DE10005202B4 - Process and apparatus for the continuous component and process-oriented production of reinforcing structure semi-finished products for fiber-plastic composite materials - Google Patents

Process and apparatus for the continuous component and process-oriented production of reinforcing structure semi-finished products for fiber-plastic composite materials

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Publication number
DE10005202B4
DE10005202B4 DE2000105202 DE10005202A DE10005202B4 DE 10005202 B4 DE10005202 B4 DE 10005202B4 DE 2000105202 DE2000105202 DE 2000105202 DE 10005202 A DE10005202 A DE 10005202A DE 10005202 B4 DE10005202 B4 DE 10005202B4
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Germany
Prior art keywords
process
scrim
sewing
fiber
seam
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DE2000105202
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German (de)
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DE10005202A1 (en
Inventor
Christian Weimer
Andreas WÖGINGER
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Institut fuer Verbundwerkstoffe GmbH
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Institut fuer Verbundwerkstoffe GmbH
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Priority to DE2000105202 priority Critical patent/DE10005202B4/en
Publication of DE10005202A1 publication Critical patent/DE10005202A1/en
Application granted granted Critical
Publication of DE10005202B4 publication Critical patent/DE10005202B4/en
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Classifications

    • DTEXTILES; PAPER
    • D05SEWING; EMBROIDERING; TUFTING
    • D05CEMBROIDERING; TUFTING
    • D05C17/00Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/40Shaping or impregnating by compression not applied
    • B29C70/50Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/54Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/543Fixing the position or configuration of fibrous reinforcements before or during moulding
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/52Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by applying or inserting filamentary binding elements
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00Other non-woven fabrics
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/04Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
    • D04H3/045Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles for net manufacturing
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/10Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
    • D04H3/115Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by applying or inserting filamentary binding elements

Abstract

Process for the continuous production of reinforcing structure semi-finished products for fiber-plastic composites, comprising the following steps:
a) depositing fiber bundles in a laying device in predeterminable relative position to the longitudinal axis of a single or multi-layer fabric to be produced;
b) feeding the individual fiber bundles to a first sewing station and forming a first group of sewing stitches for securing the relative position of the fiber bundles to each other, wherein the shape of the seam has a component or process-oriented course and the component represents the final contour;
c) feeding the web formed according to process steps a) and b) to at least one second sewing station downstream of the first sewing station;
d) placing at least one fastener of predetermined shape on the scrim;
e) forming at least one second group of stitches in the edge region of the fastener to its attachment to the scrim by at least one to its outline substantially parallel seam.

Description

  • The The invention relates to a method and an apparatus for the production a novel textile reinforcing semi-finished product class according to the preamble of claims 1 and 8 respectively.
  • to Production of continuous fiber-reinforced fiber-plastic composite components (FKV) become the reinforcing fibers generally in the form of a sheet introduced semi-finished textile. An increase in efficiency in the Manufacturing of components made of continuous fiber reinforced plastics is by improved technologies for the production of textile reinforcement structures reached. The technology used for the production of semi-finished fiber products is for the later achievable strength, or utilization of the fiber properties crucial. The semi-finished products to be produced on the one hand have different May have fiber orientations, and on the other hand be compatible with the matrix. Be fabric as reinforcing semi-finished used, can in the composite, for example, only 50-60% of the possible strength of a precise aligned fiber can be generated. This creates the demand for Semi-finished products that have precisely aligned fibers.
  • going one of the existing manufacturing processes for the production of continuous fiber reinforced FKV, this creates individual requirements for the textile Semi-finished products resulting from the processing process and the component-specific requirements result. This leads to the demand for, process- and component-oriented, prefabricated fiber semi-finished products. Conventional processing methods for such Materials are based on the use of given textile structures. The way to the solution component- and process-specific problems and requirements, via a Adaptation of textile semi-finished products has not gone so far. The present method provides a consistent solution for the production of semi-finished fiber products that derive from specific processing process requirements (e.g., optimal binding thread architecture through custom sewing process) and simultaneously Meet the requirements of different components. Such semi-finished products will be hereinafter referred to as "Manufacturing Process Adapted Reinforcements (MPAR) ".
