CN111201132A - 制造面状复合构件的方法和由此制造的复合构件 - Google Patents

制造面状复合构件的方法和由此制造的复合构件 Download PDF

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CN111201132A
CN111201132A CN201880033414.0A CN201880033414A CN111201132A CN 111201132 A CN111201132 A CN 111201132A CN 201880033414 A CN201880033414 A CN 201880033414A CN 111201132 A CN111201132 A CN 111201132A
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layer
thermoplastic
core layer
cover
fibers
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CN201880033414.0A
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CN111201132B (zh
Inventor
B.贝瑟
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Mitsubishi Chemical Advanced Materials And Composite Materials Co
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Mitsubishi Chemical Advanced Material Plastic Composite Co
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Abstract

本发明涉及一种用于制造面状复合构件的方法，所述面状复合构件具有布置在两个覆盖层(A,A′)之间的并且材料接合地与所述覆盖层连接的芯层(B)，其中，所述覆盖层包含覆盖层热塑性塑料，并且其中，所述芯层包含芯层热塑性塑料，所述方法包括以下步骤：a)提供层顺序A‑B‑A′的经加热的叠置结构；b)挤压经加热的叠置结构(A‑B‑A′)；c)冷却经挤压的叠置结构，其中，面状复合构件由固结的并且材料接合地相互连接的层构成。为了改善面状的3D构件的制造方法以及可制造性而建议，至少一个以未固结形式的覆盖层(A,A′)包括纤维网材料层，所述纤维网材料层由10至100重量％的覆盖层热塑性塑料的热塑性塑料纤维和0至90重量％的增强纤维构成，所述纤维网材料层具有300至3000g/m2的单位面积重量；以未固结形式的芯层(B)包括至少一个由增强纤维和芯层热塑性塑料的热塑性塑料纤维构成的无定向纤维网材料层(D)，并且在挤压之后，固结的覆盖层具有小于5体积％的气孔含量并且固结的芯层具有20至80体积％的气孔含量。

Description

制造面状复合构件的方法和由此制造的复合构件
技术领域
本发明涉及一种用于制造面状复合构件的方法，所述面状复合构件具有布置在两个覆盖层之间的并且与所述覆盖层材料接合地连接的芯层。此外，本发明设计一种通过按照本发明的方法制造的面状复合构件及其应用。
背景技术
由纤维增强的热塑性塑料制成的复合构件越来越多地作为成型件应用在不同的技术领域中。
