DE102010003356A1 - Component manufacturing method for e.g. aircraft, involves impregnating added reinforcement fibers with polymer matrix for forming component from elements, where reinforcement fibers are disrupted along parting plane - Google Patents
Component manufacturing method for e.g. aircraft, involves impregnating added reinforcement fibers with polymer matrix for forming component from elements, where reinforcement fibers are disrupted along parting plane Download PDFInfo
- Publication number
- DE102010003356A1 DE102010003356A1 DE102010003356A DE102010003356A DE102010003356A1 DE 102010003356 A1 DE102010003356 A1 DE 102010003356A1 DE 102010003356 A DE102010003356 A DE 102010003356A DE 102010003356 A DE102010003356 A DE 102010003356A DE 102010003356 A1 DE102010003356 A1 DE 102010003356A1
- Authority
- DE
- Germany
- Prior art keywords
- component
- reinforcing fibers
- polymeric matrix
- impregnated
- joining
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000011159 matrix material Substances 0.000 title claims abstract description 57
- 239000000835 fiber Substances 0.000 title claims abstract description 24
- 238000004519 manufacturing process Methods 0.000 title claims description 17
- 229920000642 polymer Polymers 0.000 title abstract description 4
- 230000002787 reinforcement Effects 0.000 title abstract 6
- 238000000034 method Methods 0.000 claims abstract description 45
- 239000002131 composite material Substances 0.000 claims abstract description 13
- 239000004744 fabric Substances 0.000 claims abstract description 11
- 239000012783 reinforcing fiber Substances 0.000 claims description 92
- 238000005304 joining Methods 0.000 claims description 44
- 238000005470 impregnation Methods 0.000 claims description 20
- 229920005992 thermoplastic resin Polymers 0.000 claims description 14
- 229920005989 resin Polymers 0.000 claims description 13
- 239000011347 resin Substances 0.000 claims description 13
- 239000000463 material Substances 0.000 claims description 11
- 229920001187 thermosetting polymer Polymers 0.000 claims description 10
- 230000004888 barrier function Effects 0.000 claims description 6
- 229920001169 thermoplastic Polymers 0.000 claims description 4
- 239000004416 thermosoftening plastic Substances 0.000 claims description 3
- 238000005520 cutting process Methods 0.000 abstract description 2
- 238000010276 construction Methods 0.000 description 7
- 230000005540 biological transmission Effects 0.000 description 5
- 238000002844 melting Methods 0.000 description 4
- 230000008018 melting Effects 0.000 description 4
- 230000000295 complement effect Effects 0.000 description 3
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- 238000007731 hot pressing Methods 0.000 description 3
- 239000004696 Poly ether ether ketone Substances 0.000 description 2
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- 230000001070 adhesive effect Effects 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 230000002349 favourable effect Effects 0.000 description 2
- 230000008595 infiltration Effects 0.000 description 2
- 238000001764 infiltration Methods 0.000 description 2
- 229920002530 polyetherether ketone Polymers 0.000 description 2
- 229920001601 polyetherimide Polymers 0.000 description 2
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- 239000004962 Polyamide-imide Substances 0.000 description 1
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- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000000903 blocking effect Effects 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
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- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 229920001652 poly(etherketoneketone) Polymers 0.000 description 1
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- 229920002312 polyamide-imide Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920000069 polyphenylene sulfide Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
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- 230000003313 weakening effect Effects 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Images
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/7394—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/7394—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
- B29C66/73941—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset characterised by the materials of both parts being thermosets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
- B29L2031/082—Blades, e.g. for helicopters
- B29L2031/085—Wind turbine blades
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
- B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING
- B63B2231/00—Material used for some parts or elements, or for particular purposes
- B63B2231/40—Synthetic materials
- B63B2231/52—Fibre reinforced plastics materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B64—AIRCRAFT; AVIATION; COSMONAUTICS
- B64C—AEROPLANES; HELICOPTERS
- B64C1/00—Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
- B64C2001/0054—Fuselage structures substantially made from particular materials
- B64C2001/0072—Fuselage structures substantially made from particular materials from composite materials
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
- F05C2253/00—Other material characteristics; Treatment of material
- F05C2253/04—Composite, e.g. fibre-reinforced
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
- F05C2253/00—Other material characteristics; Treatment of material
- F05C2253/22—Reinforcements
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/70—Wind energy
- Y02E10/72—Wind turbines with rotation axis in wind direction
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/40—Weight reduction
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Abstract
Description
Die vorliegende Erfindung betrifft ein Verfahren zur Herstellung eines Bauteils aus einem Verbundmaterial, welches mindestens eine polymere Matrix und in die Matrix eingebettete Verstärkungsfasern umfasst.The present invention relates to a method for producing a component from a composite material which comprises at least one polymeric matrix and reinforcing fibers embedded in the matrix.