  • Textile, prefabricated semi-finished
  • It is known to deposit fibers in accordance with load (component-oriented, load-appropriate and ready-made) and to stitch them together in a subsequent knitting process in one direction, ie in one direction ( DE 196 24 912 A1 and DE 197 26 831 A1 and Hörsting, K .; Huster, M .: Targetting cost reduction by FEA-designed reinforcement textiles. Proceedings 'ECCM-8', Naples / June 1998, pp. 635-643). Such flat textile semi-finished products are referred to as ready-made scrim. Furthermore, in the sense of a fabrication of reinforcement structures, a further processing of these prefabricated multi-axial scrims by means of conventional sewing technology to form complex preforms takes place. Various textile semi-finished products, as well as force application elements, can be interconnected ( DE 196 08 127 A1 ). Another process for the load-oriented storage of fibers, and for the production of component-oriented individual parts, is the so-called tailored fiber placement (TFP) ( DE 197 16 666 A1 ), which uses the embroidery technology to lay down individual fibers under load.
  • at The preform manufacture from made-up fabrics are additional Cutting work required. It creates fraying edges of Individual parts or an elevated Amount of waste. Continue to have in this case measures to avoid further fraying.
  • In the case the further processing of prefabricated layers to thermoplastic FKV systems need Matrix compatible binding threads (stitch threads, knitting threads) used which are, however, often through various sewing preparations (Texturing, stretching) not completely as matrix or fiber content to enter the FKV. The processing of such threads on conventional knitting machines is limited possible.
  • By the increased Number of courses in the knitting process is further one damage the fibers (fiber dondulations, local compaction) resulting in a Lowering the mechanical properties of the FKV leads. Should such scrim in subsequent Nähprozessen are processed into complex preforms, so are local Schiebenverfestigungen to perform shifts (e.g., fiber dondulations, scrim delay) to avoid, so as to ensure an optimal result. This requires a further step in addition to the production of scrim or the actual preforming.
  • The Sewing threads serve for fixing the individual layers to each other. This feature can do that Do not treat scrubber when dry. After the impregnation process is the predominant one Part of the stitch-forming threads superfluous and leads to lowered mechanical in-plane characteristics compared to UD tapes.
  • A method for the direct production of Parts, or the complete component as a preform is the so-called TFP, in which case a carrier material must be used. This method uses a modified embroidery technology, which is why the problem of the back of this reinforcing fabric of importance. This results in knotting layers of the lockstitch used, which in the individual fixation of each individual required roving, of greater extent. Based on these knotting layers, defects in the FRP are to be expected, which can be considerable in connection with the carrier material. Furthermore, several parts can be made in parallel, but then the carrier material must be removed from the embroidery machine, and then the machine be re-equipped with new carrier material. Furthermore, this method requires a fixation of each individual roving, which, in particular for large laminate thicknesses, leads to frequent penetration of the embroidery needles through the reinforcing structure. Damage to the reinforcing rovings does not stay out. Another obstacle to this technology is represented by different and not exactly predictable component thicknesses and the calculation of such structures.
  • The WO 93/19235 A1 discloses a process for the preparation of non woven webs, which are formed from a multitude of threads, which in different Angle to the longitudinal axis the web can be addressed. The individual threads, their relative position to the longitudinal axis the web is determined by the laying device fixed.
  • In WO 93/19235 A1 is merely stated that the stitch pattern means exclusively the connection and securing the relative position of the individual threads of Train serve. So exhausted the revelation of this publication in supplying a laying device fiber bundles and their relative position through seams ensuring neither the technical properties of the seams, nor their shape in any relation to the products to be manufactured, still to the type of further processing of the Geleges stand. The expert can the pre-publication Therefore, there is no suggestion to what extent the web thus produced, neither to the end product to be produced, nor adapted to the type of specific processing technical Features.
  • The DE 695 10 491 T2 "Figure 1 shows a method and apparatus for making a reinforcing plate for a composite part consisting of the reinforcing layer laid in a cured matrix of superimposed suture layers, and a machine for carrying out the method together with several examples of reinforcements made by this method.
  • in this connection The scrim of warp and / or weft threads on one of a rectangular Frame existing underlay alternately superposed so that, for example above a level with (warp) yarns running in the X direction Scrim with running in the Y direction (weft) threads comes to lie, wherein the ends of the respective threads attached to pins, which in turn fixed to the frame are connected. The relative position of the superimposed scrim is then secured by means of an endless thread which is vertical to the planes formed by the directions X and Y, thereby the connection of the scrim through the endless thread is not in Form of a knot or at least one entanglement of the endless thread but only by forming loops of the endless thread, extending into the extend from foam formed pad.
