DE102016210064A1 - Method and manufacturing arrangement for producing a workpiece by press molding, and method and welding arrangement for welding - Google Patents

Abstract

The invention relates to a method for producing a workpiece by press molding using a press mold with at least a first and a second rigid tool part. One or more sections of a semi-finished product comprising a thermoplastic plastic material and reinforcing fibers are arranged to form a semifinished assembly. Pressure and elevated temperature are applied to the semifinished arrangement, wherein the pressure is applied by applying force to the tool parts via an at least partially deformable and / or at least partially preformed cushion between the semifinished assembly and the first tool part on the semi-finished product assembly. Furthermore, the invention relates to a method for welding at least two workpieces by means of a welding tool having at least a first and a second rigid tool part, wherein at least one of the workpieces comprises a thermoplastic plastic material. The workpieces are arranged to each other to form a workpiece assembly. Pressure and elevated temperature are applied to the workpiece assembly. The pressure is applied by applying force to the tool parts via an at least partially deformable and / or at least partially preformed pillow between the workpiece assembly and the first tool part on the workpiece assembly. The invention further relates to a manufacturing arrangement and a welding arrangement.

Description

FIELD OF THE INVENTION

The present invention relates to a method and a manufacturing arrangement for producing a workpiece as a fiber composite workpiece by press molding. Furthermore, the invention relates to a method and a welding arrangement for welding at least two workpieces, of which at least one has a thermoplastic material.

TECHNICAL BACKGROUND

Although the present invention is applicable to a variety of workpieces, and in particular fiber composite workpieces in many fields of technology, the present invention and the underlying problems are described below using the example of producing a fuselage shell for an aircraft.

It has already been proposed, for example, to produce a fuselage skin for a fuselage made of a composite material with reinforcing fibers and a matrix of a curable synthetic material.

In fiber composite components, which are formed with thermosetting resins as a matrix, however, relatively much effort is often required to show that a resulting from the production process component has a required quality. For example, non-destructive testing methods (so-called "nondestructive testing") can be used for this purpose.

However, it would be desirable to have a method for producing fiber-reinforced composite components and a corresponding manufacturing arrangement, which can be reliably ensured with reduced effort that the quality requirements are met to the component to be produced. In addition, it would be desirable if the production of the composite components can be carried out expediently and efficiently. Furthermore, it would also be desirable to be able to securely and efficiently connect workpieces together in such a way that the quality of the connection can be reliably ensured with as little testing effort as possible.

SUMMARY OF THE INVENTION

Against this background, the present invention is based on the object to provide a correspondingly improved manufacturing method and an improved arrangement, which allow a convenient production of fiber composite components of high quality. In addition, a method and a welding arrangement for producing a high-quality welded joint are proposed.

According to the invention, this object is achieved by a method having the features of patent claim 1 and / or by a manufacturing arrangement having the features of patent claim 13 and / or by a method having the features of patent claim 14 and / or by a welding arrangement having the features of patent claim 15 ,

• – Anordnen eines oder mehrerer Abschnitte eines Halbzeugs, welches ein thermoplastisches Kunststoffmaterial und Verstärkungsfasern aufweist, zur Bildung einer Halbzeuganordnung; und
• – Aufbringen von Druck und erhöhter Temperatur auf die Halbzeuganordnung, wobei der Druck durch Aufbringen von Kraft auf die Werkzeugteile über ein zumindest abschnittsweise verformbares und/oder zumindest abschnittsweise vorgeformtes Kissen zwischen der Halbzeuganordnung und dem ersten Werkzeugteil auf die Halbzeuganordnung aufgebracht wird.

A method is proposed for producing a workpiece by press molding using a press mold having at least a first rigid tool part and a second rigid tool part, wherein the workpiece is formed as a fiber composite piece with a thermoplastic matrix, and wherein the method comprises the following steps:

• Arranging one or more sections of a semifinished product comprising a thermoplastic material and reinforcing fibers to form a semifinished assembly; and
• - Applying pressure and elevated temperature to the semi-finished product assembly, wherein the pressure is applied by applying force to the tool parts via an at least partially deformable and / or at least partially preformed cushion between the semifinished assembly and the first tool part on the semi-finished product assembly.

It is further proposed a manufacturing arrangement for producing a workpiece by press molding as a fiber composite workpiece with a thermoplastic matrix, wherein the manufacturing arrangement comprises a press tool having at least a first rigid tool part and a second rigid tool part and the manufacturing arrangement is adapted to pressure and elevated temperature to a Semifinished arrangement, which is formed by arranging one or more sections of a semifinished product with a thermoplastic material and reinforcing fibers exercise. Here, the manufacturing arrangement has an at least partially deformable and / or at least partially preformed cushion over which by applying force to the tool parts of the pressure on the semi-finished product assembly can be applied.

• – Anordnen der Werkstücke zueinander zur Bildung einer Werkstückanordnung; und
• – Aufbringen von Druck und erhöhter Temperatur auf die Werkstückanordnung, wobei der Druck durch Aufbringen von Kraft auf die Werkzeugteile über ein zumindest abschnittsweise verformbares und/oder zumindest abschnittsweise vorgeformtes Kissen zwischen der Werkstückanordnung und dem ersten Werkzeugteil auf die Werkstückanordnung aufgebracht wird.

It is further proposed a method for welding at least two workpieces by means of a welding tool having at least a first rigid tool part and a second rigid tool part, wherein at least one of the workpieces is a thermoplastic Plastic material, and wherein the method comprises the following steps:

• - Arranging the workpieces to each other to form a workpiece assembly; and
• - Applying pressure and elevated temperature to the workpiece assembly, wherein the pressure is applied by applying force to the tool parts via an at least partially deformable and / or at least partially preformed cushion between the workpiece assembly and the first tool part on the workpiece assembly.

Furthermore, a welding arrangement is provided for welding at least two workpieces, at least one of which has a thermoplastic material, wherein the welding arrangement comprises a welding tool with at least a first rigid tool part and a second rigid tool part and wherein the welding arrangement is arranged for pressure and elevated temperature to exert on a workpiece assembly formed with the workpieces. Here, the welding arrangement has an at least partially deformable and / or at least partially preformed cushion over which by applying force to the tool parts of the pressure on the workpiece assembly can be applied.

An underlying realization of the invention is that it can be ensured in the proposed molding a fiber composite component with a thermoplastic matrix under pressure and elevated temperature and also in the proposed welding with reduced effort that the finished workpiece or the finished connection of workpieces the Quality requirements. Thermoplastic plastic materials do not require a curing process, such as thermosetting resins, and offer the possibility of re-plasticity with renewed heating. By monitoring the temperature and pressure applied to the thermoplastic resin material, the behavior of the material can be readily understood in a consolidation and molding operation or in a thermoplastic welding operation. The cost of a non-destructive testing of the resulting workpiece or the compound obtained can be advantageously reduced in this way, which also has a favorable effect on the manufacturing cost.

In the press molding neither an autoclave nor a vacuum bag are needed. In the methods and arrangements of the invention, the application of compressive forces across the pad succeeds in a uniform, well distributed manner. In particular, application of the pressure can essentially be achieved as hydrostatic pressure, even if the pressure force is applied by applying force to the tool parts, for example globally via a pressing device. The application of high hydrostatic pressures is possible, for example, to process powerful thermoplastic materials. The use of the pad further offers the advantageous possibility of compensating small deviations or changes in the component geometry, as may occur, for example, when, for example, a skin element is locally adapted with additional fiber layers, doppler, or the like to a limited extent. Thus, a new tool does not have to be provided for every minor geometric change in the workpieces to be produced or joined. If the pad is preformed in sections, it can thereby be adapted even better to the desired geometry, for example of the finished fiber composite workpiece, or to the geometry of the workpiece arrangement.

The invention thus enables a convenient production of fiber composite components with thermoplastic matrix and the production of a high-quality thermoplastic welded joint by softening or melting and subsequent reconsolidation of a thermoplastic material.

The inventive method for producing can be carried out in particular by means of the manufacturing arrangement according to the invention. Furthermore, the method according to the invention for welding can be carried out in particular by means of the welding arrangement according to the invention.

Further proposed is a workpiece, produced by means of the inventive method for manufacturing and / or by means of the manufacturing arrangement according to the invention, as well as an arrangement with two welded workpieces which have been connected by means of the inventive method for welding and / or the welding arrangement according to the invention.

