DE102011114494A1 - Fiber-reinforced composite component and method for producing such a composite component - Google Patents

Abstract

The invention relates to a composite component (10) comprising at least two layers (12, 14, 16, 18), wherein a first layer (12) consists at least partially of a plastic reinforced by fibers (14) and wherein a second layer (16) at least partially made of an elastomer. According to the invention, the first layer (12; 22), the second layer (16; 26) and a third layer (18; 28) of a gelcoat or a synthetic resin paint are joined together as a composite component (10) with high surface quality by a common crosslinking or curing , The invention also relates to a method for producing such a composite component. ( 1 )

Description

The invention relates to a fiber-reinforced composite component having at least one plastic layer and having at least one elastomer layer according to the preamble of patent claim 1 and a method for producing such a composite component according to claim 9.

There are known fiber reinforced plastics (FRP), which are usually less energy-elastic and brittle and therefore can absorb or absorb little energy when vibrations occur due to vibrations, shocks or impacts. If such fiber-reinforced plastics are to be produced with a high surface quality, as is the case, for example, for body shell components or interior spoilers of vehicles, this encounters considerable difficulties. This is due in particular to the undulation of the roving in the tissue. This results in thickness variations of the surrounding resin surrounding the fabric which in turn leads to irregular surfaces due to shrinkage and different thermal expansion coefficients.

From the WO 2010/083980 A1 a vehicle component is known in which a bonding layer made of elastomer and to this then a cover layer of carbon fiber reinforced plastic is applied to a carrier layer of metal or fiber-reinforced synthetic resin. In this case, the cover layer should be made transparent in order to make the fibers embedded in the cover layer visible.

From the WO 2006/122749 A1 a composite component is known in which a first, at least partially made of a thermosetting synthetic resin layer and a second, at least partially made of an elastomer layer are joined together by a common heat treatment in one operation.

The present invention has for its object to provide a composite component and a method for its production, whose surface has an excellent quality with ease of manufacture.

This object is achieved by the means specified in claim 1 with respect to the device and by the means specified in claim 9 with respect to the method for production. Advantageous embodiments of the invention can be found in the respective subclaims.

The invention provides that a first layer of a fiber-reinforced plastic, a second layer of an elastomer and a third layer consisting of a gelcoat or a synthetic resin paint are joined together as a composite component by a common crosslinking or hardening. By using the preferably colored in the desired color gelcoat or synthetic resin coating layer, the composite component with a simple production in one operation receives a smooth Oberfäche that meets the high demands of the automotive industry ("Class-A-visible surface"). The composite component can thus be made ready for installation without further rework, such as grinding or painting, in one operation.

When in the present invention of "layers" is mentioned, it may be wholly or just partially superimposed or embedded in one another strips, pieces or regions of said materials. Of a plastic composite component in the context of the present invention is also spoken of when one or more layers of the plastic composite component of metal or other, not to be designated as plastics materials.

The reinforcing layer, fiber-reinforced layer and the elastomer layer are built together with the cover layer in a single operation in a mold and then connected together under the action of energy. All of the raw materials involved are coordinated so that they network or harden together.

The first layer is formed as a plastic carrier layer of a fiber reinforced plastic (FRP), a carbon fiber reinforced plastic (CFRP) or a glass fiber reinforced plastic (GRP).

The elastomer layer preferably consists of one of the following substances:
of ethylene-propylene rubber (EPM), ethylene-propylene-diene rubber (EPDM), ethylene-acrylate rubber (EAM), fluorocarbon rubber (FKM), acrylate rubber (ACM), acrylonitrile butadiene rubber ( NBR), optionally blended with polyvinyl chloride (PVC), hydrogenated nitrile rubber (HNBR), carboxylate nitrile rubber (XNBR), hydrogenated carboxylate nitrile rubber (XHNBR), natural rubber (NR), ethyl vinyl acetate ( EVA), chlorosulfonyl polyethylene rubber (CSM), chlorinated polyethylene (CM), butyl or halobutyl rubber, silicone rubber (VMQ, MVQ), fluoro-silicone rubber (FVMQ, MFQ), chlorohydrin rubber (CO ), Epichlorohydrin rubber (ECO), polychloroprene rubber (CR), one-component polyurethane (PU) or a combination or a blend of the aforementioned substances. Alternatively, it can the at least one elastomer layer also consist of a thermoplastic elastomer (TPE).

