DE102010033288A1 - Method for manufacturing closed, complex three-dimensional formed fiber composite material components under utilization of mold core, involves force flow placing of fiber material on mold core that limits component inner volume - Google Patents

Method for manufacturing closed, complex three-dimensional formed fiber composite material components under utilization of mold core, involves force flow placing of fiber material on mold core that limits component inner volume

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Publication number
DE102010033288A1
DE102010033288A1 DE102010033288A DE102010033288A DE102010033288A1 DE 102010033288 A1 DE102010033288 A1 DE 102010033288A1 DE 102010033288 A DE102010033288 A DE 102010033288A DE 102010033288 A DE102010033288 A DE 102010033288A DE 102010033288 A1 DE102010033288 A1 DE 102010033288A1
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DE
Germany
Prior art keywords
mandrel
fiber
preform
mold core
component
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.)
Withdrawn
Application number
DE102010033288A
Other languages
German (de)
Inventor
Dipl.-Ing. Krüger Jan
Dipl.-Ing. Salkic Asmir
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Daimler AG
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Daimler AG
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Filing date
Publication date
Application filed by Daimler AG filed Critical Daimler AG
Priority to DE102010033288A priority Critical patent/DE102010033288A1/en
Publication of DE102010033288A1 publication Critical patent/DE102010033288A1/en
Application status is Withdrawn legal-status Critical

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00Moulds or cores; Details thereof or accessories therefor
    • B29C33/76Cores
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00Moulds or cores; Details thereof or accessories therefor
    • B29C33/38Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B29C33/3814Porous moulds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00Moulds or cores; Details thereof or accessories therefor
    • B29C33/44Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
    • B29C33/46Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles using fluid pressure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06Fibrous reinforcements only
    • B29C70/10Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • B29C70/205Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres the structure being shaped to form a three-dimensional configuration
    • B29C70/207Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres the structure being shaped to form a three-dimensional configuration arranged in parallel planes of fibres crossing at substantial angles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/40Shaping or impregnating by compression not applied
    • B29C70/42Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B29C70/865Incorporated in coherent impregnated reinforcing layers, e.g. by winding completely encapsulated
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2903/00Use of resin-bonded materials as mould material
    • B29K2903/04Inorganic materials
    • B29K2903/08Mineral aggregates, e.g. sand, clay or the like

Abstract

The present invention provides a method of making a closed, complex three-dimensionally shaped fiber composite component using a lost mandrel (1). The method comprises providing a preform (2) of the component by laying down and fixing a fiber material, which is impregnated in a flow-wise manner, on the mandrel (1), which delimits a component inner volume, whereupon the preform (2) in a device (5) is arranged, which comprises at least one heating device. In it, the preform (2) is heated and an internal pressure by means of the mandrel (1) on the preform (2) exerted. Then the preform (2) is allowed to cure to the component. Furthermore, the invention discloses a mold core (1) and a device (5) for producing the fiber composite component.

Description

  • The invention relates to a method for producing a closed, complex three-dimensionally shaped fiber composite component using a lost mandrel. Furthermore, the invention relates to the mold core and a device for producing the component.
  • It is known that tools and plant components such as presses or closing tools are necessary for the production of fiber composite plastic components in order to achieve a good bond between fiber and plastic matrix and to the production of complex geometric components. Designs such as undercuts can only be realized by pusher tools that push the fiber material into the undercuts. In such complex three-dimensionally shaped components, the wall thickness or fiber volume content is not homogeneous using the existing open mold technology, it may come to local fiber depletion and resin agglomeration. The tools and system components must be tempered, which requires time-consuming heating and cooling processes.
  • In order to produce a bodyshell structure such as a self-supporting frame structure for a motor vehicle body made of fiber reinforced plastic, is in the DE 10 2008 027 429 A1 discloses a method for their production, which allows a cost-effective and technically simple production of the bodyshell structure while reducing the Fügestellenzahl. In this case, initially a flat, impregnated with a curable matrix material, textile carrier element made of reinforcing fibers is provided, are positioned on the reinforcing and shaping elements. The carrier element is formed around a mandrel, whereupon the matrix material is cured and the mandrel is removed. The body shell structure thus formed results in a hollow profile in the region of the removed core.
