DE102007040609A1 - A method for producing a rope-like spring element semifinished product, a helical spring element, a tool for processing a cable-like spring element semifinished product, a shaping body for forming a rope-like spring element semifinished product and a spiral-shaped spring element - Google Patents

Abstract

The invention relates to a method for producing a rope-like spring element semifinished product (10), in which a spring core body (20) and a reinforcing fiber sheath (30) surrounding the spring core body (20) and comprising at least one fiber filament (32) , provided. At least the reinforcing fiber sheath (30) is impregnated with a liquid or pasty, curable matrix material (78), thereby establishing a provisional mutual arrangement of the spring core body (20) and the reinforcing fiber sheath (30) and a predetermined cross-sectional shape of the spring element ( 10) is formed. A method for producing a helical spring element (200) by means of a spring element semifinished product (10) comprises the steps of winding the impregnated and / or at least partially hardened spring element semifinished product (10) around a shaping element (100) having a surface which corresponds to the final geometric shape of the Spring element (200) is tuned and / or these and the complete curing (118) of the liquid or pasty curable matrix material (78), whereby the spiral-shaped spring element (200) is formed. Furthermore, the invention relates to a tool (40) for processing a cable-like spring element semifinished product (10) and a shaping body (100) for forming a rope-like spring element semifinished product (10) in a spiral spring element semifinished product. Finally, the invention relates to a spiral spring element ...

Description

The The invention relates to a method for producing a rope-like Spring element semifinished product, a method for producing a helical spring element, a tool for processing a cable-like spring element semifinished product, a shaping body for forming a cable-like spring element semifinished a spiral spring element semifinished product and a spiral Spring element.

conventional Steel spring elements require a high load big cross section and therefore have a big one Weight, are dynamically little to change and susceptible to corrosion.

Further rope-like spring elements are known, made of fiber composites consist. Such coil springs are particularly suitable for recording of torsional stresses. In addition to cylindrical coil springs are also flat coil springs or springs with rectangular cross-section known.

Indeed designed the production of such spring elements made of fiber composites as very difficult.

Of the Invention is based on the object measures in the context of production a spiral Specify spring element and such a spring element, the simple can be produced, in particular in the continuous process. Furthermore, should different cross-sectional shapes produced and the spring element be versatile.

These Task is governed by the objects of claims 1, 16, 19, 26, 30, 40 and 41 solved. advantageous Embodiments of the invention are the subject of the dependent claims.

A The idea of the invention is therefore to be found in a method for Production of a rope-like spring element semifinished a spring core body and a spring core body surrounding reinforcing fiber cladding at least one fiber filament to provide. At least the reinforcing fiber cladding becomes with a liquid or pasty, curable Soaked matrix material and thereby a provisional one mutual arrangement of the spring core body and of reinforcing fiber cladding and set and a predetermined cross-sectional shape of the spring element semifinished product educated.

With In other words, the reinforcing fiber sheath is in embedded in the matrix material. This material is preferably corrosion resistant. The matrix material is preferably a resin, in particular a Epoxy resin used. The serving forms a reinforcing fiber structure. Preferably, the reinforcing fiber sheath may be at least a reinforcing fiber or at least one filament or one of a plurality of filaments Have thread.

Further can be the spring core body in the manufacture of the spring element semifinished product or the below yet explained Method for producing a spiral fiber composite spring element only one auxiliary body ensure that when soaking with the matrix material or later Winding the "soaked" spring element semifinished product whose cross-sectional shape is largely maintained.

Of the Spring core body may consist of a solid material or of a fiber or a fiber bundle, wherein the spring core body preferably a thermoplastic or elastomeric material or a fiber material, in particular glass fiber, comprises. The Materials and the one- or multi-part construction of spring core body and wrapping will be described below, in particular in connection with the final Fiber composite spring member explained.

So are spring-core body and reinforcing fiber cladding in the provisional mutual arrangement preferably in a loose cohesion under formation of gaps between the thread or bundle of threads and the spring core body. In the final mutual arrangement of the thread or the threads are below Minimization of the gaps and air pockets close to each other and to the spring core body. Preferably takes place the compression with the help of a traction, at the same time for transportation of the spring element semifinished product in the advancing direction of the method can be used.

Instead of The term spring element semifinished product is hereinafter also the term "rope" and instead of Conceptual spring core body also the term "inner Soul "used. Under a thread bundle is also a variety of threads, Filaments or monofilaments to understand.

at A preferred embodiment of the method is used Spring core body at its outside against penetration of the liquid or pasty, curable Sealed matrix material. Furthermore, the spring core body for the liquid or pasty, curable Be matrix material impermeable. Preferably, the spring core body is rubbery or foam-like elastic and reversible compressible.

at a further preferred embodiment is in step b) of Claim 1 and the spring core body soaked becomes. Preferably, when soaking an excess amount supplied to the matrix material become.

To the Soak can the spring element semifinished with an excess amount of the matrix material by one with the liquid or pasty, curable Matrix material filled drinking trough promoted become. Preferably, the transport of the spring element semifinished product takes place through the drinking basin in a non-tensioned state, leaving enough spaces between the individual components of the spring element semifinished product are present, through which the matrix material as large as possible with the surface of the Thread, the threads and / or reinforcing fiber cladding as well optionally the spring core body in Contact can come. To this unstressed transport through the drinking bowl to enable it is advantageous if downstream and / or upstream of the Basin each voltage regulator device is present.

at Another advantageous variant of the method is the spring element semifinished product for watering through a conveyor channel promoted and the liquid one or pasty, curable Matrix material is in the conveyor channel injected.

Preferably The matrix material is injected under pressure into the delivery channel, so that he in the interstices can get. To provide sufficient pressure for the supply of the matrix material can reach the matrix material via an injection molding machine supplied and for example over several holes in the delivery channel be injected. Furthermore, it is preferred if the injection of the matrix material takes place in a region of the conveying channel, in which the components of the spring element semifinished product are in the provisional mutual Arrangement under formation of intermediate spaces are.