Weiterhin betrifft die Erfindung eine Komponente für ein Bauteil aus einem Verbundmaterial.Furthermore, the invention relates to a component for a component made of a composite material.
Bauteile aus faserverstärkten Verbundmaterialien werden seit einiger Zeit vermehrt in der Luft- und Raumfahrttechnik eingesetzt, in erster Linie aufgrund ihres zum Teil deutlich geringeren Gewichts im Vergleich zu metallischen Werkstoffen. So werden z. B. im Flugzeugbau mittlerweile tragende Teile wie der Rumpf oder die Flügel ganz oder teilweise aus Verbundmaterialien hergestellt.Components made of fiber-reinforced composite materials have been used more and more for some time in the aerospace industry, primarily due to their sometimes significantly lower weight compared to metallic materials. So z. B. in aircraft now supporting parts such as the fuselage or wings completely or partially made of composite materials.
Ein Nachteil dieser Bauweise ist jedoch, dass die Herstellung von größeren Bauteilen mit einer relativ komplexen Geometrie (z. B. eines Rumpfelements mit Stringern) sehr aufwändig ist. Die einstückige Herstellung solcher Bauteile ist zwar möglich (Integralbauweise), erfordert aber spezielle, an die Geometrie des Bauteils angepasste Werkzeuge für die Imprägnierung der Verstärkungsfasern mit der polymeren Matrix (z. B. einem duroplastischen Harz). Die Herstellung ist daher schlecht automatisierbar und bei komplexen Bauteilen, die oft nur in geringer Stückzahl benötigt werden, auch nicht unbedingt wirtschaftlich. Ein weiterer Nachteil der Integralbauweise ist, dass eine Reparatur des Bauteils durch den Austausch einzelner Komponenten nicht möglich ist.However, a disadvantage of this design is that the production of larger components with a relatively complex geometry (eg a core element with stringers) is very complicated. Although the one-piece production of such components is possible (integral construction), it requires special tools adapted to the geometry of the component for impregnating the reinforcing fibers with the polymeric matrix (for example a thermosetting resin). The production is therefore difficult to automate and complex components, which are often needed only in small quantities, not necessarily economical. Another disadvantage of Integralbauweise is that a repair of the component by replacing individual components is not possible.
Eine Alternative stellt daher die Verwendung einzelner Komponenten mit einfacherer Geometrie dar, die dann zu einem komplexeren Bauteil gefügt werden. Voraussetzung hierfür ist die Möglichkeit einer ausreichend stabilen Verbindung der einzelnen Komponenten, d. h. ein geeignetes Fügeverfahren.An alternative therefore is the use of individual components with simpler geometry, which are then joined into a more complex component. The prerequisite for this is the possibility of a sufficiently stable connection of the individual components, d. H. a suitable joining method.
Als Fügeverfahren kommen zum einen mechanische Lösungen in Betracht, wie sie aus dem Metallbau bekannt sind, d. h. insbesondere Nieten und Schrauben. Dieses Verfahren wird in der Luft- und Raumfahrttechnik eingesetzt, verursacht aber einen hohen Personal- und Kontrollaufwand. Ein weiterer Nachteil besteht darin, dass durch die notwendigen Bohrungen die Verstärkungsfasern durchtrennt werden und dadurch eine lokale Schwächung der Struktur verursacht wird.As a joining process come on the one hand mechanical solutions into consideration, as they are known from metal, d. H. especially rivets and screws. This method is used in the aerospace industry, but causes a high personnel and control effort. Another disadvantage is that the reinforcing fibers are severed by the necessary holes and thus a local weakening of the structure is caused.
Eine weitere Möglichkeit ist das Fügen einzelner Komponenten durch Klebeverbindungen. Diese Lösung ist zwar im Automobilbau relativ weit verbreitet, kommt im Flugzeugbau jedoch aufgrund der meist unzureichenden mechanischen Eigenschaften der verfügbaren Klebstoffe kaum zum Einsatz.Another possibility is the joining of individual components by adhesive bonds. Although this solution is relatively widespread in the automotive industry, it is hardly used in aircraft because of the usually insufficient mechanical properties of the available adhesives.
Der Erfindung liegt die Aufgabe zugrunde, ein verbessertes Verfahren zur Herstellung eines Bauteils aus einem Verbundmaterial vorzuschlagen.The invention has for its object to propose an improved method for producing a component of a composite material.