  • From the DE 10 2007 057 110 A1 Also, a method for producing an endless, three-dimensional closed fiber composite semifinished product is known in order to produce a semifinished product such as a stiffening structure for a shell construction simply, inexpensively and lastfallgerecht. For this purpose, a planar, flat fiber preform is laid flat and aligned in order to achieve a load-oriented fiber orientation of the sheet-like fiber preform, which is then formed into a three-dimensional structure, which is closed to the closed fiber composite semifinished product. This closing is preferably carried out by sewing, in particular using a fusible thread.
  • Finally, out of the EP 2145 751 A1 discloses a method for producing a fiber composite plastic hollow body, wherein a preform assembly in the form of a braid of reinforcing fibers is provided on a soluble core made on the basis of a liquid dispersible molding material. After the reinforcing fibers have been infiltrated with hardenable matrix material in the infusion method, wherein the matrix material is sucked in by an underpressure in an infusion space bounded by a vacuum foil surrounding the preform assembly, the matrix material is hardened and then the soluble material Core removed by dissolution by means of a liquid. In order for the hollow body to be produced inexpensively and in particular with low investment costs.
  • Based on this prior art, it is desirable to provide a method by which closed, complex three-dimensionally shaped fiber composite components can be manufactured without tools and with only a few plant components. The geometrically complex hollow chamber components should have an improved high quality.
  • This object is achieved by a method having the features of claim 1.
  • Furthermore, an object of the invention is to provide a mold core, by means of which the closed, complex three-dimensionally shaped fiber composite component can be produced.
  • This object is disclosed by a mold core having the features of claim 11.
  • The object of providing a device which is suitable for producing a fiber composite component using the mold core is achieved with the device having the features of claim 13.
  • Further developments of the method, the mold core and the device are disclosed in the respective subclaims.
  • A first embodiment of the method according to the invention for producing the complex three-dimensionally shaped hollow-chamber fiber composite component using a lost mandrel, which limits a component internal volume, respectively the hollow chamber volume, comprises first providing a preform of the component, in which a fiber material on the Form core deposited and fixed there. The fiber material is before, during or after the Deposit with a matrix material, in particular impregnated with synthetic resin. The impregnated preform is then placed in a device equipped with a heater to apply heat to the preform. In this case, an internal pressure is exerted on the preform with the aid of the mold core, as a result of which a pressure is exerted on the resin fiber arrangement of the preform starting from the internal volume of the component, as a result of which the fibers deposited in the direction of load flow are streamlined or stretched. As the heat is applied, the matrix material hardens to a solid matrix.
  • Long fibers or continuous fibers, for example in the form of bundles or rovings, are particularly suitable among the fibers or the fiber material. Furthermore, fiber prepregs are also particularly suitable. Depending on the configuration of the fiber deposit, for example in prepregs, which only partially enclose the fiber body, it is necessary to use fixing aids, so that the fiber material adheres to the mold core. Endless fibers are preferably deposited around the mandrel such that they have sufficient tension to be substantially fixed on the mandrel without further fixation. By means of the lost mandrel, geometrically complex components can be fabricated in both small and large numbers. The tool and plant technology as well as the plant periphery are reduced to the device in which the preform is arranged. There are advantageously no pressing or closing necessary.
  • In one embodiment, in order to build up the internal pressure, the mandrel is an expansive mandrel made of a material having a high coefficient of thermal expansion and in which the thermal expansion due to the heating of the preform by thermal expansion builds up the internal pressure on the deposited fibers. As a result, the fibers or the preform are held in shape until the matrix material has hardened to a solid matrix.