Preferably the spring element semifinished product is transported after impregnation through a conveyor channel.

advantageously, be in the conveyor channel Spring core body and reinforcing fiber cladding as far as possible in their final Position brought to each other ge. For this purpose can be a suitably designed and further down still described tool with different processing zones be used. For the case that the spring core body is not removed, results in the final arrangement of the reinforcing fiber sheath after complete Harden of the matrix material.

at Another preferred embodiment is the spring element semifinished product while of drinking and / or after soaking compressed and thereby elastically and reversibly deformed. With others Words, the spring element semifinished by pressure from the Outside of the spring element semifinished ago compressed. The Compression is preferably carried out in and / or by means of the delivery channel.

From Another advantage is when the spring core body elastic and reversible is compressible and while Compressing the spring core body is compressed and so by means of the spring core body a directed against the inside of the reinforcing fiber sheath Counterpressure is generated.

Preferably can after soaking any excess matrix material be removed. The removal of the excess matrix material can over the delivery channel or by means of the delivery channel respectively. Removed excess liquid or pasty, curable Matrix material can be collected and reused for soaking.

In preferred development can in a step c) the matrix material at least partially cured be so that the spring element semi-finished a prepreg-like and has largely dry, limp, rope-like state.

One The advantage of the method described above is that the excess matrix material is collected and can be reused. Furthermore, the processing steps of drinking and Compression be coordinated or summarized be, so that, for example, the resulting excess matrix material at the same time easier transport of the spring element through the conveyor channel allows.

The tool according to the invention for processing a cable-like spring element semifinished product, in particular the above-described rope-like spring element semifinished product, comprises a conveyor channel through which the spring element semifinished product can be conveyed and which has a feed region, a compression region and a discharge region in the conveying direction, the conveying channel being in the conveying direction from an inlet of the Tapered tapered to the compression region, and wherein the cross-sectional area or the diameter of the inlet of the feed region is greater than or equal to the outer diameter of the conveyed into the conveyor channel spring element semifinished product, and wherein the cross-sectional area or the diameter of the compression region smaller than that to be formed desired cross-sectional area or the desired is to be formed outer diameter of the spring element semifinished product.

The Tool or its delivery channel allows to push the matrix material into the fiber structure, excess matrix material strip or inject the matrix material in the delivery channel. The used semi-finished product may have an oval cross-section, through promoted a round channel and subsequently cure with an oval cross-section. This may in particular arise because of the spring core body, the later cross-sectional shape decisively influenced.

So provides the delivery channel an elongated cavity with one extending along the conveying direction at least partially variable cross-sectional area ready. This cross-sectional area is substantially transverse, in particular perpendicular, to the conveying direction. After going through In this tool, the reinforcement fiber cladding is tight on the spring core body at.

at A preferred embodiment is between feed area and compression area provided an injection area, and in the At least one bore opens in the area of the injection area in the conveyor channel, by the semi-finished spring element of the liquid or pasty, curable matrix material supplied is. In this way, the pressed out in the compression region excess matrix material on the feeding and / or the discharge area derived and for impregnation be returned.

Preferably is the cross-sectional area or the diameter of the discharge area essentially the same size or greater than the desired shape to be formed Cross sectional area or the desired to be formed Outer diameter of the spring element semifinished product.

There in most cases a substantially circular one or a substantially oval cross section is selected for the cable-like spring element semifinished product, the tool is configured in a preferred embodiment such that is the cross-sectional area of the feed area in the conveying direction of tapered a first diameter to a second diameter, wherein the second diameter is larger than the desired to be formed Diameter of the spring element semifinished product and wherein a third diameter the compression region is substantially equal to or smaller as the desired Diameter of the spring element semifinished product is.

• a) Wickeln des getränkten und/oder zumindest teilweise ausgehärteten Federelementhalbzeugs um einen Formgebungskörper mit einer Oberfläche, die auf die endgültige geometrische Form des Federelementes abgestimmt ist und/oder diese abbildet; und
• b) vollständiges Aushärten des flüssigen oder pastösen, aushärtbaren Matrixwerkstoffs. Auf diese Weise wird ein spiralförmiges Federelement gebildet.

The inventive method for producing a spiral spring element by means of a spring element semifinished product, in particular by means of the above-described rope-like spring element semifinished product, comprises the following steps:

• a) winding the impregnated and / or at least partially cured semi-finished spring element around a shaping body having a surface which is adapted to the final geometric shape of the spring element and / or images; and
• b) complete curing of the liquid or pasty, curable matrix material. In this way, a spiral spring element is formed.

With In particular, a helical fiber composite spring element is to be formed in this method or produced.

ever according to the desired Cross-sectional shape of the spring element, the shaping body in cross section considered a substantially circular, elliptical, rectangular or have the same cross-sectional shape. Furthermore, the progress speed and / or the rotational speed of the forming body the desired Be tuned shape.

at A preferred embodiment of the method is a to the shaping body further shaping body by means of a torsion-proof, preferably form-fitting, Connection connected. The connection of the shaping body can done with or without interrupting the winding process. For example can be connected further shaping bodies at the same speed and a suitable relative position be driven in relation to the other shaping body, so that the two forming body to be connected during their preferably synchronous Rotation can be moved towards each other until the non-rotating Connection is made. In this way it is possible an endless spring element to produce by a winding process, where it is not required must be to interrupt the winding process. To according to the requirement produce different length spring elements, shaping bodies can be different lengths be held, wherein a shaping body of desired length in a simple manner put together several shaping bodies can be provided quickly.

In A preferred embodiment is the liquid or pasty, hardenable matrix material by heat and / or by a photochemical reaction, in particular by means of UV radiation, cured.

Further, before winding the spring element semi-finished product around the shaping body, a band, preferably a foil strip, of predetermined thickness can be wound onto the shaping body the. Such a band can be removed after the completion of the molding process, whereupon the spring element can be removed more easily from the shaping body.

Farther can the cured spiral Spring element can be cut to a predetermined length.

at a preferred variant of the spring core body after complete curing of the liquid or pasty, curable Matrix material from the spiral Spring element removed. In other words, the spring core body forms here an auxiliary body or supporting body, which subsequently removed becomes. This is particularly advantageous in the context of lightweight construction applications.