Advantageous embodiments and further developments of the invention will become apparent from the other dependent claims and from the description with reference to the figures of the drawing.

In one embodiment of the method for manufacturing and the manufacturing arrangement, the cushion between the semifinished arrangement and the first tool part with a Membrane or foil formed skin and is filled with a fluid. In an analogous embodiment of the method for welding and the welding arrangement, the pad between the workpiece arrangement and the first tool part has a skin formed with a membrane or foil and is filled with a fluid. With the help of the fluid advantageously the application of pressure succeeds substantially as hydrostatic pressure. In addition, the fluid in order to effectively apply the desired temperature to the semifinished arrangement or the workpiece arrangement can advantageously be tempered, ie heated or cooled.

In one embodiment, the membrane or film to form the at least partially deformable pad deformable or flexible or the membrane or film for forming the partially preformed pad is preformed, for example, corresponding to a geometry of the workpiece to be produced or corresponding to a geometry of the workpiece assembly.

As the fluid, in preferred embodiments of the invention, an oil may be used. In this way, an effective application of high pressures succeeds.

In an alternative embodiment of the invention, the pad between the semifinished assembly and the first tool part or between the workpiece assembly and the first tool part may be filled with a granular material, such as granules, instead of a fluid. Even such a granular material allows an application of compressive forces substantially in the manner of a hydrostatic pressure, in which embodiment, the handling of a fluid can be omitted.

The granular material may include in polymer developments of the invention a polymer granulate or a rubber granule or metal beads.

The membrane or foil of the pad may be formed in further developments with a metal material or with a plastic or with a composite material which includes a metal material and a plastic. In particular, when the membrane or film is formed with a metal material, an advantageously temperature-resistant membrane or film can be achieved. For example, a steel membrane or a stainless steel membrane can be used as membrane or foil. On the other hand, the use of a plastic material for the membrane or film can allow good deformability of the same and a good seal with the fluid. These advantageous properties can be combined in a composite material with a metal and a plastic material.

In one embodiment, the plastic of the membrane or film may be a polyimide. It could be used as the material offered by the name Kapton ^® from EI du Pont de Nemours & Company to form the membrane or film. Such a membrane or film can advantageously be exposed to high temperatures.

In a further embodiment of the method for producing and the manufacturing arrangement, the membrane or foil formed with a metal material is polished and / or coated on the side facing the semifinished product arrangement. In an analogous embodiment of the method for welding and the welding arrangement, the membrane or foil formed with a metal material is polished and / or coated on the side facing the workpiece arrangement. This can contribute to avoid adhesion of the semifinished arrangement or the workpiece arrangement to the membrane or film.

In one embodiment of the method for manufacturing and the manufacturing arrangement, a pressure-filled fluid filled, gap-like space is formed in the application of pressure and elevated temperature to the semi-finished assembly between the first tool part and the membrane or film. In an analogous embodiment of the method for welding and the welding arrangement, when the pressure and elevated temperature are applied to the workpiece arrangement, a gap-like space filled with the pressurized fluid is formed between the first tool part and the membrane or foil. By the space filled with the fluid is formed like a gap and thus has a relatively limited volume in relation to the dimensions of the workpiece or the workpieces can be applied with a relatively small amount of fluid effectively the hydrostatic pressure and a contour compensation can be achieved. In addition, the comparatively small amount of fluid, for example, by supplying and discharging heated or cooled fluid, enables rapid control of the temperature applied to the semifinished assembly or the workpiece assembly.

In one embodiment, the membrane or film may be attached to the first tool part such that a pad interior is bounded by a surface of the first tool part and surface of the membrane or film.

In an alternative embodiment, it can be provided that the membrane or foil defines a cushion interior substantially on all sides.

In one embodiment of the method of manufacture, during the application of the pressure to the semifinished arrangement, the temperature of the fluid is reached in order to reach a predefined temperature value or a predefined temperature value Temperature course controlled or regulated over time. In one embodiment of the method for welding, during the application of the pressure to the workpiece arrangement, the temperature of the fluid for achieving a predefined temperature value or a predefined temperature profile over time is controlled or regulated. In appropriate embodiments of the manufacturing arrangement and the welding arrangement suitable means for such control or regulation of the temperature of the fluid are provided. By means of the fluid, it becomes possible to apply a desired temperature to the semifinished product or workpiece arrangement in a rapid and easily controllable or controllable manner.

In particular, the fluid can be heated or cooled. In this case, it can be provided, in particular in a further development, that the fluid is first heated to apply the elevated temperature to the semifinished arrangement or the workpiece arrangement and cause softening and / or melting of the thermoplastic material, and that the fluid at a later time, to preferably still the pressure acts, is cooled to cause re-stiffening of the thermoplastic material. In this way, the behavior of the thermoplastic material in the compression molding or the welding, and in particular during cooling and re-solidification, can be well influenced.

In embodiments of the method of manufacture, the semifinished assembly is subjected to an elevated temperature of between about 300 degrees Celsius and about 450 degrees Celsius. In an analogous embodiment of the method of welding, the workpiece assembly is exposed to an elevated temperature between about 300 degrees Celsius and about 450 degrees Celsius. For this purpose, the fluid can be heated, for example, to a fluid temperature between about 300 degrees Celsius and about 450 degrees Celsius. In corresponding embodiments of the manufacturing arrangement and the welding arrangement, this is in each case adapted to apply a temperature increased in this way to the semifinished arrangement or the workpiece arrangement and preferably to heat the fluid for this purpose.

In one embodiment of the invention, the first tool part and / or the second tool part is heated and / or cooled to apply the elevated temperature. In this way, the applied temperature can be controlled even better.

In one embodiment, a temperature of the first rigid tool part and / or a temperature of the second rigid tool part is regulated. The temperature control can thus be further improved. In further developments, the temperature of the first and / or second rigid tool part can be set to a temperature which is lower than the elevated temperature to be applied to the semifinished arrangement.

In one embodiment, at the same time a temperature of the first rigid tool part and / or a temperature of the second rigid tool part is regulated by means of the fluid. The heated or cooled fluid can thus be used expediently and efficiently not only for the heating or cooling of the semifinished or workpiece arrangement, but also for the additional regulation of the temperature of one or both of the rigid tool parts.

In an alternative embodiment, at least one further fluid may be used in a fluid circuit separate from the fluid of the pad to regulate the temperature of the first and / or second rigid tool parts, wherein heating and / or cooling of the first and / or second rigid tool parts may occur ,

In one embodiment, at least one temperature of the fluid and / or pressure of the fluid, preferably both, are measured while performing the method of manufacturing or welding. In a corresponding embodiment of the manufacturing arrangement and the welding arrangement, one or more measuring devices are provided for measuring a temperature of the fluid and / or a pressure of the fluid, preferably at least one such temperature measuring device and at least one such pressure measuring device. The behavior of the thermoplastic material during the manufacture of the fiber composite workpiece or during welding can thus be easily understood. The quality of the workpiece to be produced or the thermoplastic weld to be achieved can be suitably ensured in this way.

In a further development, temperatures of the first and / or second rigid tool part are additionally measured, with the first and / or second tool part being equipped in each case with a suitable measuring device in corresponding configurations of the manufacturing arrangement and the welding arrangement. The monitoring of the manufacturing or welding process can be further improved in this way.

In one embodiment of the method for producing and the manufacturing arrangement, a protective film for protecting the semifinished arrangement and the workpiece produced therefrom is also arranged in front of the fluid between the membrane or film of the cushion and the semifinished arrangement. In a Embodiment of the method for welding and the welding arrangement is further arranged between the membrane or foil of the pad and the workpiece assembly, a protective film for protecting the workpiece assembly from the fluid. Contamination of the semifinished arrangement or the workpiece arrangement with the fluid can be advantageously avoided in this way.

In one embodiment, a deformable and / or stretchable protective film is used as the protective film. The protective film can thus adapt well to the geometry of the semifinished arrangement or the workpiece arrangement.

In one embodiment, the protective film is preformed. In one development, the protective film is preformed in advance corresponding to the geometry of the workpiece to be produced or the workpiece arrangement. In embodiments, the protective film could be preformed by deep drawing. Thus, in the method for manufacturing and the manufacturing arrangement, the protective film can advantageously be used to hold individual components of the semifinished product arrangement in position relative to one another. In the method for welding and the welding arrangement, the protective film can be advantageously used in an analogous manner in order to keep the workpiece to be welded correctly positioned relative to one another.