By combining with the colored for the respective purpose third layer finished composite components can be produced inexpensively. After joint shaping and curing, the composite components according to the invention are in a ready-to-use condition and no longer need to be additionally painted. As a result, body shell components, such as doors, fenders, hoods, trunk lids, roof modules, spoilers or the like can be made in finished form and matching color and mounted directly to the vehicle.

• a) Gemäß einer ersten Alternative erfolgt zunächst die Zufuhr der dritten Schicht in eine vorzugsweise mit einem Trennmittel versehene Form, insbesondere durch Aufsprühen des Gelcoats oder Kunstharzlacks,
• b) dann das Zuführen der zweiten Schicht durch Aufbringen einer unvernetzten Elastomerschicht (z. B. durch Auflegen einer rohen Gummi- oder TPE-Folie) auf die dritte Schicht;
• c) dann das Zuführen der ersten Schicht aus einem mittels Fasern verstärkten Kunststoff auf die zweite Schicht, insbesondere als fertig getränktes Prepreg oder als trockenes Gewebe, Vlies oder Matte, welche(s) dann in einem Zwischenschritt mit Kunstharz infiltriert wird;
• d) Verbinden der ersten Schicht, der zweiten Schicht und der dritten Schicht durch ein gemeinsames Aushärten bzw. Vernetzen unter Energiezufuhr. – Gemäß einer zweiten Alternative wird zwischen die dritte Schicht und die zweite Schicht noch eine weitere insbesondere mit Carbonfasern verstärkte Kunststoffschicht eingefügt, die dann ebenfalls mit den übrigen Schichten durch ein gemeinsames Aushärten bzw. Vernetzen unter Energiezufuhr verbunden wird.

The structure of the composite component of the fiber-reinforced layer, the elastomer layer and the cover layer is preferably as follows:

• a) According to a first alternative, first the supply of the third layer takes place in a mold, preferably provided with a release agent, in particular by spraying the gelcoat or synthetic resin paint,
• b) then feeding the second layer by applying an uncrosslinked elastomer layer (eg, by laying a green rubber or TPE film) on the third layer;
• c) then feeding the first layer of fiber reinforced plastic to the second layer, in particular as a pre-soaked prepreg, or as a dry web, mat or mat which is then infiltrated with synthetic resin in an intermediate step;
• d) joining the first layer, the second layer and the third layer by co-curing under energization. - According to a second alternative, between the third layer and the second layer, a further plastic layer reinforced in particular with carbon fibers is inserted, which is then likewise connected to the remaining layers by co-curing or crosslinking while supplying energy.

As a result of the softer elastomeric layer, both vibration absorption in the composite component according to the invention and vibration isolation by the composite component according to the invention can be achieved. For interior trim parts, optically and / or haptically pleasing surface layers can be produced.

• • einfache Verarbeitungsweise
• • kurze Zykluszeiten
• • niedriger Energieverbrauch
• • Mehr-Komponenten-Verarbeitung und somit die Reduzierung des Montageaufwands
• • Kombination dreier Materialien (Hart-Weich-Hart-Verbund)
• • vielfältige Einfärbbarkeit auch mit Effekten und damit Designfreiheit

The composite component according to the invention has the following further advantages:

• • easy processing
• • short cycle times
• • low energy consumption
• • Multi-component processing and thus the reduction of assembly work
• • Combination of three materials (hard-soft-hard composite)
• • Diverse coloring with effects and therefore design freedom

The optional introduction of flame-retardant elastomer layers impedes fire propagation.

