CN116600729A - 用于制造纤维增强制品的方法和设备 - Google Patents

用于制造纤维增强制品的方法和设备 Download PDF

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Publication number
CN116600729A
CN116600729A CN202080107444.9A CN202080107444A CN116600729A CN 116600729 A CN116600729 A CN 116600729A CN 202080107444 A CN202080107444 A CN 202080107444A CN 116600729 A CN116600729 A CN 116600729A
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China
Prior art keywords
preform
fibre
forming
piston
compression
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CN202080107444.9A
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English (en)
Inventor
米可·胡托宁
维萨·武奥里萨罗
哈里·黑诺
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Arctic Biomaterials Oy
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Arctic Biomaterials Oy
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Publication of CN116600729A publication Critical patent/CN116600729A/zh
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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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
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    • A61B17/58—Surgical instruments or methods for treatment of bones or joints; Devices specially adapted therefor for osteosynthesis, e.g. bone plates, screws, setting implements or the like
    • A61B17/68—Internal fixation devices, including fasteners and spinal fixators, even if a part thereof projects from the skin
    • A61B17/84—Fasteners therefor or fasteners being internal fixation devices
    • A61B17/86—Pins or screws or threaded wires; nuts therefor
    • A61B17/866—Material or manufacture
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L31/00—Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