In one embodiment, a leakage detection film is further arranged between the membrane or film of the pad and the protective film. Alternatively, the membrane or foil of the pad or the protective film may be equipped with a leakage detection function. Thus, leaks and leaks can be detected expediently and reliably and contamination of the semifinished product or the workpiece arrangement can be avoided.

In one embodiment, a protective film formed with at least two layers is used as the protective film. In a further development, a medium can be provided between the two layers of the protective film which, for example, discolors on contact with the fluid. A multi-layered protective film can provide greater security in protecting the semifinished or workpiece assembly from the fluid. A discoloring on contact with the fluid medium can clearly indicate possible leaks, so that such leaks can be detected early and eliminated.

Alternatively, the protective film and the membrane or film together form a skin of the pad in a further development. Alternatively, the membrane or foil of the pad itself may form the protective film to protect the semifinished assembly and the workpiece made therefrom, or to protect the workpiece assembly from the fluid.

In particular, the membrane or film may be a multilayer membrane or multilayer film. For example, the membrane or foil may include a metal layer for receiving compressive forces, a leakage detection layer for visualizing leaks, and a protective layer formed with, for example, a temperature-resistant polymer to protect the semi-finished or workpiece assembly.

In one embodiment of the invention, the cushion is designed as a temperature-resistant polymer cushion. By means of such a cushion can be achieved in a simple manner, a relatively uniform pressure distribution and adaptation to smaller geometry deviations or changes in geometry. In a simple way, a tolerance compensation is thus possible.

In embodiments of the invention, the polymer pad may be formed in one piece or in several pieces.

In particular, in one embodiment, the polymer cushion can be resistant up to temperatures of about 300 degrees Celsius to about 450 degrees Celsius.

The polymer pad may be mat-shaped in another embodiment. Such a mat-shaped cushion can easily make a contour compensation and a good pressure distribution possible. Here, the mat-shaped pad may be formed with or without heating and / or cooling devices.

In one embodiment of the method for producing and the manufacturing arrangement, the semifinished arrangement is heated by means of at least one heating device arranged in the polymer cushion and / or cooled by means of at least one cooling device arranged in the polymer cushion. In an analogous embodiment of the method for welding and the welding arrangement, the workpiece arrangement is heated by means of at least one heating device arranged in the polymer cushion and / or cooled by means of at least one cooling device arranged in the polymer cushion.

The pillow, in particular its membrane or film, can be preformed in developments of the invention such that by applying the pressure over the pad, a surface structure of the workpiece or one of the workpieces modified or a structure can be molded into a workpiece surface. The pillow can be on this Way an additional "embossing" take over. Alternatively, the protective film may be preformed in this way.

In one embodiment of the method for manufacturing and the manufacturing arrangement, the one or more sections of the semifinished product are placed on a shaping surface of the second tool part to form the semifinished arrangement. The shaping surface may in this case be planar or curved in further developments, for example curved in one direction or in several directions. Thus, flat or curved, for example, flat, workpieces can be produced efficiently and with reduced testing costs.

In one embodiment of the method for manufacturing and the manufacturing arrangement takes place during the laying of the sections of the semifinished a local consolidation. In particular, the sections are thereby stapled together at least locally. This can contribute to the fact that the sections of the semi-finished product do not slip during the lay-up operation and when moving the tool parts together.

The semifinished product which comprises the reinforcing fibers and the thermoplastic plastic material for forming the matrix can, in embodiments of the method for production and the production arrangement, be present as a pre-consolidated semi-finished product or as a non-pre-consolidated, for example merely stapled, semi-finished product.

In further embodiments of the method for the production and the manufacturing arrangement, the semifinished product may be fiber tapes having the matrix material and the reinforcing fibers or so-called "tailored blanks". The tailored blanks can for example be provided ready-cut by a semi-finished parts supplier.

In further embodiments of the method for manufacturing and the manufacturing arrangement, the laying can be automated, for example by automated storage of tape by means of the so-called "automated tape laying", in particular for the formation of planar or only simply curved semi-finished assemblies. Alternatively, the laying can be carried out automatically by means of the so-called "automated fiber placement", for example for semifinished arrangements which are curved in several directions.

In one embodiment, the first tool part as a male tool part and the second tool part are formed as a female tool part. However, in one variant, for example, the arrangement may be reversed such that the first tool part is formed as a female tool part and the second tool part is formed as a male tool part. Alternatively, the tool parts, for example, for use in the welding arrangement, but also for use in the manufacturing arrangement, be substantially flat.

In the press molding for producing the workpiece as a fiber composite workpiece, a global consolidation of the semifinished arrangement to form the workpiece preferably takes place. In a corresponding embodiment, the manufacturing arrangement is set up to bring about such a global consolidation of the semifinished product arrangement. In this way, a consolidated workpiece is produced by means of press-forming.

In one embodiment of the method for manufacturing and the manufacturing arrangement, the workpiece is designed as a fiber composite component for an aircraft or spacecraft, in particular for an aircraft. In one embodiment of the method for welding and the welding arrangement, workpieces formed as components for an aircraft or spacecraft, in particular for an aircraft, are welded. Especially in the field of aerospace, on the one hand reliable and high quality, on the other hand, lightweight components are needed, the invention may be advantageous.

In one embodiment of the method for producing and the manufacturing arrangement, the workpiece is a skin element, for example for a fuselage section or a fuselage shell of the aircraft or spacecraft. The skin element in embodiments may be curved two-dimensionally or three-dimensionally, i. have a simple curvature in only one spatial direction or a curvature in several spatial directions. A skin element for a support surface or for a tail unit could also be produced by means of the proposed method and / or the proposed production arrangement.

According to embodiments of the invention, a high-performance thermoplastic is provided as the thermoplastic material, for example, a polyaryletherketone (PAEK), a polyetheretherketone (PEEK), or the like. If, for example, a polyetheretherketone is used, the application of a temperature of about 360 degrees Celsius to the semifinished or workpiece arrangement may prove to be suitable in exemplary embodiments, wherein the temperature can also be selected differently if required.

Carbon fibers, glass fibers or other suitable fibers, or combinations thereof, may be used as reinforcing fibers in a matrix formed with the thermoplastic material embedded, preferably as so-called continuous or "endless" fibers.

In one embodiment of the method for welding and the welding arrangement is in at least one, but preferably both, to be welded workpieces to fiber composite workpieces with a thermoplastic resin matrix.

It should be noted that the abovementioned embodiments and further developments of the invention can each be applied analogously to the method according to the invention, the production arrangement according to the invention and the welding arrangement according to the invention.

The above embodiments and developments can, if appropriate, combine with each other as desired. Further possible refinements, developments and implementations of the invention also include combinations of features of the invention which have not been explicitly mentioned above or described below with regard to the exemplary embodiments. In particular, the person skilled in the art will also add individual aspects as improvements or additions to the respective basic form of the present invention.

CONTENT OF THE DRAWING

The present invention will be explained in more detail with reference to the exemplary embodiments indicated in the schematic figures of the drawings. It shows:

1 - 3 an aircraft as an example of an aircraft or spacecraft, in which thermoplastic fiber composite workpieces and / or thermoplastic welded joints, which were prepared according to the embodiments of the invention can be used;

4 a schematic illustration of the laying of portions of a semifinished product on a female tool part of a press-forming tool with curved shaping surface;

5 a schematic illustration of the laying of sections of a semifinished product on a tool part with a flat shaping surface;

6 a manufacturing arrangement according to a first embodiment, before a press-forming operation;

6A a detail D off 6 ;

7 a manufacturing arrangement according to a variant of the first embodiment, before a press-forming operation;

8th the manufacturing arrangement of 6 while performing a method of manufacturing a workpiece by press molding according to the first embodiment;

9 a detail of the manufacturing arrangement of 8th during press-forming;

10 a manufacturing arrangement, partially shown, according to a second embodiment, before a press-forming operation;

11 a manufacturing arrangement during the implementation of a method for producing a workpiece by press molding, according to a third embodiment;

12 a detail of a manufacturing arrangement during the press molding, according to a fourth embodiment;

13 a detail of a manufacturing arrangement during the press forming, according to a fifth embodiment;

13A -D variants of providing a protective function for a semi-finished product assembly and a leakage detection function, according to embodiments of the invention;

14 a manufacturing arrangement according to a sixth embodiment, before a press-forming operation;

15 a detail of the manufacturing arrangement according to 14 during a press-forming operation;

16 a manufacturing arrangement according to a variant of the sixth embodiment, before a press-forming operation;

17 a detail of a manufacturing arrangement during the press forming, according to a seventh embodiment;

17A a detail of a manufacturing arrangement during the press molding, according to an eighth embodiment;

18 - 18A two variants of a modification of the surface structure of a manufactured workpiece by press molding, according to embodiments of the invention;

19 a manufacturing arrangement according to a ninth embodiment, before a press-forming operation;

19A a detail D 'off 18 ;

20 a manufacturing arrangement according to a variant of the ninth embodiment, before a press-forming operation;

20A a manufacturing arrangement according to a tenth embodiment, before a press-forming operation;

21 the manufacturing arrangement according to 19 while performing a method of manufacturing a workpiece by press molding, according to the ninth embodiment;

22 the manufacturing arrangement according to 20 while performing a method of manufacturing a workpiece by press molding, according to the variant of the ninth embodiment;

23 a welding arrangement according to an eleventh embodiment; and

24 a welding arrangement according to a twelfth embodiment.