A particularly advantageous use of a composite component according to the invention is that the composite component is used as energy-absorbing component. In general, use as a stable, vibration-damping lightweight component is advantageous. In this case, for example, a use as interior trim or body shell component of vehicles or as a housing for high-quality consumer goods, such as computers or notebooks or the like is possible, this list is to be seen only as an example and not exhaustive.

At a minimum, only a first layer or inserted or embedded strips, pieces or regions of a fiber-reinforced plastic and a second layer of an elastomer are provided in conjunction with the third layer of a gelcoat or synthetic resin lacquer. For certain applications, a multi-layer structure is advantageous, wherein advantageously each of a plastic layer and an elastomer layer alternate with each other. In this case, advantageously, an outer layer or both outer layers can be formed by gelcoat or synthetic resin paint.

• – Die separate Herstellung eines harzbasierenden Festigkeitsträgers ist nicht mehr notwendig.
• – Der Aufbau des gesamten Verbundbauteils geschieht in einem durchgehenden Arbeitsgang an demselben Arbeitsplatz.
• – Eine Verwendung von Haftvermittlern ist nicht nötig.
• – Geringerer Zeitaufwand für die Herstellung, dadurch erhebliche Kostensenkung.
• – Die Herstellung einer elektrisch ableitenden Variante ist ohne signifikant höhere Materialkosten durch Einbetten leitender Fäden, Streifen oder Gewebe möglich.
• – Es sind völlig neuartige Konstruktionen möglich.
• • Energieabsorbierende Bauteile in Leichtbauweise
• • Verbundbauteile mit integriertem Oberflächenschutz gegen Kratzer oder Abrieb
• • Bauteile mit reduzierter Bruch- oder Splitterneigung bei Deformation
• • Flammhemmende Verbundteile durch Einbau unbrennbarer elastischer Schichten (z. B. Metall- oder Metallhydroxidpartikel oder halogenierte Paraffine als Zuschlagstoffe im Elastomer).

Further advantages of the invention are:

• - The separate production of a resin-based reinforcement is no longer necessary.
• - The structure of the entire composite component is done in a continuous operation at the same workplace.
• - A use of adhesion promoters is not necessary.
• - Less time required for the production, thereby significant cost reduction.
• - The production of an electrically dissipative variant is possible without significantly higher material costs by embedding conductive threads, strips or fabric.
• - Completely new constructions are possible.
• • Energy-absorbing components in lightweight construction
• • Composite components with integrated surface protection against scratches or abrasion
• • Components with reduced fracture or splinter inclination during deformation
• • Flame-retardant composite parts by incorporation of incombustible elastic layers (eg metal or metal hydroxide particles or halogenated paraffins as aggregates in the elastomer).

Hereinafter, embodiments of the invention are described with reference to the drawing. In detail shows:

1 the basic structure of a composite component with three layers, a first layer of a fiber-reinforced plastic, an elastomer layer arranged above it as a second layer and a third layer of gelcoat or synthetic resin lacquer forming the outer layer, and

2 an alternative to 1 in which a further fiber-reinforced plastic layer is provided between the second and the third layer.

In 1 is a composite component according to the invention 10 schematically shown in its construction. The composite component 10 has a first layer 12 , a second layer disposed thereon 16 and an adjoining third layer 18 as a cover layer or outer layer.

If in connection with the figure description of "on" or "up" is spoken, it should be noted that in 1 and 2 the cover layer or outer layer 18 is down, as is the case in the production in a form not shown. When using the finished composite component 10 forms the cover layer or outer layer 18 in each case its outer visible side.

The first shift 12 is made as a plastic backing layer of one with fibers 14 reinforced plastic (FRP), a carbon fiber reinforced plastic (CFRP) or a glass fiber reinforced plastic (GRP) formed. As material for the fiber reinforcement 14 , which is used in the form of loose fibers, a fabric, Geleges or as pulp, are preferably glass fibers, nylon, polyester, carbon fibers, viscose, aramid fibers or metal fibers and fibers from natural, renewable raw materials into consideration.