Diese Aufgabe wird bei dem Verfahren der eingangs genannten Art erfindungsgemäß dadurch gelöst, dass das Verfahren folgende Schritte umfasst:
- – Bereitstellen der Verstärkungsfasern einer ersten Komponente des Bauteils,
- – teilweises Imprägnieren der Verstärkungsfasern der ersten Komponente mit einer ersten polymeren Matrix, wobei die Verstärkungsfasern in mindestens einem Fügebereich nicht imprägniert werden,
- – Bereitstellen der Verstärkungsfasern einer zweiten Komponente des Bauteils,
- – Fügen der nicht-imprägnierten Verstärkungsfasern in dem mindestens einen Fügebereich der ersten Komponente mit den Verstärkungsfasern in einem Fügebereich der zweiten Komponente, und
- – Imprägnieren der gefügten Verstärkungsfasern mit einer zweiten polymeren Matrix unter Ausbildung des aus der ersten Komponente und der zweiten Komponente gebildeten Bauteils.
- Providing the reinforcing fibers of a first component of the component,
- Partially impregnating the reinforcing fibers of the first component with a first polymeric matrix, wherein the reinforcing fibers are not impregnated in at least one joining region,
- Providing the reinforcing fibers of a second component of the component,
- Joining the unimpregnated reinforcing fibers in the at least one joining region of the first component with the reinforcing fibers in a joining region of the second component, and
- - Impregnating the joined reinforcing fibers with a second polymeric matrix to form the formed of the first component and the second component component.
Das erfindungsgemäße Verfahren ermöglicht eine homogene, stoffschlüssige Verbindung zwischen zwei Komponenten eines Bauteils aus einem faserverstärkten Verbundmaterial, wobei die Kraftübertragung zwischen den Komponenten im Wesentlichen über die miteinander gefügten und gemeinsam imprägnieren Verstärkungsfasern erfolgt. Die Fügebereiche der ersten und der zweiten Komponente bilden hierbei den Verbindungsbereich zwischen den zwei Komponenten.The method according to the invention enables a homogeneous, cohesive connection between two components of a component made of a fiber-reinforced composite material, wherein the force transmission between the components essentially takes place via the reinforcing fibers joined together and jointly impregnated. The joining areas of the first and second components form the connecting area between the two components.
Das Verfahren kann zur Herstellung eines komplexeren Bauteils unter Hinzufügung weiterer Komponenten wiederholt werden, oder es können auch gleichzeitig mehr als zwei Komponenten in der entsprechenden Weise zu einem Bauteil zusammengefügt werden. In diesem Fall kann z. B. die erste Komponente mehrere Fügebereiche umfassen. Die einzelnen Komponenten weisen in der Regel eine einfachere Geometrie auf als das hergestellte Bauteil, sodass ihre Herstellung (d. h. das teilweise Imprägnieren der Verstärkungsfasern mit einer polymeren Matrix) effizient durchzuführen ist und relativ leicht automatisiert werden kann, im Gegensatz zu der eingangs beschriebenen Integralbauweise.The method can be repeated to produce a more complex component with the addition of further components, or at the same time more than two components can be assembled in the appropriate manner to form a component. In this case, z. B. the first component comprise a plurality of joining areas. The individual components are typically of simpler geometry than the component being manufactured, so that their manufacture (i.e., partial impregnation of the reinforcing fibers with a polymeric matrix) is efficient and relatively easy to automate, in contrast to the integral design described above.
Günstigerweise wird die erste polymere Matrix nach dem teilweisen Imprägnieren der Verstärkungsfasern der ersten Komponente erstarren und/oder aushärten gelassen. Auf diese Weise wird die erste Komponente (oder mehrere erste Komponenten) teilweise fertiggestellt (bis auf den oder die Fügebereiche) und ist für den folgenden Verfahrensschritt sehr gut handhabbar, d. h. das Fügen der nicht-imprägnierten Verstärkungsfasern der beiden Komponenten wird vereinfacht.Conveniently, after partially impregnating the reinforcing fibers of the first component, the first polymeric matrix is allowed to solidify and / or harden. In this way, the first component (or several first components) is partially completed (except for the joining region (s)) and is very easy to handle for the following method step, ie the joining of the non-component parts. impregnated reinforcing fibers of the two components is simplified.
Durch den homogenen Aufbau des erfindungsgemäß hergestellten Bauteils und den Verzicht auf zusätzliche mechanische Verbindungselemente können auch thermische Spannungen aufgrund von unterschiedlichen Wärmeausdehnungskoeffizienten vermieden werden. Des Weiteren ergeben sich keinerlei Korrosionsprobleme, und es wird eine optimale Abdichtung des Verbindungsbereichs durch die Imprägnierung der gefügten Verstärkungsfasern erreicht.Due to the homogeneous structure of the component according to the invention and the absence of additional mechanical fasteners and thermal stresses due to different thermal expansion coefficients can be avoided. Furthermore, there are no corrosion problems, and it is achieved an optimal sealing of the connection area by the impregnation of the joined reinforcing fibers.
