DE102009031336A1 - Fiber arrangement for use in thermosetting resin-based composites, e.g. automobile components, comprises reinforcing fibers and crosslinkable reactive resin fibers - Google Patents

Abstract

A fiber arrangement (1) for producing fiber-reinforced composite materials with a thermosetting resin matrix, comprising several reinforcing fibers (2), includes a fibrous crosslinkable reactive resin which forms the matrix and is located adjacent to the reinforcing fibers. Independent claims are included for: (1) a fiber-reinforced composite material including the fiber arrangement; (2) a fibre composite component for an automobile, obtained from the claimed fiber-reinforced composite material; and (3) the production of a fibre composite component, involving (a) shaping the fiber arrangement (1), in such a way as to optimize force flow and tension in the component to be produced, and (b) hardening the reactive resin to form the composite component.

Description

The The invention relates to a fiber assembly for producing fiber-reinforced Composite materials with a thermoset matrix, in particular suitable for the production of fiber composite components. Furthermore, the corresponding manufacturing process for fiber composite components using a fiber arrangement according to the invention disclosed.

Around in the automotive industry for weight optimization also for load-bearing Design components lighter components with desired To use strength properties is increasingly on fiber-reinforced Composite components used. It is known Semi-finished products, also called prepregs, based on thermoset matrices to create an impregnation of the fibers with the still do not require crosslinked resin. Such prepregs can immediately further processed. The disadvantage is in use the well-known prepregs to date that they in ribbon form be created, resulting in geometric constraints during processing into fiber-reinforced plastic components leads.

Around Overcome disadvantages caused by limitations in the component geometry of the as a substrate material web or carrier material band present fiber fabrics, which is impregnated and finally processed further become, the technology for the production of so-called "comingled yarns" was created. In this case, a yarn is created that consists of at least two threads, respectively fibers, provided with different properties is.

That's how it describes US 2008 02 99 856 A1 a process for producing continuous coextruded "intermingled" glass fibers and endless organic thermoplastic fibers which enable non-spinnable compounds to be incorporated into thermoplastic fibers. Here, the thermoplastic fibers are obtained by co-extruding the thermoplastic material serving as a core and a thermoplastic material containing at least one non-spinnable compound. The principle of creating a fiber core, which is enveloped by another material with completely different properties, is also in the WO 99/31025 There is disclosed a glass fiber coating compound containing polymerizable constituents.

outgoing From this prior art, it is desirable to have a Fiber assembly for the production of fiber reinforced composites with a thermosetting matrix that allows any geometric component form of the fiber-reinforced composite material to create in a simple way. Likewise, a corresponding fiber reinforced composite with a thermoset Matrix are created. Another task is a procedure to provide that allows fiber composite components of such Produce fiber assemblies.

These Objects are provided with an improved fiber assembly having the features of claim 1, and with an improved fiber reinforced Composite material with the features of claim 11 and by the improved fiber composite component having the features of the claim 12 solved. Further developments emerge from the subclaims.

The Task, an improved process for the production of fiber composite components is provided by the method having the features of the claim 13 solved. In the subclaims are appropriate Embodiments of the method claimed.

The Fiber assembly according to the invention, which is a plurality of reinforcing fibers and for the production of fiber reinforced composites with a thermoset Matrix is suitable, comprises in a first embodiment a crosslinkable one besides the reinforcing fibers Reaction resin, which is also in the form of fibers. In the Fiber arrangement are the fibrous reaction resin elements arranged adjacent to the reinforcing fibers.