The accompanying drawings are intended to provide further understanding of the embodiments of the present invention. They illustrate embodiments and, together with the description, serve to explain principles and concepts of the invention. Other embodiments and many of the stated advantages will become apparent with reference to the drawings. The elements of the drawings are not necessarily shown to scale to each other.

In the figures of the drawings are the same, functionally identical and same-acting elements, features and components - unless otherwise stated - each provided with the same reference numerals.

DESCRIPTION OF EMBODIMENTS

1 to 3 show a plane 1 in which a fiber composite workpiece produced in accordance with the embodiments described below and / or a thermoplastic welded joint of workpieces produced according to the embodiments described below can be used. In the 1 to 3 are a hull 3 of the plane 1 , as well as wings 4 and tail units 6 and 7 exemplified. 2 further shows by way of example a fuselage shell 10 as a half-shell for an upper half of the hull 3 as well as a hull shell 11 as a half-shell for a lower half of the hull 3 , It is understood that the hull 3 alternatively, split into shell components in other ways.

4 schematically shows the laying of in 4 not shown sections of a semifinished product, which comprises a thermoplastic plastic material to form a matrix and reinforcing fibers, on a forming surface 29 a lower female tool part 28 , By laying on a semifinished arrangement 31 formed, then, for example, a shell skin element for a fuselage shell of the aircraft 1 , for example, for one of the hull half-shells 10 or 11 , can be generated as described below. In 4 is the shaping surface 29 curved, for example shaped approximately semi-cylindrical. However, the forming surface may alternatively be curved in multiple directions rather than in only one direction. Furthermore, the shaping surface 29 alternatively be essentially flat, see 5 , Thus, z. B. flat workpieces or single or multiple curved shell skin elements are made.

As semifinished product, for example, a preconsolidated semifinished product with a thermoplastic matrix material and reinforcing fibers or a non-preconsolidated semifinished product in which the thermoplastic material and the fibers are merely stapled can be used.

The semifinished product sections can act as so-called "tapes" on the shaping surface 29 be automatically hung up. In 4 is the laying on of the "tapes" by means of a device 15 for automatically depositing "tape", which may also be referred to as an "automated tape laying machine" or "ATL machine", and a suitable laying head 15a has, shown schematically. In addition shows 4 in that additionally or alternatively to the laying on of fiber tapes by means of the "automated tape laying" a depositing of z. B. relatively narrow "tapes" can be done using the method of "automated fiber placement" or "AFP", which is particularly in complicated curved shaping surfaces 29 , for example, to form a double-curved shell skin, may prove advantageous. 4 additionally shows schematically a suitable device 16 , which can also be referred to as "AFP machine" and with a facility 16a equipped to take off the "tapes". In the variant of 5 can by means of the "AFP-machine" 15 also semi-finished sections on the flat forming surface 29 be filed. Thus, in the 4 and 5 the semifinished sections each efficiently direct to the forming surface 29 of the female or even tool part 28 who later than, in the case of 4 outer, mold part is used for press molding, filed. During lay-up of the sections of the semifinished product, only local consolidation takes place, whereby the semifinished sections are stapled locally and thus secured together to hold them in place. The only local consolidation when depositing makes it possible to store the semifinished product sections at high speed. The prepared semifinished product arrangement 31 is already in the forming tool part for subsequent consolidation by press molding 28 in front.

According to a not shown in detail in the figures, but also advantageous variant, the semifinished arrangement 31 Alternatively, be formed in such a way that on a flat table sections of the semifinished product in the form of so-called "tailored blanks", ie prefabricated blanks, which are provided ready tailored, for example, finished by a semi-finished supplier, initially laid just. In this variant, therefore, a two-dimensional semifinished arrangement is first formed by arranging the sections of the semifinished product. This can then be used as a semifinished arrangement 31 in the tool part 28 are inserted and thus brought into the desired three-dimensional shape. So that the semi-finished sections do not slip in this case, they can be stapled when placed on the table, such as by local consolidation or local heating. Thus, in this variant, a two-dimensional placement of blanks can be combined with a three-dimensional compression molding, which in particular for the production z. B. of hull shells for cylindrical fuselage sections may be useful. In this case, it is preferred if the elevated temperature which is on the semifinished arrangement 31 is applied during the press molding, is sufficiently high, z. B. above the melting temperature of the thermoplastic material, so that the fibers for the transformation into the three-dimensional final shape can move relative to each other.

The semifinished assembly provided as described above 31 can be used in the manufacturing methods and arrangements, which are described below with reference to embodiments of the invention, for the production of fiber composite workpieces such as for aircraft or spacecraft.

A method and a manufacturing arrangement according to a first embodiment illustrate the 6 . 6A . 8th and 9 schematically. After completion of the semi-finished product arrangement 31 this is for the production of a fiber composite workpiece, in particular a shell skin for one of the fuselage shells 10 or 11 , subjected to compression molding. In the compression molding, the semi-finished assembly 31 consolidated globally to obtain a consolidated thermoplastic composite fiber composite workpiece.

The compression molding is carried out by means of a compression molding tool 19 with a male tool part 21 which is a first, in 6 forms upper tool part, and the female tool part 28 , which is a second, in 6 forms lower tool part. The tool parts 21 and 28 are rigid, for example made of a metal material, and are part of a manufacturing arrangement 30 , which is adapted to pressure and elevated temperature on the Halbzeuganordung 31 exercise.

The manufacturing arrangement 30 According to the first embodiment, this has an at least partially deformable and / or partially preformed cushion 36 on, about the pressure on the semifinished arrangement 31 can be applied. For this purpose, in the manufacturing arrangement 30 of the 6 the tool parts 21 and 28 be brought together against each other, as in 6 by arrows to illustrate the relative movement 20 the tool parts 21 . 28 indicated. It is understood that in this case both tool parts 21 . 28 can be moved, or only one of these, while the other is provided fixed. The tool parts 21 . 28 can also be pressed against each other with a force K to the pressure on the semifinished arrangement 31 Apply, using a press with suitable press jaws 18 (in 6 only indicated in sections) is used.

The pillow 36 between the semifinished arrangement 31 and the first tool part 21 has a skin in the first embodiment 37 which are in the states of the 6 . 6A . 8th . 9 between the first tool part 21 and the semifinished arrangement 31 located. The skin 37 is formed such that it is at least partially deformable, whereby the cushion 36 an at least partially deformability and flexibility is awarded. The skin 37 is with a membrane or foil 50 formed, which may be formed with a metal material or with a plastic or with a composite material which includes a metal material and a plastic. The skin 37 For example, it may be a metal membrane or may have a metal membrane, wherein the metal membrane is preferably made thin and flexible, such as steel or stainless steel. In addition to its flexibility, the membrane or foil 50 of the skin 37 be at least partially preformed, for example, this to the geometry of the semi-finished product assembly 31 already at least roughly adjusted.

The membrane or foil 50 of the skin 37 is in attachment areas 39 , in the 6 . 6A a border area of the skin 37 form, so on the first tool part 21 attached and sealed against this, that a surface 22 of the first tool part 21 , which of the shaping surface 29 facing, and the membrane or foil 50 of the skin 37 a pillow room 38 limit.