Die Verstärkungsfasern umfassen vorzugsweise Endlosfasern, die als Gelege, Gewebe, Geflecht oder Gestrick vorliegen. Als Endlosfasern werden Fasern mit einer Länge von mehr als 50 mm bezeichnet. Die Endlosfasern liegen in der Regel als Faserbündel (Rovings) vor, die dann als Gelege, Gewebe, Geflecht oder Gestrick eine im Wesentlichen flächige Struktur bilden. Besonders günstig ist ein mehrlagiger Aufbau der Verstärkungsfasern, z. B. ein Multiaxialgelege.The reinforcing fibers preferably comprise continuous fibers, which are present as a scrim, fabric, braid or knitted fabric. The continuous fibers are fibers with a length of more than 50 mm. The continuous fibers are usually in the form of fiber bundles (rovings), which then form a substantially flat structure as a scrim, fabric, braid or knitted fabric. Particularly favorable is a multilayer structure of the reinforcing fibers, for. B. a Multiaxialgelege.
Günstig ist es, wenn das Fügen der Verstärkungsfasern ein Überlappen der Verstärkungsfasern der ersten Komponente mit den Verstärkungsfasern der zweiten Komponente umfasst. Insbesondere überlappen hierbei die aus den Fasern bzw. Rovings gebildeten flächigen Strukturen (z. B. Gewebe), wodurch eine gute Kraftübertragung im Verbindungsbereich zwischen den beiden Komponenten sowohl in der Faserebene als auch senkrecht hierzu ermöglicht wird. Bei einem mehrlagigen Aufbau der Verstärkungsfasern, wie z. B. einem mehrlagigen Gewebe oder einem Multiaxialgelege, kann die Kraftübertragung und damit die Stabilität der Verbindung in dem hergestellten Bauteil weiter erhöht werden, indem die Überlappung der Verstärkungsfasern in den einzelnen Lagen gestaffelt ist.It is favorable if the joining of the reinforcing fibers comprises an overlapping of the reinforcing fibers of the first component with the reinforcing fibers of the second component. In particular, the planar structures (eg tissue) formed from the fibers or rovings overlap in this case, whereby a good force transmission in the connection region between the two components is made possible both in the fiber plane and perpendicular thereto. In a multilayer structure of the reinforcing fibers, such. As a multi-layer fabric or a Multiaxialgelege, the power transmission and thus the stability of the compound in the manufactured component can be further increased by the overlap of the reinforcing fibers is staggered in the individual layers.
Gemäß einer bevorzugten Ausführungsform der Erfindung werden im Zuge des Imprägnierens der gefügten Verstärkungsfasern die gesamten Verstärkungsfasern der zweiten Komponente mit der zweiten polymeren Matrix imprägniert. D. h. im Gegensatz zur ersten Komponente erfolgt hier bei der zweiten Komponente kein teilweises Imprägnieren der Verstärkungsfasern vor dem Fügen, sodass das Herstellungsverfahren insgesamt mit sehr wenigen Arbeitsschritten auskommt. Diese Vorgehensweise bietet sich insbesondere an, wenn es sich bei der zweiten Komponente um ein Element handelt, das nur in geringer Stückzahl (oder nur als Einzelexemplar) benötigt wird, wie z. B. ein Element der Außenhaut eines Flugzeugs, während die erste Komponente ein häufig benötigtes Standardelement ist, bei dem sich eine automatisierte Herstellung lohnt. Insbesondere kann es sich bei der ersten Komponente um einen Stringer handeln, der mit der Außenhaut zu einem Rumpfelement als Bauteil verbunden wird. Auf diese Weise kann eine große Menge an ersten Komponenten durch Teilimprägnierung der Verstärkungsfasern hergestellt und für die Verbindung mit der jeweiligen zweiten Komponente zur Verfügung gestellt werden, wobei die Imprägnierung der zweiten Komponente einschließlich der Verstärkungsfasern im Fügebereich dann in einem einzigen Arbeitsschritt erfolgen kann.According to a preferred embodiment of the invention, in the course of impregnating the joined reinforcing fibers, the entire reinforcing fibers of the second component are impregnated with the second polymeric matrix. Ie. In contrast to the first component, in the case of the second component no partial impregnation of the reinforcing fibers takes place before joining, so that the manufacturing process altogether requires very few work steps. This approach is particularly useful when the second component is an item that is needed only in small numbers (or just as a single item), such as a single item. As an element of the outer skin of an aircraft, while the first component is a commonly used standard element in which an automated production is worthwhile. In particular, the first component may be a stringer, which is connected to the outer skin to form a fuselage element as a component. In this way, a large amount of first components can be prepared by partial impregnation of the reinforcing fibers and provided for the connection with the respective second component, wherein the impregnation of the second component including the reinforcing fibers in the joining region can then take place in a single operation.