The reaction resin may be present as a reaction resin fiber without further components or the reaction resin fiber may contain a core of a carrier fiber. It is also possible that the reaction resin surrounds a reinforcing fiber and thus also has the fiber shape. Thus created fiber assemblies consisting of either a combination of reinforcing fibers and reaction resin fibers or multiple reinforcing fibers surrounded by reaction resin advantageously enable them to be spun into yarn. The presentation of components of any geometry from the fiber reinforced composite is made possible without wasting fiber material, while at the same time eliminates an additional impregnation in the representation of the component, since the matrix-forming reaction resin content is already included in the fiber assembly and are not applied during the molding got to. Inasmuch as the fiber assembly is not ribbon or ribbon, but is presented as a spun yarn of greater or lesser diameter, which can be directly brought and cured by any processing technology such as weaving, knitting, embroidering or other directly in the form of the component; a direct method is provided which is advantageous reduced in the production of lightweight components, the value creation stage number and thus enables cost-effective production. The use of the fibrous reaction resin in the fiber assembly allows the simultaneous impregnation of the reinforcing fiber and the shaping of the component. This advantageously reduces the cycle time in the manufacturing cycle of the components, which can contribute to significant cost reductions.

Especially it is advantageous if the reaction resin is intermediate is meltable or at least softenable. This means that Rection resin before it hardens molten or at least plastically deformable. This is possible the reaction resin immediately before curing to a Reshaping dense matrix.

Around To further protect the fiber assembly, the fiber can a sizing be surrounded as a protective material. This sizing is applied to the fiber before the reaction resin is applied becomes.

at the reinforcing fibers may be glass or carbon fibers whereas the carrier fiber is one Thermoplastic fiber such as a polyester, a polyamide, a polyethylene or a polypropylene fiber. This has the advantage that for the carrier fiber a variety of materials is available, the optional for reinforcement the fiber assembly can, but does not have to, as in the case of the polyester.

to Formation of the thermosetting matrix can be advantageous as a reaction resin a phenyl resin, a polyurethane or a polyester resin, in particular a vinyl ester urethane hybrid resin can be selected. For networking These resins can be advantageous in the appearance of the Molding be melted at low temperatures. These Temperature is more preferably in the range of about 40-50 ° C. Likewise are also suitable epoxy resins suitable. Preference is given to Reaction resins set to melting temperatures in the range of 40 to 70 ° C. For thermosetting reaction resins, the height the melting or softening temperature limited by that with increasing temperature also the start of curing begins.

By the intermediate melting becomes a low expenditure of energy required. In particular, but forms by the melting Reaction resin a uniform, or continuous Matrix phase off. The confluence of the resin may be due to external Print supported. This is particularly useful when the reaction resin only softens before curing.

One suitable resin is available from DSM under the name Daron XP 45 available. (DSM Composite Resins Germany GmbH, Ludwigshafen / Rhine). In the fiber arrangement, a plurality of reinforcing fibers with a variety of reaction resin fibers as approximate parallel arranged individual fibers arranged and of the sizing be enveloped and thus form a so-called "roving". A roving can also be obtained if a variety of Reinforcing fibers surrounded by reaction resin, summarized in parallel and surrounded by the sizing.

It it is also possible that the reaction resin fiber itself or the reinforcing fiber or carrier fiber surrounding reaction resin layer a polygonal, in particular a has rectangular cross-section. This ensures that a variety arranged such fibers with rectangular cross section packed closer can be.

through suitable areas of creative processing like weaving, knitting, embroidering, etc., the fiber arrangement becomes one Component blank, a so-called "preform" processed, so that after curing let the reactive resin content the fiber assembly, the component as a fiber reinforced composite material is present.

The inventive method for the preparation of Fiber composite components therefore initially includes the creation a fiber assembly of a plurality of reinforcing fibers and a crosslinkable fibrous reaction resin for Formation of the thermoset matrix. The reaction resin is respectively arranged adjacent to the reinforcing fibers. It deals the reaction resin around a fibrous structure, the a carrier fiber core or the reinforcing fiber may contain. The fiber composite component is connected to the fiber assembly formed, wherein the shaping of the fiber assembly, based on the produced fiber composite component power flow and voltage optimized he follows. In a final step, the reaction resin will cure left and thus obtained the fiber composite component. The curing can be done thermally or photoinitiated. For thermal curing it is sufficient to heat the resin to 40-50 ° C to have. The photoinitiated curing system is preferred a radical curing system that uses photoinitiators includes.