Of the Shaping body according to the invention Forming a rope-like spring element semifinished product, in particular of the above rope-like spring element semifinished product, into a spiral-like spring element semifinished product has a tuned to the geometric shape of the spring element semifinished product or this shape-imaging surface and at least one End a connection for connection with another shaping body.

The spiral-like spring element semifinished product can still after this transformation be in limp form and then after curing of the Matrix material the desired Properties, such as elasticity and strength.

In preferred embodiment, the connection is formed rotationally fixed. Advantageously, the connection for forming a positive connection formed with the further shaping body. More preferably, the terminal has a groove and / or a spring on.

advantageously, indicates the surface at least one groove for spiral-like shaping of the spring element semifinished product on, wherein the rope-like spring element semifinished in this groove around the shaping body is windable. In this way, a uniform shape at increased speed of progress be achieved.

The The invention further relates to a helical spring element, in particular a spiral fiber composite spring element, with a hollow tubular fiber composite spring element body.

Of the hollow, tubular fiber composite spring element body is preferably produced by the above-mentioned method and in Essentially through the reinforcing fiber cladding with the cured one Matrix material formed. The term "fiber composite" is intended in the context of present invention mean that in addition to fibers, filaments, Threads and / or Bundle up also the matrix material is present.

at According to a preferred embodiment, the fiber composite spring element body comprises at least a fiber or filament of glass, Kevlar, carbon or boron fiber. Preferably, the fiber composite spring element body comprises at least a thread or a bundle of threads, formed from several fibers and / or filaments.

Provided in the context of the present invention, one of the aforementioned terms mentioned This also applies to the other aforementioned terms. For the sake of simplicity, in Following from a thread as single-fiber or single-filament and from a thread bundle spoken as a variety of fibers and / or filaments.

Preferably is the thread and / or the thread bundle in a predetermined Winding wound. More preferably, the thread bundle several Groups of threads comprise, each group in opposite directions or rectified with respect to a longitudinal direction the fiber composite spring element is wound. Furthermore, the Threads of a Group with the threads to be interwoven in another group.

In a preferred embodiment, a group forms a layer of the fiber composite spring element body, the along the longitudinal direction essentially at a uniform distance from the longitudinal axis the spring element is removed. It can be arranged several layers become rectified or in opposite directions.

In a further preferred embodiment For example, the hollow tube-like fiber composite spring element body may include a spring core body filled out be. In this regard, can be the spring core body be formed of a fiber or a fiber bundle. The spring core body can a thermoplastic or elastomeric material or a fiber material, preferably glass fiber.

The invention further relates to a method for producing a spiral spring element, in particular a spiral fiber composite spring element, wherein by a method according to one of claims 1 to 15, a rope-like spring element semifinished product is produced and wherein by a method according to one of claims 19 to 25, the rope-like spring element semifinished product to a spiral spring element semifinished verarbei tet and by curing from the spiral spring element semifinished the spiral spring element (or spiral fiber composite spring element) is made.

Farther the invention relates to a device for producing a helical spring element, in particular a spiral Fiber composite spring element, comprising a hollow tubular fiber composite spring element body a drinking basin for watering a rope-like spring element semifinished product, a tool after a the claims 16 to 18, at least one shaping body for forming the rope-like Spring element semifinished product in a spiral spring element semifinished product according to one of the claims 20 to 25 and a curing device for Harden of the spiral Spring element semifinished product for forming the spiral spring element, in particular a spiral Fiber composite spring element.

at a preferred embodiment is at least one tensioning device for tensioning the rope-like Spring element semi-finished provided. At least two are preferred Clamping devices used, wherein a first tensioning device upstream and a second tensioning device is arranged downstream of the drinking basin.

advantageously, a catch basin is provided for collecting excess matrix material. Furthermore, a return line, the excess matrix material from the catch basin to the drinking basin be provided. To cut to length of the rope-like, the spiral-shaped Spring element semifinished product or the spiral (Faserverbundwerkstoff-) spring element to enable a separation device can be provided.

A preferred embodiment of the aforementioned manufacturing method has a process for mass production of cylindrical coil springs of constant cross section to the object.

Furthermore is an object of the invention, a semi-finished fiber product (hereinafter also called "rope"), which for the technical realization of the o. g. Method is usable.

One Advantage of the manufacturing process is that under utilization in particular the directional strength properties of fiber composites a dynamically highly changeable, lightweight and against a Variety of corrosive media resistant Machine element can be created.

A preferred use of the spring element according to the invention is on the field of aircraft and spacecraft, such as aircraft, helicopters and space ferries, in the maritime sector and in other areas where components are involved high strength, long life, good corrosion resistance and at the same time with a low weight are desired.

embodiments The invention will be explained in more detail with reference to the accompanying drawings. In this shows:

1 a top view of a first embodiment of a rope-like spring element semifinished product with a spring core body and two spring bundles surrounding the spring core body;

2 to 5 several cross sections through different filament bundle arrangements;

6 a schematic cross section through a rope-like spring element semifinished with spring core body and reinforcing fiber sheath;

7 a top view of a first embodiment of a spring element semifinished product with a spring core body and a plurality of the spring core body surrounding filament bundles with opposite, interwoven winding;

8th a top view of a second embodiment of a rope-like spring element semifinished product with a spring core body and a plurality of the spring core body surrounding filament bundles with opposite, interwoven winding;

9 a view according to 1a . 1b to a third embodiment of the rope-like spring element semifinished product with a plurality of bundles surrounding the spring core body of the same direction winding;

10 a view from above of a fourth embodiment of the rope-like spring element semifinished product with a plurality of the spring core body surrounding in layers arranged thread bundles with opposite winding;

11 a schematic representation of a first variant of a method for producing a rope-like spring element semifinished product with subsequent transformation of the rope-like spring element semifinished product in a spiral spring element;

12 a sectional side view of a first embodiment of a tool for processing the rope-like spring element semifinished product;

13 a schematic representation of a second variant of the method for producing egg nes rope-like spring element semifinished product with subsequent transformation of the rope-like spring element semifinished product into a spiral-shaped spring element; and

14 a sectional side view of a second embodiment of a tool for processing the rope-like spring element semifinished product.