Bei einer alternativen Ausführungsform des erfindungsgemäßen Verfahrens werden die Verstärkungsfasern der zweiten Komponente teilweise mit der zweiten polymeren Matrix imprägniert, bevor die nicht-imprägnierten Verstärkungsfasern in den Fügebereichen miteinander gefügt werden. Bei dieser Variante der Erfindung werden demnach beide miteinander zu verbindende Komponenten (bis auf die Fügebereiche) teilweise imprägniert, d. h. als gut handhabbare Elemente vorgefertigt. Dies ist insbesondere von Vorteil, wenn beide Komponenten in relativ hoher Stückzahl benötigt werden und sich daher jeweils eine automatisierte Herstellung lohnt. Gegenüber einer integralen Herstellung des gesamten Bauteils bietet diese Vorgehensweise Vorteile, da die einzelnen Komponenten in der Regel eine einfachere Geometrie aufweisen als das fertige Bauteil.In an alternative embodiment of the method according to the invention, the reinforcing fibers of the second component are partially impregnated with the second polymeric matrix before the unimpregnated reinforcing fibers are joined together in the joining regions. In this variant of the invention, therefore, both components to be joined together (except for the joint areas) are partially impregnated, d. H. prefabricated as easy to handle elements. This is particularly advantageous if both components are needed in relatively high numbers and therefore each worth an automated production. Compared to an integral production of the entire component, this procedure offers advantages, since the individual components generally have a simpler geometry than the finished component.
Die erste polymere Matrix und die zweite polymere Matrix können gleich oder verschieden sein, d. h. gleiche oder verschiedene polymere Materialien umfassen. In vielen Fällen ist es jedoch bevorzugt, für die erste Komponente und für die zweite Komponente bzw. den Verbindungsbereich die gleiche polymere Matrix zu verwenden, um ein möglichst homogen aufgebautes Bauteil herzustellen.The first polymeric matrix and the second polymeric matrix may be the same or different, i. H. include the same or different polymeric materials. In many cases, however, it is preferable to use the same polymeric matrix for the first component and for the second component or the connection region in order to produce a component which is as homogeneously structured as possible.
Die erste und/oder die zweite polymere Matrix umfasst bevorzugt ein thermoplastisches Harz. Als thermoplastische Harze für Faserverbundmaterialien eignen sich insbesondere so genannte Hochleistungskunststoffe, wie z. B. Polyetheretherketon, Polyetherketonketon, Polyphenylensulfid, Polysulfon, Polyamid oder Polyetherimid.The first and / or the second polymeric matrix preferably comprises a thermoplastic resin. As thermoplastic resins for fiber composite materials are particularly suitable so-called high performance plastics, such. As polyether ether ketone, polyether ketone ketone, polyphenylene sulfide, polysulfone, polyamide or polyetherimide.
Der wesentliche Vorteil einer thermoplastischen polymeren Matrix besteht in der Lösbarkeit der Verbindung, d. h. durch Aufschmelzen der Matrix können die Komponenten des erfindungsgemäß hergestellten Bauteils wieder voneinander getrennt werden. Dies eröffnet die Möglichkeit, einzelne Komponenten nach Beschädigung oder Verschleiß zu demontieren und auszutauschen. Eine solche Reparaturmöglichkeit ist insbesondere im Flugzeugbau unter Kostengesichtspunkten von großem Vorteil.The essential advantage of a thermoplastic polymeric matrix is the solubility of the compound, i. H. By melting the matrix, the components of the component according to the invention can be separated from each other again. This opens up the possibility of disassembling and replacing individual components after damage or wear. Such a repair option is particularly advantageous in aircraft construction from a cost point of view.
Wie bereits angesprochen, sind das zur teilweisen Imprägnierung der ersten Komponente verwendete thermoplastische Harz und das zur Imprägnierung der Verstärkungsfasern in den Fügebereichen verwendete thermoplastische Harz vorzugsweise identisch, sodass das gesamte Bauteil eine homogene polymere Matrix aufweist. Es ist jedoch auch möglich, unterschiedliche thermoplastische Harze in einem Bauteil miteinander zu kombinieren.As already mentioned, the thermoplastic resin used for the partial impregnation of the first component and that for Impregnation of the reinforcing fibers in the bonding areas used thermoplastic resin preferably identical, so that the entire component has a homogeneous polymeric matrix. However, it is also possible to combine different thermoplastic resins in one component.