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    • A61L31/125—Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix
    • A61L31/129—Composite materials, i.e. containing one material dispersed in a matrix of the same or different material having a macromolecular matrix containing macromolecular fillers
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

一种形成纤维增强制品的方法，包括以下步骤：101)提供包括热塑性聚合物基体和增强纤维的复合材料预成型件(1)，其中，预成型件(1)包括初始体积和初始纤维取向；102)将预成型件装载在径向模制设备内，该径向模制设备包括至少三个相邻模件块(2)，这些模件块(2)彼此紧邻从而在初始位置形成具有初始体积的模腔(3)；103)通过移动模件块(2)来模制预成型件(1)，模件块(2)在初始位置和移动以及压缩位置期间彼此直接接触，并且垂直于预成型件(1)的公共纵向轴线(A)，其中，模腔(3)的初始体积减小且模件块(2)将预成型件(1)压缩到由处于压缩位置的模腔(3)限定的具有最终体积的形式，该最终体积小于或等于预成形件(1)的初始体积；104)打开模腔(3)；以及105)将所获得的具有定制的纤维取向的纤维增强制品(6)从模腔(3)中移出，其中，连续增强纤维遵循所述制品(6)的表面轮廓。

Description

用于制造纤维增强制品的方法和设备
技术领域
本发明涉及用于制造纤维增强制品的设备和方法，更具体地，涉及一种具有定制多向纤维取向的纤维增强制品。
背景技术
复合型材料(也称为复合材料)是在宏观层面上混合或结合的两种或更多种材料的组合。它们用于纯材料无法提供所需特定性能的工程应用中。它们可以被认为是一种通过添加另一种材料而得以增强的单一材料。
纤维被添加作为增强手段并为该复合材料提供强度、刚度或任何其他所需的性能。与上述布置相关的问题之一是如何在制造阶段期间保持复杂形状的制品所需的多向纤维取向。
发明内容
因此，本发明的目的是提供一种方法来解决与制造具有所需纤维取向的制品有关的上述问题。根据最终产品的要求，所需的纤维取向可以只是简单的单轴取向或复杂的多层多向取向。本发明的目的通过特点在于在独立权利要求中所述的内容的方法和设备来实现。在从属权利要求中公开了本发明的优选实施方式。
本发明基于使用从模腔径向模制并形成包括定制纤维取向的纤维增强制品的理念，其中，连续增强纤维遵循所述制品的表面设计。
附图说明
在下文中，将参照附图、借助优选实施方式更详细地描述本发明，在附图中：
图1是根据一个实施方式的方法的流程图；
图2和图3示出了示例性的模件块；
图4示出了一种示例性的复合材料预制件；
图5a-图5f示出了一系列利用活塞的示例性制造步骤；以及
图6示出了示例性制造步骤的替代步骤。
具体实施方式
本发明聚焦于纤维增强热塑性聚合物复合材料，其特别适用于诸如骨螺钉和骨紧固件之类的医疗器械。所述医疗器械通常由不锈钢或钛合金制成。然而，这些材料往往具有某些挑战，诸如与骨组织的机械性能的机械失配，这可能会引起进一步的挑战，诸如应力遮挡。金属植入物也可能在诸如MRI之类的成像中引起干扰。这促使工程师们寻找能够满足所需效果和性能的替代材料。
其中一种替代方案是纤维增强聚合物复合材料。这种类型的复合材料由增强纤维和围绕这些纤维的热塑性聚合物基体材料的组合构成。纤维为在没有增强的情况下会缺乏某些应用所需的机械性能的原本粘弹性聚合物增加了强度和刚度。纤维和基体协同工作，从而提供了一种具有受益于这两种元素贡献的特性的复合材料。
纤维被添加作为一种增强手段并为复合材料提供强度、刚度或任何其他所需的性能。基体将纤维结合在一起，保护纤维免受损伤，并将载荷从一根纤维分散到另一根纤维。复合材料的性能由纤维的性能、纤维的长度、直径、取向和数量、以及基体的性能和基体与纤维之间的结合决定。当使用增强纤维时，纤维可以是短切的和/或连续的。
当排列连续纤维时，这些纤维沿排列方向提供最大强度。复合材料沿其他方向可能相当弱，并因此可能具有高度地各向异性。这种各向异性可以通过沿所需方向(即纤维取向)排列的纤维来克服。