例如专利文献WO 2015/117799A1描述了一种具有泡沫芯的复合构件，在所述复合构件的表面上双侧地布置有与所述泡沫芯材料接合地连接的覆盖层。为了制造复合构件，对覆盖层和泡沫芯进行加热，之后将覆盖层定位在泡沫芯的表面上并且将整体置入压力机或者模具中，所述压力机或者模具印制出完成的复合构件。加热也可以在模具中才进行。接着将泡沫芯和覆盖层变形并且在确定的变形时间之后重新冷却，其中，在泡沫芯和覆盖层之间构成材料接合的连接。作为覆盖层，一方面描述了尤其是由铝制成的金属的覆盖层。备选地也描述了由纤维增强的塑料制成的覆盖层。由于覆盖层在变形步骤期间能够在泡沫芯的表面上移动，所述方法被证实针对制造具有复杂形状的非平面的复合材料尤其有利。
在专利文献WO 2006/133586 A1中描述了按照本发明所述类型的复合构件和用于制造所述复合构件的方法。所述专利文献涉及抗弯曲的复合板，所述复合板包括：
A.一个或者两个具有0.5至5mm的厚度的由玻璃纤维增强的聚丙烯制成的覆盖层，其具有20至60重量％的玻璃含量和低于5体积％的气孔含量，和
B.具有2至40mm的厚度的由玻璃纤维增强的聚丙烯制成的芯层，其具有35至80重量％的玻璃含量和20至80体积％的气孔含量。
在所述的制造方法中，提供多孔板作为所使用的芯层，其中，所述多孔板能够如专利文献WO 2006/105682 A1所描述的那样通过干式混合聚丙烯纤维和玻璃纤维、对混合纤维网进行针刺(vernadeln)以及热压来制造。提供传统的玻璃纤维毡-热塑性塑料板(通常称为“GMT板”)作为覆盖层。覆盖层以及芯层的增强纤维在制造抗弯曲的复合板之前就已经通过前置的加热和挤压过程被以热塑性塑料浸渍并且之后作为抗弯曲的板元件暂存。为了制造真正的复合板则将待压的层以板的形式提供、在压力机中相互叠置并且在180至220℃的温度下挤压5至50分钟。所述复合板尤其在建筑业中用作分隔壁或者模板元件，然而也在家具制造中用于代替压制板。
为了通过上述的其中提供已经固结的并且刚性的板作为覆盖层和芯层的方法制造抗弯曲的复合板，总共需要九个过程步骤，即：
-提供芯层：1)制造纤维网材料，2)在热压力机中(在压力和温度下)浸渍增强纤维，3)在冷压力机中固结；
-提供覆盖层：1)制造毡件，2)挤出，3)在热压力机中浸渍，4)在冷压力机中固结；
-制造复合板：1)在热压力机中加热覆盖层和芯层，2)冷却覆盖层和芯层。
专利文献DE 195 20 477 A1描述了纤维增强的GMT板，所述GMT板由于玻璃毡的回复力而在加热时膨胀并且包含分布不均匀的气泡。为了制造该GMT板首先制造相应的玻璃毡。接着用逐层地挤出的聚丙烯熔融物或者用聚丙烯膜在热压力机中浸渍所述玻璃毡并且接着在冷压力机中固结所述玻璃毡。这样制造的GMT板在固结之后在需要时重新加热，以便产生期望的膨胀。膨胀的GMT板可以作为支撑芯与覆盖层共同挤压成夹层成型件。在专利文献DE 195 20 477A1中描述的制造方法涉及将冷却至室温的并且因此凝固的支撑芯与形式为未膨胀的GMT膜的外部层共同热挤压。
为了通过专利文献DE 195 20 477A1的方法制造抗弯曲的复合构件甚至需要十二个过程步骤，即：
-提供芯层：1)制造毡件，2)在毡件上挤出熔融物层，3)在热压力机中(在压力和温度下)浸渍增强纤维，4)在冷压力机中固结，5)对固结的芯层进行加热，从而使所述芯层膨胀，6)冷却芯层；
-提供覆盖层：1)制造毡件，2)挤出，3)在热压力机中浸渍，4)在冷压力机中固结；
-制造复合板：1)加热覆盖层，2)将覆盖层与冷的芯层挤压；因此仅限于制造平坦的板，针对3D的部件必须先将芯在其它步骤中相应地变形并且接着与覆盖层挤压。
由此始终存在着针对其它的、尤其是抗弯曲的、面状的并且根据需求三维地成形的复合构件的需求或者对相应的、简单且经济的制造方法的需求。尤其期望的是用于制造其特性针对确定的应用明显改善的复合构件的方法。
发明内容
本发明所要解决的技术问题在于，提供一种用于制造面状复合构件的方法。本发明所要解决的其它技术问题在于，提供相应的复合构件以及给出所述复合构件的用途。
所述技术问题通过由权利要求1定义的制造方法以及通过权利要求14定义的面状复合构件和权利要求16定义的所述复合构件的应用解决。