1 shows the basic structure of a rope-like spring element semifinished product 10 or "rope" with representation of the soul and the opposite type of winding on the basis of two filaments or threads 32 or two bundles of fibers or bundles 36 ,

The "rope soul" 20 consists of individual fibers bundled into a concentric bundle or, in the case of "ropes", for producing larger spring dimensions from a flexible, light but pressure-resistant solid material, eg a thermoplastic foam or the like The "soul" serves as a shaped body of the "rope" and also mainly for transmitting tensile forces in the spring manufacturing process 30 the soul" 20 includes at least a single thread or a single filament 32 or based thereon bundles or bundles of fibers 36 ,

2 shows different filament bundle shapes. The forms b and c are for the production of the "rope" 20 and subsequently the spring element most favorable, as in the wrapping of the "soul" the smallest voids between the individual threads 32 or filament bundles 36 arise.

There Fiber materials very sensitive to stress across the grain it is advantageous to avoid or reduce this stress, that the "core diameter" is very large compared to the Filament diameter of the thread bundles is. However, since the filament diameter is in the μm range, the core diameter however, in the mm range and the reinforcing fiber sheath the "soul" in general multi-layered is done, this requirement is generally met.

The thickness of the wound and woven reinforcing fiber sheath 30 is small compared to the "rope diameter". 6 illustrates the proportions of cladding layer to "rope diameter".

The 7 to 10 show further embodiments of the rope-like spring element semifinished product 10 extending in a longitudinal direction L and a spring core body 20 and a spring core body 20 surrounding reinforcing fiber cladding 30 with at least one thread 32 or a thread bundle 36 includes. As will be explained below, the spring core twill 20 used only as an auxiliary body in the context of wrapping and after production of the spring element semifinished product 10 or be removed at a later stage. Alternatively, the spring core body 20 also remain, ie then forms a part of the final spring element.

In the context of the embodiments described below, the spring element semifinished product 10 also called "rope" and the spring core body 20 Also called "inner soul." Such a rope corresponds to the spring wire in conventional steel springs.

Around the spring core body 20 be used to produce the rope or spring element semifinished product 10 preferably helically, depending on the intended use of the final finished spring element, either with the same direction or opposite direction of impact, the individual threads 32 or thread bundle 36 . 37 winding or winding and interwoven.

Preferably the wrapping of the inner soul in this way takes place in several ways Layers. The pitch of the thread bundle screw line is in general at 45 ° with respect to longitudinal direction L, however, can achieve certain properties during the Processing or differ on the final product by several degrees.

The spring core body 20 (inner soul) may consist of several combined into a concentric bundle individual fibers or of a flexible, lightweight but pressure-resistant solid body, eg. B. made of thermoplastic foam or the like. The spring core body 20 is used during the spring manufacturing process for the transmission of tensile forces, as a shaping body for the spring element semifinished product 10 and, if not removed, for partial transmission of force. As a material for the spring core body 20 For example, materials can be used which have sufficient strength properties even with transverse stress. In the case of fiber materials, glass fiber material is particularly suitable here. For larger diameters of the spring core body 20 is the use of thermoplastics or elastomers useful. For the reinforcing fiber cladding 30 forming threads 32 or thread bundle 36 . 37 In particular, high-strength fiber material, such as glass, Kevlar, coal or boron fibers are suitable. Since fiber materials are very sensitive to a load across the grain, it is advantageous to avoid or reduce this stress that the diameter of the spring core body 20 very large compared to the diameter of the thread 32 or the thread bundle 36 . 37 is. Because the diameter of the thread 32 However, in micrometer range, the diameter of the spring core body 20 However, in the millimeter range, this requirement is usually in particular special then fulfilled when the reinforcing fiber sheath 30 multilayered. The thickness of the wound and woven reinforcing fiber sheath 30 is small compared to the diameter of the spring core 20 ,

The 7 and 8th each show a rope-like spring element semifinished product 10 in which the spring core body 20 surrounding reinforcing fiber cladding 30 six threads 32 or thread bundle 36 includes with opposite, interwoven winding. The direction of impact is inclined at about 45 ° to the longitudinal direction L. at 8th is in addition to the in 7 shown assembly a single thread 32 or a thread bundle 37 with a different directional orientation, in the present case parallel to the longitudinal direction L, in the reinforcing fiber sheath 30 woven. In this way, certain mechanical properties of the spring element semifinished product can be achieved 10 produce. In a completed interwoven wrapping the bundles of fibers lie 36 . 37 then without gap firmly together and to the spring core body 20 at. The required number of filament bundles 36 . 37 varies depending on the type of bundle of filaments used and their structure and the desired rope diameter.

9 shows the winding principle of a spring element semifinished product 10 with only rectified around the spring core body 20 wrapped threads 32 or filament bundles 36 , To achieve a sufficient cohesion and the handling of such a rope during the subsequent forming process for spiral shaping is a thread 32 or a thread bundle 37 wound in opposite direction of impact and partly with the other bundles of threads 36 interwoven. The entire reinforcing fiber cladding 30 the inner soul 20 is built in several layers. This way unidirectionally wound ropes 10 are mainly intended for use with spring elements with only one constant loading direction.

10 shows a spring element semifinished product 10 with oppositely layered winding in several layers 38 , every layer 38 includes a plurality of filament bundles 36 which are all substantially parallel to each other and rectified. The winding direction of the individual layers 38 to each other, however, is in opposite directions. Again, in a particular layer 38 individual threads, also known as support threads, be incorporated. For better processability and handling, it is advantageous to have a very thin outermost interwoven layer 38 to install.

Generally allow the threads 32 or thread bundle 36 . 37 mutually a mechanically positive and frictional cohesion, which allows a shift against each other, without a significant change in shape and structure of the spring element semifinished product 10 to effect. This is the rope 10 flexible, elastic to a certain extent and tractable. For the inner soul 20 If a material should be used which has sufficient strength properties even with transverse stress. In the case of fiber materials, glass fiber is particularly suitable here. For larger rope diameters, the use of certain thermoplastics or elastomers is suitable. For the reinforcing fiber cladding 30 forming thread bundle 36 . 37 All high-strength fiber materials such as glass, Kevlar, coal and drilling fiber are suitable. Up to a rope diameter of about 4 mm, glass fiber is particularly suitable for the inner soul. The flexible ropes 10 can be wound on rolls and drums, stored and made available for further processing.