  • In a further embodiment of the invention, the mandrel can be porous and therefore have a void volume that can be connected to a connecting piece. The porous mandrel, which is in particular a sand core, an elastic core or a foam core, then a fluid can be supplied through the connecting piece, which exerts the internal pressure on the deposited on the mandrel preform. The possibility of supplying a fluid such as water, oil or air in the porous mandrel also has the advantage of local, targeted Preform- or component temperature control directly through the core for rapid cooling or heating by the temperature of the supplied fluid. In principle, this is an expandable mold core.
  • An elastic core is formed in particular from an elastic foam or from a flexible plastic or rubber material. Such elastic cores may also have a plurality of inflatable cavities. This embodiment has the advantage that the degree of expansion of the core can be set very precisely before or during the curing of the matrix. The influence of the thermal expansion of the material of the core can be easily compensated here by the expansion of the void volume.
  • Especially for elastic or foam cores, the possibility of reuse is given. Since these cores shrink after hardening of the matrix by discharging the fluid or can disappear to a considerable extent the fiber-reinforced plastic formed, it is possible with suitable component geometry to remove the foam core or elastic core nondestructively and reused.
  • To be able to apply to the preform during the heating or the curing phase, and then not only with an internal pressure, but also with pressure from the outside, it can be provided that the device in which the preform is arranged is a device with both a heater and a pressure generating device, so that the preform can also be subjected to an external pressure.
  • When using a mandrel made of sand this can be removed by curing the component after curing of the hollow chamber. A mold core made of a foam material can also remain in the component can
  • The internal pressure and the internal temperature in the porous mandrel can be controlled by supplying the fluid not only once, and discharging it again, but by providing about a second or even a plurality of connecting pieces, by means of which the supply and discharge of the fluid can be controlled. By adjusting the internal pressure and the internal temperature, the curing speed and the homogeneity can be controlled.
  • When using a porous mandrel with connecting pieces, the deposition of the fiber material from the mandrel and the fixing can be supported by the connecting piece is connected to a suction device, so that a suction pressure can be applied to the porous mandrel. As a result of this negative pressure, the fibers can advantageously also be applied precisely to undercuts which are difficult or impossible due to a laying robot are reachable. The negative pressure or the Suagleistung can be set so low that only insignificant amounts are sucked off matrix material.
  • The fiber material used may have a ferromagnetic, inductively activatable fiber portion. When a magnetic field is applied to the mold core, such as the application of a negative pressure, the ferromagnetic fiber component causes the fiber material to lie close to this mold core and to be drawn into undercuts.
  • The fiber material used may be preimpregnated or unimpregnated long or continuous fibers, fiber bundles or fiber rovings. In principle, the common resins for the production of fiber-reinforced plastics can be used. Preferably, the fiber material is preimpregnated with a so-called bi-stage resin, which then gels after depositing on the mandrel before curing.
  • If an unimpregnated fiber material is deposited on the mandrel to provide the preform, impregnation with the matrix material prior to placement in the oven or autoclave occurs, such as by a resin injection process.
  • Alternatively, the fiber material may comprise a thermoplastic fiber portion, which provides the fixation on the mandrel by melting and gluing. An alternative deposit option is also to lay down the long fibers by fiber spraying together with an adhesive and to fix. It is also possible to deposit an endless fiber or a roving by a laying head on the mandrel, wherein the fixing on the mandrel either, as mentioned above, by gelled resin, molten thermoplastic part or an adhesive, or additionally or alternatively, the deposited fiber a previously placed on the mandrel fiber fleece is embroidered or sewn.
  • An embodiment according to the invention of a mold core, with which a geometrically complex hollow-chamber fiber composite component can be produced economically even in small quantities, refers to the fact that the mold core, which delimits a component inner volume, is designed such that it rests on a preform of the Component, which is provided by kraftflussgerechtes depositing and fixing an impregnated fiber material on the mandrel, exerts an internal pressure. This makes it possible to dispense with a system component such as a press, which otherwise requires high investment costs for complicated shaped components.