以下阐述并且在从属权利要求中定义本发明的有利的设计方案。
按照本发明的用于制造面状复合构件的方法，所述复合构件具有布置在两个覆盖层(A,A′)之间的并且材料接合地与所述覆盖层连接的芯层(B)，其中，所述覆盖层包含覆盖层热塑性塑料，并且其中，所述芯层包含芯层热塑性塑料，所述方法包括以下步骤：
a)提供两个覆盖层和芯层的相应的坯料并且由所述坯料按照A-B-A′的层顺序构成叠置结构，所述叠置结构被加热至既高于覆盖层热塑性塑料的熔化温度也高于芯层热塑性塑料的熔化温度的温度；
b)挤压经加热的叠置结构(A-B-A′)；
c)冷却经挤压的叠置结构，其中，面状复合构件由固结的并且材料接合地相互连接的层构成。
通过:
-在步骤a)中以未固结的柔性形式提供两个覆盖层(A,A′)的最初提供的坯料，其中，至少一个覆盖层(A)包括未固结的柔性的纤维网材料层(C)，所述纤维网材料层(Faservliesstoffschicht)由10至100重量％的覆盖层热塑性塑料的热塑性塑料纤维和0至90重量％的增强纤维构成，所述纤维网材料层具有300至3000g/m2的单位面积重量，和
-在步骤a)中，芯层(B)的最初提供的坯料包括至少一个由增强纤维和芯层热塑性塑料的热塑性塑料纤维构成的无定向纤维网材料层(D)，所述无定向纤维网材料层(Wirrfaservliesstoffschicht)具有500至10000g/m2的单位面积重量，和
-在步骤c)之后，固结的覆盖层具有小于5体积％的气孔含量并且固结的芯层具有20至80体积％的气孔含量，
从按照本发明的方法中由此得出不同的优点。
按照本发明的方法尤其能够制造特殊地成型的、非平面的面状构件(也称为“3D构件”)。通过提供的具有纤维网材料柔性层的覆盖层和芯层的高悬垂性(Drapierbarkeit)，还能够实现高的变形程度。
此外，按照本发明的方法能够以工艺经济的方式、即有利地通过短的过程持续时间和/或通过相对较低的能量需求进行浸渍。在按照本发明的方法中，在构件制造时才进行增强纤维的热塑性塑料浸渍。因此相对于专利文献WO 2006/133586 A1和专利文献DE 19520 477 A1需要明显更少的过程步骤，即仅三个步骤:
-提供芯层：1)制造无定向纤维网材料；
-提供覆盖层：1)制造纤维网材料，优选用织物；
-制造复合构件：1)(在一个步骤中)在可变温挤压模具中加热和冷却。
按照本发明的面状复合构件由于其层状的结构也被称为“夹层构件”。这种构件可以构造为平面的或者弯曲的板，也可以构造为具有不同厚度和形变程度的构件。
术语“相应的坯料”在本发明上下文中应当在待制造的复合构件的尺寸方面进行理解。即用于其中一个覆盖层的材料的“相应的坯料”基本上具有复合构件的长度和宽度。这对于用于芯层的材料的“相应的坯料”同样适用，然而其中，还应当考虑或者应当已经置入在一些实施方式中规定的附加的结构层。此外，术语“坯料”并不一定意味着单件式提供。
术语“最初提供”在本发明上下文中尤其针对步骤a)。所述步骤a)从最初提供的材料出发形成加热的叠置结构A-B-A′，其中，这在原则上能够如以下仍将阐述的那样以不同的方式实现。
术语“固结”在上下文中针对按照本发明规定的挤压步骤。因此“固结”并不强制地理解为“完全固结”或者“无气孔的”，而是理解为由于在热的状态中进行挤压产生的状态。
而术语“以未固结的形式”理解为对于起始材料的参考状态，在所述参考状态中尚未发生热塑性基体的实质性形成。
术语“覆盖层热塑性塑料”和“芯层热塑性塑料”原则上理解为表示用来形成存在于相关的层中的热塑性塑料纤维的热塑性塑料。这并不一定意味着热塑性塑料纤维在给定的层中必须仅由一种热塑性塑料材料构成。尤其也可以使用由不同的、但是兼容的热塑性塑料构成的混合纤维。“兼容”理解为能够实现材料接合式连接的热塑性塑料。同样不排除的是，在两个覆盖层A和A′中使用两种不同的覆盖层热塑性塑料。