Das Imprägnieren der Verstärkungsfasern mit dem thermoplastischen Harz erfolgt bevorzugt mittels Heißpressen. Bei diesem Verfahren wird das Harz vorzugsweise in Pulverform auf die zu imprägnierenden Fasern aufgebracht und in einer Heißpresse aufgeschmolzen. Aufgrund der hohen Viskosität der Polymerschmelze lässt dich der Bereich der Verstärkungsfasern, der imprägniert werden soll, sehr gut eingrenzen. Somit ist es problemlos möglich, bei der teilweisen Imprägnierung der ersten Komponente den mindestens einen Fügebereich von der Imprägnierung auszunehmen.The impregnation of the reinforcing fibers with the thermoplastic resin is preferably carried out by means of hot pressing. In this method, the resin is preferably applied in powder form to the fibers to be impregnated and melted in a hot press. Due to the high viscosity of the polymer melt, the area of the reinforcing fibers to be impregnated allows you to confine very well. Thus, it is easily possible to exclude the at least one joining region of the impregnation in the partial impregnation of the first component.
Als Alternative zum Heißpressen kann zur Imprägnierung mit einem thermoplastischen Harz auch das Vakuumheizverfahren angewendet werden.As an alternative to hot pressing, the vacuum heating method may also be used for impregnation with a thermoplastic resin.
Das Abkühlen und Erstarren des thermoplastischen Harzes nach dem Imprägnieren erfolgt relativ schnell, sodass die erste Komponente kurze Zeit nach dem Imprägnieren im Rahmen des erfindungsgemäßen Verfahrens weiter verwendet werden kann.The cooling and solidification of the thermoplastic resin after impregnation takes place relatively quickly, so that the first component can be used a short time after the impregnation in the context of the inventive method on.
Gemäß einer weiteren Ausführungsform der Erfindung umfasst die erste und/oder die zweite polymere Matrix ein duroplastisches Harz. Duroplaste, die unter anderem im Flugzeugbau häufig für faserverstärkte Verbundmaterialien eingesetzt werden, umfassen insbesondere Epoxidharze, Vinylesterharze und ungesättigte Polyesterharze.According to a further embodiment of the invention, the first and / or the second polymeric matrix comprises a thermosetting resin. Thermosets, which are commonly used in aircraft construction for fiber-reinforced composite materials, include in particular epoxy resins, vinyl ester resins and unsaturated polyester resins.
Bei Verwendung von duroplastischen Harzen erfolgt die Imprägnierung der Verstärkungsfasern durch Infiltration mit dem noch nicht ausgehärteten Harz, wobei die Begrenzung der Infiltration auf einen vorgegebenen Bereich etwas schwieriger ist als bei Verwendung eines thermoplastischen Harzes. Um dieses Problem zu vermeiden, ist es vorteilhaft, wenn nach dem Bereitstellen der Verstärkungsfasern der ersten Komponente diese in dem mindestens einen Fügebereich zunächst mit einem Sperrwerkstoff imprägniert werden, dann der übrige Bereich der Verstärkungsfasern mit der ersten polymeren Matrix, d. h. insbesondere einem duroplastischen Harz, imprägniert wird, und anschließend der Sperrwerkstoff aus dem mindestens einen Fügebereich entfernt wird. Hierdurch wird eine Sperrzone für die erste polymere Matrix gebildet, mit deren Hilfe der nicht zu imprägnierende Fügebereich relativ genau festgelegt werden kann.When using thermosetting resins, the impregnation of the reinforcing fibers is carried out by infiltration with the not yet cured resin, wherein the limitation of the infiltration to a predetermined range is slightly more difficult than when using a thermoplastic resin. In order to avoid this problem, it is advantageous if after providing the reinforcing fibers of the first component they are first impregnated in the at least one joining region with a barrier material, then the remaining region of the reinforcing fibers with the first polymeric matrix, d. H. in particular a thermosetting resin, is impregnated, and then the barrier material is removed from the at least one joining region. As a result, a blocking zone for the first polymeric matrix is formed, with the aid of which the non-impregnating joining region can be set relatively precisely.
Der Sperrwerkstoff umfasst günstigerweise ein Material, das durch Aufschmelzen wieder aus der Sperrzone entfernt werden kann (z. B. ein thermoplastisches Polymer oder Oligomer oder ein sonstiges Material mit einem geeigneten Schmelzpunkt), oder auch ein lösliches Material, das mit Hilfe eines geeigneten Lösungsmittels wieder entfernt werden kann.The barrier material conveniently comprises a material which can be removed by reflow from the barrier zone (eg a thermoplastic polymer or oligomer or other material with a suitable melting point), or also a soluble material which is recovered by means of a suitable solvent can be removed.
Die erste polymere Matrix und die zweite polymere Matrix können das gleiche oder zwei verschiedene duroplastische Harze umfassen. Des Weiteren kann auch die erste polymere Matrix ein thermoplastisches Harz und die zweite polymere Matrix ein duroplastisches Harz umfassen oder umgekehrt.The first polymeric matrix and the second polymeric matrix may comprise the same or two different thermosetting resins. Furthermore, the first polymeric matrix may also comprise a thermoplastic resin and the second polymeric matrix may comprise a thermosetting resin or vice versa.
