DE102014101446A1 - Tape laying device and method for building a laminate - Google Patents

Abstract

The invention relates to a method for constructing and consolidating a laminate (90) and an associated tape laying device (1). The invention for the method consists in carrying out the following method steps: a) feeding tape (93) to be deposited with binder and / or matrix materials to a depositing device (20); b) depositing supplied tape (93) by means of the depositing device (20); wherein juxtaposed tape (93) defines a stacking (92) of a tape structure (91); and c) controlling the receipt of a consolidated laminate (90) by: - bringing an already laid down tape structure (91) and tape (93) to be deposited thereon onto an excitation device (50) and / or vice versa; - Simultaneously plasticizing the binder and / or matrix materials only in the surfaces (96) of the contiguous joining zones (95) supplied to the exciter (50) already deposited tape structure (91) and tape to be deposited on it (93); - Laying the only superficially excited tape (93) on the already deposited exclusively superficially excited tapestry (91) by means of the depositing device (20), so that their joining zones (95) adjacent to each other; - Simultaneously bringing together only in the surfaces (96) plasticized binder and / or matrix materials of the adjacent joining zones (95) of stored tape (93) and this tape (93) carrying already deposited tape structure (91). 1472

Description

• a) eine Zuführeinrichtung (10) für das Zuführen von mit Binder- und/oder Matrix-Werkstoffen versehenem abzulegenden Tape (93) an eine Ablegeeinrichtung (20);
• b) eine Ablegeeinrichtung (20) für das Ablegen von zugeführtem Tape (93); wobei nebeneinander abgelegtes Tape (93) eine Tapelage (92) einer Tapestruktur (91) definiert; und
• c) eine Steuereinrichtung (30) zur Steuerung des Erhalts eines konsolidierten Laminats (90) durch: – eine Führungseinrichtung (40) für das Heranführen von einer bereits abgelegten Tapestruktur (91) und darauf abzulegendem Tape (93) an eine Anregungseinrichtung (50) und/oder umgekehrt; – eine Anregungseinrichtung (50) für ein simultanes Plastifizieren der Binder- und/oder Matrix-Werkstoffe ausschließlich in den Oberflächen (96) der zur Aneinandergrenzung vorgesehenen Fügezonen (95) von an die Anregungseinrichtung (50) herangeführter bereits abgelegten Tapestruktur (91) und darauf abzulegendem Tape (93); und – die Ablegeeinrichtung (20) für das Ablegen des ausschließlich oberflächlich angeregten Tape (93) auf die bereits abgelegte ausschließlich oberflächlich angeregte Tapestruktur (91) mittels der Ablegeeinrichtung (20), so dass deren Fügezonen (95) aneinandergrenzen; und – eine Konsolidierungseinrichtung (60) für ein simultanes Zusammenbringen der ausschließlich in den Oberflächen (96) plastifizierten Binder- und/oder Matrix-Werkstoffe der aneinandergrenzenden Fügezonen (95) von abgelegtem Tape (93) und der dieses Tape (93) tragenden bereits abgelegten Tapestruktur (91).

The present invention relates to a tape laying apparatus and to a method of constructing and consolidating a laminate for, for example, automotive components by means of a tape laying apparatus, which comprises at least:

• a) a feeder ( 10 ) for feeding binder and / or matrix materials to be deposited ( 93 ) to a depositing device ( 20 );
• b) a depositing device ( 20 ) for depositing supplied tape ( 93 ); where juxtaposed tape ( 93 ) a stack ( 92 ) of a tape structure ( 91 ) Are defined; and
• c) a control device ( 30 ) for controlling the obtaining of a consolidated laminate ( 90 ) by: - a management device ( 40 ) for the introduction of a previously deposited tape structure ( 91 ) and tape to be deposited thereon ( 93 ) to an excitation device ( 50 ) and / or vice versa; - an excitation device ( 50 ) for a simultaneous plasticizing of the binder and / or matrix materials exclusively in the surfaces ( 96 ) of the joining zones provided for the adjoining ( 95 ) from the excitation device ( 50 ) already deposited tapestry structure ( 91 ) and tape to be deposited thereon ( 93 ); and - the depositing device ( 20 ) for storing the superficially stimulated tape ( 93 ) on the already deposited superficially stimulated tapestry ( 91 ) by means of the depositing device ( 20 ), so that their joining zones ( 95 ) adjoin one another; and - a consolidation facility ( 60 ) for simultaneously bringing together exclusively in the surfaces ( 96 ) plasticized binder and / or matrix materials of the adjoining joining zones ( 95 ) of stored tape ( 93 ) and this tape ( 93 ) already laid down tapestry structure ( 91 ).

Fiber composite applications have continued to increase over the past decades, especially when viewed as a cost-effective alternative to metallic materials, with the benefits of design freedom and application-specific formulation capabilities. Specifically, the material CFK (carbon fiber reinforced plastic) has an extremely high potential for lightweight construction, while being characterized by its high strength and very high structural rigidity. The latter is an important criterion in automotive engineering, for example.

Therefore, today's development activities for fiber composite processing equipment ranges from pure machine development to turnkey production systems. The former usually include preform manufacturing units, press and optionally injection units and post-processing units - the latter the corresponding automation for preform handling, tool cleaning, component removal and the like.