  • The mold core, which is either an expansive mandrel made of a material having a high coefficient of thermal expansion or alternatively or additionally having a porosity or elasticity with a void volume, thus allows virtually any design of the component and a uniform pressure exerted in the component internal volume during curing. While an expansive mandrel exerts internal pressure through thermal expansion of the mandrel, a porous mandrel or resilient and expandable mandrel provides the ability to connect the void volume or cavities to one or more spigot through which fluid can be delivered , In particular mold cores made of sand or a foam material come into question for this purpose.
  • In the apparatus in which the preform deposited on the mandrel is thermally cured, it may be, depending on the oven or an autoclave, which, in the case of using a porous mandrel, additionally equipped with a fluid conduit system, which consists of a or more fluid lines, which have fluid connections that can be connected to the connecting piece of the porous mandrel, in order to be able to supply the fluid for exerting the internal pressure and possibly also for tempering the preform or the component.
  • After curing of the matrix material, the core mold is removed from the cavity of the component analogously to the procedure for lost mandrels. For sand cores, the removal is usually done by rinsing with water, whereby a water-soluble binder is dissolved. In addition to sand, the sand core can also contain additives which influence or increase the thermal expansion during heating. This may, for example, be plastic granules or beads which have a high thermal expansion coefficient.
  • The elastic and expandable mandrels are preferably vented for removal from the cavity and folded.
  • Depending on the size of the component or on the size of the autoclave or furnace, several components can be produced simultaneously in batches. For this purpose, the fluid conduit system may be designed such that it has such a number of fluid connections, which corresponds to the connecting piece of the mold cores arranged in the device.
  • By the heat exerted during the heating of the method according to the invention and also during the curing phase and optionally thereafter Internal pressure can be created a high-quality fiber composite component in which the lastfallgerecht deposited fibers without ripple and thread rotation as possible stretched in the direction of stress, so that the finished component is high demands. Wall thickness and fiber volume content can be made homogeneous, without causing local fiber depletion and resin agglomeration. Due to the elimination of tool closing movements, such as in a press, there are no fiber shifts. The pressing pressure exerted by the internal pressure allows a greater fiber content, while the component advantageously has lower internal stresses and hardly any component distortion or surface markings in the finished component. The component can be made to final dimensions so that no further finish is required.
  • These and other advantages are set forth by the following description with reference to the accompanying figures.
  • The reference to the figures in the description is to aid in the description and understanding of the subject matter. The figures are merely a schematic representation of an embodiment of the invention.
  • Showing:
  • 1 FIG. 2 a perspective sectional view of a rotary mold provided on a mandrel with outlined, force-flow-oriented fibers, FIG.
  • 2 schematically the process steps of Faserablgens, as well as the Aushärtphase in the autoclave.
  • The invention relates to the production of geometrically complex hollow chamber components made of a fiber composite material, that is, to the production of a component which limits a closed internal volume. For the production of this fiber composite component according to the invention only a lost mandrel and as a system component, a furnace or an autoclave are required. For the purposes of the invention, any suitable reinforcing fiber, comprising glass fibers, carbon fibers, aramid fibers, ceramic fibers, which are present in a load-elastic manner in association with a plastic matrix, can be used as the fiber composite material. The fibrous material used may be long fibers or continuous fibers such as rovings or fabrics; hybrid fiber materials may also be used which, in addition to the reinforcing fiber, also comprise a portion of, for example, a thermoplastic resin or, as in one embodiment, a ferromagnetically and inductively activatable one Materials may include. Preferably, continuous fibers are used as rovings or fabrics, since they achieve the highest stiffness and strength values. In addition to individual fibers and fiber bundles, it is thus also possible to use fabrics, scrims, multi-axial scrims, embroidery, braids, mats and tiles.
  • For the thermoset matrix, especially various resin systems come into question, wherein in particular a so-called bi-stage resin is preferred, which gels after application, before the T-form is cured. Pre-impregnated semi-finished products, in particular duroplastic semifinished products made of continuous fibers, for example, from unidirectional tapes are also used. An unsaturated polyester resin or a vinyl ester resin, like other matrix systems, is frequently used as the matrix here. The curing of such systems is carried out by heating, optionally by additional pressure.