与上述布置相关的问题之一是如何在制造阶段期间保持复杂形状的制品所需的纤维取向。在层压式平面结构上，这可以通过在不同层上按所需纤维取向排列纤维或通过选择具有所需纤维取向的预制片材而容易地克服。如果所制造的纤维增强制品是简单的旋转对称物体，则可以通过纤维缠绕来实现所需的纤维取向。在更复杂的形状上，可以通过诸如自动胶带放置和/或自动纤维放置之类的自动复合材料制造技术来制造所需的纤维取向。然而，如果要在需要在工业规模上大规模生产的小尺寸产品上制造复杂的纤维取向，则优选的制造技术包括压缩模制和注射模制。
在传统的压缩模制期间，预成型件的纤维取向会发生变化，或者在某些几何形状的制品上保持预成型件的纤维取向是相当具有挑战性的。在平面结构上保持所需的纤维取向在某种程度上是简单的，但更复杂的几何形状不那么容易用可预测的纤维取向复现出。例如，当压缩模制旋转对称的实心物体时，在压缩预成型件来模制限定制品的最终形状时，预成型件的形状变换沿着物体的表面是不均匀的。因此，由于不均匀的形状变换，预成型件的初始纤维取向在不同的截面上以不同的量扭曲、挪移和/或打乱。
在注射模制时，可以通过使用包含具有所需纤维取向的纤维的插入件来实现所制造制品的所需纤维取向。在注入填充模具的基体聚合物之前，将插入件放置在模具内，从而限定制品的最终形状。插入件的最大外部尺寸需要小于模具的最小外部尺寸，否则当模具闭合时，纤维插入件会在模具部件之间挤压在模具部件上，使得无法进行注射模制。
本发明涉及一种利用径向模制的连续纤维增强结构的成型方法。对于某些产品几何形状，通过该方法获得的连续纤维增强结构可以包括在每一层上具有限定的纤维取向的层结构，该层结构可以定制为具有所需性能。使用诸如压缩模制之类的传统方法，这种层结构和/或纤维取向在模制期间趋向于挪移和打乱，这使得最终产品的所需性能减弱，并且在某些情况下甚至使其变得无用。使用径向模制则因为在模具闭合期间的形状转变在径向上均匀地围绕预成型件的最长尺寸，所以可以定制/预测具有最终产品的所需纤维取向的构造/结构。理想情况下，纤维取向结构甚至可以在最终产品中保持不变，这最大化了所需性能的有益之处。这样的性能可以是例如韧性、刚度或任何其他期望的机械性能。
图1示出了根据一个实施方式的形成纤维增强制品的方法的流程图。第一步骤101包括提供由热塑性聚合物基体和增强纤维构成的复合材料预成型件，其中，预成型件包括初始体积和初始纤维取向。预成型件可以是旋转对称的，并且包括混合的或互锁的层结构，该结构将被保持在最终制品中。预成型件还可以包括定制的纤维结构，其中，纤维最初位于分离且叠加的层中，并且在最下层的纤维结构上具有设计间隙，在具有间隙的层之上的层上具有额外的纤维。最上层上的这些额外纤维可以与最下层上的间隙位于相同的位置。因此，当径向压缩预成型件时，最上层上的额外纤维向芯件的方向移动并填充间隙，进而最终产品的纤维结构是在径向模制阶段期间产生的3D混合或互锁结构。每一层可以由相同或不同的材料构成，并且另外可以包括具有诸如例如90°、45°或30°等期望角度的螺旋取向。预成型件可以包含缠绕在具有不同螺旋、单轴等取向的多个层上的芯件或插入件。在某些结构中，不同层之间可以存在间隙，这将进一步促进最终制品中的纤维互锁。
热塑性材料是指当将其加热到一定的材料特定温度(例如，玻璃化转变温度、熔化温度等)时形状可以转变的材料。热塑性聚合物的某些材料特性(诸如结晶度、强度特性等)也可以作为温度和时间的函数而改变。当热塑性塑料被加热到某一温度(玻璃化转变温度Tg)时，它们会软化，并且它们的形状也会发生转变。半结晶和结晶的热塑性聚合物在被加热到它们的熔点(Tm)或高于熔点时会熔化。非晶态热塑性聚合物没有熔点。通常，热塑性聚合物在高于Tg或高于Tm的温度被模制。当被冷却到它们的玻璃化转变温度以下时，它们会固化成玻璃态。有许多不同类型的纤维可用于增强聚合物基体复合材料。最常见的是碳纤维(AS4、IM7等)和玻璃纤维(S-玻璃、E-玻璃等)。纤维预成型件通常以片材、连续的毡、管状结构或作为连续细丝或使用基体聚合物浸渍的连续细丝/带的形式制造。