Below are two variants of a method for producing the rope-shaped spring element semifinished product 10 described ( 11 . 13 ). In this manufacturing method, the above-described spring core body 20 with the spring core body 20 surrounding reinforcing fiber cladding 30 provided. Subsequently, at least the reinforcing fiber sheath 30 with a liquid or pasty, hardenable matrix material 78 soaked and thereby a preliminary mutual arrangement of the spring core body 20 and the reinforcing fiber cladding 30 set and a predetermined cross-sectional shape of the spring element semifinished product 10 educated.

The first method variant according to 11 is preferably suitable for ropes of thinner diameter. The second variant according to 13 is preferably suitable for ropes with thicker diameters.

In the first method variant according to 11 is from a pulley 70 a spring element semifinished product 10 , for example, with one in the 7 to 10 shown construction, and a not yet final cohesion of the components of the reinforcing fiber sheath 30 and the spring core body 20 over pulleys 72 unwound and provided for further processing. To promote the spring element semifinished product or rope 10 This is about a jig 74 with a rope tension regulator through a drinking basin 76 drawn. The drinking bowl 76 is with a corrosion-resistant matrix material 78 filled, preferably with liquid reaction resin, for example based on epoxy resin. The cable tension regulator of the tensioning device 74 is set in such a way that there is almost no tension on the watering bowl 76 located section of the rope 10 lies. The thread bundles 36 . 37 reinforcing fiber cladding 30 form in the This state of a loose cohesion, which allows the matrix material 78 due to the static pressure in the drinking basin 76 and due to capillary effects in the rope 10 penetrate and the individual threads or filaments 32 can wrap. About further pulleys 72 becomes the soaked rope 10 from the drinking basin 76 and a second tensioning device 75 with a second cable tension regulator in a nozzle-shaped tool 40 drawn. Here, the second voltage regulator is set so that the rope 10 in the area of the tool 40 taut.

12 shows this tool 40 , which for processing the rope-like spring element semifinished product 10 serves, in a cross section. The tool 40 comprises a nozzle-like shaped base body 42 with a protruding flange with holes 43 for stationary fixing of the tool 40 , The base body 42 has a continuous along the conveying direction F inner cavity, a conveying channel 44 provides.

The conveyor channel 44 is in the conveying direction F in a feed area 45 , a compression area 47 and a discharge area 48 divided. Viewed along the conveying direction F, the cross-sectional area of the conveying channel tapers 44 in the area of the feed area 45 starting from an inlet opening conical up to the compression area 47 and then expands in a steady curve to the outlet opening in the discharge area 48 , The compression area 47 This can also be formed only selectively. All transitions between the aforementioned areas are softly rounded. Preferably, as in 12 to recognize, points the delivery channel 44 a substantially circular cross section. Here, a first diameter D _e (inlet diameter) is greater than a second diameter D _k (compression diameter). Further, a third diameter D _a (outlet diameter) is larger than the second diameter D _k . Further, the first diameter D _e and the third diameter D _{a is} greater than the desired diameter of the rope 10 , The second diameter D _k as the minimum nozzle inner diameter, however, is substantially equal to or smaller than the desired diameter of the rope 10 ,

Stressed on train, the rope has 10 in particular, in the case of a rope with a counter-interwoven winding, the tendency to contract, whereby the bundles of threads 36 . 37 reinforcing fiber cladding 30 to each other and close to the inner soul 20 lay. This is excess matrix material 78 from the rope 10 squeezed out and usually stick to the rope surface. This process is already done by the tensile stress to transport the rope 10 before the rope 10 in the tool 40 enters. Then the rope goes through 10 the conveyor channel 44 , wherein the excess matrix material still remaining on the cable surface 78 at least partially in the feed area 45 is stripped off.

Then the rope 10 in the compression area 47 further compressed, including the last excess matrix material 78 from the rope 10 is pressed. The excess matrix material 78 can on the inclined inner surface of the conveyor channel 44 drain and in a catch basin 80 to be collected. Via a return line 82 becomes the collected excess matrix material 78 the drinking basin 76 recycled and can be used again. As a further effect, any air pockets will be due to the initial loose cohesion of spring core 20 and reinforcing fiber cladding 30 through the nozzle-like inner shape of the conveyor channel 44 and eliminated by the pressure component of the resin directed both to the cable interior and to the inlet opening of the feed area.

Hereinafter, the second process variant according to 13 explained. As already mentioned, this variant is primarily used for processing ropes 10 larger diameter, where the impregnation in a drinking bowl is difficult. The impregnation of the rope 10 takes place in this process variant during transport of the rope 10 through the delivery channel 44 the in 14 illustrated second embodiment of the tool 40 ,

From the basic principle, the impregnation takes place here by injecting the matrix material 78 in the conveyor channel 44 , To accomplish this, the tool is different 40 the second embodiment of the first embodiment of the tool 40 according to 12 in that viewed in the conveying direction F between the feed area 45 and the compression area 47 an injection area 46 is provided. This injection area 46 has along its length a constant cross-sectional area with a fourth diameter D _i . Alternatively, a cross-sectional shape tapering in the conveying direction F can also be used for the injection area 46 to get voted. The first diameter D _e (inlet diameter), the second diameter D _k (compression diameter) and the third diameter D _a (outlet diameter) behave relative to one another as already described above in connection with FIG 12 described. The additional fourth diameter D _i (injection diameter) is substantially the same size as the desired diameter of the rope 10 and preferably larger than the second diameter D _k .