The pillow 36 is filled with a fluid F, which is in the pad interior 38 located. The fluid F is preferably an oil. In particular from the 6 . 8th and 9 it will be seen that in the first embodiment thus a narrow pad interior 38 is formed, and thus after moving together of the tool parts 21 . 28 a gap-like, filled with the fluid F space between the membrane or foil 50 of the skin 37 and the first tool part 21 is present. These are the surfaces 22 and 29 formed in the manner corresponding to the shape that the desired gap-like space for receiving the pad 36 arises, ie the surfaces 22 and 29 can not be brought together exactly to the plant. The gap-like fluid-filled space may have a gap width t that is in a range of about 1.0 mm to about 10.0 mm, but gap widths t deviating therefrom are conceivable.

For producing a fiber composite workpiece starting from the semifinished product arrangement 31 after the provision of the semifinished assembly 31 on the shaping surface 29 , the tool parts 21 . 28 moved together, thus the press mold 19 closed, and forces K are on the tool parts 21 . 28 upset, see 8th , This will get an outer surface 40 of the skin 37 in contact with the semifinished product arrangement 31 ,

Depending on the design and construction of the fiber composite workpiece to be produced, the semifinished assembly 31 be formed in different areas with more or less fiber layers. This can be done by appropriately depositing the semifinished product sections 45 , eg "tapes", can be achieved. In one as a skin element for the fuselage shell 10 or 11 fiber composite component to be produced is the semifinished arrangement used for this purpose 31 , such as in 8th and 9 is indicated schematically, for example in some areas 32 Thicker while outside these areas 32 is thinner.

The deformable pillow 36 can the thickness profile of the semifinished arrangement 31 , please refer 9 , to adjust. This advantageously makes it possible to compensate for tolerances; in addition, it is also possible to make changes to the geometry of the component which, for example, results in an adaptation of the number of fiber layers in the regions 32 and outside of this can be compensated. It is therefore not at every slight adjustment of the layer structure of the semifinished arrangement 31 with the semi-finished sections 45 a new tool part 21 necessary.

It is also advantageous by means of the fluid-filled pad 36 Pressure evenly and well distributed substantially as hydrostatic pressure on the semi-finished product assembly 31 applied. In a simple manner, this is achieved by applying the external force K globally by means of a press, wherein advantageously by the cushion 36 the pressure substantially perpendicular to the semifinished assembly 31 and the shaping surface 29 acts. On the pillow 36 opposite side of the semifinished arrangement 31 this lies on the shaping, rigid surface 29 of the second tool part 28 at. The consolidation of the semi-finished product arrangement 31 thus takes place in contact on the one hand with a deformable element in the form of the pad 36 and a rigid element in the form of the second tool part 28 ,

For the global consolidation of the semi-finished product arrangement 31 to form the fiber composite workpiece, the pressure is transmitted across the pad 36 , As well as an elevated temperature on the semifinished arrangement 31 applied. The applied temperatures are in this case to the thermoplastic material contained in the semi-finished, from which the semifinished arrangement 31 is formed, adapted and can be between 300 degrees Celsius and 450 degrees Celsius.

To the semifinished arrangement 31 to heat, in the first embodiment of the invention, the fluid F is heated to a corresponding fluid temperature, in other words, the cushion 36 is filled with hot fluid F at a temperature also exemplary between about 300 degrees Celsius and about 450 degrees Celsius. The membrane or foil 50 of the skin 37 is formed sufficiently resistant to temperature in the first embodiment. The use of a metal membrane or metal foil may be advantageous in terms of temperature resistance.

In the first embodiment, the fluid temperature is preferably while the pressure is transmitted across the pad 36 is applied, controlled or regulated by suitable means to achieve a predefined temperature value or a predefined temperature profile over time. The value at which the fluid temperature is maintained over time or how its value should vary over time can in turn be determined by the semifinished product arrangement 31 , in particular of the thermoplastic material used, but possibly also of other parameters are made dependent. In this way, high-performance thermoplastics can be reliably processed. By applying the temperature by means of the fluid F, the temperature of the Semi-finished arrangement 31 not only well controlled during the process, but also varied quickly. Here is also the relatively small volume of fluid in the approximately in 8th visible, slit-like cushion interior 38 is included, advantageous.

According to the first embodiment of the invention, therefore, not only is the expedient application of a high temperature to the semifinished arrangement 31 allows, but at the same time balancing tolerances and a certain flexibility in view of minor changes in the workpiece to be produced, high hydrostatic pressures on the semi-finished product assembly 31 exercise. Efficient high-temperature thermoplastics can thus be reliably processed. By monitoring the temperature applied to the thermoplastic material and the applied pressure by means of suitable measuring devices, it is possible to check whether the processing of the thermoplastic material takes place as desired.

The 8th shows an exemplary fluid circuit 66 in which the fluid F circulates, as in 8th by arrows along the fluid circuit 66 indicated. The fluid circuit 66 is according to the first embodiment 8th closed, the fluid F is thus when applying the pressing force K on the jaws 18 under pressure, causing pressure on the semifinished assembly as described above 31 can muster. The circulation of the fluid F is by a pump 64 the manufacturing arrangement 30 brought about, the fluid F also by means of a heating and / or cooling device 55 can be heated and / or cooled. The device 55 is in 8th exemplarily upstream of the pump 64 However, in variants, it can also be found elsewhere in the fluid circuit 66 to be ordered. It should be mentioned that if necessary the pump 64 can be designed in such a way that it allows to contribute to the construction of the required fluid pressure in the gap. However, it is preferred to apply the pressure directly via the force K provided by the press.

Furthermore, the shows 8th measuring equipment 67 . 68 . 69 . 70 . 70 ' , By means of temperature measuring equipment 67 , in the 8th are indicated by way of example and schematically, the temperatures of the rigid tool parts 21 and 28 be measured. In this case, depending on the desired spatial resolution of the temperature measurement, a plurality of temperature measuring devices 67 used as part of the manufacturing arrangement 30 in the tool part 21 and the tool part 28 be arranged distributed. By means of temperature measuring equipment 68 on the other hand, the temperature of the fluid F is in each case at one point of the fluid circuit 66 measured. The pressure measuring device 69 is used to measure the pressure of the fluid F within the fluid circuit 66 , In 8th is only a pressure measuring device 69 However, it is understood that in different place of the fluid circuit 66 if required pressure measuring equipment 69 can be provided. In addition shows 8th a displacement measuring device 70 , By means of the travel of the upper, first tool part 21 can be measured. If the lower, second tool part 28 is also movable, can for measuring the travel of the same also a displacement measuring device, in 8th exemplified and with 70 ' designated, be provided. With the proposed measuring devices, the behavior of the thermoplastic material during the press molding can be reproduced to ensure the quality of the finished fiber composite workpiece.

The measuring equipment 67 . 68 . 69 . 70 and possibly also 70 ' , as well as the pump 64 and the heating and / or cooling device 55 are preferably with a suitable control device 78 as shown schematically in 8th sketched with dashed lines, connected, such that the measured values provided by the measuring devices by the control device 78 for controlling the pump 64 and / or the heating and / or cooling device 55 and possibly for the regulation of the fluid circuit 66 pending fluid temperatures and pressures can be used. If additional heating and / or cooling equipment (in 8th not shown) for additional heating and / or cooling of one or both of the tool parts 21 . 28 are provided, the control of these additional heating and / or cooling devices by the controller 78 be taken over. The control device 78 can also be equipped with a press control (in 8th also not shown) for controlling the movement of the press jaws 18 communicate or take over their tasks in whole or in part.

The fluid circuit 66 can, for example, with the help of suitable, pressure and temperature resistant hoses or pipes, in 8th not shown in detail, be realized.

The fluid F may in the manufacturing arrangement 30 according to 8th thus by means of the device 55 preferably both heated and cooled, the device 55 can be divided into several sub-facilities for heating or cooling of the fluid F.

