的情况下，本领域的专家可以对本文示出和描述的实施方式做出变型或补充。特别地，另外的实施方式可以包括一个或多个所附权利要求的技术特征，其额外具有单独或以任何组合方式考虑的文本中描述的或附图中示出的一个或多个技术特征。

Claims (28)

1.一种用于生产由复合材料制成的产品的方法，其特征在于，包括以下操作步骤：
-在第一模具(12)和至少一个第二模具(23)之间放置至少一个复合材料纤维织物的织物层(1)和至少一个复合材料纤维的第一纤维层(16)，其中在所述织物层(1)和所述第一模具(12)之间放置不含固化剂的非聚合的复合材料的树脂层(3)，所述树脂层(3)与所述第一模具(12)接触；
-将树脂和固化剂注入所述第一模具(12)和所述第二模具(23)之间，以用注入的所述树脂浸渍所述织物层(1)和所述第一纤维层(16)，并用注入的所述固化剂使注入的所述树脂和所述树脂层(3)聚合。
2.根据权利要求1所述的方法，其特征在于，在所述织物层(1)和所述第一纤维层(16)之间放置至少一个热塑膜(7)。
3.根据权利要求1或2所述的方法，其特征在于，在将所述树脂注入所述第一模具(12)和所述第二模具(23)之间之前，在所述第一纤维层(16)和所述第二模具(23)之间放置至少一个第二纤维层(20)，使得所述第二纤维层(20)也用注入的所述树脂浸渍。
4.根据权利要求3所述的方法，其特征在于，在将所述树脂注入所述第一模具(12)和所述第二模具(23)之间之前，在所述第一纤维层(16)和所述第二纤维层(20)之间放置至少一个隔层(17)。
5.根据权利要求1或2所述的方法，其特征在于，在将所述织物层(1)放置在所述第一模具(12)上之前，在所述织物层(1)上施加所述树脂层(3)。
6.根据权利要求1或2所述的方法，其特征在于，注入到所述第一模具(12)和所述第二模具(23)之间的所述固化剂包括足以使注入的所述树脂聚合的第一数量的固化剂和足以使放置在所述织物层(1)上的所述树脂层(3)也聚合的第二数量的固化剂。
7.根据权利要求1或2所述的方法，其特征在于，在将所述树脂注入所述第一模具(12)和所述第二模具(23)之间之前，所述织物层(1)被第一真空袋(13)覆盖并通过抽出空气而被压紧到所述第一模具(12)上，其中所述第一真空袋(13)包括无孔的剥离膜(14)。
8.根据权利要求2所述的方法，其特征在于，在将所述树脂注入所述第一模具(12)和所述第二模具(23)之间之前，所述织物层(1)和所述第一纤维层(16)被第二真空袋(19)覆盖、被压紧到所述第一模具(12)上并被加热从而使所述热塑膜(7)压缩且至少部分地熔化，以将外部的所述织物层(1)连接至所述第一纤维层(16)。
9.根据权利要求1或2所述的方法，其特征在于，所述织物层(1)在被放置在所述第一模具(12)和所述第二模具(23)之间之前被加压。
10.根据权利要求1或2所述的方法，其特征在于，通过至少设置在所述织物层(1)的或所述第一纤维层(16)的一个边缘处的至少一个第一喷嘴(24)将所述树脂注入所述第一模具(12)和所述第二模具(23)之间，使得树脂注入发生在与所述边缘基本相切的方向上。
11.根据权利要求1或2所述的方法，其特征在于，当将所述树脂注入所述第一模具(12)和所述第二模具(23)之间时，通过至少设置在所述织物层(1)的或所述第一纤维层(16)的一个边缘处的至少一个第二喷嘴(25)从所述第一模具(12)和所述第二模具(23)中抽出空气，使得空气抽出发生在与所述边缘基本相切的方向上。
12.根据权利要求1或2所述的方法，其特征在于，注入所述第一模具(12)和所述第二模具(23)之间的所述树脂与施加在所述织物层(1)上的所述树脂层(3)相同。
13.根据权利要求3所述的方法，其特征在于，所述第一纤维层(16)或所述第二纤维层(20)包括一个或多个干碳纤维织物，所述干碳纤维织物具有1mm和8mm之间的厚度，和/或具有700g/m2和900g/m2之间的克重。
14.根据权利要求2所述的方法，其特征在于，所述热塑膜(7)包括尼龙、聚丙烯、ABS、PLA、聚碳酸酯或聚对苯二甲酸乙二醇酯的网片。
15.根据权利要求1或2所述的方法，其特征在于，所述织物层(1)包括具有基本均匀的织纹图案的干碳纤维织物。
16.根据权利要求1或2所述的方法，其特征在于，所述织物层(1)的厚度为0.2mm和0.3mm之间，和/或克重为230g/m2和260g/m2之间。
17.根据权利要求1或2所述的方法，其特征在于，所述树脂层(3)以所述织物层(1)的重量的2％和7％之间的量施加在所述织物层(1)上。
18.一种由包括经过聚合的树脂的复合材料制成的产品，所述产品由根据权利要求2所述的方法制造，其包括至少一个复合材料纤维织物的织物层(1)和至少一个复合材料纤维的第一纤维层(16)，其特征在于，至少一个热塑膜(7)放置在所述织物层(1)和所述第一纤维层(16)之间。
19.根据权利要求18所述的产品，其特征在于，所述第一纤维层(16)包括一个或多个干碳纤维织物，所述干碳纤维织物具有1mm和8mm之间的厚度，和/或具有700g/m2和900g/m2之间的克重。
20.根据权利要求18或19所述的产品，其特征在于，所述热塑膜(7)包括尼龙、聚丙烯、ABS、PLA、聚碳酸酯或聚对苯二甲酸乙二醇酯的网片。
21.根据权利要求18或19所述的产品，其特征在于，所述织物层(1)包括具有基本均匀的织纹图案的干碳纤维织物。
22.根据权利要求18或19所述的产品，其特征在于，所述织物层(1)的厚度为0.2mm和0.3mm之间，和/或克重为230g/m2和260g/m2之间。
23.一种用于生产复合材料产品的半成品，其包括至少一个复合材料纤维织物的织物层(1)，其特征在于，至少一个基本不含固化剂的非聚合的复合材料的树脂层(3)施加在所述织物层(1)的至少一个表面上，并且在所述织物层(1)的与设置有所述树脂层(3)的表面相对的表面上施加至少一个热塑膜(7)。
24.根据权利要求23所述的半成品，其特征在于，在所述树脂层(3)上可移除地施加保护片(5)。
25.根据权利要求23或24所述的半成品，其特征在于，所述热塑膜(7)包括尼龙、聚丙烯、ABS、PLA、聚碳酸酯或聚对苯二甲酸乙二醇酯的网片。
26.根据权利要求23或24所述的半成品，其特征在于，所述织物层(1)包括具有基本均匀的织纹图案的干碳纤维织物。
27.根据权利要求23或24所述的半成品，其特征在于，所述织物层(1)的厚度为0.2mm和0.3mm之间，和/或克重为230g/m2和260g/m2之间。
28.根据权利要求23或24所述的半成品，其特征在于，所述树脂层(3)以所述织物层(1)的重量的2％和7％之间的量施加在所述织物层(1)上。
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