To the matrix material 78 Being able to deploy includes the tool 40 a connection 50 , a supply line 52 , a ring channel 54 and several holes 56 , The matrix material 78 is powered by a worm-driven injection molding device 58 provided under a predetermined pressure and over the terminal 50 the supply line 52 fed. About the supply line 52 becomes the matrix material 78 in the ring channel 54 passed and finally over the holes 56 in the conveyor channel 44 brought in. This allows a fast and complete impregnation of the rope 10 and thus a fast passage speed of the rope 10 through the tool 40 ,

Downstream of the injection area 46 closes the compression area 45 to the components of the spring element semifinished product 10 in a mutual Po position with a close to the spring core body 20 adjacent reinforcing fiber cladding 30 to press and at the same time excess matrix material 78 to remove. The derivation of the excess matrix material 78 takes place in the same way as in the first method variant, preferably via the feed area 45 , but also about the discharge area 48 respectively. After passing through the tool 40 has the rope 10 its approximate cross-sectional shape provided later and can be further processed into a spring element with a spiral shape. The final cross-sectional shape receives the spring element after curing of the matrix material 78 ,

Such further processing is described below, can follow both methods described above and is therefore both in 11 as well as in 13 shown schematically. After passing through the tool 40 The rope is now on a rotating shaping body 100 in the form of a cylinder for forming the rope-like spring element semifinished product 10 wrapped in a spiral spring element semifinished product. In this winding process are cylinder diameter, rotation and speed of progress to the desired geometry of the desired spiral spring element semifinished product 10 Voted. Preferably, the shaping body 100 a surface 106 with a spiral groove 107 with a substantially semicircular to allow an exact winding.

To achieve a continuous manufacturing process, several shaping bodies can 100 . 102 . 104 with identical trained surface 106 and the same or different lengths are joined together. For this purpose, each shaping body 100 . 102 . 104 a first end 108 and a second end 109 on, being at the two ends 108 . 109 one connection each 110 to rotationally fixed connection with the respective adjacent shaping body 100 . 102 . 104 is provided. The connection 110 is preferably formed such that the adjacent shaping body 100 . 102 . 104 can be positively connected, for example, with a tongue and groove connection, either during the continuous manufacturing process, ie rotating forming bodies 100 . 102 . 104 or at an interruption of the winding process.

After completed winding, the molded and cured (Faserverbundwerkstoff-) spring element 200. slightly from the forming body 100 to be able to decrease, in a preferred embodiment, prior to winding of the spring element semifinished product 10 a foil tape 116 on the surface 106 wound. Later, the foil tape 116 under the fiber composite spring element wound on the forming body 200. be pulled out, so that a certain clearance or space is created and the fiber composite spring element 200. more easily from the forming body 100 can be removed.

Alternatively to a groove-like surface 106 can the shaping body 100 . 102 . 104 be designed as a simple round cylinder. In this case, it comes during the winding of the spring element semifinished product 10 to a slight flattening of the substantially round rope cross-section. Such a flattening to an elliptical cross-sectional shape is dependent on the ratio of the diameter of the round cylinder to the diameter of the rope as well as the tensile load with which the rope during the winding process is claimed. Since the rope diameter is small compared to the diameter of the cylinder and the rope just has to be wound so tightly that it does not slide off the cylinder, the change in shape to the elliptical cross section and thus the cross-sectional area change is small. As can be demonstrated with the Bredt's formulas known from the technical mechanics, the torsional strength of the slightly flattened cross section is thus only slightly changed. In addition, other variants of the shaping body 100 conceivable, although this can also be used as a lost form.

By winding the spring element semi-finished product gets a spiral-like shape. To the final (Faserverbundwerkstoff-) spring element 200. It is then produced in a curing device or heating chamber 118 driven, in which the matrix material 78 , preferably a reaction resin, hardens and that spring element 200. gets a stable form. For curing can be used instead of the heat chamber 118 , In particular, depending on the type of resin used, a UV light chamber or the like are used.

The continuously wound and now cured fiber composite spring element 200. , now also referred to as a spiral spring, can at the joint of two shaping body 100 . 102 . 104 by means of a separating device 120 be separated, so that one or more shaping body 100 . 102 . 104 together with the (Faserverbundwerkstoff-) spring element thereon 200. can be removed from the production. After pulling out the foil strip 116 receives the spring element 200. a game to the surface 106 of the shaping body and can be unwound or stripped from this. Subsequently, the shaping body the magazine 90 be returned. This enables a continuous manufacturing process.

Depending on the intended use of the spiral fiber composite spring element 200. a corresponding type of rope must be selected. For train-pressure springs come ropes 10 with opposing, interwoven winding or oppositely layered wound ropes 10 into consideration. In particular, care must be taken that a very close-meshed interweaving takes place, since otherwise due to the pressure component from the normal stresses of the reinforcing fiber sheath 30 for a Auswickeln the appropriately oriented thread bundles 36 . 37 and to a destruction of the spring element semifinished product 10 can lead. For spring element semi-finished products 10 with unilateral loading are ropes 10 with rectified winding of the thread bundle 36 . 37 suitable. Special attention is therefore on the winding direction of the thread bundles 36 . 37 during rope making and the subsequent winding of the rope 10 around the forming body 100 to judge.

The methods described above are preferably carried out fully automatically, but are in principle also manually executable. Furthermore, in particular small series with spring element semifinished products 10 large dimension with a lost positive shape, z. B. a cylindrical molding body with a semicircular groove made of hard foam plastic or molding sand. The lost form can be destroyed to remove the hardened spring. Due to the great hardness of the fiber materials are used for the tool 40 , in particular the base body 42 , Materials made of hardened and polished steel alloys or suitable ceramics used.

Furthermore, when using appropriate resin types for the matrix material 78 the rope 10 also be provided as a "prepreg" and contains the resin required for curing in a rubbery, dry state 10 can be stored on rolls for further processing. Thus, no elaborate systems are required for impregnation and the prefabricated ropes 10 can with the shaping body 100 be brought into a spiral shape and then in a heat chamber 118 be cured.

With the winding method described above are preferably spiral or cylindrical (Faserverbundwerkstoff-) spring elements 200. or coil springs produced. Alternatively, but also flat spring elements 200. or spring elements 200. be formed with rectangular cross-section and slightly rounded corner radii.

The molded with the novel spring element semi-finished products 10 have a density greater than or equal to about 1.9 g / cm ³ . For spring element semifinished products 10 greater dimension, the density can be less than 1 g / cm ³ , since in this case as a material for the spring core body 20 lightweight plastic foams can be used and make up the bulk of the spring volume. The actual torsional load carrying reinforcing fiber sheath 30 takes up only a small part of the spring weight. The weight of a spring made of fiber composite material is therefore at least 60% lower than that of a comparable steel spring.