For the production of a fiber composite workpiece, as described above, a substantially hydrostatic pressure acts on the only locally consolidated semifinished product arrangement 31 exercised, also the semi-finished arrangement 31 heated by means of the hot fluid F. The thermoplastic material used in the finished Fiber composite component is to form the matrix is heated and softens or melts sufficiently to a global consolidation of the semifinished assembly 31 and to embed the reinforcing fibers in the matrix. That in the fluid circuit 66 circulating fluid F may, in particular due to the relatively small volume in the pad interior 38 , quickly brought to the desired temperature and the fluid F with the correct set fluid temperature quickly in the pad interior 38 be pumped. The fluid circuit 66 , in which the fluid F circulates at the desired temperature, thus advantageously allows a rapid and accurate control of the temperature, which on the semi-finished product assembly 31 acts. The behavior of the thermoplastic material can be accurately influenced. In addition, by cooling the fluid F to the desired extent, a controlled cooling and thus a controlled re-solidification of the thermoplastic matrix possible. Especially with semi-crystalline thermoplastics, this can be useful, for example, to achieve a controlled crystallization. For this purpose, also the tool parts 21 and or 28 additionally heated and / or cooled separately, between the pillows 36 and shaping surface 29 to influence acting temperatures even more precisely. In a preferred variant, both the "hard" shaping surface 29 , by heating the second tool part 28 , as well as the fluid F heated.

The on the semifinished arrangement 31 acting pressure during the implementation of the method can be checked based on the measured fluid pressure, with a control in addition to the measured travel of one or both tool parts 21 . 28 is possible. The fluid pressure may be, for example, in a range of about 10 bar to about 20 bar.

By means of the method and the manufacturing arrangement thus succeeds in the production of a fiber composite workpiece with a thermoplastic matrix in an efficient and easy to control manner, the method and the manufacturing arrangement can be used to advantage for producing a two-dimensional or three-dimensionally curved skin element for an aircraft or spacecraft. After consolidation of the semi-finished product arrangement 31 to the fiber composite workpiece is the press mold 19 open, such as the upper tool part 21 by means of the upper press jaw 18 is raised. The metal-formed membrane or foil 50 can be beneficial on the side on which they are the semi-finished 31 or the finished fiber composite workpiece facing outer surface 40 of the skin 37 forms, polished and / or suitably coated to adhere the finished fiber composite workpiece to the skin 37 to avoid.

While a metal membrane or metal foil 50 advantageously formed temperature-resistant and may be suitable to absorb the acting pressure, for a good deformability of the membrane or film and a good tightness instead a suitable, mechanically sufficiently strong and temperature-resistant plastic material can be used, for example, a polyimide such as the under the name Kapton ^® available material could be used.

On the in 7 shown variant of the first embodiment, the above statements are also applicable to the first embodiment, wherein the variant of 7 from that of the 6 to the effect that in 7 the shaping surface 29 of the second tool part 28 as well as the surface facing this 22 of the first tool part 21 are each substantially planar. In this way, a flat fiber composite workpiece can be generated, which in turn in 7 exemplified areas 32 can be made thicker by appropriate application of semi-finished products.

At the in 10 shown second embodiment, in which the surfaces 22 and 29 are also flat, limited the membrane or foil 50 that the skin 37 of the pillow 36 makes, the pillow interior 38 from all sides, except for connection points for the supply and discharge of the fluid F, which in 10 not shown in detail. Thus, there are sections of the membrane or film 50 on the surface 22 on, thus not directly in the second embodiment, the cushion interior 38 limited. The other embodiments of the first embodiment are analogously applicable to the second embodiment, it being understood that in the second embodiment in variants, the surfaces 22 and 29 can be curved.

The third embodiment shown in FIG 11 , represents a variant of the first embodiment. Also in the manufacturing arrangement 30 of the 11 can the measuring equipment 67 . 68 . 69 . 70 and possibly 70 ' as in 9 be provided shown. From the first embodiment, the third embodiment differs in that in the manufacturing arrangement of 11 the fluid circuit 66 in addition, the temperature of the second tool part is used 28 to influence. For this purpose, in the second tool part 28 channels 65 provided by the fluid F in the fluid circuit 66 be flowed through, whereby the fluid F also by the second tool part 28 circulated. Thus, the fluid F also contributes to the regulation of the temperature of the second tool part 28 at. Alternatively or additionally, the fluid F could have an influence the temperature of the first tool part 21 be co-used.

The fourth embodiment shown in FIG 12 , again represents a variant of the first embodiment. In the fourth embodiment is between the made of a metal material membrane or foil 50 and the semifinished arrangement 31 a heat and pressure resistant protective film 51 arranged, which is designed and provided for, the semifinished arrangement 31 to protect against the fluid F and thus contamination of the semi-finished product assembly 31 and the finished fiber composite workpiece with the fluid F to avoid. The protective film 51 can before closing the mold 19 such between the tool parts 21 and 28 be inserted that the protective film 51 the semifinished arrangement 31 completely covers. The semifinished product arrangement 31 is thus protected from contact with the fluid F, even in a case where the metal membrane or foil 50 in places fluid F can pass. The protective film 51 is formed in the fourth embodiment as a deformable and preferably also stretchable, temperature-resistant polymer film, which thus conforms to the geometry of the semifinished product assembly 31 can adapt well without tearing.

The protective film 51 may be preformed in variants of the fourth embodiment, for example, corresponding to the geometry of the workpiece to be produced, whereby individual semifinished product sections 45 , about in the area 32 , can be kept even better in their relative position during consolidation and also the protective film 51 already adapted to a certain degree to the workpiece geometry. In addition, it is possible the protective film 51 to change for successive manufactured fiber composite workpieces with little effort and comparatively low cost, if the workpieces show in detail with respect to their final geometry deviations.

The protective film 51 could not be provided separately in a variant, but part of the skin 37 be the skin 37 formed in such a variant multi-layered, such as with a metal membrane 50 and a protective film 51 made of a plastic material.

The fifth embodiment of 13 also represents a variant of the first embodiment. Here, in addition to the protective film 51 , as above 12 described between the protective film 51 and the membrane or foil 50 a leak detection foil 52 arranged, which makes it possible to visually detect leaks for the worker, for example by appropriate discoloration. For this purpose, the leak detection film 52 for example two-layered with one between two parallel layers 52a . 52b arranged medium M are formed, see 13A , wherein this medium M discolored on contact with the fluid F and thus makes the leak clearly visible. In one variant, the leak detection function may be in the protective film 51 be integrated, see 13B , wherein the medium M between two layers 51a and 51b the protective film 51 is arranged. In another variant, the leak detection function may be in the membrane or foil 50 of the skin 37 be integrated, cf. 13C where the membrane or foil 50 in this case, for example, a location 50a made of metal, for example a steel or a stainless steel, one layer 50b made of a plastic material, and that between the layers 50a , b arranged medium M for leakage detection includes. In case of 13C is thus the membrane or foil 50 even equipped with the leak detection function.

It should also be noted that in the aforementioned variants of the fifth embodiment, a multi-layer membrane or multi-layer film can be used, which is the membrane or film 50 , in particular of a metal material, the leakage detection film 52 and / or the protective film 51 in a multilayer element, wherein the layer sequence as in one of 13 . 13A -C can be taken. A further variant of the fifth embodiment also shows 13D , Here are the protective function for the semi-finished product assembly 31 and the leakage detection function both into a multi-layer membrane 50 which the skin 37 of the pillow 36 forms, integrated, these being a metal layer 50a to absorb the pressure and a protective, dense and temperature-resistant plastic layer 50c between which the medium M is arranged. For the plastic layers 50b or 50c can in turn z. For example, a polyimide may be considered.

The production of a fiber composite workpiece starting from the semifinished product arrangement 31 According to a sixth embodiment is in the 14 and 15 shown. In the sixth embodiment, a protective film 51 for example, like the 12 . 13 . 13A -C may be formed after the formation of the Halbzeuganordung 31 on the semifinished arrangement 31 placed on and in fastening and sealing areas 53 on a lower tool part 28 attached and sealed against this. Subsequently, the press-forming process can be carried out as described above, in turn, an upper tool part 21 with a pillow 36 is provided. About the attachment of the protective film 51 in the fields of 53 In addition, reference is made to the above comments on the preceding embodiments. In variants, the leak detection foil 52 on the protective film 51 put on and just like these are attached. at according to the variant 16 are the surfaces 22 and 29 again essentially flat.

In 14 - 16 will be the protective film 51 through the semifinished arrangement 31 over a large part of the extent of the protective film 51 supported. Tensions in the protective film 51 are limited in this way, being at the edges, in the area 53 , the protective film 51 through the lower tool part 21 is supported. If necessary, to bridge the transition region at the edge of the semi-finished product assembly 31 suitable facilities to support the protective film 51 be provided (not shown in 14 - 16 ), z. B. if the pillow 36 laterally over the edge of the semifinished arrangement 31 extends.