  • The inventive method for producing the closed hollow-chamber fiber composite components with complex three-dimensional geometry is in 2 outlined. There, on the left side, is the step of placing the fibrous material on the mandrel in a way that conforms to the force 1 shown to the preform 2 of the component, see right-hand illustration, which together with the mold core 1 in the device 5 is arranged to cure the preform. This is the device 5 around an autoclave in which the preform 2 both temperature and pressure is applied. The laying down of the fiber material, here a fiber roving 2 ' is done by means of a laying head 6 For example, according to TFP technology (Tailored Fiber Placement), which makes it possible to effectively convert force flow and stress calculations into a textile structure. It is using an embroidery machine, the reinforcing fiber or roving 2 ' on a base material such as a thin non-woven fabric, which on the mold core 1 is applied, sewn on.
  • 1 shows one by the flow of force appropriate laying of the reinforcing fiber 2 ' obtained preform 2 around the mandrel 1 is applied, which is a porous mold core 1 , for example, made of sand. The preform 2 may already be impregnated here, for example by using a preimpregnated fiber material, but it can also be impregnated in a further step by a resin infusion before entering the curing device 5 is transferred.
  • As in 1 is shown, is the porous mandrel 1 with the connecting piece 3 connected by the supply of a fluid in the void volume of the porous mandrel 1 is possible.
  • As 2 shows, the preform becomes 2 after getting by dropping the fiber roving 2 ' of a alternate bearing 7 was obtained in the autoclave 5 placed and the connecting piece 3 comes with a respective fluid port 4 ' connected to the fluid line system. In 2 are two fluid lines 4 represented, each of the four fluid connections 4 ' branch off, with each of which a mold core 1 over his connecting piece 3 connected is.
  • The number of preforms 2 simultaneously in the autoclave 5 Of course, it depends on the size of the component and the size of the autoclave. In the autoclave, the preform is subjected to a curing temperature corresponding to the matrix used, at the same time a medium L is passed through the fluid line system 4 . 4 ' in the mold core 1 supplied under pressure, so that the preform 2 can be acted upon from the outside both by the autoclave and from the inside by the supplied fluid L both pressure and temperature. The pressurization is indicated by the pressures p in and p out . The component is cured here under external pressure and temperature and internal pressure and temperature, wherein the fiber pressure through the mandrel 1 is maintained. Is used as a mold core 1 a sand core used, this can then be rinsed with water.
  • Previously, the fiber laying and fixing by a likewise via the connecting piece 3 applied vacuum (or a magnetic field, if ferromagnetic, inductively activatable fibers are used) are supported. The over the connecting pieces 3 the supply and possibly also removal of fluids accessible mold core 1 In addition to rapid heating during or after curing, it also enables homogeneous and rapid cooling of the component.
  • In a simple embodiment, it may be in the mold core 1 also merely act by an expandable in consequence of a high coefficient of thermal expansion mandrel, which exerts the internal pressure by its thermal expansion. As a further variant, the use of a swellable material is conceivable in a porous mandrel, which swells through the supply of a fluid and thus exerts the internal pressure on the preform by the increase in volume.
  • Depending on the matrix used, only one oven may be used instead of an autoclave for curing, so that the fiber press pressure is applied only by the internal pressure generated.
  • Advantageously, however, both the internal expansion pressure and the internal temperature through the through the connection piece 3 controlled medium supplied, optionally for recirculation, a further connection piece for discharging the fluid may be provided on the core (not shown figuratively). The fiber tightening in the direction of loading achieved by the internal pressure as a result of the core expansion can be regulated by the control of the applied internal pressure. Homogeneity of fiber distribution and wall thickness is also realized by the applied internal pressure, as well as by the supplied medium, which allows a core temperature.
  • The laying down of the fibers 2 ' , as in 1 can be seen in undercuts, using the mold core according to the invention 1' be supported by that over the connecting piece 3 a negative pressure in the mold core 1 is generated, which is the fibers 2 ' pulls in the undercuts.