不言而喻的是，在按照步骤b)的挤压方面，术语“加热”理解为存在适用于热塑性变形的温度。因此应当将所有设置用于变形的热塑性塑料区域加热至略高于相应的热塑性塑料熔化温度的温度。
根据使用的热塑性塑料材料，在约180℃(例如使用聚丙烯时)至约400℃(例如使用聚醚醚酮时)的温度范围中并且在0.5至5bar的压力范围中进行挤压。变模温地(在相同的模具中加热和挤压)进行加工或者通过预先在接触炉、红外线炉具或者空气循环加热炉中加热并且接着在模具中挤压来进行加工。
按照本发明，以未固结的柔性的形式提供两个覆盖层(A,A′)的最初提供的坯料。至少一个覆盖层(A)的最初提供的坯料包括未固结的柔性的纤维网材料层(C)，所述纤维网材料层由10至100重量％的覆盖层热塑性塑料的热塑性塑料纤维和0至90重量％的增强纤维构成，其中，所述纤维网材料层(C)作为整体具有300至3000g/m2的单位面积重量。如果这仅适用于两个层A和A′的其中一个，则该层在没有普遍性的约束的情况下定义为层A。在最后提到的情况下，另外的层A′包括例如包含热塑性塑料纤维并且必要时包含增强纤维的构成物，所述构成物同样以未固结的柔性的形式提供。
按照本发明的以未固结形式的芯层(B)与专利文献WO 2006/133586 A1中使用的泡沫芯不同地包括至少一个由增强纤维和热塑性塑料纤维构成的无定向纤维网材料层(D)。这种层也被称为“无纺织物(Nonwovens)”。
此外，按照本发明规定，在挤压之后，固结的覆盖层具有小于5体积％的气孔含量并且固结的芯层具有20至80体积％的气孔含量。由此产生耐抗的、相对硬且刚性的外层和蓬松的、隔音且隔热的具有相对较低密度的内层。与之相应地，这些构件对于规定的刚度来说相对较轻。
以上提到的结构基本上如下产生，即在挤压先前提供的加热的叠置结构时，固结过程首先主要在靠近边缘的层A中并且必要时在层A′中进行，而在芯层的区域中由于无定向纤维层的回复力而发生较小程度的固结。
在挤压的构件中，覆盖层具有0.1至10mm的厚度，而芯层具有0.5mm至50mm的厚度。由无纺织物构成的芯层和覆盖层优选具有相同的或者兼容的基体，从而材料接合地并且没有附加的粘合膜或者粘合剂的情况下实现附着。
在芯层中使用的由作为基体的热塑性塑料纤维和可选地增强纤维构成的无定向纤维网材料层的优点在于，所述无定向纤维网材料层是柔性的并且能够具有远远大于在挤压的构件中的最终厚度的厚度(4倍、8倍、必要时甚至直到10倍)。在夹层制造中，由无纺织物制成的芯层被挤压成最终的厚度。与泡沫材料相反，在按照本发明的方法中不存在以下风险，即由无纺织物构成的芯在温度和压力的加载下萎缩并且由此无法达到要求的厚度。这如下实现，即无纺织物的增强纤维在挤压过程中在压力和温度下沿着z方向(即垂直于层面)产生抵抗力，所述抵抗力呈现为“膨胀力”。通过在整个挤压过程中始终存在的“膨胀力”能够实现的厚度高达完全固结的厚度的4倍(未萎缩)。
在一种有利的实施方式(权利要求2)中，对在步骤a)中提供的芯层(B)的无定向纤维网材料层(D)进行针刺(genadelt)，由此能够沿着z方向进一步增强在专业术语中也被称为“蓬起(Loft)”的回复效应。在此能够根据纤维含量、纤维长度和针刺参数影响纤维的膨胀力。
原则上存在一系列的被证实的热塑性塑料可供按照本发明的方法使用，所述热塑性塑料的选择属于专业知识的领域。按照一种有利的实施方式(权利要求3)，覆盖层热塑性塑料和芯层热塑性塑料各自独立地选自聚丙烯(PP)、聚醚酰亚胺(PEI)、聚醚醚酮(PEEK)、聚苯硫醚(PPS)、聚酰胺(PA)、聚芳醚酮(PAEK)、聚醚酮酮(PEKK)和聚碳酸酯(PC)。
针对增强纤维的选择也可使用整个系列的被证实的纤维材料。按照一种有利的实施方式(权利要求4)，增强纤维选自碳纤维、玻璃纤维、芳纶纤维、玄武岩纤维和高熔点的热塑性塑料纤维。术语“高熔点的热塑性塑料纤维”是由热塑性塑料构成的纤维，所述热塑性塑料具有高于在按照本发明的加热过程和挤压过程中使用的工作温度的熔点。