The Incorporation of the energy for curing can, among other things also via microwave irradiation, infrared radiation, UV exposure or induction process done.

The Forming the fiber composite component can thereby weaving, knitting, Spinning or shaping the fiber assembly in another way included.

In order to it is possible in a few steps a fiber arrangement to gain the creation of fiber composite components, which makes it possible in the Direct method Lightweight components made from a fiber-reinforced material To produce composite material for the design of automotive elements.

These and further advantages will become apparent from the following description and the accompanying figures further apparent.

Of the Reference to the figures in the description is for assistance the description. Objects or parts of objects, which are essentially the same or similar be provided with the same reference numerals. The figures are merely a schematic representation of an embodiment of the Invention.

there demonstrate:

1 a schematic representation of the fiber assembly comprising between reaction fibers arranged reaction resin fibers,

2 a schematic representation of a fiber assembly comprising reaction resin fibers arranged between reinforcing fibers with a carrier fiber core,

3 a schematic representation of a fiber assembly comprising the plurality of juxtaposed reaction resin fibers with reinforcing fiber core, surrounded by a size,

4 a schematic fiber arrangement of a plurality of reinforcing fibers surrounded by reaction resin, which are combined as a parallel bundle and enveloped by a sizing,

5a a cross-sectional view of a reinforcing fiber, which is surrounded by a reaction resin fiber having a rectangular cross section,

5b a round fiber cross-section reinforcing fiber concentrically surrounded by a round-sectioned reaction resin fiber, wherein the volume ratio of reaction resin to reinforcing fiber is 8: 1,

5c a cross-sectional view of a circular reinforcing fiber concentric surrounded by a reaction resin fiber, wherein the volume ratio of the reaction resin to reinforcing fiber is 3: 1.

The Fiber arrangement according to the invention for the production of fiber reinforced composites with duroplastic Matrix refers to the use of multiple reinforcing fibers in a fiber arrangement. These reinforcing fibers become adjacent arranged to crosslinkable fibrous reaction resins. The reinforcing fibers may be glass or carbon fibers act and the reaction resin, the fibrous formed can be a phenyl resin, a polyurethane or a polyester resin, especially a vinyl ester-urethane hybrid resin Act as it is under the brand name Daron XP 45 from the manufacturer DSM (DSM Composite Resins Germany GmbH, Ludwigshafen / Rhein) becomes. This is advantageously achieved that impregnation tasks for a composite material according to the invention, the can be created from this fiber array, by the integrated Resin fibers is taken over. By the reaction resin fibers can be arranged together with the reinforcing fibers can a fiber-reinforced component of any desired Component geometry are generated, which after crosslinking or Curing the thermosetting reaction resin the desired Stability, tear resistance and elasticity having.

By it is the use of the fibrous reaction resin possible to compensate for the disadvantage of lack of strength of reaction resin fibers, by using thermoplastic fibers as carrier fibers for the Reaction resin can be used. So the reaction resin fiber can Carrier fiber core or a reinforcing fiber core exhibit.

As 1 shows, in the fiber arrangement 1 reinforcing fibers 2 in addition to reaction resins in fiber form 3 to be ordered. Alternatively it is possible to use the in 2 to choose shown arrangement in which the reinforcing fibers 2 alternatively with carrier fibers 4 are arranged, wherein the carrier fibers 4 merely as the core of a reaction resin fiber 3 serve. Another alternative is in the 3 shown arrangement in which the reinforcing fiber 2 the core of a reaction resin fiber 3 which finally forms of a sizing layer 5 is surrounded.

The simplicity 5 facilitates further processing of the fiber assembly 1 For example, when weaving, because the sizing 5 that from the fiber assembly 1 made yarn smoother and more resistant to mechanical stress. Such a suitable yarn for further processing by a spun fiber assembly 1 be formed.