  • to Making these loops is done by using motors along from appropriate guides movable sewing head, with that at certain intervals so many independent Loops are inserted into the clutches that at least the largest part the area the nets are stitch-like Loops are present.
  • In order to it is obvious that the Contour of the reinforcing plate to be produced the shape of the frame or through the line of connection the pins resulting shape is determined, even in the Z direction running loops only in this direction, but not in the Secure X or Y direction.
  • in the Following are the comments divided into Duromere-FKV and Thermoplastic-FKV to the different Problems and solutions divide.
  • Thermosets-FRP
  • in the Case of processing to FKV systems with thermoset matrix resin injection technology (RTM) is a very flexible manufacturing process established. This prefabricated preforms and / or textile reinforcing structures (made-up scrims, braids, knits, fabrics, etc.) as Gain semis used.
  • For the production of complex preforms, textile structures produced in an upstream process are used. Each individual required layer of these semi-finished products is cut separately to be joined together in a subsequent process to thicker packages (sewing or bonding or binder technologies). All properties of these semi-finished products are taken over (see above). If one follows these processes numerous further ones arise Manufacturing steps that significantly negatively affect the overall process in terms of cost-effectiveness. This applies in particular if the individual layers required must be fixed to one another prior to assembly. Handling is of immense importance here.
  • edge issues which lead to defects or process errors, can only by further process steps be avoided e.g. Race tracking (this is a lead of the resin in the edge region or in unfilled areas of the tool Understood). Dry edges of textile fabrics fray out and thus prevent a final contour accurate production.
  • improvements The damage tolerance (crash or impact properties) are produced by means of final sewn. Here are several gel layers combined into packages and again forfeits what is called end-sewn referred to as. Such measures significantly reduce the mechanical "in-plane" properties from. In particular, this is crucial, if not the complete one component area the raised Impact requirements (impact or impact loads) must withstand, but locally the in-plane Properties are more crucial.
  • Thermoplastic FRP
  • in the Trap thermoplastic FKV systems is generally an impregnation and consolidating the fibers with the matrix in a separate step make (semis production). For this purpose, flat textile Semi-finished products used.
  • current available Prefabricated fabrics are in terms of binder thread or binder thread arrangement, this usually corresponds to a one-dimensional areal mesh structure, not optimized. In case of processing of matrix compatible Yarns, which usually have greater subtleties and Diameter, found by the very high proportion of binding threads one significant damage the fibers take place in the plane.
  • These made-up clutches can by powder impregnation method due to the sometimes very thick ply packages and in conjunction with high-temperature (HT) thermoplastics (melting or decomposition the binding threads and the associated resolution the skeleton structure) are not processed.
  • In the case of the film stacking method, two ways can be followed. In order to keep the flow paths low, it is necessary to use low basis weight scrims (<500 g / m 2 ). On the other hand, high basis weight (> 500 g / m 2 ) fabrics can only be processed if films are incorporated into the ready-made fabric during the production of the fabric. This method often fails due to the very narrow mesh bed and the limited clearance height of the active unit and can thus be used only for very thin films.
  • The currently conventionally used binding threads fulfill after the semifinished product often no function in combination. Furthermore, these binding threads are harmful in Regard to the laminate qualities, because of the treatment with spool oils and lubricants, and partly by the thread itself, foreign matter get into the composite matrix. Soften or melt these threads too early during the Semifinished production, the fiber layers shift, resulting in lowered mechanical properties leads. The same applies to the impregnation or direct impregnation of made-up layers based on hybrid threads.
  • A Optimal workmanship of made-to-order clothing is only possible through the use of special yarns (carbon, glass or aramid fiber or matrix compatible binding threads), which have the necessary temperature resistance to the fibers during impregnation or to keep the consolidation fixed.
  • The Further processing of "TFP" semi-finished products to thermoplastic FKV is produced by direct impregnation and thermoplastic injection method possible. The advantages of the load-oriented Depositing reinforcing fibers remain preserved, however, is the Nähfadenanteil, for reasons such as described above as critical. The tools are due the thickness variations kom plex, whereby by the knotting layers the sewing threads and the Sewing threads themselves no smooth surfaces can arise. Economic continuous processes are unthinkable here.
  • to Production of complex 3D geometries for injection technologies It is advantageous to produce items that in as possible few very simple process steps to the desired structure are mounted can. Likewise, these should be optimized to a high degree of stress, local force application elements or special reinforcements have, or other functional elements integrate.