第二步骤102包括手动地或通过机器自动地将预成型件装载在径向模制设备内。所述径向模制设备包括至少三个相邻的模件块，这些模件块彼此紧邻而形成在初始位置具有初始体积且在压缩位置具有最终体积的模腔，其中，该最终体积小于初始体积。模腔的最终体积也限定了最终的纤维增强制品的最终体积和形状。
每个模件块可以是相同的，诸如是具有平面的楔状，它们被布置成形成大致圆柱形的中心腔。然而，根据腔表面的设计，也可以形成其他形状。可以铰接并一起驱动楔块以改变腔的直径，从而改变腔的体积。模件块可以具有包括形成120°或更小角度的两个相邻侧面的任何设计。
第三步骤103包括通过移动所述模件块来模制预成型件。在模具的端部位置和移动期间，诸如打开和闭合以及在初始与压缩位置期间，各个模件块相互直接接触。在这一步骤期间，压缩朝向预成型件的纵向轴线施加类似或相同的径向力和变形。
径向模制是一种由可模制的连续纤维增强预成型材料沿着多个径向方向从初始体积到最终体积形成模制制品的技术。这些径向方向基本上垂直于公共纵向轴线，并且布置成位于不同的平面中。在这种情况下，公共纵向轴线是指预成型件沿其装载并垂直于压缩的轴线。
所述可移动径向模件块可同时在初始位置与最终压缩位置之间移动，所述初始位置和所述最终压缩位置分别限定了所述初始体积和所述最终体积。在压缩位置中的模腔体积可以小于或等于预成型件的体积。此外，预成型件的体积可以小于初始位置中的模腔体积，初始位置中的预成型件的横向尺寸可以大于压缩位置中的最终制品的横向尺寸。初始位置中的预成型件的横向尺寸也可以小于或等于压缩位置中的最终制品的横向尺寸，其中，预成型件从端部沿着预成型件的公共纵向轴线被额外地压缩。
线性或弯曲路径致动器可以用于在模件块的初始位置与压缩位置之间移动所述模件块。所述径向模件块可以沿着线性或弯曲路径移动，由此，在此期间，相邻的径向模件块之间的接合面可以是线性或弯曲的。
包括本发明中描述的至少三个模件块的径向模具也可以用作注射模制的模具。在注射模制中，如本发明所述地，径向打开的模具使得能够使用连续纤维插入件，这些插入件具有甚至比模制的最终产品大的初始直径。在传统模具的情况下，当模具打开时，模具部件(也称为模件)之间总是存在间隙，因此，由于模具闭合时插入件会被挤压在模具部件之间，将不可能使用这种较大直径的插入件。如果模具如本发明中所说明的那样径向打开和闭合，则不会发生这种挤压。这使得能够在包覆成型注射模制中使用这种连续纤维增强插入件，当在注射模制中使用任何其他类型的模具时，则不能使用这些连续纤维增强插入件。
第四步骤104包括通过使模件块返回到初始位置来打开模腔，其中，每个模件块在移动期间与相邻模件块直接接触。压缩和释放运动两者都可以通过致动器来致动，以迫使所述模件块在其初始位置与压缩位置之间移动。例如，所述致动器可以是附接到模件块的液压动力缸。模件块的操作可以由阀进行控制。可以同时连接动力缸以进行压缩，并且在压缩之后使流反向通过阀。
第五步骤105包括手动地或通过机器自动地从模腔移出所获得的纤维增强制品。最终制品包括定制的取向和层结构，其中，连续增强纤维遵循或符合所述制品的表面轮廓。初始纤维取向结构甚至可以在最终制品中保持不变，这最大化了所需性能的有益之处。所获得的制品包括所需性能，诸如更好的韧性以及压缩、扭转、抗冲击或任何其他所需性能。
在另一种实施方式中，该方法还包括加热步骤，其中，将预成型件加热到高于基体聚合物的玻璃化转变温度或熔化温度。加热预成型件促进了预成型件的成形性。所述加热步骤可以在模制步骤之前或在将预成型件装载到径向模制设备内之前布置在径向模制设备内部。在一些实施方式中，可以使用放置在压缩模件体中的所需位置内的加热元件来加热模件块，并将热量传递到位于模腔内的预成型件。然后通过传导将预成型件在模腔内冷却，或者在模制步骤之后通过任何合适的冷却手段(诸如空气冷却)将最终制品冷却。
在又一种实施方式中，在模制步骤之前、之后或期间，该方法还包括使至少一个活塞沿着预成型件的公共纵向轴线在模腔内滑动，以通过从至少一端密封模腔来进一步促进预成型件的压缩。在这种情况下，活塞指的是布置成在模制设备内配装并移动的任何杆或棒或类似物。例如，可以在模腔的每个纵向端部上提供一个活塞，并且在模制步骤期间，使所述活塞朝向预成型件滑动，并由此从两端进一步压缩预成型件。通过模件块和活塞的组合，可以对产品的所有侧面进行成型。优选地，在模件块移动到最终的压缩位置之后，使活塞朝向预成型件滑动。单独的致动器可以移动所述活塞或两个活塞。所述活塞可以包括从一个活塞穿过整个模腔到另一个活塞的特征。这样的实施方式是有益的，特别是当模制在部件的最长尺寸上具有中空开口槽的部件时，这种部件的一个示例是空心螺钉。