In particular, in variants of the sixth embodiment, a preforming of the protective film 51 be useful, for example, a preform corresponding to the geometry of the fiber composite workpiece to be produced by about individual semifinished product sections 45 , z. B. in the area 32 to hold in their relative position and also on the protective film 51 acting loads reduce something by the protective film 51 already adapted to the workpiece geometry to a certain extent.

In a further variant of the sixth embodiment, the range 53 in which the protective film 51 attached and sealed, moved out of the high-temperature area exposed. This can be done by making the area 53 or at least the part of it in which the protective film 51 fixed and tight with the lower tool part 28 is connected, for example, well outside the sphere of action of the pad 36 lies. The edge region of the protective film lying outside the area exposed to high temperature 51 In this case, by providing higher elasticity at lower temperatures, it can provide the elasticity and stretchability required for contour and tolerance compensation.

Two further embodiments show the 17 and 17A which differ from the preceding embodiments in terms of the formation of the pad. In the seventh embodiment, instead of the fluid-filled pad 36 a temperature-resistant polymer pad or rubber pad 136 provided by means of which also by a compliance of the polymer pad 136 Adjustments to smaller geometry deviations, tolerance compensation and pressure application in the manner of a hydrostatic pressure is possible. When using a suitable, temperature and pressure-resistant polymer can be achieved in this way, the desired uniform pressure distribution and the geometric adjustment in a simple manner. In 17 is the polymer cushion 136 as a mat-shaped element on the surface 22 of the first tool part 21 attached flat, with also heating facilities 155 inside the polymer pad 136 are provided to the semifinished arrangement 31 to heat up. However, for example, in variants, the heaters 155 be omitted, in which case the heating of the semi-finished product assembly 31 about the heating of one or both of the tool parts 21 . 28 can be done. The heaters 155 For example, they are designed as electrical heating elements.

In variants of the seventh embodiment that are not illustrated, cooling devices can also be provided inside the polymer cushion 136 be provided to the temperature profile within the semifinished arrangement 31 to influence even better. In addition to measuring the path of one or both tool parts 21 . 28 can turn in the tool parts 21 . 28 and, if necessary, also within the polymer pad 136 Temperature measurement devices 67 be provided. As heating and / or cooling devices within the polymer cushion 136 can also be fluid-carrying channels, which are flowed through by a heated or cooled fluid into consideration.

In the eighth embodiment of the 17A is a skin, as in the first or second embodiment 37 to form a pillow 236 intended. Regarding the skin 37 Reference is made to the above statements. In the eighth embodiment is in a cushion interior 38 instead of a fluid granules G arranged which the cushion interior 38 crowded. This in turn in a simple way a certain flexibility of the pillow 236 achieved, however, eliminating the handling of a fluid. The influence on the temperature of the semifinished product arrangement 31 by heating and / or cooling, in the eighth embodiment, in turn, over one or both of the tool parts 21 . 28 and / or with the aid of heating and / or cooling devices within the cushion 236 (not shown in 17A ) can be achieved. For the measurement of temperature and travel, reference is made to the above statements.

In all embodiments described above, in addition, the membrane or film 50 and / or the protective film 51 or instead the polymer pad 136 be preformed in such a way that the surface structure of the semi-finished product assembly 31 can be influenced or modified by impressing additional structural features, whereby the finished fiber composite component is then provided in areas of its surface with the modified surface structure.

For example, by impressing an identification feature 85 such as a number or other character combination, a fiber composite workpiece 100 be furnished in a consistent manner with such an identification feature, see 18 , This could, for example, expediently by a corresponding pre-embossed protective film 51 respectively. This is particularly useful in view of the possibility of identifying a single fiber composite workpiece when the protective film 51 anyway after every press-forming process is changed.

Preforming the membrane or foil 50 and / or the protective film 51 or the polymer pad 136 However, it can also be used to prepare the surface structure of the resulting fiber composite workpiece already for a subsequent welding operation. For example, that of the shaping surface 29 weggewandte surface of the fiber composite workpiece with a corrugation, such as a microscopic ribbing, be provided to improve the weld still, such as the welding of other components such as stringers or frames on the inside of a formed as a skin element fiber composite workpiece 100 , A surface modification to facilitate subsequent welding of another component, for example an elongate member such as a stringer 92 or a frame, may also consist of that of the shaping surface 29 weggewandte surface of the fiber composite workpiece 100 with a step 91 , please refer 18A , is provided. Against the stage 91 can the stringer 92 then be created, causing the stringer 92 when attaching to the skin element, such as when welding, not slip. The stage 91 may be, for example, a few tenths of a millimeter high, for example, 0.1 mm.

In the ninth embodiment of the invention is a membrane or foil 54 , which acts equally as a protective film as well as for pressure application, arranged such that they the semi-finished assembly 31 covered. The membrane or foil 54 is in a mounting area 53 around the semifinished arrangement 31 around at a lower, second tool part 28 a press mold 19 attached and sealed against this. See also the detail of 19A , The mounting arrangement 31 is so close between a shaping surface 29 of the second tool part 28 and the membrane or foil 54 locked in. The membrane or foil 54 may, for example, be designed as a single-layer or multi-layer membrane or film, for. B. two layers. Alternatively, in place of the membrane or foil 54 an arrangement of several parallel and separate individual layers occur. The above statements on the membrane or film 50 , to the protective film 51 and to the leak detection foil 52 and their arrangement and training are on the membrane or foil 54 also applicable analogously. With regard to the possibility of preforming, what has been stated above also applies, in particular to 18 . 18A ,

In a variant, it may be in the membrane or film 54 an at least partially stretchable, temperature-resistant plastic film, such as a polyimide, act, the function of the pressure application, the tolerance and geometry compensation and the protection of the semifinished product assembly 31 before the fluid F takes over.

The function of the manufacturing arrangement 30 according to 19 shows 21 , For compression molding and global consolidation of the semi-finished product assembly 31 in turn, by means of a press a pressing force K on the tool parts 21 . 28 applied. At the same time, the space between the tool parts 21 . 28 sealed at their facing sides in a suitable manner, such that a pressurized, closed fluid circuit 366 can be formed, the space in particular between the first tool part 21 and the membrane or foil 54 includes. Exemplary are in 21 sealing devices 367 sketched schematically. In this way, in turn, by means of a fluid-filled pad 336 However, its one-sided "pillow cover" or its one-sided skin in the example of 19 . 19A and 20 through the second tool part 28 attached membrane or foil 54 is formed, the pressure applied. Also in the embodiment of 21 is that between the semifinished arrangement 31 facing surface 22 of the first tool part 21 and the semifinished arrangement 31 arranged, from the semifinished arrangement 31 through the protective foil or membrane 54 separate fluid-filled space slit-like and narrow. With regard to the formation of the membrane or film 54 , the circulation of the fluid F and the possibility of measuring temperature, pressure and / or travel is referred to the above comments on the above embodiments.

Also in 21 becomes the membrane or foil 54 through the semifinished arrangement 31 over a large part of the expansion of the membrane or film 54 supports, reducing the tension in the membrane or foil 54 be limited. At the edges, in the area 53 , becomes the membrane or foil 54 through the tool part 21 supported, if necessary, for bridging the transition region at the edge of the semifinished arrangement 31 suitable means for supporting the membrane or film 54 , in the 19 . 19A . 21 are not shown, can be provided.

The 20 and 22 show a variant of the ninth embodiment, in which the two surfaces 22 and 29 are essentially flat. Furthermore, in the variant of 20 . 22 turn channels 65 in the second tool part 28 provided, wherein the fluid F as in 11 in addition to influencing the temperature of the second tool part 28 is being used. Further, to the description above to 19 and 21 directed.

A tenth embodiment of the invention is illustrated 20A , It represents a variant of the ninth exemplary embodiment and differs from the exemplary embodiment of FIG 20 only in that 20A the semifinished arrangement 31 on all sides in the membrane or foil 54 is tightly enclosed.

Each of the above with reference to the embodiments of the 6 to 22 described manufacturing arrangements 30 and methods for producing a fiber composite workpiece, and variants thereof, may be used in further modifications to weld together two workpieces, at least one of which has a thermoplastic material. In such modifications then form the first rigid tool part 21 and the second rigid tool part 28 Parts of a welding tool as part of a welding arrangement.