The second layer 16 consists of one on the first layer 12 arranged elastomer layer, which can optionally also be provided with an insert of fibers or fabric material.

The second layer 16 subsequent cover layer or outer layer 18 consists of a gelcoat or synthetic resin lacquer layer with the color properties adapted to the respective intended use. The gelcoat, which consists, for example, of unsaturated polyester (UP), is preferably silica for increasing the abrasion resistance of the outer layer 18 added.

The second layer formed as an elastomeric layer 16 is preferably one of the following: ethylene-propylene rubber (EPM), ethylene-propylene-diene rubber (EPDM), ethylene-acrylate rubber (EAM), fluorocarbon rubber (FKM), acrylate rubber (ACM ), Acrylonitrile butadiene rubber (NBR), optionally blended with polyvinyl chloride (PVC), hydrogenated nitrile rubber (HNBR), carboxylate nitrile rubber (XNBR), hydrogenated carboxylate nitrile rubber (XHNBR), natural rubber (NR ), Ethyl vinyl acetate (EVA), chlorosulfonyl polyethylene rubber (CSM), chlorinated polyethylene (CM), butyl or halobutyl rubber, silicone rubber (VMQ, MVQ), fluorosilicone rubber (FVMQ, MFQ), chlorohydrin rubber (CO), epichlorohydrin rubber (ECO), polychloroprene rubber (CR), one-component polyurethane (PU) or a combination or a blend of the aforementioned substances. Alternatively, the at least one elastomer layer may also consist of a thermoplastic elastomer (TPE). For this particular TPE-S are (also called "TPS" = styrene block copolymers such as SBS, SEBS, SEPS, SEEPS or MBS; for example the product thermal load ^® from KRAIBURG TPE GmbH & Co. KG), TPE-V (also called "TPV" = dynamically vulcanized thermoplastics), TPE-A (also "TPA" = thermoplastic copolyamides) or TPE-E (also "TPC" = thermoplastic copolyesters) into consideration.

The elastomer layer contains - if it does not consist of TPE - a crosslinking system which, depending on the elastomer used at least one crosslinker from the group of peroxides, amines and / or bisphenols and allows a reaction with the resin of the carrier layer. Alternatively to a heat treatment for a crosslinking of the elastomer layer 16 with the synthetic resin of the carrier layer 12 and the gelcoat or synthetic resin paint layer 18 It is also possible to carry out a different crosslinking treatment, for example with ultraviolet irradiation (UV light). On top of a first elastomeric layer, further elastomeric layers, if necessary of different strength and hardness, may be applied, which are assembled to bond to the respective underlying elastomeric layer. The at least one elastomer layer particularly preferably consists of rubber-based materials.

Alternatively or in addition to reinforcement with fibers 14 is also a use of a metal powder as an insert in at least one of the layers 12 . 16 or 18 possible. This allows targeted certain physical properties of the composite component 10 be generated, such as its strength, flexibility and elasticity, its spring and damping behavior, its electrical conductivity or its flammability.