  • Furthermore, it is conceivable that the mandrel has a ferromagnetic and by induction by means of an applied to the mandrel electromagnetic field activatable portion which exerts an attractive force on a likewise ferromagnetic fiber content. In addition to the deposition of the fiber material by means of laying head, the long fiber can also be deposited by fiber spraying or spraying on the mandrel, which is then fixed there with a sprayed adhesive there.
  • When a fibrous material having a thermoplastic moiety such as a hybrid weave or hybrid roving is used, the thermoplastic moiety may be used by reflowing to fix the reinforcing fibers to the mandrel.
  • Due to the simple system technology, which requires no press, only a furnace or an autoclave with fluid line system, geometrically complex shaped hollow chamber FRP components can be produced economically both in small and large quantities.
  • With the method according to the invention quasi an arbitrarily suitable fiber material can be used for adhesion-compliant placement, the impregnation with a matrix system and the fixation in the mandrel offers a wide range of possible variations. Essenziel is the exercise of internal pressure, which is provided by the mold core, which creates the finished component with final production, low internal stresses, virtually no component distortion and without surface markings with high fiber content and thus with a pre-strength.
  • QUOTES INCLUDE IN THE DESCRIPTION
  • This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.
  • Cited patent literature
    • DE 102008027429 A1 [0003]
    • DE 102007057110 A1 [0004]
    • EP 2145751 A1 [0005]

Claims (14)

  1. Method for producing a closed, complex three-dimensionally shaped fiber composite component using a lost mandrel (US Pat. 1 ), comprising the steps of: - laying a fiber material on the mandrel in accordance with the flow of force ( 1 ), which limits a component internal volume, by providing a preform ( 2 ) of the component - impregnating the fiber material with a curable matrix material, - arranging the preform ( 2 ) with mandrel ( 1 ) in a device ( 5 ), which comprises at least one heating device, and heating the preform ( 2 ), whereby by the mold core ( 1 ) an internal pressure on the fiber material of the preform ( 2 ), - Curing of the matrix material to the fiber composite component - Removal of the lost core from the interior of the component.
  2. A method according to claim 1, characterized in that the fiber material is deposited under tension on the mandrel and / or fixed with fixing aids on the mandrel.
  3. Method according to claim 1 or 2, wherein the mandrel ( 1 ) a thermally expandable mandrel ( 1 ) is made of a material having a high coefficient of thermal expansion and wherein the application of an internal pressure by means of the mandrel ( 1 ) by thermally expanding the mold core ( 1 ) after heating the preform ( 2 ) provided.
  4. The method of claim 1, wherein the mandrel ( 1 ) a porous mandrel ( 1 ) or an elastic mandrel ( 1 ) having a void volume, the at least one connecting piece ( 3 ), in particular a sand core ( 1 ) or a foam core and wherein the exertion of an internal pressure by supplying a fluid (L), preferably by supplying a heatable fluid (L), more preferably by supplying water, oil and / or air, via the connecting piece ( 3 ) in the mold core ( 1 ) he follows.
  5. Method according to at least one of claims 1 to 4, wherein the device ( 5 ) comprises a heating device and a pressure generating device, comprising the steps - applying the preform ( 2 ) with an external pressure at least during heating.
  6. Method according to claim 4 or 5, comprising the steps of - removing the sand core ( 1 ) by rinsing after curing of the component.
  7. Method according to at least one of claims 4 to 6, comprising the steps of - discharging the fluid (L) from the mandrel ( 1 ), in particular by an at least second connecting piece, thereby controlling the internal pressure and the internal temperature.
  8. Method according to at least one of claims 4 to 7, wherein the depositing and fixing of the fiber material on the mandrel ( 1 ) comprises the step: - connecting the connecting piece ( 3 ) with a suction device and applying a suction pressure to the mandrel ( 1 ).