  • The invention is therefore based on the object to provide a method and an apparatus which make it possible, even in the production of the clutch both the position of the individual fibers or the individual fiber bundles, as well as the shape of connecting these attachment seams so arrange or to design so that the respective components are represented by the relative position of the individual fiber bundles and securing these fastening seams endkonturen, ie be limited on the clutch surfaces already during its production, their forms the respective outline of the forms to be separated from the context Preforms correspond, with the possibility should also be created to arrange immediately after the formation of the attachment seams of the preform on this additional fasteners and fasten by means of other seams.
  • Of the first part of this task, namely the creation of an appropriate procedure is characterized by the characterizing Characteristics of claim 1 solved. Advantageous developments of the method will become apparent from the back to claim 1 Dependent claims.
  • Of the second part of this task, namely the provision of a device for carrying out the method according to the patent claim 1 is characterized by the characterizing features of claim 8 solved. An advantageous development of the device according to claim Figure 8 is characterized by the features of the dependent claim 9 reached.
  • By the possibility for the production of "tailor-made" parts it also possible to specifically influence the resin injection process (e.g., locally increasing the Fiber volume content) or sensors (actuators, "life-time monitoring") targeted into the To bring in preforms.
  • A Targeted production of the required component-specific parts (Single layers) increases the efficiency of the process, and leads simultaneously to a reduction of material costs.
  • at For further processing into thermoplastic matrix FKV, the Processing properties, the processability and the quality of the product be improved. This can be used for thermoplastic FKV the Range of common semi-finished products as well as the range of prefabricated semi-finished products ("Tailored Blanks ") be opened.
  • The Further advantages of the new process "Multidimensional process- and component-oriented semi-finished products" will be examined with the help of 3 sub-areas:
  • Textile and Prefabricated semi-finished products
  • With the process for the production of so-called "Manufacturing Process Adapted Reinforcements (MPAR) "can produce flat textile reinforcing structures are produced, which do without typical textile types of binding and still workable. As a reinforcement for fiber-plastic composites Such semi-finished products are particularly suitable as the fibers are aligned present and the needed Fiber orientations are freely adjustable.
  • By the type of sewing technique used It is also, in contrast to a very close stitch-forming Bed of a knitting machine (Liba, Mayer, Malimo), possibly multi-dimensional, i. in different directions, seams contribute. Therefore, it is also possible continuously force introduction elements in the textile reinforcement structure integrate. The connection of force application elements to the textile structure takes place via Reinforcement stitching yarns when sewing be used.
  • By the generation of component-specific optimized seam geometries flat Structures are thus optimal fiber orientation at the same time warranty given the processability. The process is on a continuous Process designed, and thus offers the possibility of individual semi-finished assemblies by means of a laying program, in the sense of avoidance of waste, optimally applied. By the possibility continuous manufacturing eliminates a large number of and cutting steps. Likewise, handling simplifications be provided by positioning, etc., what the following processes considerably simplified.
  • Thermosets-FRP
  • The Semi-finished products produced by using a method according to claim 1 can, can depending on the requirement, cut to the final contour to a simplified one Preform assembly will be brought. Advantages of the resin injection process can due to the net-shape ability (no fraying by the, the edge fixing, seams) and the free adjustability of the fiber orientations, fully utilized become. The integration of inserts and other functional elements (For example, sensors) allows a further approach to the economy of injection molding processes. Find rework and the associated damage to the laminate not happening. Race tracking effects can be achieved through adjustability the fiber volume content in the edge area are avoided. By the Use of special seam parameters (needle geometry, knotting arrangement), Is it possible targeted flow channels in the Fiber preform to ensure complete impregnability of the structure.
  • Thermoplastic FRP
  • Become dependent on from the matrix, sufficiently temperature-resistant binding threads used, can such continuously manufactured "Manufacturing Process Adapted Reinforcements (MPAR) "by means of a powder impregnation unit for the production of thermoplastic FKV used.
  • Herewith It also enables the processing of HT thermoplastics. By limiting the number of threads later processing is not impaired and the mechanical characteristics in the plane are retained.
  • conditioned By reducing the number of needles and the larger passage height can also slide be continuously introduced to shorten flow paths.
  • Become direct impregnation techniques for processing hybrid threads used, offer the same potential as in the processing thermoset based FRP systems.