不言而喻的是，热塑性塑料和纤维材料的选择，并且相应地热塑性塑料和纤维材料的组合较大程度地被待制造的构件的应用领域所影响。
按照该方法(权利要求5)的一种有利的实施方式，在步骤a)中，将两个覆盖层(A,A′)和芯层(B)的提供的坯料在冷的状态中按照A-B-A′的层顺序相互叠置并且将这样构成的叠置结构(A-B-A′)加热至既高于覆盖层热塑性塑料的熔化温度又高于芯层热塑性塑料的熔化温度的温度。在这种实施方式中，从冷的坯料出发首先构造叠置结构A-B-A′并且整体地加热。接着将加热的叠置结构在步骤b)中在压力模具中挤压并且在步骤c)中冷却。根据待制造的构件的期望的形状选择压力模具的形状。针对这种实施方式，覆盖层热塑性塑料和芯层热塑性塑料必须相互兼容，由此能够在适宜的温度范围中同时实现所述覆盖层热塑性塑料和芯层热塑性塑料的热塑性变形。为了执行所述方法例如可以使用组合的加热、挤压和冷却站(所谓的变模温工艺)。然而也可行的是，在独立的接触式加热站中进行加热过程并且在后置的挤压装置中接着进行挤压和冷却。按照所述方法的一种有利的扩展设计(权利要求6)，覆盖层热塑性塑料和芯层热塑性塑料是相同的。由此能够在没有附加的粘合膜或者粘合剂的情况下形成各个单独的层之间的材料接合的相互附着。
业已证明了基于作为热塑性塑料的聚丙烯和作为增强纤维材料的玻璃的成本低廉并且可靠的材料组合。PEEK或者PEI作为热塑性塑料并且碳纤维作为增强纤维材料呈现为在机械方面具有出色的特性和相对较低的重量的高价值材料组合。碳纤维也提供了更强的回复力、即更强的蓬起效应(Loft-Effekt)的优点，这有助于制造具有高多孔性的芯层的构件。
按照方法的另一种有利的实施方式(权利要求7)，在步骤a)中，将芯层(B)以及两个覆盖层(A,A′)的坯料各自独立地加热至高于有关热塑性塑料的熔化温度的温度并且之后以经加热的形式按照A-B-A′的层顺序相互叠置。在这种情况下也构成经加热的叠置结构(A-B-A′)。由于独立的加热过程，不同的层能够被加热至不同的温度，这尤其在使用不同的芯层热塑性塑料和覆盖层热塑性塑料时可能是必要的。
不言而喻的是，在所有实施方式中，必须立即进行经加热的叠置结构的挤压，也就是说不允许发生热塑性塑料提前凝固。与之对应地在最后提及的实施方式中优选针对独立地加热覆盖层和芯层设置各自的加热站，以便实现同时运行。
按照一种有利的实施方式(权利要求8)，至少一个以未固结形式的覆盖层(A)具有与纤维网材料层(C)针刺在一起、缝制在一起或者热连接的织物层或者叠片层(Gelegeschicht)(E)，其单位面积重量为100至2000g/m2。专利文献WO 2006/111037中描述了这种层材料并且所述层材料例如以“Q-Tex”的名称已知。按照该方法的一种有利的扩展设计(权利要求9)，至少一个覆盖层(A)具有多个由不同的增强纤维材料构成的织物层或者叠片层(E1、E2等等)。例如可以为第一层配设碳纤维，为第二层配设芳纶纤维并且为第三层配设玻璃纤维。覆盖层也可以由多个具有不同取向的层构成，以便实现在刚度和可延展性方面与载荷相符的结构。例如可以设置具有+45°或者+45°取向的叠片每种玻璃纤维和具有单向玻璃纤维的另一层。
按照另一种有利的实施方式(权利要求10)，以未固结形式的芯层(B)具有至少一个其它的、与无定向纤维网材料层(D)邻接的结构层(F)，其中，尤其可能涉及其它的具有不同的增强纤维份额的无定向纤维网材料层或者也可能涉及蜂窝材料层或者泡沫材料层。在一些变型方案中，结构层由热塑性塑料、尤其由芯层热塑性塑料构成。按照一种扩展设计(权利要求11)，仅在选出的芯层区域中设置结构层(F)。在其它实施方式中，结构层使用具有更高的熔点的材料、例如铝或者
Figure BDA0002280946390000081