The automatable production of the preform is definitely the key technology in the production process of continuous fiber reinforced fiber composite components for the realization of an efficient mass production with reproducible stable component quality. But even with so-called hybrid components, ie compression-molded sheets, which are primarily pressed with carbon fiber semi-finished products in order to additionally reinforce critical load zones, all production units must be able to be integrated in terms of plant and control technology if sufficient productivity is to be achieved.

For the production of continuous fiber reinforced components, predominantly textile fiber semi-finished products such as fiber yarns and / or fabrics impregnated with a binder (hotmelt adhesive) and / or partially or fully impregnated with a matrix (so-called prepregs) such as fiber fabrics, knit fabrics, Pads or mats used. The matrix of fiber-reinforced plastics has the task of embedding the heavy-duty fibers (supporting function) and completely filling their intermediate space (blocking function).

In principle binder materials and / or matrix materials can be used materials from the groups of thermoplastics or thermosets and optionally additional elasticizing components, such as elastomers, which in the strength, the maximum elongation, the operating temperature, the processing speed and the Distinguish chemical resistance. Thermosetting molding compounds can be plasticized by the action of temperature, are malleable at this moment and then cure irreversibly under pressure and temperature. In contrast to the thermoplastics, the elastomers and thermosets (also called thermosets) after processing, d. H. in the ready-to-use state, of more or less strongly cross-linked macromolecules, which are generally neither fusible nor soluble.

From these semi-finished products, which are available as rolls or sheets in standard formats, blanks are produced in a cutting process, which usually line the formed component over its entire surface. When cutting the blanks, depending on the component geometry, a significant cutting waste is generated that can not be processed and significantly reduces the efficiency of this process.

To improve resource efficiency, continuous fiber-reinforced components can be produced substantially less waste or without wastage via processes that have become known as tape-laying methods. In particular, the use of thermoplastic continuous fiber tapes prove to be a very attractive process variant. In particular, the laying of the fibrous composite materials, which are usually present as a tape, for constructing a laminate presents a special challenge.

By "tape" in the context of the present invention is preferably meant any type of sheeted prepreg material, for example between 30 and 150 mm wide prepreg strip material, which is suitable for being laid down by means of a tape laying device. In the present case, "prepreg material" means, in particular, fiber yarns (rovings), fiber scrims and / or fiber webs which are wetted with a binder and / or partially or completely impregnated with a matrix, for example a thermoset matrix or thermoplastic matrix, in particular preimpregnated , are.

The "fibers" are in particular carbon fibers, but in the same way also for glass fibers or other, in particular artificially produced, fibers applicable.

The tape can be arranged on a carrier material, in particular a carrier film or a carrier paper, which dissolves during the laying of the tape for building the laminate from the carrier material, wherein the carrier material by means of a suitable device of the tape laying device eliminated, for example, wound. However, it is also preferable to use tapes which no longer require carrier materials.

For the processing of tapes is known to deduct these from a spool or roll to cut to length and place on a laying table or already laid on it laid tape structure. When a tape strip is deposited, it is connected pointwise to the underlying tape layer via a number of ultrasonic welding heads. The weld always holds only the parting line between two stacking layers lying together. The fiber damper structure, which is deposited in a complex manner as a result, is thus connected to one another only at points. The cohesion is sufficient to pick up the tape structure from the table and, for example, to transport it with suction gripping systems. Due to the loose cohesion, however, it is not possible to use the tape structure homogeneously, e.g. in an infrared (IR) heating field to heat and transform into a component. The individual tapes dissolve in this case and can not be transformed reliably.

Known prior art in the processing of laid and punctiform fixed tape structures is consolidating in a press. As far as the tapes are a thermoplastic polymer matrix, in this case the entire structure first has to be heated to melting or flow temperature and then cooled again under surface pressure. For this purpose, the energy consumption is very high and thus makes the entire process uneconomical. Furthermore, the complete melting of the entire structure can lead to undesired flow processes in which material is pressed outward in the press plane. This then leads to serious shifts in the fiber orientation, which leads to lower component strength.

For the processing of tape or implementation of a tape-laying process, therefore, automatic devices are often used today, which are able to store tape structured. Known are in particular so-called. Tapelegevorrichtungen, which in this case, for example, a so-called. Fiber placement device is to be understood.

During automated deposition processes tape to be deposited is pressed by means of a laying head, depending on the type of tape laying device used, for example via a shoe or a pinch roller on an already deposited tape structure with comparatively low, only local and very short-term pressure, so that the tape to be deposited successively, so only gradually or successively, with the already deposited tape structure is slightly glued or welded. For this purpose, however, a suitable tackiness or weldability of the binder and / or matrix systems in the tape to be deposited or the already deposited tape structure is required.

In the processing of tapes with duromeric binder and / or matrix system, the tackiness can be increased by moderate heating. Thus, it has become known, for example, to pass a warm air flow past the tape to be deposited, which causes heating of the tap to be deposited by thermal convection. However, it has been found that the above-described heating by means of a warm air flow has only low heat transfer properties and leads to low heating rates of the tap to be deposited, so that it is not possible to achieve desired deposition rates. In addition, the use of hot air is not suitable for near-surface melting of tapes with a thermoplastic binder and / or matrix system.