活塞的远侧端可以包括具有反向设计的模具，该反向设计在所获得的纤维增强制品的端部处复现出。模具可以由塑料制成，诸如聚醚醚酮(PEEK)，其具有在高温下保持的优异的机械和耐化学性能。在此情况中，远侧端指的是接触预成型件的端部。例如，该设计可以是螺钉头和/或螺钉梢端。在另一实施方式中，活塞可以包括用作插入件并在径向模制阶段被结合到所制造的部件上的单独部件。这种插入件在压缩模制阶段之前临时地附接到活塞，并在模制阶段期间永久地附接到所径向模制的部件。这种插入件可以由与所制造的部件相同的材料组成，或者可以由不同的材料组成，诸如金属、陶瓷等。这种插入件可以包括所制造的部件的整个梢端。例如，这种梢端可以是带螺纹的，并用于两种或更多种材料的混合物更为有利的应用中。
在另一种实施方式中，通过以下方式以连续的方式提供预成型件：装载和压缩预成型件，使模件块返回以及以使得预成型件在公共纵向轴线的方向上移动等于或小于模腔的长度且不使预成型件和所获得的纤维增强制品彼此分离的方式移出所获得的纤维增强制品。所述装载可以自动或手动执行。当自动执行时，致动器可以以如下所说明的连续方式将预成型件移动到模腔：
连续的过程：
1.通过将连续的预成型件装载到冷的模腔中来开始该过程；
2.加热并闭合模具，并将其径向模制为最终形状；
3.冷却模具；
4.打开模具；
5.将所述连续的预成型件在公共纵向轴线的方向上移动等于或小于模腔的长度；
6.加热并闭合模具，并将其径向模制为最终形状；
7.冷却模具；
8.打开模具；
9.根据需要多次重复步骤5-8以压缩预成型件的整个长度。
结果是得到具有所需的纤维取向和形状的连续径向模制制品。
在又一实施方式中，在模制步骤之前，该方法还包括沿着预成型件的公共纵向轴线滑动至少一个活塞，以进一步促进模具密封，其中，在活塞的远侧端处具有专门设计的模具密封特征。密封特征在模腔的边缘处停止。在此情况下，活塞包括在模件块移动到压缩位置(图3)之前在模腔“打开”(图2)阶段密封模具的几何特征。在这样的实施方式中，所述单独的致动器可以移动所述活塞或两个活塞。
图2和图3分别示出了在初始位置和压缩位置沿纵向轴线观察的径向模制设备的示例性模件块2。如图2和图3所示，该设备包括形成模腔3的四个模件块2。模件块2可以是相同或不同的，这取决于制造的产品。每个模件块2包括形成楔部的两个接合面2a，在初始位置(图2)、模制步骤和压缩位置(图3)期间以及在各位置之间的移动期间，这两个接合面总是与相邻模件块2的接合面2a接触。模件块2可以沿着线性路径移动，相邻模件块2之间的接合面2a可以是线性的。
图4示出了一种示例性复合材料预制件1，其包括热塑性聚合物基体和增强纤维。预成型件1包括具有单轴纤维取向的芯件11和具有大致45°螺旋取向的多个周围纤维层12。螺旋取向可以是右手方向或/和左手方向中的一者或两者。层12可以以例如45°/-45°/45°/-45°/45°等的螺旋取向搭叠。层12可以从芯件11到表面以不同或相同的螺旋取向搭叠，其中，芯件11的纤维包括平行于纵向轴线的相同取向。在一些示例中，层12可以在靠近芯件11处具有相同的螺旋取向，而在靠近表面处具有不同的螺旋取向。连续的增强纤维布置成遵循或符合最终制品的表面设计。特别是在螺钉中，螺旋角对确定扭矩至关重要。螺钉效率由螺旋角控制，并且最大效率在40度与45度之间。然而，在一些实施方式中，螺旋取向可以基本上为15°或30°或平行于纵向轴线。纤维插入件11也可以用不同的材料代替。
图5a-图5f示出了一系列示例性制造步骤，其包括与图2和图3中类似的模件块，其中，活塞4、5处于开放视角中，且未示出两个前部的相邻模件块2。图5a示出了处于初始位置的模件块2，其中，模腔3具有初始体积。在该示例中，模腔3具有螺纹螺钉的形状。在模腔3的上方和下方是用于活塞的路径。
图5b示出了处于初始位置的模件块2和活塞4、5，其中，具有初始形状和体积并且包含热塑性聚合物基体和增强纤维的预成型件1已装载在模腔3内。预成型件1具有垂直于压缩的公共纵向轴线A。预成型件1的初始体积可以小于模腔3的初始体积，并且在压缩位置中，模腔3和最终制品具有匹配的体积。第一活塞4和第二活塞5可以具有不同的直径和形状，但它们也可以具有相同的直径(如图6所示)。活塞4、5可以由金属或具有塑料(诸如PEEK)梢端的金属制成。