通过前述能够单独地或者组合地实行的措施能够实现构件的局部特性的显著的、定制的变化。
按照所述方法的一种有利的实施方式(权利要求12)，在非平面的挤压模具中进行经加热的叠置结构的挤压。由此能够制造不同类型的三维结构化的面状复合构件。
本发明的另一方面(权利要求13)普遍地涉及一种面状复合构件，所述复合构件具有布置在两个覆盖层(A,A′)之间的并且材料接合地与所述覆盖层连接的芯层(B)，其中，所述复合构件通过按照本发明的方法制造。按照一种有利的设计方案(权利要求14)，一致地使用PEEK作为覆盖层热塑性塑料和芯层热塑性塑料，并且增强纤维是碳纤维，其中，覆盖层(A,A′)具有1.0至2.0g/cm3、尤其是1.3至1.8g/cm3的密度，芯层(B)具有0.2至1.0g/cm3、尤其是0.3至0.6g/cm3的密度。按照另一种实际方案(权利要求15)，一致地使用PEI作为覆盖层热塑性塑料和芯层热塑性塑料。
按照本发明的面状复合构件具有多种应用领域。按照本发明的一个方面(权利要求16)，按照本发明的复合构件用于航空或者交通工具制造。
附图说明
以下根据附图详细阐述按照本发明的实施例，在附图中：
图1在示意性的、立体的视图中示出了第一面状复合构件；
图2在示意性的剖视图中示出了未固结的覆盖层的设计方案；
图3在示意性的、立体的视图中示出了第二面状复合构件；
图4在示意性的、立体的视图中示出了第三面状复合构件；
图5在示意性的、立体的视图中示出了第四面状复合构件；
图6在示意性的、立体的视图中示出了用于加工层叠置结构的组合的加热装置、挤压装置和冷却装置；
图7在示意性的、立体的视图中示出了具有加热站和后置的用于加工层叠置结构的挤压装置和冷却装置的装置；并且
图8在示意性的、立体的视图中示出了具有分开的用于多个单独的层的加热站和后置的用于加工层叠置结构的挤压装置和冷却装置；
具体实施方式
在附图1至5中示出的面状复合构件仅为了阐明层状结构而呈现为沿着纵向错开的层。而在实际应用中，多个单独的层棱边始终是对齐的。此外，图1至图5应当仅示出基本的层状结构而非示出层的相对的厚度。与之对应地，在图1至图5中示出的布置结构原则上既适用于分别提供的层叠置结构，也适用于在挤压过程之后产生的复合构件。
在图1中示出的复合构件具有布置在两个覆盖层A和A′之间的芯层B。
图2示出了覆盖层A的一种可行的设计方案。在最初提供的形式中，所述覆盖层A包括纤维网材料层C以及与所述纤维网材料层C针刺在一起的由增强纤维构成的织物层E。例如可以通过将层C和E贴靠并针刺来制造这种层，其中，在针刺时纤维网纤维C的一部分被增强纤维层E穿透。与之相应地，增强纤维层E在两侧由纤维网纤维C包围。
在图3中所示的复合构件中，两个覆盖层A和A′的每一个都由两个具有不同的增强纤维材料的织物层E1和E2构成。
在图4中所示的复合构件中，以未固结形式的芯层B在两侧具有布置在无定向纤维网材料层D的内部中的结构层F，所述结构层是形式为具有不同的增强纤维份额的蜂窝板或者无定向纤维层。在所示的示例中，结构层在整个面上构造并且因此夹层状地嵌入两个无定向纤维层之间。
在图5中所示的复合构件中，结构层F仅存在于芯层B的选出的区域中。如图5所示，在结构层F的所示的示例中，所述结构层作为居中的条带布置在芯层B的内部并且分别嵌入上部和下部的无定向纤维网材料层D1和D2之间并且嵌入侧向的无定向纤维网材料层D3和D4之间。
在制造方法的一种实施方式中，如图6所示的那样将先前提供的冷的层叠置结构导入组合的加热、挤压和冷却装置2中并且在那里加热并且挤压成面状复合构件。
在另一种实施方式中，如图7所示的那样将先前提供的柔性的冷的层叠置结构A-B-A′导入接触式加热装置4中并且在那里加热。接着将这样形成的经加热的层叠置结构在挤压装置6中挤压成面状复合构件。