In the winding of the spring element semifinished product 10 around the spring form forming spring shaped body 100 the orientation of the bundles of fibers remains 36 . 37 received in the rope. Ideally, the pitch of the helical winding is the filament bundle 36 . 37 about 45 ° to the longitudinal direction L of the spring core body 20 inclined. The comparatively thin annular cross section of the reinforcing fiber sheath 30 takes the case of such fiber composite spring elements 200. decisive torsional stress ideal. In the direction of the fiber flow, only normal stresses occur, whereby the direction-oriented material properties can be ideally exploited. Here comes the larger compared to the material steel modulus of elasticity of the fiber material to fruition. The almost negligible transverse forces takes the spring core body 20 on. Due to the high dynamic alternating strength of composite materials compared to conventional steel, the fiber composite spring elements according to the invention 200. an increased life. In addition, fiber composite spring elements 200. Made of fiber-reinforced plastic resistant to a variety of corrosive media.

10

Spring element semis

20

Spring core body

30

Reinforcing-fiber sheath

32

thread

36

thread bundle

37

thread bundle

38

layer

40

Tool

42

base body

43

drilling

44

delivery channel

45

feeding

46

injection area

47

compression region

48

discharge area

50

connection

52

supply

54

annular channel

56

drilling

58

injection molding machine

70

role

72

idler pulley

74

jig

75

jig

76

drinking trough

78

Matrix material

80

catch basin

82

Return line

90

magazine

100

body shaping

102

body shaping

104

body shaping

106

surface

107

groove

108

first The End

109

second The End

110

connection

116

foil tape

118

heat chamber

120

separating device

200

Fiber composite spring element

L

longitudinal direction

F

conveying direction

D _e

first diameter

D _k

second diameter

D _a

third diameter

D _i

fourth diameter

Claims (45)