  9. Method according to at least one of claims 1 to 8, wherein the depositing and fixing of the fiber material on the mandrel ( 1 ) comprises the step of providing a fiber material with a ferromagnetic fiber portion and applying an electromagnetic field to the mandrel ( 1 ), which comprises a ferromagnetic and inductively magnetizable or activatable material. ( 1 ).
  10. Method according to at least one of claims 1 to 9, wherein the fiber material - pre-impregnated long or continuous fibers, fiber bundles, fiber rovings, in particular with a bi-stage resin preimpregnated long or continuous fibers, wherein the resin in the provided from the deposited fiber material preform ( 2 ) is present gelled before curing, or - comprises long or continuous fibers, fiber bundles, fiber rovings with or without thermoplastic fiber content, and as on the mandrel ( 1 ) stored preform ( 2 ) is impregnated with matrix material.
  11. The method of claim 10, wherein - the long fibers are deposited by fiber spraying and fixed with an adhesive, - the continuous fiber, the fiber bundle, or the fiber rovings by a laying head ( 6 ) on the mandrel ( 1 ), wherein the fixing on the mandrel ( 1 ) by gelled resin, a molten thermoplastic part, an adhesive, and / or by embroidering or sewing on a previously on the mandrel ( 1 ) deposited fiber fleece takes place.
  12. Mold core ( 1 ) for producing a closed, complex three-dimensionally shaped fiber composite component according to a method according to at least one of claims 1 to 11, characterized in that the mandrel ( 1 ), which limits a component internal volume, is formed on a preform ( 2 ) of the component, which can be deposited by affixing and fixing an impregnated fiber material on the mandrel ( 1 ) is provided to exert an internal pressure.
  13. Mold core ( 1 ) according to claim 12, characterized in that the mandrel ( 1 ) - an expansive mold core ( 1 ) is made of a material having a high coefficient of thermal expansion, wherein the internal pressure on the preform ( 2 ) by a thermal expansion of the mold core ( 1 ), and / or - has a porosity with a void volume and in particular a sand core ( 1 ) or a foam core, wherein the cavity volume of the mold core ( 1 ) with at least one connecting piece ( 3 ), through which a fluid (L) into the porous mandrel ( 1 ) can be supplied to provide the internal pressure.
  14. Contraption ( 5 ) for producing a closed, complex three-dimensionally shaped fiber composite component according to a method according to at least one of claims 3 to 11 using a mandrel according to one of claims 12 or 13, wherein the device ( 5 ) comprises a heating device or a heating device and a pressure generating device, characterized in that the device ( 5 ) has a fluid line system, the at least one fluid line ( 4 ) with at least one fluid connection ( 4 ' ), which is connected to the connecting piece ( 3 ) in the device ( 5 ) arranged mold core ( 1 ), which limits an internal volume of the component and on which the impregnated fiber material forms the preform ( 2 ) is stored and fixed in accordance with the flow of power, is connectable.
DE102010033288A 2010-08-04 2010-08-04 Method for manufacturing closed, complex three-dimensional formed fiber composite material components under utilization of mold core, involves force flow placing of fiber material on mold core that limits component inner volume Withdrawn DE102010033288A1 (en)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102007057110A1 (en) 2007-11-26 2009-06-04 Eurocopter Deutschland Gmbh Process for producing an endless, three-dimensional closed fiber composite semifinished product
DE102008027429A1 (en) 2008-06-09 2009-12-17 Daimler Ag Shell structure for a motor vehicle and method for its production
EP2145751A1 (en) 2008-07-18 2010-01-20 Euro-Composites S.A. Method for producing a hollow body from fibre compound plastic

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102007057110A1 (en) 2007-11-26 2009-06-04 Eurocopter Deutschland Gmbh Process for producing an endless, three-dimensional closed fiber composite semifinished product
DE102008027429A1 (en) 2008-06-09 2009-12-17 Daimler Ag Shell structure for a motor vehicle and method for its production
EP2145751A1 (en) 2008-07-18 2010-01-20 Euro-Composites S.A. Method for producing a hollow body from fibre compound plastic

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