• • Die Form wird bei Bedarf mit einem Antihaftmittel versehen, kann aber auch selbst antihaftend (beispielsweise durch Teflon^®-Oberflächen) ausgebildet sein.
• • Als nächstes wird die Gelcoat- oder Kunstharzlackschicht als Außenschicht 18 bzw. 28 bevorzugt durch Sprühen in der Form erzeugt.
• • Auf die Außenschicht 28 wird im zweiten Ausführungsbeispiel gemäß 2 eine Carbonfaser-Matte 271 bevorzugt als fertig mit Kunstharz vorgetränktes Prepreg aufgelegt oder alternativ als trockene Carbon-Fasermatte 271 aufgelegt und in einem Zwischenschritt durch Kunstharzinfusion mit Kunstharz getränkt; beim ersten Ausführungsbeispiel gemäß 1 entfällt diese zusätzliche Kunstharzschicht 27.
• • Im nächsten Schritt wird auf die Außenschicht 18 (beim ersten Ausführungsbeispiel gemäß 1) oder auf die zusätzliche Kunstharzschicht 27 (beim zweiten Ausführungsbeispiel gemäß 2) die Elastomerschicht 16 bzw. 26 aufgebracht. Diese wird bevorzugt als rohe, unvernetzte Gummi- oder TPE-Folie aufgelegt.
• • Im nächsten Schritt wird die als Festigkeitsträger fungierende erste Schicht 12 bzw. 22 mit der Faserverstärkung 14 bzw. 24 auf die Elastomerschicht 16 bzw. 26 aufgebracht.
• • Im letzten Schritt werden alle Schichten 12, 16 und 18 bzw. 22, 26, 27 und 28 durch eine gemeinsame Wärmebehandlung oder einen anderen Energieeintrag gemeinsam vernetzt bzw. ausgehärtet. Die Aushärtetemperatur liegt vorzugsweise zwischen 80 und 200° C.

According to the embodiment 2 are those of 1 corresponding layers of a composite component 20 provided with a reference number higher by 10. In contrast to 1 is between the second layer 26 (Elastomer layer) and the third layer 28 (Outer layer of gelcoat or synthetic resin lacquer) another layer 27 made of a thermosetting synthetic resin with a fabric or fiber insert 271 intended. This layer 27 is preferably designed as prepreg impregnated with synthetic resin, but can also be applied as a dry tissue and then infiltrated with synthetic resin. The tissue 271 is for example particularly preferably formed from carbon fibers. In this case it may be desirable to have the outer layer 18 made of gelcoat or synthetic resin paint transparent or at least translucent, so that the carbon fibers are visible on the visible side and the composite component 20 give a high-tech character with a high-quality appearance The production of the component according to the invention preferably takes place in a mold with the following process steps:

• If necessary, the mold is provided with an anti-adhesive agent, but may also be self-adhesive (for example by ^Teflon® surfaces).
• • Next, the gelcoat or synthetic resin lacquer layer becomes the outer layer 18 respectively. 28 preferably produced by spraying in the mold.
• • on the outer layer 28 is in the second embodiment according to 2 a carbon fiber mat 271 preferably applied as prepreg pre-impregnated with synthetic resin or, alternatively, as a dry carbon fiber mat 271 applied and soaked in a intermediate step by synthetic resin infusion with synthetic resin; in the first embodiment according to 1 eliminates this additional resin layer 27 ,
• • The next step is on the outer layer 18 (In the first embodiment according to 1 ) or on the additional synthetic resin layer 27 (In the second embodiment according to 2 ) the elastomer layer 16 respectively. 26 applied. This is preferably applied as a raw, uncrosslinked rubber or TPE film.
• • In the next step, the first layer acting as a reinforcement is used 12 respectively. 22 with the fiber reinforcement 14 respectively. 24 on the elastomer layer 16 respectively. 26 applied.
• • In the last step, all layers become 12 . 16 and 18 respectively. 22 . 26 . 27 and 28 crosslinked or cured together by a common heat treatment or another energy input. The curing temperature is preferably between 80 and 200 ° C.

A preferred use of a composite component according to the invention 10 respectively. 20 is for example a flat vehicle component in the outer region of the body or an interior trim part of a vehicle. However, it is also a variety of other uses, such as consumer goods, sports equipment or high-quality consumer goods possible.