在另一种实施方式中，如图8所示的那样将以未固结形式的芯层(B)导入第一加热装置4a中并且在那里加热，所述芯层在所示的示例中由多个层组成。基本上同时将以未固结形式的覆盖层A导入第二加热装置4b中并且同样在那里加热。另一个未示出的覆盖层A′或者在第三加热装置中或者直接地接着同样在第二加热装置4b中加热。由这样形成的经加热的覆盖层和芯层构成热的叠置结构A-B-A′，所述叠置结构接着在挤压装置6中挤压成面状复合构件。通过使用分开的加热装置可以一方面针对芯层B并且另一方面针对覆盖层A和A′使用不同的加热温度。这使得能够在芯层和覆盖层中使用不同的热塑性塑料材料。
例1：对最大的纤维份额和厚度的说明
以下表格示出了针对作为热塑性塑料的PP和PEEK以及作为增强纤维的玻璃纤维(GF)和碳纤维(CF)的不同组合的有关数量的总览：
表1
Figure BDA0002280946390000111
其中，使用以下计算基本原理
体积份额：
Figure BDA0002280946390000112
其中，
VF 纤维的体积份额
WF 纤维的重量份额
WP 聚合物的重量份额
DF 纤维的密度(kg/m3)
DP 聚合物的密度(kg/m3)
密度：
Figure BDA0002280946390000121
其中：
DC 复合材料的密度(kg/m3)
厚度：
Figure BDA0002280946390000122
其中：
tC 复合材料的厚度(m)
AC 复合材料的单位面积重量
应当指出的是，纤维的体积份额出于几何方面的原因在正方形的排布结构中最大为79％并且在六边形的排布结构中最大为91％。在上述表1中以75％为最大的纤维体积份额。
例2：具有恒定厚度的复合构件
制造层状结构A-B-A的按照本发明的抗弯曲的复合构件。两个覆盖层A分别由纤维网材料坯料构成，所述纤维网材料坯料具有碳纤维织物和具有440g/m2的单位面积质量的PEI热塑性塑料纤维。芯层B由总共四个无定向纤维网材料的层提供，所述无定向纤维网材料由碳纤维和具有4×500g/m2的单位面积质量的PEI热塑性塑料构成。
由此制造的非平面的抗弯曲的复合构件具有约4mm的厚度、1880g/m2的单位面积重量和0.7g/m3的密度。
例3：具有不同薄厚区域的复合构件
制造层状结构A-B-A的按照本发明的抗弯曲的复合构件。两个覆盖层A分别由纤维网材料坯料构成，所述纤维网材料坯料具有碳纤维织物和具有440g/m2的单位面积质量的PEI热塑性塑料纤维。芯层B由总共四个无定向纤维网材料的层提供，所述无定向纤维网材料由碳纤维和具有7×500g/m2的单位面积质量的PEI热塑性塑料构成。
由此制造的抗弯曲的具有厚度不同的区域的复合构件在较强地固结的区域中具有约3.5mm的厚度并且在较少地固结的区域中具有约8mm的厚度。单位面积重量为4380g/m2并且密度在较强地固结的区域中为1.26g/m3或者在较弱地固结的区域中为0.55g/m3。
例4：材料检测的结果
以下表格示出了各种按照本发明的复合构件的测得的机械特性。
表2
Figure BDA0002280946390000131
*)具有CF织物和PEI基体的覆盖层A，由CF无定向纤维和PEI基体构成的芯层。

Claims (16)

1.一种用于制造面状复合构件的方法，所述面状复合构件具有布置在两个覆盖层(A,A′)之间的并且材料接合地与所述覆盖层连接的芯层(B)，其中，所述覆盖层包含覆盖层热塑性塑料，并且其中，所述芯层包含芯层热塑性塑料，并且其中，所述方法包括以下步骤：
a)提供两个覆盖层和芯层的相应的坯料并且由所述坯料按照A-B-A′的层顺序构成叠置结构，所述叠置结构被加热至既高于覆盖层热塑性塑料的熔化温度又高于芯层热塑性塑料的熔化温度的温度；
b)挤压经加热的叠置结构(A-B-A′)；
c)冷却经挤压的叠置结构，其中，面状复合构件由固结的并且材料接合地相互连接的层构成；
其特征在于，
