DE102010004530A1 - Method for producing a reinforcement matrix for a plastic part, comprises arranging two semi-finished product consists of a fibrous material partially overlapped, and connecting together in the overlap region to the reinforcing matrix - Google Patents

Method for producing a reinforcement matrix for a plastic part, comprises arranging two semi-finished product consists of a fibrous material partially overlapped, and connecting together in the overlap region to the reinforcing matrix Download PDF

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DE102010004530A1
DE102010004530A1 DE102010004530A DE102010004530A DE102010004530A1 DE 102010004530 A1 DE102010004530 A1 DE 102010004530A1 DE 102010004530 A DE102010004530 A DE 102010004530A DE 102010004530 A DE102010004530 A DE 102010004530A DE 102010004530 A1 DE102010004530 A1 DE 102010004530A1
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Prior art keywords
semi
finished product
matrix
finished products
binder material
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DE102010004530A
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German (de)
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Bruno 84051 Niesner
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Bayerische Motoren Werke AG
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Bayerische Motoren Werke AG
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Priority to DE102010004530A priority Critical patent/DE102010004530A1/en
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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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/543—Fixing the position or configuration of fibrous reinforcements before or during moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/002—Inorganic yarns or filaments
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/002—Inorganic yarns or filaments
    • D04H3/004—Glass yarns or filaments
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/12—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Textile Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Reinforced Plastic Materials (AREA)

Abstract

The method for producing a reinforcement matrix for a plastic part, comprises arranging two semi-finished product consists of a fibrous material partially overlapped, and connecting together in the overlap region to the reinforcing matrix. A binder material is applied on one of the both semi-finished product or both semi-finished product in its overlap region. Both semi-finished products are be bonded and/or matted together by activating the binder material by an ultrasonic device. The binder material is applied on a side of the semi-finished products. The method for producing a reinforcement matrix for a plastic part, comprises arranging two semi-finished product consists of a fibrous material partially overlapped, and connecting together in the overlap region to the reinforcing matrix. A binder material is applied on one of the both semi-finished product or both semi-finished product in its overlap region. Both semi-finished products are be bonded and/or matted together by activating the binder material by an ultrasonic device. The binder material is applied on a side of the semi-finished products facing towards the relevant other semi-finished product, is non-adhesive before the activation, and is present before the activation in powder form. The semi-finished products are powder-coated and sintered with the binder material. The method concerns itself into the semi-finished products around clutch. The semi-finished product consists of carbon- and/or glass fibers. The stiffness matrix is transformed to one of the molds of the produced plastic corresponding and/or resembling preform, which is introduced in a resin injection tool and is overmolded with a resin by which the plastic part is received. The semi-finished products are agglutinated together selectively and/or grid-like at a number of glue joints.

Description

Die vorliegende Erfindung betrifft ein Verfahren zum Herstellen einer Versteifungsmatrix für ein Kunststoffteil gemäß dem Oberbegriff des Patentanspruches 1.The present invention relates to a method for producing a stiffening matrix for a plastic part according to the preamble of claim 1.

Im Flugzeugbau wird bereits seit Jahrzehnten mit faserverstärkten Kunststoffteilen gearbeitet, wobei aufgrund der relativ geringen Stückzahlen viele Arbeitsgänge in Handarbeit durchgeführt werden. Ein Einsatz im Automobilbereich ist kostendeckend nur dann möglich, wenn die Fertigung hochgradig automatisierbar ist.In the aircraft industry has been working for decades with fiber-reinforced plastic parts, due to the relatively small quantities many operations are carried out by hand. An application in the automotive sector is cost-effective only possible if the production is highly automated.

Seit geraumer Zeit wird untersucht, inwieweit Fahrzeugkarosserieteile in wirtschaftlicher Weise in Form faserverstärkter Kunststoffteile dargestellt werden können. Um den hohen und sehr komplexen Festigkeitsanforderungen von Fahrzeugkarosserieteilen gerecht zu werden, werden komplexe, belastungsgerecht gestaltete, aus Fasermaterial bestehende Versteifungselemente, die im Folgenden als ”Versteifungsmatrizen” bezeichnet werden, hergestellt werden. Eine derartige Versteifungsmatrix kann je nach Anwendungsfall aus einer Vielzahl übereinander platzierter „Gelegelagen” bestehen. Um sicherzustellen, dass die einzelnen Gelegelagen in nachfolgenden Fertigungsschritten, wie z. B. Zuschneiden, Umformen (Preforming) sowie beim Injizieren von Harz in einem entsprechenden Werkzeug (Resin-Transfer-Molding) nicht relativ zueinander verrutschen, müssen die einzelnen Fasergelege relativ zueinander fixiert werden.For some time, it has been investigated to what extent vehicle body parts can be economically represented in the form of fiber-reinforced plastic parts. In order to meet the high and very complex strength requirements of vehicle body parts, complex, load-adapted, made of fiber material stiffening elements, which are hereinafter referred to as "stiffening matrices" are produced. Depending on the application, such a stiffening matrix may consist of a multiplicity of "gel layers" placed one above the other. To ensure that the individual gel levels in subsequent manufacturing steps, such. As cutting, forming (preforming) and when injecting resin in a corresponding tool (resin transfer molding) do not slip relative to each other, the individual fiber sheets must be fixed relative to each other.