LIST OF REFERENCE NUMBERS

10

composite component

12

Plastic carrier layer (first layer)

14

fiber material

16

Elastomer layer (second layer)

18

Outer layer (third layer)

20

composite component

22

Plastic carrier layer (first layer)

24

fiber material

26

Elastomer layer (second layer)

27

(further) plastic layer

271

tissue

28

Outer layer (third layer)

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

• WO 2010/083980 A1 [0003]
• WO 2006/122749 A1 [0004]

Claims (10)

Composite component ( 10 ; 20 ) of at least two layers ( 12 . 14 . 16 . 18 ; 22 . 24 . 26 . 27 . 271 . 28 ), wherein a first layer ( 12 ; 22 ) at least partially from one by means of fibers ( 14 ; 24 ) reinforced plastic (FRP, CRP, GRP) and wherein a second layer ( 16 ; 26 ) consists at least partly of an elastomer, characterized in that the first layer ( 12 ; 22 ), the second layer ( 16 ; 26 ) and a third layer consisting of a gelcoat or a synthetic resin paint ( 18 ; 28 ) by a common cross-linking or curing as a composite component ( 10 ) are joined together. Composite component according to claim 1, characterized in that between the second layer ( 16 ; 26 ) and the third layer ( 18 ; 28 ) another, in particular by means of a tissue ( 271 ) reinforced plastic layer ( 27 ) is arranged. Composite component according to one of the preceding claims, characterized in that the first layer ( 12 ; 22 ) is formed of a synthetic resin such as polyester resin, phenol-formaldehyde resin, cyanate ester resin, epoxy resin or acrylate resin Composite component according to one of the preceding claims, characterized in that the fibers ( 14 ; 24 ) of carbon fibers, glass fibers, nylon, polyester, viscose, aramid fibers, metal fibers or fibers of natural, renewable resources in loose form, in the form of a fabric, a fabric or a pulp are formed. Composite component according to one of the preceding claims, characterized in that the second layer ( 16 ; 26 ) of ethylene-propylene rubber (EPM), ethylene-propylene-diene rubber (EPDM), ethylene-acrylate rubber (EAM), fluorocarbon rubber (FKM), acrylate rubber (ACM), acrylonitrile-butadiene rubber (NBR), optionally blended with polyvinyl chloride (PVC), hydrogenated nitrile rubber (HNBR), carboxylate nitrile rubber (XNBR), hydrogenated carboxylate nitrile rubber (XHNBR), natural rubber (NR), ethyl vinyl acetate (EVA), Chlorosulfonyl Polyethylene Rubber (CSM), Chlorinated Polyethylene (CM), Butyl or Halobutyl Rubber, Silicone Rubber (VMQ, MVQ), Fluorosilicone Rubber (FVMQ, MFQ), Chlorohydrin Rubber ( CO), epichlorohydrin rubber (FCC), polychloroprene rubber (CR), one-component polyurethane (PU) or a combination or a blend of the aforementioned substances. Composite component according to one of claims 1 to 4, characterized in that the second layer ( 16 ) consists of a thermoplastic elastomer (TPE). Composite component according to one of claims 2 to 6, characterized in that the further plastic layer ( 27 ) of a resin impregnated fabric ( 271 ) is formed. Composite component according to claim 7, characterized in that the fabric ( 271 ) is formed of carbon fibers. Method for producing a composite component ( 10 ; 20 ) of at least three layers ( 12 . 14 . 16 . 18 ; 22 . 24 . 26 . 27 . 271 . 28 ), wherein a first layer ( 12 ; 22 ) at least partially made of one with fibers ( 14 ; 24 ) reinforced plastic, wherein a second layer ( 16 ; 26 ) consists at least partially of an elastomer, and wherein a third layer ( 18 ; 28 ) consists of a gelcoat or a synthetic resin varnish, characterized by the following process steps: e) feeding the third layer ( 18 ; 28 ) in a mold preferably provided with a release agent, f) supplying the second layer ( 16 ; 26 ) into the mold following the third layer ( 18 ; 28 ); g) supplying the first layer from one by means of fibers ( 14 ) reinforced plastic in the mold following the second layer ( 16 ; 26 ); h) joining the first layer ( 12 ; 22 ), the second layer ( 16 ; 26 ) and the third layer ( 18 ; 28 ) by co-curing or cross-linking with energy. A method according to claim 9, characterized in that i) between the method step a) and b) on the third layer ( 18 ; 28 ) first another layer ( 27 ) with a reinforcing fabric ( 271 ) is applied.

Images