In 3 In this case, the yarn is formed of three fibers, each fiber being provided by three layers which pass through the reinforcing fiber 2 the necessary stability, by the reaction resin fiber 3 the crosslinkability and thus formability and through the sizing 5 obtains a protective film for the fiber in the mechanical processing of the yarn.

Next, the fibers in the known arrangement 1 as "Rovings" 1' be provided as they are in 4 to be shown. The reinforcing fibers 2 , each containing the core of a reactive resin fiber 3 are arranged substantially side-by-side as parallel individual fibers and bundled by a sizing layer 5 surrounded as a protective mantle. The sizing layer 5 may advantageously be selected from a material that is strong enough to permit fiber processing such as stitching, weaving or knitting and thus to provide a component in a desired shape from the fibers so that the composite can be made by crosslinking the reactive resin portion.

To can, as soon as the component from the processed fiber assembly accordingly molded, the fiber reinforced composite produced for example, by heating the material which is in the range of about 40-50 ° C can lie when the desired reaction resin for training the thermosetting matrix, a phenyl resin, a polyurethane or a polyester resin, in particular the said vinyl ester-urethane hybrid resin is. This is the arranged in all the above cases Fiber material already impregnated and yet storable in front. The advantageous shelf life arises because the Reaction resin is solid and stops reacting if it is not is reacted to what can be achieved if either the desired heat of reaction is applied or a photochemical polymerization is stimulated by the Reaction resin fibers of the fiber assembly of the necessary exposure be subjected.

In addition, to achieve better packing densities, it is possible as in 5a shown the reinforcing fiber core 2 with a reaction resin fiber 3 to surround, which has a rectangular shape in cross section.

In order to achieve certain material properties, the volume ratio of the reaction resin to the reinforcing core can also be varied 5b exemplifies the cross section of a fiber of a reinforcing fiber core 2 surrounded by a reaction resin fiber 3 , wherein the volume of the reaction resin is about eight times as large as the volume of the reinforcing core. In the 5c shown fiber shows a lower reaction resin volume ratio: Here, the volume fraction of the reaction resin fiber 3 only three quarters of the total volume, whereas the reinforcing fiber 2 a quarter of the volume.

In the aforementioned cases in which the reinforcing fiber immediately adjacent to the reaction resin, the storable, cold reaction resin once it has been shaped and kept in shape should be heated, and thus networked. In order to the reinforcing fibers are impregnated accordingly and the resin can be allowed to cure, so that is advantageous the fiber-reinforced according to the invention Composite materials are obtained in the lightweight construction.

Corresponding sees the inventive method for production a fiber composite component with a thermoset matrix, that first, the fiber assembly of a plurality of reinforcing fibers and a crosslinkable fibrous reaction resin with the fibrous reaction resin adjacent to the reinforcing fibers is arranged. This is the Reaction resin formed into fiber, which is covered with a carrier fiber core or a reinforcing fiber core can be provided. It follows the molding of the fiber composite component, which is the fiber assembly wherein the shaping of the fiber arrangement, based on the produced fiber composite component, power flow and voltage optimized he follows. When molding or just before curing the reaction resin can be melted by heating or at least softened to a uniform Set matrix or continuous matrix phase. After all will cure the reaction resin in a final step left so that the fiber composite component in its final form formed. The curing can be thermally or photoinitiated respectively. During thermal curing, the step takes place of melting or softening expediently during the heating phase for thermal curing or as a sub-process step of the curing process.

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• US 20080299856 A1 [0004]
• WO 99/31025 [0004]

Claims (20)