This technique has been used in the WO 2009/130087 A1 further developed in order to lay down preferably also thermoplastic tapes. Here, an excitation device is mounted on the laying head, which uses the ultrasound, the induction and / or infrared, and which a tape to be deposited flying in the trigger, for example, from a coil or roll, heated shortly before the deposition time locally across its thickness and the The tape, which has been heated up over its thickness, is then pressed onto the already laid-down tape structure by means of a flexible laying roll and thus successively joined together.

However, this laying process is also limited due to its only locally limited design in its laying speed and therefore not suitable in particular for a mass production application suitable for mass production.

In addition, in the consolidation of large-area applications due to process-related over its thickness heated tapes to undesirable flow processes and fiber shifts in both be deposited tape as well as in the top stacking or a previously deposited tape structure come. This leads to residual stresses in the entire tape structure, which can lead to component distortion and a significant deterioration in the physical component properties.

• – Auftragen und Verbinden einer ersten Gruppe von Fasern mit einem Fließband in einem ersten Winkel, wobei ein Matrixmaterial mit der ersten Gruppe von Fasern verbunden ist;
• – Auftragen und Verbinden einer zweiten Gruppe von Fasern mit einem Fließband in einem zweiten Winkel, wobei ein Matrixmaterial mit der zweiten Gruppe von Fasern verbunden ist;
• – wobei der erste Winkel ungleich dem zweiten Winkel ist, und
• – wobei die erste Gruppe der Fasern intermittierend aufgetragen wird, und
• – wobei auch die zweite Gruppe der Fasern intermittierend aufgetragen wird, um Ausschnitte im Verbundwerkstoff-Teil vorsehen zu können.

Finally, be on the EP 1 315 613 B1 which discloses a method and equipment for producing advanced composite structures comprising the steps of:

• Applying and bonding a first group of fibers to a conveyor belt at a first angle, wherein a matrix material is bonded to the first group of fibers;
• Applying and bonding a second group of fibers to a conveyor belt at a second angle, wherein a matrix material is bonded to the second group of fibers;
• - wherein the first angle is not equal to the second angle, and
• - wherein the first group of fibers is applied intermittently, and
• - Wherein the second group of fibers is applied intermittently to provide cutouts in the composite part can.

On this basis, the present invention seeks to provide an improved tape laying device or an improved method for building and consolidating a laminate for example, automotive components by means of a tape laying device, which or which avoids the disadvantages described above.

According to the invention, this object is achieved by a method for constructing a laminate having the features of patent claim 1 and by a tape laying device for carrying out a method for constructing a laminate having the features of patent claim 7.

• a) ein Zuführen von mit Binder- und/oder Matrix-Werkstoffen versehenem abzulegenden Tape an eine Ablegeeinrichtung;
• b) ein Ablegen von zugeführtem Tape mittels der Ablegeeinrichtung; wobei nebeneinander abgelegtes Tape eine Tapelage einer Tapestruktur definiert; und
• c) ein Steuern des Erhalts eines konsolidierten Laminats durch: – ein Heranführen von einer bereits abgelegten Tapestruktur und darauf abzulegendem Tape an eine Anregungseinrichtung und/oder umgekehrt; – ein simultanes Plastifizieren der Binder- und/oder Matrix-Werkstoffe ausschließlich in den Oberflächen der zur Aneinandergrenzung vorgesehenen Fügezonen von an die Anregungseinrichtung herangeführter bereits abgelegten Tapestruktur und darauf abzulegendem Tape; – ein Ablegen des ausschließlich oberflächlich angeregten Tape auf die bereits abgelegte ausschließlich oberflächlich angeregte Tapestruktur mittels der Ablegeeinrichtung, so dass deren Fügezonen aneinandergrenzen; und – ein simultanes Zusammenbringen der ausschließlich in den Oberflächen plastifizierten Binder- und/oder Matrix-Werkstoffe der aneinandergrenzenden Fügezonen von abgelegtem Tape und der dieses Tape tragenden bereits abgelegten Tapestruktur.

The method according to the invention for constructing and consolidating a laminate for, for example, automobile components by means of a tape laying device is characterized by:

• a) feeding to be deposited with provided binder and / or matrix materials tape to a depositing device;
• b) depositing supplied tape by means of the depositing device; wherein juxtaposed tape defines a stack of a tape structure; and
• c) controlling the receipt of a consolidated laminate by: - bringing an already laid down tape structure and tape to be deposited thereon onto an excitation device and / or vice versa; A simultaneous plasticizing of the binder and / or matrix materials exclusively in the surfaces of the joining zones provided for the adjoining zone and of the tape structure already laid down and of the tape to be deposited on the starting device; - A store the only superficially excited tape on the already deposited exclusively superficially excited tape structure by means of the depositing device, so that their joining zones adjacent to each other; and - simultaneously bringing together the binder and / or matrix materials plasticized in the surfaces of the adjoining joining zones of deposited tape and the already deposited tape structure carrying this tape.

By according to the invention, the binder and / or matrix materials are simultaneously plasticized and consolidated exclusively in the surfaces of the joining zones provided for the adjoining of the already deposited tape structure and tape to be deposited thereon, the plasticizing of binder and / or matrix materials in advantageous advantageous all-over or full surface in said surfaces of the joining zones provided for the adjoining, without it neither to a complete melting of the binder and / or matrix materials in the already deposited tapestry brought to the exciter nor to a complete melting in the Tape to be deposited comes.