Die vorliegende Erfindung betrifft des Weiteren ein Bauteil aus einem Verbundmaterial, das gemäß dem vorstehend beschriebenen Verfahren hergestellt ist.The present invention further relates to a component made of a composite material produced according to the method described above.
Der Erfindung liegt ferner die Aufgabe zugrunde, eine Komponente für ein Bauteil aus einem Verbundmaterial mit verbesserten Eigenschaften zur Verfügung zu stellen.A further object of the invention is to provide a component for a component made of a composite material with improved properties.
Diese Aufgabe wird bei der Komponente der eingangs genannten Art erfindungsgemäß dadurch gelöst, dass die Komponente Verstärkungsfasern umfasst, die teilweise mit einer polymeren Matrix imprägniert sind, wobei die Verstärkungsfasern in mindestens einem Fügebereich nicht imprägniert sind.This object is achieved according to the invention in the component of the aforementioned type in that the component comprises reinforcing fibers, which are partially impregnated with a polymeric matrix, wherein the reinforcing fibers are not impregnated in at least one joining region.
Die erfindungsgemäße Komponente kann insbesondere als Zwischenprodukt im Rahmen des erfindungsgemäßen Verfahrens eingesetzt werden, und zwar als teilweise imprägnierte erste Komponente oder auch als teilweise imprägnierte zweite Komponente. Wesentliche Vorteile der erfindungsgemäßen Komponente wurden bereits im Zusammenhang mit dem erfindungsgemäßen Verfahren beschrieben.The component of the invention can be used in particular as an intermediate in the context of the method according to the invention, as a partially impregnated first component or as a partially impregnated second component. Significant advantages of the component according to the invention have already been described in connection with the method according to the invention.
Der mindestens eine Fügebereich der erfindungsgemäßen Komponente umfasst vorzugsweise mehrere Lagen von Verstärkungsfasern. Die einzelnen Lagen können insbesondere aus einem Gelege, Gewebe, Geflecht oder Gestrick aus Endlosfasern bzw. aus Rovings aus Endlosfasern gebildet sein, wie dies bereits oben beschrieben wurde.The at least one joining region of the component according to the invention preferably comprises a plurality of layers of reinforcing fibers. The individual layers may in particular be formed from a scrim, woven fabric, braid or knitted fabric made of continuous fibers or rovings made of continuous fibers, as already described above.
Besonders vorteilhaft ist es, wenn die Lagen von Verstärkungsfasern in dem mindestens einen Fügebereich gestaffelt angeordnet sind. Hierbei überlappen sich zwei benachbarte Lagen von Verstärkungsfasern jeweils nur teilweise, sodass eine Überlappung mit den Lagen eines komplementären Fügebereiches einer weiteren Komponente möglich ist. Dadurch wird eine besonders hohe Kraftübertragung zwischen den beiden miteinander verbundenen Komponenten erreicht.It is particularly advantageous if the layers of reinforcing fibers are staggered in the at least one joining region. In this case, two adjacent layers of reinforcing fibers each only partially overlap, so that an overlap with the layers of a complementary joining region of another component is possible. As a result, a particularly high power transmission between the two interconnected components is achieved.
Weitere bevorzugte Ausführungsformen der erfindungsgemäßen Komponente wurden bereits im Zusammenhang mit dem erfindungsgemäßen Verfahren beschrieben. Die polymere Matrix der erfindungsgemäßen Komponente kann insbesondere ein oder mehrere thermoplastische und/oder duroplastische Harze umfassen. Further preferred embodiments of the component according to the invention have already been described in connection with the method according to the invention. The polymeric matrix of the component according to the invention may in particular comprise one or more thermoplastic and / or thermosetting resins.
Gemäß einer weiteren Ausführungsform der erfindungsgemäßen Komponente sind die Verstärkungsfasern entlang einer Trennebene oder mehrerer sich schneidender Trennebenen unterbrochen. Bei Verwendung eines thermoplastischen Harzes als polymere Matrix kann eine solche Komponente durch Aufschmelzen des Harzes entlang der Trennebene in zwei Teilkomponenten zerlegt werden. Bei relativ komplexen Bauteilen kann eine Reparatur einfacher und kosteneffizienter durchgeführt werden, wenn lediglich derartige Teilkomponenten ausgetauscht werden müssen.According to a further embodiment of the component according to the invention, the reinforcing fibers are interrupted along a parting plane or a plurality of cutting parting planes. When using a thermoplastic resin as a polymeric matrix, such a component can be decomposed by melting the resin along the parting plane into two sub-components. For relatively complex components, repair can be made easier and more cost effective if only such subcomponents need to be replaced.