Method for producing a cable-like spring element semifinished product ( 10 ), comprising the following steps: a) providing a spring core body ( 20 ) and a spring core body ( 20 ) surrounding reinforcement fiber cladding ( 30 ) containing at least one fiber filament ( 32 ) having; b) impregnating at least the reinforcing fiber sheath ( 30 ) with a liquid or pasty, curable matrix material ( 78 ), and thereby - establishing a provisional mutual arrangement of the spring core body ( 20 ) and the reinforcing fiber cladding ( 30 ) and - formation of a predetermined cross-sectional shape of the spring element semifinished product ( 10 ). Method according to claim 1, characterized in that the spring core body ( 20 ) on its outside against penetration of the liquid or pasty, curable matrix material ( 78 ) is sealed. Method according to claim 1 or 2, characterized in that the spring core body ( 20 ) for the liquid or pasty curable matrix material ( 78 ) is impermeable. Method according to one of the preceding claims, characterized in that the spring core body ( 20 ) is rubbery or foam-like elastic and reversible compressible. A method according to claim 1, characterized in that in step b) also the spring core body ( 20 ) is soaked. Method according to one of the preceding claims, characterized in that when impregnating an excess amount of the matrix material ( 78 ) is supplied. Method according to one of the preceding claims, characterized in that the spring element semifinished product ( 10 ) for impregnation with an excess amount of the matrix material ( 78 ) by a with the liquid or pasty, curable matrix material ( 78 ) filled drinking bowl ( 76 ). Method according to one of the preceding claims, characterized in that the spring element semifinished product ( 10 ) for impregnation through a conveyor channel ( 44 ) and the liquid or pasty curable matrix material ( 78 ) in the conveyor channel ( 44 ) is injected. Method according to one of the preceding claims, characterized in that the spring element semifinished product ( 10 ) after soaking through a conveyor channel ( 44 ) is transported. Method according to one of the preceding claims, characterized in that the spring element semifinished product ( 10 ) - during the drinking; and / or - compressed after impregnation and thereby elastically and reversibly deformed. Method according to one of the preceding claims, characterized in that the spring core body ( 20 ) is elastically and reversibly compressible and during the compression of the spring core body ( 20 ) is compressed and so by means of the spring core body ( 20 ) against the inside of the reinforcing fiber sheath ( 30 ) directed back pressure is generated. Method according to one of the preceding claims, characterized in that after impregnation any excess matrix material ( 78 ) Will get removed. A method according to claim 12, characterized in that the removal of the excess matrix material ( 78 ) via the delivery channel ( 44 ) or by means of the delivery channel ( 44 ) he follows. Method according to one of claims 12 or 13, characterized in that removed excess liquid or pasty curable matrix material ( 78 ) ( 78 ; 80 ) and used again for drinking ( 78 ; 82 ) becomes. Method according to one of the preceding claims, characterized in that in a step c) the matrix material ( 78 ) is at least partially cured, so that the spring element semifinished product ( 10 ) has a prepreg-like and largely dry, limp, rope-like state. Tool for processing a cable-like spring element semifinished product ( 10 ) with a delivery channel ( 44 ), through which the spring element semifinished product ( 10 ) is conveyable and in the conveying direction (F) a feed area ( 45 ), a compression area ( 47 ) and a discharge area ( 48 ), wherein the conveyor channel ( 44 ) in the conveying direction (F) from an input of the feed region ( 45 ) to the compression area ( 47 ), and wherein the cross-sectional area or the diameter (D _e ) of the input of the feed area ( 45 ) greater than or equal to the outer diameter of the in the delivery channel ( 44 ) subsidized spring element semifinished product ( 10 ), and wherein the cross-sectional area or the diameter (D _K ) of the compression region ( 47 ) smaller than the desired cross-sectional area to be formed or the desired outer diameter of the spring element semifinished product ( 10 ). Tool according to claim 16, characterized in that between feed area ( 45 ) and compression range ( 47 ) an injection area ( 46 ), and in the area of the injection area ( 46 ) at least one bore ( 56 ) in the conveyor channel ( 44 ), through which the spring element semifinished product ( 10 ) the liquid or pasty, hardenable matrix material ( 78 ) can be fed. Tool according to claim 16 or 17, characterized in that the cross-sectional area or the diameter (D _A ) of the discharge area ( 48 ) substantially equal to or larger than the desired cross-sectional area to be formed or the desired outer diameter of the spring element semifinished product ( 10 ). Method for producing a helical spring element ( 200. ) by means of a spring element semifinished product ( 10 ), with the following steps: a) winding of the impregnated and / or at least partially cured spring element semifinished product ( 10 ) around a shaping body ( 100 ) with a surface which is based on the final geometric shape of the spring element ( 200. ) and / or depicts it; and b) complete curing ( 118 ) of the liquid or pasty curable matrix material ( 78 ), whereby a spiral spring element ( 200. ) is formed. Method according to claim 19, characterized in that the shaping body ( 100 ) another shaping body ( 102 . 104 ) by means of a twist-proof, preferably form-fitting, connection ( 110 ) is connected. A method according to claim 19 or 20, characterized in that the further shaping body ( 102 . 104 ) is connected with or without interrupting the winding process. Method according to one of claims 19 to 21, characterized in that the liquid or pasty, hardenable matrix material ( 78 ) by means of heat ( 118 ) and / or cured by a photochemical reaction, in particular by means of UV radiation. Method according to one of claims 19 to 22, characterized in that before step a) a band, preferably a foil strip ( 116 ), predetermined thickness on the shaping body ( 100 . 102 . 104 ) is wound. Method according to one of claims 19 to 23, characterized in that the hardened spiral spring element ( 200. ) is cut to a predetermined length ( 120 ) becomes. Method according to one of claims 19 to 24, characterized in that the spring core body ( 20 ) after complete curing of the liquid or pasty curable matrix material ( 78 ) from the spiral spring element ( 200. ) Will get removed. Shaping body ( 100 ) for forming a cable-like spring element semifinished product ( 10 ) in one helical spring element semifinished product, wherein the shaping element ( 100 ) one on the geometric shape of the spiral spring element semifinished product ( 200. ) or surface reflecting this shape ( 106 ) and at least one end ( 108 . 109 ) a connection to the connection ( 110 ) with a further shaping body ( 102 . 104 ) having. Shaping body ( 100 ) according to claim 26, characterized in that the connection for forming a positive connection ( 110 ) with the further shaping body ( 102 . 104 ) is trained. Shaping body ( 100 ) according to claim 26 or 27, characterized in that the connection has a groove and / or spring. Shaping body ( 100 ) according to one of claims 26 to 28, characterized in that the surface ( 106 ) at least one groove ( 107 ) for spiral-like shaping of the spring element semifinished product ( 200. ), and the rope-like spring element semifinished product ( 10 ) in this groove ( 107 ) around the shaping body ( 100 ) is windable. Spiral spring element ( 200. ) with a hollow, tubular fiber composite spring element body ( 30 ). Spiral spring element ( 200. ) according to claim 30, characterized in that the fiber composite spring element body ( 30 ) comprises at least one fiber or filament of glass, Kevlar, carbon or boron fiber. Spiral spring element ( 200. ) according to claim 30 or 31, characterized in that the fiber composite spring element body ( 30 ) least a thread ( 32 ) or a bundle of threads ( 36 . 37 ) formed of a plurality of fibers and / or filaments. Spiral spring element ( 200. ) according to claim 32, characterized in that the thread ( 32 ) or the thread bundle ( 36 . 37 ) is wound in a predetermined winding. Spiral spring element ( 200. ) according to one of claims 30 to 33, characterized in that the thread bundle ( 36 . 37 ) several groups of threads ( 32 ), each group being opposed or rectified with respect to a longitudinal direction (L) of the fiber composite spring element (FIG. 200. ) is wound. Spiral spring element ( 200. ) according to one of claims 30 to 34, characterized in that the threads ( 32 ) a group with the threads ( 32 ) are interwoven in another group. Spiral spring element ( 200. ) according to one of claims 30 to 35, characterized in that a group comprises a layer ( 38 ) of the fiber composite spring element body ( 30 ) formed along the longitudinal direction (L) substantially at a uniform distance from the longitudinal axis of the spring element ( 200. ) is removed. Spiral spring element ( 200. ) according to claim 30, characterized in that the hollow, tubular fiber composite spring element body ( 30 ) with a spring core body ( 20 ) is filled out. Spiral spring element ( 200. ) according to claim 37, characterized in that the spring core body ( 20 ) is formed of a fiber or a fiber bundle. Spiral spring element ( 200. ) according to claim 37 or 38, characterized in that the spring core body ( 20 ) comprises a thermoplastic or elastomeric material or a fiber material, preferably glass fiber. Method for producing a helical spring element ( 200. ), wherein with a method according to one of claims 1 to 15, a cable-like spring element semifinished product ( 10 ) and wherein with a method according to one of claims 19 to 25, the cable-like spring element semifinished product ( 10 ) to a spiral-shaped spring element semifinished product ( 10 ) and by curing from the spiral spring element semifinished product ( 10 ) the spiral spring element ( 200. ) will be produced. Device for producing a helical spring element ( 200. ) with a hollow, tubular fiber composite spring element body ( 30 ), comprising a drinking basin ( 76 ) for impregnating a cable-like spring element semifinished product ( 10 ), a tool ( 40 ) according to one of claims 16 to 18, at least one shaping body ( 100 ) for forming the cable-like spring element semifinished product ( 10 ) in a spiral spring element semifinished product ( 10 ) according to one of claims 20 to 25 and a curing device ( 118 ) for curing the helical spring element semifinished to form the spiral spring element ( 200. ). Apparatus according to claim 41, characterized by at least one tensioning device ( 74 . 75 ) for tensioning the cable-like spring element semifinished product ( 10 ). Apparatus according to claim 41 or 42, since characterized by a catch basin ( 80 ) for collecting excess matrix material ( 78 ). Device according to one of claims 41 to 43, characterized by a return line ( 82 ) containing the excess matrix material ( 78 ) from the catch basin ( 80 ) to the drinking basin ( 76 ). Device according to one of claims 41 to 44, characterized by a separating device ( 120 ) for cutting the rope-like, the spiral-shaped spring element semifinished product ( 10 ) or the spiral spring element ( 200. ).