-在步骤a)中以未固结的柔性形式提供两个覆盖层(A,A′)的最初提供的坯料，其中，至少一个覆盖层(A)包括未固结的柔性的纤维网材料层(C)，所述纤维网材料层由10至100重量％的覆盖层热塑性塑料的热塑性塑料纤维和0至90重量％的增强纤维构成，所述纤维网材料层具有300至3000g/m2的单位面积重量，并且
-在步骤a)中，芯层(B)的最初提供的坯料包括至少一个由增强纤维和芯层热塑性塑料的热塑性塑料纤维构成的无定向纤维网材料层(D)，所述无定向纤维网材料层具有500至10000g/m2的单位面积重量，并且
-在步骤c)之后，固结的覆盖层具有小于5体积％的气孔含量并且固结的芯层具有20至80体积％的气孔含量。
2.根据权利要求1所述的方法，其中，芯层(B)的在步骤a)中提供的无定向纤维网材料层(D)被针刺。
3.根据权利要求1或2所述的方法，其中，覆盖层热塑性塑料和芯层热塑性塑料各自独立地从PP、PEI、PEEK、PPS、PA、PEAK、PEKK和PC中选择。
4.根据权利要求1至3之一所述的方法，其中，增强纤维从碳纤维、玻璃纤维、芳纶纤维、玄武岩纤维和高熔点的热塑性塑料纤维中选择。
5.根据权利要求1至4之一所述的方法，其中，在步骤a)中，两个覆盖层(A,A′)和芯层(B)的坯料在冷的状态中按照A-B-A′的层顺序相互叠置并且这样构成的叠置结构(A-B-A′)被加热至既高于覆盖层热塑性塑料的熔化温度又高于芯层热塑性塑料的熔化温度的温度，其中，构成经加热的叠置结构(A-B-A′)，以便接着进行挤压步骤b)。
6.根据权利要求5所述的方法，其中，所述覆盖层热塑性塑料和芯层热塑性塑料是相同的。
7.根据权利要求1至4之一所述的方法，其中，在步骤a)中，将芯层(B)以及两个覆盖层(A,A′)的坯料各自独立地加热至高于有关热塑性塑料的熔化温度的温度并且之后以经加热的形式按照A-B-A′的层顺序相互叠置，其中，构成加热的叠置结构(A-B-A′)，以便接着进行挤压步骤b)。
8.根据权利要求1至7之一所述的方法，其中，至少一个以未固结形式的覆盖层(A)具有与纤维网材料层(C)针刺在一起、缝制在一起或者热连接的由增强纤维构成的织物层或者叠片层(E)，所述织物层或者叠片层(E)的单位面积重量为100至2000g/m2。
9.根据权利要求8所述的方法，其中，至少一个覆盖层(A)具有多个由不同的增强纤维材料构成的织物层或者叠片层(E1、E2等)。
10.根据权利要求1至9之一所述的方法，其中，以未固结形式的芯层(B)具有至少一个其它的、与无定向纤维网材料层(D)邻接的结构层(F)、尤其是其它的具有不同的增强纤维份额的无定向纤维网材料层或者蜂窝材料层或者泡沫材料层。
11.根据权利要求10所述的方法，其中，仅在芯层的选出的区域中设置所述结构层(F)。
12.根据权利要求1至11所述的方法，其中，在非平面的挤压模具中进行经加热的叠置结构(A-B-A′)的挤压。
13.一种面状复合构件，具有布置在两个覆盖层(A,A′)之间的并且材料接合地与所述覆盖层连接的芯层(B)，其中，所述复合构件通过按照前述权利要求之一所述的方法制造。
14.根据权利要求13所述的面状复合构件，其中，所述覆盖层热塑性塑料和芯层热塑性塑料是PEEK，并且其中，增强纤维是碳纤维，并且其中，覆盖层(A,A′)具有1.0至2.0g/cm3、尤其是1.3至1.8g/cm3的密度，并且芯层(B)具有0.2至1.0g/cm3、尤其是0.3至0.6g/cm3的密度。
15.根据权利要求13所述的面状复合构件，其中，所述覆盖层热塑性塑料和芯层热塑性塑料是PEI，并且其中，增强纤维是碳纤维，并且其中，覆盖层(A,A′)具有1.0至2.0g/cm3、尤其是1.3至1.8g/cm3的密度，并且芯层(B)具有0.2至1.0g/cm3、尤其是0.3至0.6g/cm3的密度。
16.一种按照前述权利要求之一所述的面状复合构件在航空或者交通工具制造中的应用。
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