  • embodiments The invention are illustrated in the drawings and are in The following are divided into two areas, Duromere-FKV and Thermoplastic-FKV and closer described:
  • It demonstrate:
  • 1 Plant for the continuous production of component- and process-oriented reinforcement structure semi-finished products
  • 2 Image of a continuously produced semi-finished product for radome production with integrated fasteners and local additional reinforcements
  • three Image of a radome preform item
  • 4 Integration of force discharges
  • 5 Semi-finished product for surface processing
  • With a device according to claim 1 ( 1 ), it is possible to produce prefabricated semi-finished fiber products, these are optimized in terms of fiber orientation and contour of the later component. Local reinforcements or seam feeds are made exactly according to given component or process specific requirements and circumstances.
  • Fiber bundles or rovings ( 1 ) with a laying unit ( 2 ), (see Gelege production Liba, Malimo) with different fiber orientations filed ( three ). The fiber bundles are hereby mounted on a transport gate ( 4 ) to the sewing station ( 5 ). The sewing station has at least one sewing head which can be programmed in any desired way in the plane. The sewing speed or the movement of the sewing head are independent of the movement of the conveyor belts. In a following sewing station ( 6 ) additional functional elements (eg force introduction elements) and local reinforcements are integrated. The semi-finished product thus produced can be wound up on rolls ( 7 ) be transported. Any number of laying and sewing stations can be operated in series (not only connected in series), which is why the introduction of fiber bundles oriented in the direction of production succeeds by a preceding sewing process transversely to the production direction. Before, or after laying down the fiber bundles, additional surface reinforcements, eg sandwich elements, can be fed to the layer structure ( 8th ).
  • in the The following are two examples from the processing technology for thermoset or thermoplastic FKV given.
  • Thermosets-FRP
  • Example Radom-Preform ( 2 . three and 4 )
  • By the use of the method according to claim 1, a plurality of process steps avoided or produced for the preparation of the dry reinforcing structure be simplified. The separate production of a textile semifinished product for the Preforming is omitted. The hand-labor intensive preparation for the production of the preforms can be automated and greatly simplified. A power flow oriented positioning local, additional Stiffeners or fasteners already found during the Semifinished production instead. Through the use of such semi-finished products is also avoided a reworking of the fiber-plastic composites.
  • On a plant ( 1 ), the basic structure of the layer structure is first stored ( three ). The structure here corresponds to a laying unit according to principle Liba. Fiber orientations and number of layers can be set arbitrarily (eg quasi-isotropic). The geometry contour ( 9 ) of Radom processing ( 2 ) is sewn on the surface deposited fibers as often as desired ( 10 ). The laying down of the ply structure and sewing is controlled relative to each other but independently. The round outer geometry is realized by sewing heads that can be moved in x and y axes. With the sewing head, where individual stitches are programmable, the fastening elements ( 11 ), ie sewed on ( 16 ) ( 4 ). These inserts are positioned exactly on the deposited fibers. Another sewing head fixes local reinforcements such as braided sleeving ( 12 ), additional fiber bundles or other reinforcing structures. Outbreaks ( 13 ), such as for bolt connections, are mapped in the same process. To stiffen the structure, additional seams ( 14 ) introduced to increase the slip resistance.
  • Several Individual processes are replaced by this process, the process Tailored instead of. Cutting work and positioning during preform assembly individual blanks are reduced to a minimum. Of the Cuttings will go through these measures significantly reduced, in particular if an optimal number of preforms is projected onto the laying width of the machine.
  • After the sewing process, the roll with the prefabricated reinforcing semi-finished products ( 7 ), this serves for optimal handling of the component-oriented semi-finished products, a displacement of the individual layers, or fraying is avoided.
  • After unrolling, the preforms are punched or cut out, the finished preform ( three ) ( 15 ) can be inserted in the tool. The positioning of the preform in the tool, to secure the fiber orientations is done via the fasteners ( 11 ) or local reinforcements ( 12 ). A wrinkling of the textile reinforcing element does not take place, since no binding was made between the individual layers. The number of inserted seams ( 14 ) depends on the necessary slip resistance for preform assembly or thermosetting processing.
  • The component produced in this way has a final contour ( 15 ), which results from the semi-finished product manufacturing process. The process steps of post-processing are eliminated.