图5c示出了其中模件块2处于压缩位置而活塞4、5仍处于初始位置的步骤。在径向压缩期间，形成预成型件1的纵向形状，并具有定制纤维取向，其中，使连续增强纤维遵循或符合表面轮廓。从图5c中可以看出，两个端部区段都具有形状不受控制的突起(如图5c所示为圆形)，这可能不是理想的设计。
图5d示出了完全压缩位置，其中，两个活塞4、5在径向压缩后都已滑到模腔3内。处于压缩位置的模腔3的体积等于最终制品6的体积。第一活塞4和/或第二活塞5具有远侧端，该远侧端是接触预成型件1或非最终制品的端部，该远侧端起到具有反向设计的模具的作用，该反向设计在最终制品6的端部部分处复现出。
图5e示出了其中模件块2以及活塞4和5返回到初始位置，且最终制品6准备好被移出的步骤。
图5f示出了最终制品6的特写图。最终制品6可被分为端部部分6a、中间部分6b和梢端部分6c。端部部分6a具有由第一活塞4形成的顶部形状。中间部分6b具有螺旋螺纹，其具有定制的纤维取向并具有优化的机械性能。梢端部分6c可以是平的，或者在一些实施方式中，包括由预成型件1以外的其他材料制成的梢端。其可以是全螺纹的、部分螺纹的或光滑的。
图6示出了示例性制造步骤的替代步骤。图6的实施方式与结合图5c说明的实施方式非常相似。因此，以下主要通过指出差异来说明图6的实施方式。
图6示出了径向压缩前的步骤，其中，活塞4、5处于压缩位置，而模件块2仍处于初始位置(即5b)。活塞4、5可以在径向压缩之前将预成型件1的端部部分压缩到期望的设计，或者在径向压缩期间保持预成型件不会从模腔3中流出，同时径向压缩力使预成型件推向活塞4、5或者两者。在这两种情况下，获得具有定制纤维取向的最终制品，其中，连续增强纤维遵循或符合表面轮廓。
在又一实施方式中，活塞4、5可以进一步包括沿着预成型件1的公共纵向轴线A在模腔3的接合面处的密封特征7，以进一步促进模具密封。在此情况中，术语“模腔3的接合面”是指模腔3由最终体积限定情况下的边界。密封特征7成形为当模件块2仍处于初始位置时密封模腔3的近侧端和/或远侧端处的接合面，并且布置为聚焦并锁定为防止模件块2在压缩位置处的旋转。在模腔3的端部处的密封接合面因此防止了可模制的预成型件1向这些方向泄漏，因此，密封的接合面改善了模制阶段期间的压力调节。当使用密封特征7时，活塞4、5的直径可以小于处于压缩阶段的模腔3的直径。密封特征7可以由任何合适的密封剂材料制成，诸如橡胶、金属或诸如PEEK之类的塑料。密封特征7也可以由与活塞的其余部分相同的材料构成。密封特征7也可以是活塞4、5的几何特征，其集成或无缝地结合到活塞4、5并且由任何合适的材料构成。

Claims (19)

1.一种形成纤维增强制品的方法，其特征在于包括以下步骤：
101)提供包括热塑性聚合物基体和增强纤维的复合材料预成型件(1)，其中，所述预成型件(1)具有初始体积和初始纤维取向；
102)将所述预成型件装载到径向模制设备内，该径向模制设备包括至少三个相邻的模件块(2)，所述模件块(2)彼此紧邻从而形成在初始位置中具有初始体积的模腔(3)；
103)通过移动所述模件块(2)来模制所述预成型件(1)，所述模件块(2)在所述初始位置和移动以及压缩位置期间彼此直接接触，并且垂直于所述预成型件(1)的公共纵向轴线(A)，其中，所述模腔(3)的初始体积减小并且所述模件块(2)将所述预成型件(1)压缩到由处于所述压缩位置的所述模腔(3)限定的具有最终体积的形式，所述最终体积小于或等于预成形件(1)的所述初始体积；
104)打开所述模腔(3)；以及
105)将所获得的纤维增强制品(6)从所述模腔(3)中移出，所述纤维增强制品(6)具有定制的纤维取向，其中，连续的增强纤维遵循所述制品(6)的表面轮廓。
2.根据权利要求1所述的形成纤维增强制品的方法，其中，所述模制步骤包括径向压缩模制。
3.根据权利要求2所述的形成纤维增强制品的方法，其中，在所述模制步骤之前或期间，或者在将所述预成型件(1)装载到径向模制设备内之前，将所述预成型件(1)加热到高于所述径向模制设备内的基体聚合物的玻璃化转变温度(Tg)或熔化温度(Tm)，并且在所述模制步骤期间或之后，使所述预成型件(1)冷却。