Fiber arrangement ( 1 ) for the production of fiber-reinforced composite materials with a thermosetting matrix, wherein the fiber arrangement ( 1 ) a plurality of reinforcing fibers ( 2 ), characterized in that the fiber arrangement ( 1 ) comprises a crosslinkable fibrous thermosetting matrix-forming reaction resin, wherein the reaction resin adjacent to the reinforcing fibers ( 2 ) is arranged. Fiber arrangement ( 1 ) according to claim 1, characterized in that the reaction resin - a reaction resin fiber ( 3 ), - a reaction resin fiber ( 3 ) with a carrier fiber core ( 4 ), or - the reinforcing fiber ( 2 ) surrounds. Fiber arrangement ( 1 ) according to claim 2, characterized in that a size ( 5 ) the reaction resin fiber ( 3 ) surrounds. Fiber arrangement ( 1 ) according to at least one of claims 1 to 3, characterized in that the reinforcing fiber ( 2 ) is a glass fiber or a carbon fiber. Fiber arrangement ( 1 ) according to at least one of claims 1 to 4, characterized in that the reaction resin is a phenyl resin, a polyurethane or a polyester resin, in particular a vinyl ester-urethane hybrid resin, which is fusible or at least softenable before curing. Fiber arrangement ( 1 ) according to at least one of claims 2 to 5, characterized in that the carrier fiber ( 4 ) is a thermoplastic fiber, in particular a polyester, a polyamide, a polyethylene or a polypropylene fiber. Fiber arrangement ( 1 ) according to at least one of claims 2 to 6, characterized in that - a plurality of reinforcing fibers ( 2 ) with a plurality of reaction resin fibers ( 3 ) and / or - a plurality of surrounding with the reaction resin reinforcing fibers ( 2 ) arranged as approximately parallel individual fibers and from a sizing ( 5 ) are wrapped. Fiber arrangement ( 1 ) according to at least one of claims 2 to 7, characterized in that the carrier or the reinforcing fiber ( 2 ) surrounding reaction resin fiber ( 3 ) has a polygonal, in particular a rectangular cross-section. Fiber arrangement ( 1 ) according to at least one of claims 2 to 8, characterized in that a reaction resin portion of the fiber arrangement ( 1 ) over a volume ratio of the reaction resin fiber ( 3 ) and the carrier or reinforcing fiber ( 2 . 4 ) is adjustable. Fiber arrangement ( 1 ) according to at least one of claims 1 to 9, characterized in that the fiber arrangement ( 1 ) is a spun yarn. Fiber-reinforced composite material with a thermosetting matrix, characterized in that the fiber-reinforced composite material has a fiber arrangement ( 1 ) according to at least one of claims 1 to 10, comprising a plurality of reinforcing fibers ( 2 ) and a crosslinkable fibrous thermosetting resin forming reaction resin adjacent to the reinforcing fibers ( 2 ) is arranged. Fiber composite component for a motor vehicle, characterized characterized in that the fiber composite component of a fiber-reinforced Composite material according to claim 11. A method of manufacturing a fiber composite component, comprising the steps of: a) providing the fiber assembly ( 1 ) of a plurality of reinforcing fibers ( 2 ) and a crosslinkable fibrous thermosetting resin forming reaction resin, and arranging the reaction resin adjacent to the reinforcing fibers ( 2 b) forming the fiber composite component with the fiber assembly ( 1 ), wherein the shaping of the fiber arrangement ( 1 ) Based on the fiber composite component produced kraftfluß- and voltage optimized, and c) curing of the reaction resin and forming the fiber composite component. Method according to claim 13, characterized in that that the curing (c) an intermediate melting or softening comprises the reaction resin. Method according to claim 14, characterized in that that when melting or softening a uniform or continuous matrix phase is formed. The method of claim 15, comprising the step of - Forming the reaction resin to a reaction resin fiber. The method of claim 16, comprising the step of forming the reaction resin into a reaction resin fiber incorporating a carrier fiber kernels 4 ), or - forming the reaction resin into a reaction resin fiber with the incorporation of a reinforcing fiber core ( 2 ). Method according to at least one of the claims 13 to 17, comprising the step of thermal and / or photoinitiated Curing. The method of claim 18, wherein the thermal Curing at a temperature in the range 40-70 ° C, preferably 40-50 ° C takes place. Method according to at least one of claims 13 to 19, comprising the step of interweaving, knitting, spinning, embroidering or shaping the fiber arrangement ( 1 ) in another way for shaping the fiber composite component.

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