  • Thermoplastic FRP
  • Example of a case half shell ( 5 )
  • Of the Use of a method according to claim 1 enables a component-oriented Production of semi-finished fiber products for further processing to thermoplastic Fiber reinforced plastics. The consolidation of the component-oriented Semi-finished products can continue with the help of a double belt press continuously respectively. A continuous production of thermoplastic prepregs on a powder dispersion system is possible, provided that temperature-resistant sewing threads used become.
  • On a plant ( 1 ), the basic structure ( three ) of the layer structure filed. The necessary number of seams ( 18 ), for fixing the individual layers, are applied by means of a sewing head. There are only as many seams as absolutely necessary introduced. Locally increased Z-thread portions can be introduced at impact-prone zones ( 17 ). The production takes place continuously, on a defined laying width. The still flat semi-finished product can be transported on wheels. Due to the closed surface and the defined width of the semifinished product carrier, a powder impregnation or an impregnation on a double belt press can take place.
  • Be on the plant ( 1 ) Processed hybrid yarns, the impregnation can take place on a double belt press or by direct impregnation. For the direct impregnation process, the same procedure as for duromeric FRP is provided. In terms of near-net-shape technologies, of simple geometries, the same possibilities open up as for thermoset systems.

Claims (9)

  1. Process for the continuous production of reinforcing structure semi-finished products for fiber-plastic composites having the following steps: a) depositing fiber bundles in a laying device in predeterminable relative position to the longitudinal axis of a one or more layers to be produced; b) feeding the individual fiber bundles to a first sewing station and forming a first group of stitches to secure the Relative position of the fiber bundles to each other, wherein the shape of the seam is a component or process oriented Has course and the component represents the final contour accurate; c) Respectively to the geleges formed by the process steps a) and b) at least one, the first sewing station downstream second sewing station; d) Laying at least one fastener predetermined shape on the clutch; e) forming at least a second group of stitches in the edge region of the fastener to its attachment the scrim by at least one to its outline substantially parallel running seam.
  2. Method according to claim 1, characterized by further step: f) cutting out the preforms formed the scrim along an attachment seam substantially parallel and at a distance to this running cut line and / or drop of the money at a supply point.
  3. A method according to claim 1 characterized gekenn records that force introduction elements are introduced into the scrim.
  4. Method according to claim 1, characterized that regionally additional reinforcing structures like textile fabrics, Rovings and similar applied to the scrim and attached by sutures on this.
  5. Method according to claim 1, characterized that regionally Integrated matrix systems in the form of films or films in the scrim become.
  6. Method according to claim 1, characterized that core materials regional or areal be integrated into the clutch.
  7. Method according to claim 1, characterized that the Function of the seam adapted sewing thread be used.
  8. Apparatus for carrying out the method according to claim 1, comprising: a) a device for placing a or several fiber bundles in predeterminable relative position of the fibers to the longitudinal axis of a produced Train; b) a transport device for feeding the fibers to a sewing station with at least one sewing machine or a sewing head for forming the relative position of the fibers securing each other seams, whose form has a component or process-oriented course and represents the component endkonturengenau, as well as to continue the thus formed to a stacking or one or more further processing stations; c) a device for hanging up at least one fastener of predetermined shape on the scrim; d) one of the first sewing stations downstream second sewing station for forming at least a second group of stitches in the edge region of the Fastening element for its attachment to the scrim by at least one of its outline in essentially parallel running seam.
  9. Apparatus according to claim 8, comprising: e) a device for cutting out the formed preforms from the Scrim by means of a fastening seam substantially parallel and at a distance to this running cutting line and / or optionally f) a device for depositing the slip within a supply point.
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DE102007025556B4 (en) * 2007-05-31 2010-06-17 Eurocopter Deutschland Gmbh Process for the production of components from fiber reinforced plastics
DE102009053289A1 (en) 2009-11-13 2011-05-26 Irene Brockmanns Method for producing a textile semi-finished product for a textile fiber-composite structure, which consists of roving pieces, comprises discarding and overlapping the roving pieces as final product depends on defined position
DE102009053289B4 (en) * 2009-11-13 2011-12-08 Irene Brockmanns Process for the production of a semi-finished textile product and semi-finished textile product for a textile fiber composite structure
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DE102016111080A1 (en) 2016-06-17 2018-01-11 Cetex Institut für Textil- und Verarbeitungsmaschinen gemeinnützige GmbH Process for producing semi-finished products for fiber-plastic composite components

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