By the binder and / or matrix materials in each of the excitation device opposite side or surface of the intended for adjoining joining zones supplied to the exciter already deposited tape structure and tape to be deposited not melt or flow temperature of the plastic matrix used can also large-scale tape structures or laminates of, eg 30 to 150 mm wide, Advantageously, tapes can be constructed and consolidated without undesired flow and fiber shifts. Advantageous embodiments and developments, which can be used individually or in combination with each other, are the subject of the dependent claims.

The limitation of undesired flow processes and / or fiber displacements can be increased if, in a preferred sequence of the process, the simultaneous plastification of the binder and / or matrix materials is not restricted exclusively to the surface of the joining zone provided for joining by means of the adhesive tape to be deposited also takes place exclusively in the surface of the intended for adjoining joining zone of the uppermost stack of an already deposited tape structure.

Alternatively or cumulatively, in the context of the consolidation of individual tapes and / or stackings, or undesired flow processes and / or fiber displacements of individual tapes and / or stack layers within the tapestry in a preferred sequence of the method, the simultaneous plastification of the binder can be achieved depending on the degree. and / or matrix materials, at least in the top layer of the tape to be deposited, of an already deposited tape structure across its thickness.

In a further development of this, in a preferred sequence of the method, simultaneous plastification of the binder and / or matrix materials can also take place in tufts below the topmost stacking layer of an already deposited tape structure exclusively in the surfaces of the adjoining joining zones and / or across their thickness respectively. In all cases, however, the lowest stacking layer of a previously deposited tape structure should never be plasticized across its thickness in order not to jeopardize the dimensional stability of the laminate.

• – in einer minimalen Tiefe von jeweils nur zu 10 %, insbesondere jeweils nur zu 20 %, vorzugsweise von nur 30 %
• – bis zu einer maximalen Tiefe von 60 %, insbesondere von 75 %, vorzugsweise von maximal 90 %

des jeweiligen Querschnitts Q von abzulegendem Tape, der jeweiligen obersten Tapelage oder der bereits abgelegten Tapestruktur erfolgen.According to the invention, in a sequence of the method, simultaneous plastification of the binder and / or matrix materials may take place exclusively in the surfaces of the joining zones provided for adjoining of tape to be deposited, topmost stacking layer or already laid down tape structure

• - At a minimum depth of only 10%, in particular only 20%, preferably only 30%
• - up to a maximum depth of 60%, in particular of 75%, preferably of not more than 90%

of the respective cross-section Q of tape to be deposited, the respective uppermost stacking layer or the already deposited tape structure.

Alternatively or cumulatively, in one embodiment of the method, it is preferred if the simultaneous plasticizing of the binder and / or matrix materials is defined exclusively in the surfaces of the joining zones provided for abutment of tape to be deposited, topmost stacking layer or already laid down tape structure Surface portions of the surfaces of the joining zones takes place at different depths.

• a) eine Zuführeinrichtung für das Zuführen von mit Binder- und/oder Matrix-Werkstoffen versehenem abzulegenden Tape an eine Ablegeeinrichtung;
• b) eine Ablegeeinrichtung für das Ablegen von zugeführtem Tape; wobei nebeneinander abgelegtes Tape eine Tapelage einer Tapestruktur definiert; und
• c) eine Steuereinrichtung zur Steuerung des Erhalts eines konsolidierten Laminats: – eine Führungseinrichtung für das Heranführen von einer bereits abgelegten Tapestruktur und darauf abzulegendem Tape an eine Anregungseinrichtung und/oder umgekehrt; – eine Anregungseinrichtung für ein simultanes Plastifizieren der Binder- und/oder Matrix-Werkstoffe ausschließlich in den Oberflächen der zur Aneinandergrenzung vorgesehenen Fügezonen von an die Anregungseinrichtung herangeführter bereits abgelegten Tapestruktur und darauf abzulegendem Tape; und – die Ablegeeinrichtung für das Ablegen des ausschließlich oberflächlich angeregten Tape auf die bereits abgelegte ausschließlich oberflächlich angeregte Tapestruktur mittels der Ablegeeinrichtung, so dass deren Fügezonen aneinandergrenzen; und – eine Konsolidierungseinrichtung für ein simultanes Zusammenbringen der ausschließlich in den Oberflächen plastifizierten Binder- und/oder Matrix-Werkstoffe der aneinandergrenzenden Fügezonen von abgelegtem Tape und der dieses Tape tragenden bereits abgelegten Tapestruktur.

A tape laying device according to the invention for carrying out a method for constructing and consolidating a laminate for, for example, automotive components has the advantages described for the method and is characterized by:

• a) a feeding device for supplying provided with binder and / or matrix materials to be deposited tape to a depositing device;
• b) a depositing device for depositing supplied tape; wherein juxtaposed tape defines a stack of a tape structure; and
• c) a control device for controlling the receipt of a consolidated laminate: - a guide device for bringing an already laid down tape structure and tape to be deposited thereon onto an excitation device and / or vice versa; An excitation device for a simultaneous plasticizing of the binder and / or matrix materials exclusively in the surfaces of the joining zones provided for the adjoining zone and of the tape structure already laid down and applied to the excitation device; and - the depositing device for depositing the exclusively superficially excited tape on the already deposited exclusively superficially excited tapestry means of the depositing device so that their joining zones adjacent to each other; and - a consolidation device for simultaneously bringing together the plasticized in the surfaces binder and / or matrix materials of the adjacent joining zones of stored tape and this tape carrying already deposited tape structure.