Als Technologien zum Verbinden bzw. Fixieren der einzelnen Gelegelagen einer derartigen ”Versteifungsmatrix” kommen unterschiedliche Verfahren in Betracht.As technologies for bonding or fixing the individual gel layers of such a "stiffening matrix", different methods can be considered.

Die einzelnen Gelegelagen können beispielsweise mittels Metallklammern zusammengetackert werden, was den Nachteil hat, dass mit den Klammern ”Fremdkörper” in die Versteifungsmatrix und somit in das herzustellende Kunststoffbauteil eingebracht werden.The individual layers of gel can, for example, be stapled together by means of metal clamps, which has the disadvantage that "foreign bodies" are introduced into the stiffening matrix and thus into the plastic component to be produced with the clamps.

Alternativ dazu ist es auch denkbar, die einzelnen Gelegelagen durch Kleberschichten in einem Heißprägeverfahren miteinander zu verkleben, was zwar mit vergleichsweise geringen Materialkosten, aber hohem Energieverbrauch verbunden und im übrigen relativ zeitintensiv ist.Alternatively, it is also conceivable to glue together the individual layers of gel by means of adhesive layers in a hot embossing process, which is associated with comparatively low material costs but high energy consumption and, moreover, is relatively time-consuming.

Alternativ dazu könnten die einzelnen Gelegelagen auch durch ein induktives Schweißverfahren miteinander verbunden werden.Alternatively, the individual layers of gel could also be joined together by an inductive welding process.

Aufgabe der Erfindung ist es, ein Verfahren zur Herstellung einer aus mehreren Gelegelagen bestehenden Versteifungsmatrix für ein Kunststoffteil zu schaffen, das kostengünstig durchführbar ist und eine hohe Prozessgeschwindigkeit ermöglicht.The object of the invention is to provide a method for producing a stiffening matrix consisting of several gel layers for a plastic part, which is inexpensive to carry out and enables a high process speed.

Diese Aufgabe wird durch die Merkmale des Patentanspruches 1 gelöst. Vorteilhafte Ausgestaltungen und Weiterbildungen der Erfindung sind den Unteransprüchen zu entnehmen.This object is solved by the features of claim 1. Advantageous embodiments and further developments of the invention can be found in the dependent claims.

Ausgangspunkt der Erfindung ist ein Verfahren zum Herstellen einer Versteifungsmatrix für ein Kunststoffteil, bei dem mindestens zwei, vorzugsweise aber mehr als zwei, jeweils aus einem Fasermaterial bestehende Halbzeuge zumindest teilweise überlappend angeordnet und im Überlappungsbereich zu einer Versteifungsmatrix miteinander verbunden werden. Die Halbzeuge können in der Form mattenartiger Gelege, Gewebe, Gestricke o. ä. vorliegen.The starting point of the invention is a method for producing a stiffening matrix for a plastic part, in which at least two, but preferably more than two, each consisting of a fiber material semifinished products are arranged at least partially overlapping and connected to one another in the overlap region to a stiffening matrix. The semi-finished products may be in the form of mat-like scrim, fabric, knit or the like.

Der Kern der Erfindung besteht darin, dass auf eines der mindestens zwei Halbzeuge oder auf beide Halbzeuge zumindest im Überlappungsbereich bzw. in ihren Überlappungsbereichen ein ”Binderstoff” appliziert wird und dass die beiden Halbzeuge durch ”Aktivieren” des Binderstoffs mittels einer Ultraschalleinrichtung miteinander verklebt und/oder verfilzt werden.The core of the invention is that a "binder" is applied to one of the at least two semi-finished products or to both semi-finished products at least in the overlapping region or in their overlapping regions and that the two semi-finished products are glued together by "activating" the binder by means of an ultrasound device and / or or matted.

Bei dem Binderstoff kann es sich beispielsweise um ein langkettiges Epoxidharzsystem handeln. Der Binderstoff kann vor der Aktivierung in Pulverform vorliegen. Der pulverförmige Binderstoff kann dann in einfacher Weise gleichmäßig oder ungleichmäßig entsprechend einer vorgegebenen Beladungsverteilung auf das bzw. auf die Halbzeuge appliziert werden. Eines der beiden Halbzeuge oder beide Halbzeuge können vor der Aktivierung mit dem Binderstoff bepulvert und angesintert werden.The binder may be, for example, a long-chain epoxy resin system. The binder may be in powder form prior to activation. The pulverulent binder can then be applied in a simple manner uniformly or non-uniformly in accordance with a predetermined loading distribution onto or onto the semifinished products. One of the two semi-finished products or both semi-finished products can be powdered and sintered before activation with the binder.