Die Komponente ist vorzugsweise eine Komponente für ein Bauteil eines Fahrzeugs. Die erfindungsgemäße Komponente und das erfindungsgemäße Verfahren können insbesondere im Karosseriebau in der Kraftfahrzeugindustrie, im Schiffsbau, sowie in der Luft- und Raumfahrttechnik eingesetzt werden. Besondere Vorteile bietet die Erfindung hier vor allem bei der Herstellung von Bauteilen in Modulbauweise, d. h. bei der automatisierten Herstellung häufig benötigter Komponenten durch Teilimprägnierung der Verstärkungsfasern.The component is preferably a component for a component of a vehicle. The component according to the invention and the method according to the invention can be used in particular in body construction in the motor vehicle industry, in shipbuilding, as well as in the aerospace industry. Particular advantages of the invention, especially in the production of components in modular design, d. H. in the automated production of frequently required components by partial impregnation of the reinforcing fibers.
Eine bevorzugte Ausführungsform der Erfindung betrifft eine Komponente für ein Bauteil eines Rumpfs eines Luftfahrzeugs oder eines Schiffes, insbesondere einen Stringer für ein Rumpfelement. Durch das erfindungsgemäße Verfahren können die Stringer durch Teilimprägnierung der Verstärkungsfasern in einem automatisierten Prozess vorgefertigt und durch Imprägnierung der entsprechenden Fügebereiche mit Teilen der Außenhaut verbunden werden. Des Weiteren kann das erfindungsgemäße Verfahren auch für die Verbindung mehrerer Rumpfelemente miteinander eingesetzt werden oder für das Zusammenfügen von Komponenten der Tragflächen oder der Leitwerke.A preferred embodiment of the invention relates to a component for a component of a fuselage of an aircraft or a ship, in particular a stringer for a fuselage element. By the method according to the invention, the stringer can be prefabricated by partial impregnation of the reinforcing fibers in an automated process and connected by impregnation of the corresponding joining regions with parts of the outer skin. Furthermore, the method according to the invention can also be used for connecting a plurality of fuselage elements to one another or for assembling components of the wings or tail units.
Das erfindungsgemäße Verfahren und die erfindungsgemäße Komponente sind jedoch nicht auf den Fahrzeugbau beschränkt, sondern können in sämtlichen Bereichen der Technik, in denen Faserverbundmaterialien eingesetzt werden, zur Anwendung gelangen. Beispielsweise können auch Rotoren für Windkraftanlagen bzw. deren Bauteile mit dem erfindungsgemäßen Verfahren hergestellt werden, wobei die erste Komponente z. B. ein Verstärkungselement für den Rotor ist.However, the method and component according to the invention are not limited to the construction of vehicles, but can be used in all fields of technology in which fiber composite materials are used. For example, rotors for wind turbines or their components can be produced by the method according to the invention, wherein the first component z. B. is a reinforcing element for the rotor.
Diese und weitere Vorteile der Erfindung werden anhand der nachfolgenden Ausführungsbeispiele unter Bezugnahme auf die Figuren der Zeichnung näher erläutert.These and other advantages of the invention will be explained in more detail with reference to the following embodiments with reference to the figures of the drawing.
Es zeigen im Einzelnen:They show in detail:
In den
Im nächsten Verfahrensschritt werden die Verstärkungsfasern
Im folgenden Schritt des erfindungsgemäßen Verfahrens werden Verstärkungsfasern
Im abschließenden Verfahrensschritt werden schließlich die gefügten Verstärkungsfasern
Bei dem auf diese Weise hergestellten Bauteil
Die teilweise mit der polymeren Matrix
Bei Verwendung eines thermoplastischen Harzes als polymere Matrix
In den
Die erste Komponente ist bei diesem Ausführungsbeispiel ein Stringer
Die Verstärkungsfasern
Die
Die nicht imprägnierten Verstärkungsfasern
Die Außenhaut
BezugszeichenlisteLIST OF REFERENCE NUMBERS
- 1010
- Verstärkungsfasernreinforcing fibers
- 1212
- erste Komponentefirst component
- 1414
- Faserbündelfiber bundles
- 1616
- erste Lagefirst location
- 1818
- zweite Lagesecond location
- 2020
- dritte Lagethird location
- 2222
- vierte Lagefourth location
- 2424
- Fügebereichjoining area
- 26a26a
- erste polymere Matrixfirst polymeric matrix
- 26b26b
- zweite polymere Matrixsecond polymeric matrix
- 2828
- Verstärkungsfasernreinforcing fibers
- 3030
- zweite Komponentesecond component
- 3232
- Bauteilcomponent
- 3434
- StringerStringer
- 3636
- Längsachselongitudinal axis
- 3838
- U-förmiger BereichU-shaped area
- 4040
- Randbereichborder area
- 4242
- Außenhautshell
- 4444
- Rumpfelementbody member
Claims (19)
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