In one embodiment of the tape-laying device, it is provided that by means of the control device, the exciting device can be controlled variably with regard to heating surfaces and / or heating depths. For this purpose, the control device can for example comprise a pyrometric sensor with which the surface temperature of the surface of the associated tapes is measured during the heating process. Ideally, the sensor can be used to measure the surface temperature of the tap to be deposited on the side facing away from the joining zone. This is the best way to control the heating power or the heating time. The heating power or heating time is controlled in each case such that the binder and / or matrix materials in the surface facing away from the excitation device does not quite reach the melting or flow temperature. In a further embodiment of the tape laying device, an excitation device is preferred, which comprises a heating device, which is designed for processing tapes of variable width and length to be deposited with zones which can be switched on and off. This can be advantageous to turn off unoccupied heating zones.

In a further embodiment of the tape laying device, an excitation device is preferred, which comprises a heating device and is preferably designed such that the distance between the heater and the tape to be laid and also to the already laid tape structure is approximately equal or the heating power of the heater to compensate for any distance differences and / or heating depths can be adjusted.

In a further embodiment of the tape-laying device, the excitation device comprises a mask with which a fine adjustment of the radiating surface, matching the surface and position of the tape and associated surface of the underlying tape structure, can be made. Such, preferably variable adjustable, mask covers off protruding Heizflächenbereiche so that overheating of the edges and also an undesirable heating of the device can be avoided. If masks are arranged on all four edges of a laying area, both the width and the length and laying position can be adjusted. This advantageously allows the control device, which controls the heating surfaces and / or heating depths of the excitation device variable.

In a further embodiment of the tape laying device is provided that the consolidation device comprises at least one laying table and / or stamp, which is designed to be vacuumable. This advantageously allows a fixation of first deposited tapes on the table or stamp without bonding with other tapes.

In a further embodiment of the tape laying device is provided that the consolidation device comprises at least one laying table and / or stamp, which are provided with a cooling. This advantageously prevents melting or even plasticizing of the lowermost and uppermost stackings of a tape structure across its thickness, thus supporting the desired preservation of a form-true laminate.

In a further embodiment of the tape-laying device, it is provided that the laying device comprises a single or alternately operating laying bar, wherein mutually-operating laying bars advantageously increase the process speed.

In a further embodiment of the tape laying device is provided that the / the beam and / or punch and / or Legetische are formed more articulated, so that advantageously the individual members are controlled by means of the control device on corresponding to a three-dimensional tapestry spatial points out.

The present invention advantageously permits the construction and consolidation of a laminate without undesirable flow and fiber displacements.

By advantageously keeping the structure as well as the simultaneous consolidation of laid tape structures on one and the same laying table, a release of individual tapes or stackings as a result of separation of the structure on the one hand and consolidation of laid tape structures on the other hand is reliably avoided.

The present invention is particularly suitable for industrial construction and consolidation of a laminate for, for example, automotive components, which are converted to the final component by a thermoforming process or in conjunction with a flowable fiber composite material in the extrusion or injection molding process.

These and other features and advantages of the invention will be explained in more detail below with reference to the exemplary embodiments illustrated in the drawings of the structure and consolidation of a laminate, to which the present invention is not limited.

They show schematically:

1 a first, in particular with regard to the apparatus construction simple held, embodiment of a tape laying device for carrying out a method for building and consolidating a laminate;

2 a second, in particular with respect to the heating surface and / or heating depth held controllable, embodiment of a tape laying device for carrying out a method for building and consolidating a laminate; and

3 a third, particularly in terms of laying speed further increased, embodiment of a tape laying device for performing a method for building and consolidating a laminate.

In the following description of preferred embodiments, like reference numerals designate like components.

1 shows a first, in particular with regard to the apparatus structure simple held, embodiment of a tape laying device 1 for carrying out a method of constructing a laminate 90 ,

The illustrated tape laying device 1 includes a feeder 10 for feeding tape to be deposited 93 to one, for example at least one guide bar 21 comprehensive, depositing facility 20 for the construction of the laminate 90 through structured laying of tapes 93 and their, preferably complete, consolidation, that is, as far as possible the entire surface bonding or welding of the binder and / or matrix materials in at least all joining zones 95 of tape to be deposited 93 with the binder and / or matrix materials in the joining zones 95 the topmost stackage 92 an already deposited tape structure 91 in such a way that the near-surface binder and / or matrix materials in the plasticized state of aggregation completely bond together and ideally polymer chains are partially looped and / or form covalent bonds.

It is in the feeder 10 first tape to be deposited 93 for example, from a spool or reel 11 subtracted, cut to the required length (not shown) and after feeding to the depositing device 20 by means of this over the Legetisch 61 a consolidation facility 60 positioned.

An excitation device 50 for heating the tap to be deposited 93 and a possibly already deposited tape structure 91 , Can in this apparatus simply kept and thus inexpensive design, for example, a both sides of the depositing device 20 for tapes to be deposited 93 rigidly arranged heater 51 which may preferably be formed of radiators, ideally infrared (IR) emitters. Such infrared (IR) emitters advantageously have very short turn-on times and fast response.