Es kann vorgesehen sein, dass der Binderstoff vor der ”Ultraschallaktivierung” im Wesentlichen nicht klebend ist, was die Applizierung erleichtert.It can be provided that the binder is essentially non-adhesive before the "ultrasonic activation", which facilitates the application.

Nach einer Weiterbildung der Erfindung wird der Binderstoff nur auf eine dem betreffenden anderen Halbzeug zugewandten Seite, d. h. ”einseitig” auf eine Halbzeuglage appliziert.According to a development of the invention, the binder is only on a side facing the respective other semi-finished, d. H. "One-sided" applied to a semi-finished product.

Die Halbzeuge können aus Carbon- und/oder Glasfasern sowie gegebenenfalls aus zusätzlichen Komponenten, wie z. B. Textilfäden, bestehen.The semi-finished products can be made of carbon and / or glass fibers and optionally from additional components such. B. textile threads exist.

Durch die dem Binderstoff über die Ultraschalleinrichtung bzw. eine Ultraschall-Sonotrode zugeführte Schwingungsenergie wird der Binderstoff klebrig und verklebt die übereinander angeordneten Fasermateriallagen.Due to the vibrational energy supplied to the binder via the ultrasonic device or an ultrasonic sonotrode, the binder becomes sticky and bonds the fiber material layers arranged one above the other.

Die auf diese Weise erhaltene Versteifungsmatrix kann z. B. mittels eines oszillierenden Messers in eine dem zu herzustellenden Kunststoffteil entsprechende oder ähnelnde Form geschnitten werden. Anschließend wird die geschnittene Versteifungsmatrix in einen sogenannten Vorformling umgeformt (Preforming), welcher im Wesentlichen der Form des herzustellenden Kunststoffteils entspricht.The stiffening matrix obtained in this way can, for. B. be cut by means of an oscillating knife in a corresponding to the plastic part to be produced or similar shape. Subsequently, the cut stiffening matrix is converted into a so-called preform (preforming), which substantially corresponds to the shape of the plastic part to be produced.

Der Vorformling wird dann in einer Harzinjektionsmaschine mit einem Harzsystem, d. h. mit einem Gemisch aus einem Harz und einem Härter, umspritzt. Nach einer gewissen Aushärtezeit kann das fertige Kunststoffteil entnommen werden.The preform is then placed in a resin injection machine with a resin system, i. H. with a mixture of a resin and a hardener, overmoulded. After a certain curing time, the finished plastic part can be removed.

Nach einer Weiterbildung der Erfindung werden die einzelnen Fasermateriallagen ”punktuell” entsprechend einem vorgegebenen Kleberaster miteinander verklebt. In Bereichen zwischen einzelnen ”Klebepunkten” bzw. Klebebereichen bleiben die Faserlagen unverklebt, d. h. frei relativ zueinander verschieblich.According to a development of the invention, the individual fiber material layers are "selectively" bonded together according to a predetermined adhesive grid. In areas between individual "gluing points" or adhesive areas, the fiber layers remain unglued, i. H. freely displaceable relative to each other.

Ein wesentlicher Vorteil der Erfindung besteht darin, dass die einzelnen Faserlagen an den Klebestellen nur mehr oder weniger leicht miteinander verklebt sind. Beim Umformen der Versteifungsmatrix in den Vorformling können einzelne Klebestellen bei entsprechendem Umformgrad bzw. bei entsprechender Belastung aufreißen, d. h. die Fasermateriallagen können sich in begrenztem Umfang weiterhin relativ zueinander verschieben.A significant advantage of the invention is that the individual fiber layers are glued to the splices only more or less easily together. When reshaping the stiffening matrix into the preform, individual splices can be torn open at the appropriate degree of deformation or under appropriate load, i. H. the fiber material layers may continue to shift relative to one another to a limited extent.

Ein wesentlicher Vorteil der Erfindung gegenüber dem eingangs beschriebenen Heißprägen besteht darin, dass das ”Setzen” eines Verbindungspunkts mittels einer Ultraschalleinrichtung in deutlich weniger als einer Sekunde, d. h. sehr schnell und mit geringem Energieaufwand möglich ist.A significant advantage of the invention over the hot embossing described above is that the "setting" of a connection point by means of an ultrasonic device in less than one second, ie. H. very fast and with low energy consumption is possible.