4.根据权利要求1所述的形成纤维增强制品的方法，其中，模制步骤包括注射模制，并且其中，所获得的制品(6)是纤维插入件，该纤维插入件在包覆模制工艺中用作插入件。
5.根据权利要求1-3中任一项所述的形成纤维增强制品的方法，其中，通过以下方式连续地提供所述预成型件(1)：装载和压缩预成型件(1)，使所述模件块(2)返回以及以使得预成型件(1)在所述公共纵向轴线(A)的方向上移动等于或小于所述模腔(3)的长度且不使预成型件(1)和所获得的纤维增强制品(6)彼此分离的方式移出所获得的纤维增强制品(6)。
6.根据权利要求1-4中任一项所述的形成纤维增强制品的方法，其中，在模制步骤之前或之后，使至少一个活塞(4，5)沿着预成型件(1)的公共纵向轴线(A)滑动到所述模腔(3)内，以通过从至少一端密封所述模腔(3)而进一步促进预成型件(1)的压缩。
7.根据权利要求6所述的形成纤维增强制品的方法，其中，所述活塞(4)的远侧端包括具有反向设计的模具，所述反向设计在所获得的纤维增强制品(6)的端部部分(6a)处复现出。
8.根据权利要求6或7所述的形成纤维增强制品的方法，其中，所述活塞(5)布置为在压缩期间将插入件或者金属或陶瓷的梢端附接到所述预成型件(1)。
9.根据权利要求6-8中任一项所述的形成纤维增强制品的方法，其中，所述活塞(4，5)还在所述模腔(3)的接合面处包括密封特征(7)，所述密封特征被布置成在所述压缩位置和/或在所述模制步骤期间密封模腔(3)。
10.根据权利要求1-9中任一项所述的形成纤维增强制品的方法，其中，所述预成型件(1)的初始体积小于所述模腔(3)在所述初始位置中的体积，并且所述预成形件(1)在所述初始位置中的横向尺寸大于所获得的制品(6)在所述压缩位置中的横向尺寸。
11.根据权利要求1-10中任一项所述的形成纤维增强制品的方法，其中，在压缩步骤期间，所述模件块(2)沿着相邻模件块(2)移动相同的线性或弯曲位移长度，它们的移动通过至少一个致动器同步，并且其中，所述模件块(2)彼此直接接触。
12.根据权利要求1-11中任一项所述的形成纤维增强制品的方法，其中，所述预成型件(1)的纤维取向能够预先定制，其中，所述预成型件(1)包括具有单轴纤维取向的纤维插入件(11)和具有螺旋取向的多个周围纤维层(12)，其中，所述螺旋取向具有任意所需的纤维角。
13.根据权利要求1-12中任一项所述的形成纤维增强制品的方法，其中，所述预成型件(1)包括混合的或互锁的层结构。
14.根据权利要求1-13中任一项所述的形成纤维增强制品的方法，其中，所述纤维增强制品是医疗器械。
15.一种径向压缩模制设备，其特征在于，所述设备包括至少三个相邻的模件块(2)，所述模件块(2)彼此紧邻从而形成用于预成型件(1)的模腔(3)，其中，在压缩期间，所述模件块(2)沿着相邻的模件块(2)移动相同的线性或弯曲位移长度，它们的移动通过至少一个致动器同步，并且其中，所述设备还包括至少一个活塞(4，5)，所述活塞布置在所述模腔(3)的端部处并且在所述压缩之前或之后被布置为沿着所述预成型件(1)的公共纵向轴线(A)朝向所述预成形件(1)滑动到所述模腔(3)中。
16.根据权利要求15所述的径向压缩模制设备，其中，所述活塞(4)的远侧端包括具有反向设计的模具。
17.根据权利要求15或16所述的径向压缩模制设备，其中，所述活塞(5)还包括金属或陶瓷的梢端，所述金属或陶瓷的梢端在所述压缩期间被附接到预成型件(1)的端部。
18.根据权利要求15-17中任一项所述的径向压缩模制设备，其中，所述活塞(4，5)还在所述模腔(3)的接合面处包括密封特征(7)，所述密封特征(7)被布置成在压缩位置处密封所述模腔(3)。
19.根据权利要求18所述的径向压缩模制设备，其中，所述密封特征(7)是所述活塞(4，5)的几何特征，所述几何特征被集成或无缝地结合至所述活塞(4，5)。
CN202080107444.9A 2020-11-30 2020-11-30 用于制造纤维增强制品的方法和设备 Pending CN116600729A (zh)

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