The performance of the excitation device 50 is in any case adjusted so that the opposite sides of tape to be deposited 93 and already laid tapestry 91 not be brought over melting or flow temperature of the plastic matrix used.

Because of her on both sides of the depositing device 20 rigid arrangement is suitable in 1 illustrated embodiment in particular for a simultaneous, ie simultaneous and possibly full-surface and only superficial plasticizing the binder and / or matrix materials of the surfaces 96 the joining zones 95 of tape to be deposited 93 and the top tier 92 or a previously deposited tape structure 91 ,

After sufficient plasticizing the binder and / or matrix materials is preferably with punches 62 the consolidation facility 60 the superficially plasticized tape 93 on the plasticized surface 96 the joining zone 95 the topmost stackage 92 an already deposited tape structure 91 guided down and pressed as far as possible over the entire surface.

To thereby already laid tapestry structures 91 To fix, can the laying table 61 and / or the stamp 62 the consolidation facility 60 be formed vacuumable (not shown).

stamp 62 and / or laying table 61 the consolidation facility 60 may also be provided with a cooling (also not shown) to the means of the excitation device 50 dissipate introduced heat and / or a faster solidification of the plastic matrix in the just-consolidated tape structure 91 to achieve.

For the realization of three-dimensional tape structures 91 are beams formed from limbs 21 and / or stamp 62 and / or laying tables 61 preferred, which are controllable to different spatial points. The multi-limbed formation of laying beams 21 and / or stamp 62 and / or laying tables 61 has the advantage that the individual limbs on to a three-dimensional tapestry structure 91 Corresponding room points can be designed to be controllable.

For tape-laying of three-dimensional laminates 90 is finally an excitation device 50 preferred with a heating device, which can be adapted to the 3D contour of the component to be built in such a way that the distance of the heating device 52 and the tape to be laid 93 and also to the already laid tape structure 91 is approximately equal or alternatively the heating power of the heater 52 to compensate for any distance differences can be adjusted.

The preferred control device 30 is a drawing of the consolidation device 60 assigned, but of course, according to the requirements earmarks arbitrary in the tape-laying device 1 be arranged.

2 shows a second, in particular with respect to the heating surface and / or heating depth held controllable, embodiment of a tape laying device 1 for carrying out a method of constructing a laminate 90 , The rest of the exemplary embodiment after 1 identical holding tape device 1 differs mainly in the design of the excitation unit 50 for heating the binder and / or matrix materials in the tape to be deposited 93 and a possibly already deposited tape structure 91 ,

At the in 2 illustrated embodiment of a tape laying device 1 is the excitation unit 50 preferably a movable heating device 52 For example, in the form of, preferably as narrow as possible, infrared (IR) -Heizfeldes, which between, for example by means of at least one bar 21 the depositing device 20 , positioned tape 93 and one under it on a laying table 61 already laid tapestry structure 91 can be retracted. After retraction, the infrared (IR) heating field can be reversed in both directions towards the tapes 93 and the upper stacking layer 92 in the presentation of 2 So up and down, so radiate that the binder and / or matrix materials of the entire surface 96 but preferably at least the joining zone 95 of tape to be deposited 93 and the top tier 92 or the already deposited tape structure 91 at the same time and over the entire surface and preferably only superficially plasticized.

Alternatively or cumulatively, depending on the degree desired, namely in the context of the consolidation of individual tapes 93 and / or stackings 92 , or unwanted flow processes and / or fiber shifts of individual tapes 93 and / or stackings 92 within the tapestry structure 91 in a preferred sequence of the method, the simultaneous plasticizing of the binder and / or matrix materials at least in the tape to be deposited 93 carrying top stacking 92 an already deposited tape structure 91 take place across its thickness.

In a further development of this, in a preferred sequence of the method, the simultaneous plastification of the binder and / or matrix materials can also be carried out in tufts 92 below the the tape 93 carrying top stacking 92 an already deposited tape structure 91 exclusively in the surfaces 96 the adjoining joining zones 95 and / or across their thickness. In all cases, however, should be the lowest stacking 92 an already deposited tape structure 91 never be plasticized across the thickness to ensure the dimensional stability of the laminate 90 not to endanger.

Compared to plasticizing the binder and / or matrix materials of the entire surface 96 avoids simultaneous and full surface and only superficial plasticizing only the binder and / or matrix materials in all joining zones 95 of tape to be deposited 93 and the top tier 92 or a previously deposited tape structure 91 in addition to a higher energy consumption in particular undesirable flow processes and fiber shifts in not in contact with a joining zone 95 lying surfaces 96 the tapes 93 and / or stackings 92 how these surfaces 96 especially with complex tape structures 91 are found regularly.

The heating by means of, for example, an infrared (IR) heating field can be advantageous with high power and in a very short time of example 1s respectively. It is preferably such controlled that of abzulegendem tape 93 and the top tier 92 or a previously deposited tape structure 91 in a minimum depth of only 10%, in particular only 20%, preferably of only 30% up to a maximum depth of 60%, in particular of 75%, preferably of not more than 90% of the thickness of the tape 93 or the respective stacking 92 be plasticized. Alternatively or cumulatively thereto, a control of the heating field can be provided, with which the binder and / or matrix materials in the tape to be deposited 93 and the binder and / or matrix materials in the topmost stack 92 an already deposited tape structure 91 in defined joining zones 95 the total surface 96 and / or at least the joining zone 95 be plasticized in different depths. This can also be used in complex tape structures 91 the energy input and / or unwanted flow processes are minimized.