Claims (9)

Verfahren zum Herstellen einer Versteifungsmatrix für ein Kunststoffteil, wobei mindestens zwei, jeweils aus einem Fasermaterial bestehende Halbzeuge zumindest teilweise überlappend angeordnet und im Überlappungsbereich zu der Versteifungsmatrix miteinander verbunden werden, dadurch gekennzeichnet, dass auf eines der beiden Halbzeuge oder auf beide Halbzeuge zumindest in seinem Überlappungsbereich bzw. in ihren Überlappungsbereichen ein Binderstoff appliziert wird und dass die beiden Halbzeuge durch Aktivieren des Binderstoffs mittels einer Ultraschalleinrichtung miteinander verklebt und/oder verfilzt werden.A method for producing a stiffening matrix for a plastic part, wherein at least two, each consisting of a fiber material semi-finished at least partially overlapping and interconnected in the overlap region to the stiffening matrix, characterized in that on one of the two semi-finished products or on both semi-finished at least in its overlap region or in their overlapping areas, a binder material is applied and that the two semi-finished products are glued together and / or matted by activating the binder material by means of an ultrasonic device. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass der Binderstoff nur auf eine dem betreffenden anderen Halbzeug zugewandten Seite des einen Halbzeugs appliziert wird.A method according to claim 1, characterized in that the binder material is applied only to the respective other semifinished product side facing a semifinished product. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass der Binderstoff vor der Aktivierung im Wesentlichen nicht klebend ist.A method according to claim 1 or 2, characterized in that the binder is substantially non-adhesive prior to activation. Verfahren nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass der Binderstoff vor der Aktivierung in Pulverform vorliegt und dass eines oder beide Halbzeuge mit dem Binderstoff bepulvert, insbesondere bepulvert und angesintert werden. werden.Method according to one of claims 1 to 3, characterized in that the binder before activation in powder form and that one or both semi-finished products are powdered with the binder, in particular powdered and sintered. become. Verfahren nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass es sich bei den Halbzeugen um Gelege handelt.Method according to one of claims 1 to 4, characterized in that it is scrim with the semifinished products. Verfahren nach einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, dass die Halbzeuge Carbon- und/oder Glasfasern enthalten bzw. aus Carbon- und/oder Glasfasern bestehen.Method according to one of claims 1 to 5, characterized in that the semi-finished products contain carbon and / or glass fibers or consist of carbon and / or glass fibers. Verfahren nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, dass die Versteifungsmatrix zu einem der Form des herzustellenden Kunststoffteils entsprechenden bzw. ähnelnden Vorformling umgeformt wird.Method according to one of claims 1 to 6, characterized in that the stiffening matrix is formed into a shape corresponding to the shape of the plastic part to be produced or similar preform. Verfahren nach Anspruch 7, dadurch gekennzeichnet, dass der Vorformling in ein Harzinjektionswerkzeug eingebracht und mit einem Harz umspritzt wird, wodurch man das Kunststoffteil erhält.A method according to claim 7, characterized in that the preform is introduced into a resin injection tool and molded with a resin, whereby the plastic part is obtained. Verfahren nach einem der Ansprüche 1 bis 8, dadurch gekennzeichnet, dass die Halbzeuge punktuell bzw. rasterartig an einer Vielzahl von Klebestellen miteinander verklebt werden.Method according to one of claims 1 to 8, characterized in that the semi-finished products are adhesively bonded to one another at points or raster-like at a plurality of splices.
DE102010004530A 2010-01-14 2010-01-14 Method for producing a reinforcement matrix for a plastic part, comprises arranging two semi-finished product consists of a fibrous material partially overlapped, and connecting together in the overlap region to the reinforcing matrix Pending DE102010004530A1 (en)

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DE102010004530A DE102010004530A1 (en) 2010-01-14 2010-01-14 Method for producing a reinforcement matrix for a plastic part, comprises arranging two semi-finished product consists of a fibrous material partially overlapped, and connecting together in the overlap region to the reinforcing matrix

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DE102012219267A1 (en) * 2012-10-22 2014-04-24 Wobben Properties Gmbh Method and device for producing preforms for producing a rotor blade
DE102013213653A1 (en) * 2013-07-12 2015-01-15 Bayerische Motoren Werke Aktiengesellschaft motor vehicle
DE102014216305A1 (en) * 2014-08-18 2016-02-18 Bayerische Motoren Werke Aktiengesellschaft Process for the production of semi-finished fiber products, semi-finished fiber products and use thereof

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Publication number Priority date Publication date Assignee Title
DE102012219267A1 (en) * 2012-10-22 2014-04-24 Wobben Properties Gmbh Method and device for producing preforms for producing a rotor blade
DE102013213653A1 (en) * 2013-07-12 2015-01-15 Bayerische Motoren Werke Aktiengesellschaft motor vehicle
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DE102014216305A1 (en) * 2014-08-18 2016-02-18 Bayerische Motoren Werke Aktiengesellschaft Process for the production of semi-finished fiber products, semi-finished fiber products and use thereof

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