Subsequently, the excitation device 50 with her heater 52 from the depositing area of the depositing device 20 laterally moved away or swung out and with one or more punches 62 a consolidation facility 60 at least at all joining zones 95 plasticized binder and / or matrix materials in the tape 93 on the corresponding plasticized binder and / or matrix materials in the contact surfaces 95 the topmost stackage 92 or a previously deposited tape structure 91 guided down and pressed as far as possible over the entire surface.

3 shows a third, in terms of laying speed further increased embodiment of a tape laying device 1 for carrying out a method of constructing a laminate 90 , The rest of the exemplary embodiment after 2 identical holding tape device 1 differs primarily in a further embodiment of an excitation unit 50 for heating the tap to be deposited 93 and a possibly already deposited tape structure 91 ,

At the in 3 illustrated embodiment of a tape laying device 1 includes the depositing device 20 two or more, for example mutually working, horizontal beams 21a . 21b , ... One between the depositing device 20 and the consolidation facility 60 positionable excitation device 50 is now preferably alternately between the individual beams 21a and 21b designed to be movable back and forth, so that during the heating time in the area of a bar 21b the previously heated tape 93 in the other beam 21a filed and a new tape 93 in these bars 21a can be recovered.

According to the invention, the binder and / or matrix materials exclusively in the surfaces 96 the joining zones provided for the adjoining 95 from to the excitation device 50 brought up already laid tapestry 91 and tape to be placed on it 93 can be simultaneously plasticized and consolidated, plasticizing binder and / or matrix materials in said surfaces 96 the joining zones provided for the adjoining 95 at the same time be advantageous all-over or full surface, without it neither to a complete melting of the binder and / or matrix materials in the excitation device 50 brought up already laid tape structure 91 still to a complete melting in the tape to be deposited on it 93 comes.

By the binder and / or matrix materials in each of the excitation device 50 opposite side or surface of the intended for adjoining joining zones 95 from to the excitation device 50 brought up already laid tapestry 91 and tape to be placed on it 93 can not be brought about melting or flow temperature of the plastic matrix used, can also large-scale tape structures 91 or laminates 90 from, for example, 30 to 150 mm wide, tapes 93 can be advantageously built and consolidated without undesirable flow and fiber shifts.

The present invention advantageously permits the construction and consolidation of a laminate 90 without unwanted flow and fiber shifts.

By favoring the construction as well as the simultaneous consolidation of laid tapestries 91 on one and the same laying table 61 is a loosening of individual tapes 93 or stackings 92 as a result of prior art separation of construction on the one hand and consolidation of laid tape structures 91 on the other hand, reliably avoided.

The present invention is particularly useful for industrial construction and consolidation of a laminate 90 For example, for automotive components, which are formed by a thermoforming process or in conjunction with a flowable fiber composite material in the extrusion or injection molding process to the final component.

LIST OF REFERENCE NUMBERS

1

 Tape laying device

10

 feeding

11

 role

20

 laying device

21

 put bar

21a, 21b

 put bar

30

 control device

50

 exciter

51

 heater

52

 heater

60

 consolidation means

61

 Legetisch

62

 stamp

90

 laminate

91

 Tape structure

92

 Tape position

93

 Tape

95

 joining zones

96

 surface

Q

 cross-section

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 2009/130087 A1 [0017]
• EP 1315613 B1 [0020]

Claims (15)

Method for constructing and consolidating a laminate ( 90 ) for example for automotive components by means of a tape laying device ( 1 ), characterized by: a) feeding in tapes and / or matrix materials to be deposited ( 93 ) to a depositing device ( 20 ); b) depositing supplied tape ( 93 ) by means of the depositing device ( 20 ); where juxtaposed tape ( 93 ) a stack ( 92 ) of a tape structure ( 91 ) Are defined; and (c) controlling the receipt of a consolidated laminate ( 90 ) by: - an approach from an already deposited tape structure ( 91 ) and tape to be deposited thereon ( 93 ) to an excitation device ( 50 ) and / or vice versa; A simultaneous plasticizing of the binder and / or matrix materials exclusively in the surfaces ( 96 ) of the joining zones provided for the adjoining ( 95 ) from the excitation device ( 50 ) already deposited tapestry structure ( 91 ) and tape to be deposited thereon ( 93 ); - a deposition of the superficially excited tape ( 93 ) on the already deposited superficially stimulated tapestry ( 91 ) by means of the depositing device ( 20 ), so that their joining zones ( 95 ) adjoin one another; A simultaneous bringing together of exclusively in the surfaces ( 96 ) plasticized binder and / or matrix materials of the adjoining joining zones ( 95 ) of stored tape ( 93 ) and this tape ( 93 ) already laid down tapestry structure ( 91 ). Process according to Claim 1, in which, in a sequence of the process, the simultaneous plastification of the binder and / or matrix materials exclusively in the surfaces ( 96 ) of the joining zones provided for the adjoining ( 95 ) from the excitation device ( 50 ) topmost stackage ( 92 ) of a previously deposited tape structure ( 91 ) and tape to be deposited thereon ( 93 ) he follows. Method according to one of claims 1 to 3, wherein in a sequence of the method simultaneous plastification of the binder and / or matrix materials at least in the tape to be deposited ( 93 ) carrying topmost stack ( 92 ) of a previously deposited tape structure ( 91 ) takes place across its thickness. Method according to one of the preceding claims, in which, in a sequence of the method, simultaneous plastification of the binder and / or matrix materials is also carried out in tufts ( 92 ) below the tape to be deposited ( 93 ) carrying topmost stack ( 92 ) of a previously deposited tape structure ( 91 ) exclusively in the surfaces ( 96 ) of the adjoining joining zones ( 95 ) and / or over the thickness thereof takes place. Method according to one of the preceding claims, wherein in a sequence of the method simultaneous plastification of the binder and / or matrix materials exclusively in the surfaces ( 96 ) of the joining zones provided for the adjoining ( 95 ) from the excitation device ( 50 ) to be deposited ( 93 ), topmost stack ( 92 ) or a previously deposited tape structure ( 91 ) - At a minimum depth of only 10%, in particular only 20%, preferably of only 30% - up to a maximum depth of 60%, in particular of 75%, preferably of at most 90% of the respective cross-section (Q ) of tape to be deposited ( 93 ), the respective topmost stack ( 92 ) or the already deposited tape structure ( 91 ) he follows. Method according to one of the preceding claims, wherein in a sequence of the method simultaneous plastification of the binder and / or matrix materials exclusively in the surfaces ( 96 ) of the joining zones provided for the adjoining ( 95 ) from the excitation device ( 50 ) to be deposited ( 93 ), topmost stack ( 92 ) or a previously deposited tape structure ( 91 ) in defined surface sections of the surfaces ( 96 ) of the joining zones ( 95 ) takes place at different depths. Tape laying device ( 1 ) for carrying out a method for constructing and consolidating a laminate ( 90 ) for, for example, automotive components, in particular according to one of the preceding claims, characterized by: a) a feed device ( 10 ) for feeding binder and / or matrix materials to be deposited ( 93 ) to a depositing device ( 20 ); b) a depositing device ( 20 ) for depositing supplied tape ( 93 ); where juxtaposed tape ( 93 ) a stack ( 92 ) of a tape structure ( 91 ) Are defined; and c) a control device ( 30 ) for controlling the obtaining of a consolidated laminate ( 90 ) by: - a guide device for the introduction of a previously deposited tape structure ( 91 ) and tape to be deposited thereon ( 93 ) to an excitation device ( 50 ) and / or vice versa; - an excitation device ( 50 ) for a simultaneous plasticizing of the binder and / or matrix materials exclusively in the surfaces ( 96 ) of the joining zones provided for the adjoining ( 95 ) from the excitation device ( 50 ) already deposited tapestry structure ( 91 ) and tape to be deposited thereon ( 93 ); and - the depositing device ( 20 ) for storing the superficially stimulated tape ( 93 ) on the already deposited superficially stimulated tapestry ( 91 ) by means of the depositing device ( 20 ), so that their joining zones ( 95 ) adjoin one another; and - a consolidation facility ( 60 ) for simultaneously bringing together exclusively in the surfaces ( 96 ) plasticized binder and / or matrix materials of the adjoining joining zones ( 95 ) of stored tape ( 93 ) and this tape ( 93 ) already laid down tapestry structure ( 91 ). Tape laying device ( 1 ) according to claim 7, characterized in that by means of the control device ( 30 ) the excitation device ( 50 ) is variably controllable with respect to heating surfaces and / or heating depths. Tape laying device ( 1 ) according to claim 7 or 8, characterized in that the excitation device ( 50 ) a heating device which can be switched on and off ( 51 ; 52 ). Tape laying device ( 1 ) according to one of claims 7 to 9, characterized in that the excitation device ( 50 ) comprises a heating device which is designed such that the distance between the heating device and the tape to be laid ( 93 ) and also to the already established tapestry structure ( 91 ) is approximately equal or the heating power of the heater to compensate for any distance differences and / or heating depths can be adjusted. Tape laying device ( 1 ) according to one of claims 7 to 10, characterized in that the excitation device ( 50 ) comprises a mask which is opposite to the tape to be deposited ( 93 ) protruding heating surface areas so that overheating of the edges of tape to be deposited ( 93 ) and / or deposited tape structure ( 91 ) are avoided. Tape laying device ( 1 ) according to one of claims 7 to 11, characterized in that the consolidation device ( 60 ) at least one laying table ( 61 ) and / or stamps ( 62 ), which is designed to be vacuumable. Tape laying device ( 1 ) according to one of claims 7 to 12, characterized in that the consolidation device ( 60 ) at least one laying table ( 61 ) and / or stamps ( 62 ), which is provided with a cooling. Tape laying device ( 1 ) according to one of claims 7 to 13, characterized in that the depositing device ( 20 ) a single or alternate working beam ( 21 ). Tape laying device ( 1 ) according to any one of claims 7 to 14, characterized in that the laying beam (s) ( 21 ) and / or stamps ( 62 ) and / or laying tables ( 61 ) are formed mehrgliedrig, so that the individual members by means of the control device ( 30 ) to a three-dimensional tape structure ( 91 ) corresponding room points are controllable.

Images