In corresponding modifications of the embodiments described above, first two workpieces to each other as they are to be welded, angeordet each other. For example, a first one of the workpieces may be a skin element of a fuselage shell for an aircraft or spacecraft, such as an aircraft, as described above, while the second workpiece may be a stringer or frame. Instead of the semi-finished product arrangement 31 Thus, a workpiece assembly is on the surface 29 on. The workpiece assembly is then subjected to pressure and elevated temperature over the pad as in the case of the above-described molds 36 . 136 . 236 or 336 applied. The surface acting as a shaping surface in the manufacturing arrangements 29 then serves as a counter-holding surface in the welding arrangements and methods in order to apply the pressure required for the welding process on the workpiece assembly can. After completion of the welding process, there is an arrangement with two reliably welded workpieces. The above-described improvements and advantages achieved with regard to the production of a thermoplastic composite fiber composite workpiece are also achieved analogously for the welding process. In particular, the targeted control of pressure and temperature and the good opportunities to monitor them and apply the pressure evenly, it is possible to produce a high-quality welded connection with reduced testing costs. In the methods and arrangements modified for welding according to the embodiments described above, a preformed protective film also helps to keep the workpieces to be welded in the correct relative position and position relative to each other.

In 23 and 24 are welding orders 35 schematically indicated according to an eleventh and twelfth embodiment. Between two tool parts 21 . 28 a welding tool 33 a welding arrangement 35 becomes an arrangement 103 of two workpieces 101 . 102 , which are fiber composite workpieces with a thermoplastic matrix and in these embedded reinforcing fibers formed. While in 23 similar to in 19 a cushion is formed and pressure and elevated temperature via a fluid F, in particular an oil, in a gap between the first tool part 21 and a membrane or foil 54 , how to 19 described on the workpiece assembly 103 will be applied in 24 a pillow 36 . 136 or 236 , Analogous to the embodiments of the 6 to 18 , used to provide the pressure and the elevated temperature. It should be noted again, however, that all in the 6 - 22 sketched embodiments and their variants for welding thermoplastic fiber composite workpieces can be used.

In all of the above-described embodiments, the thermoplastic plastic material used is preferably a high-performance thermoplastic, for example a polyaryletherketone, a polyetheretherketone or another thermoplastic which is suitable as a high-performance thermoplastic and in particular in the aerospace industry. Carbon fibers, glass fibers or other suitable fibers or combinations of these, which are already provided with the semifinished product and preferably embedded as continuous fibers in the thermoplastic matrix, are used as the reinforcing fibers.

The methods and arrangements described with reference to the preceding embodiments make it possible to produce flat or curved, in particular flat, workpieces, such as skin elements for aircraft fuselage structures, as well as welded workpiece arrangements, in particular in the field of aerospace, efficiently and to reduce the testing effort ,

It should also be mentioned that the production of a skin element, for example, for the hull shell 10 or 11 in 2 , According to one of the above-described embodiments of the invention, the integration of one or more elements of a hindleg structure for the skin element, such as the integration of a Spants or stringers, follow and after opening the mold 19 directly in the second, lower tool part 28 can take place, ie the consolidated skin element remains for this purpose in the female tool part 28 , In particular, the bulkhead or stringer can be welded onto the inside of the skin element, for example by means of the welding process according to the present invention, although other bonding methods are also conceivable.

Although the present invention has been fully described above with reference to preferred embodiments, it is not limited thereto but is modifiable in a variety of manners.

LIST OF REFERENCE NUMBERS

1

 plane

3

 hull

4

 wing

6

 tail

7

 tail

10

 fuselage shell

11

 fuselage shell

15

 contraption

15a

 laying head

16

 contraption

16a

 Facility

18

 Press jaws

19

 Press mold

20

 relative movement

21

 first tool part (press mold)

22

 Surface (first tool part)

28

 second tool part (press mold)

29

 shaping surface (second tool part)

30

 manufacturing arrangement

31

 Semi-finished arrangement

32

 Area (semifinished arrangement)

33

 welding tool

35

 welding arrangement

36

 pillow

37

 Skin (cushion)

38

 Cushion interior

39

 fastening area

40

 Outer surface (skin)

41

 Surface (protective film)

45

 Semi-finished sections

50

 Membrane or foil

50a, b

 Position (membrane or foil)

51

 protector

51a, b

 Location (protective film)

52

 Leak detection foil

52a, b

 Location (leakage detection foil)

53

 Mounting and sealing area

54

 Membrane or foil

55

 Heating and / or cooling device

64

 pump

65

 channel

66

 Fluid circuit

67

 Temperature measuring device

68

 Temperature measuring device

69

 Pressure measuring device

70

 displacement measuring system

70 '

 displacement measuring system

78

 control device

85

 identification feature

91

 step

92

 Stringer

100

 Fiber composite workpiece

101

 Fiber composite workpiece

102

 Fiber composite workpiece

103

 Workpiece arrangement

136

 polymer cushion

155

 heater

236

 pillow

336

 pillow

366

 Fluid circuit

367

 sealing device

F

 fluid

G

 granules

K

 force

M

 medium

t

 gap width

Claims (15)

Method for producing a workpiece by press-forming using a press-forming tool ( 19 ) with at least one first rigid tool part ( 21 ) and a second rigid tool part ( 28 ), wherein the workpiece is formed as a fiber composite workpiece with a thermoplastic matrix, comprising the steps of: arranging one or more sections of a semifinished product, which comprises a thermoplastic material and reinforcing fibers, to form a semifinished assembly ( 31 ); and applying pressure and elevated temperature to the semifinished assembly ( 31 ), wherein the pressure by applying force (K) to the tool parts ( 21 . 28 ) via an at least partially deformable and / or at least partially preformed cushion ( 36 ; 136 ; 236 ; 336 ) between the semifinished arrangement ( 31 ) and the first tool part ( 21 ) on the semi-finished product assembly ( 31 ) is applied. Method according to claim 1, characterized in that the cushion ( 36 ; 336 ) between the semifinished arrangement ( 31 ) and the first tool part ( 21 ) one with a membrane or foil ( 50 ; 54 ) formed skin ( 37 ) and filled with a fluid (F). A method according to claim 2, characterized in that when applying pressure and elevated temperature to the semifinished arrangement ( 31 ) between the first tool part ( 21 ) and the membrane or film ( 50 ; 54 ) is formed with the pressurized fluid (F) filled, gap-like space. A method according to claim 2 or 3, characterized in that during the application of the pressure on the semifinished arrangement ( 31 ) the temperature of the fluid (F) is controlled or regulated over time to reach a predefined temperature value or a predefined temperature profile. Method according to one of claims 2 to 4, characterized in that between the membrane or film ( 50 ) of the pillow ( 36 ) and the semifinished product arrangement ( 31 ) a protective film ( 51 ) for the protection of the semifinished product arrangement ( 31 ) and the workpiece made therefrom before the fluid (F) is arranged. Method according to one of claims 2 to 5, characterized in that between the membrane or film ( 50 ) of the pillow ( 36 ) and the protective film ( 51 ) a leakage detection film ( 52 ) or that the membrane or film ( 50 ; 54 ) of the pillow ( 36 ; 136 ) or the protective film ( 51 ) is equipped with a leakage detection function. Method according to claim 1, characterized in that the cushion ( 136 ) as a temperature resistant polymer pad ( 136 ) is trained. Method according to claim 7, characterized in that the semifinished arrangement ( 31 ) by means of at least one in the polymer pad ( 136 ) arranged heating device ( 155 ) and / or by means of at least one in the polymer pad ( 136 ) arranged cooling device is cooled. Method according to one of the preceding claims, characterized in that a temperature of the first rigid tool part ( 21 ) and / or a temperature of the second rigid tool part ( 28 ) is regulated. Method according to one of the preceding claims, characterized in that the one or more sections of the semifinished product for forming the semifinished arrangement ( 31 ) on a shaping surface ( 29 ) of the second tool part ( 28 ). Method according to one of the preceding claims, characterized in that the first tool part ( 21 ) as a male tool part and the second tool part ( 28 ) are formed as a female tool part. Method according to one of the preceding claims, characterized in that the workpiece as a fiber composite component ( 100 ) for an aircraft or spacecraft, in particular for an aircraft ( 1 ) is formed. Manufacturing arrangement ( 30 ) for producing a workpiece by press molding as a fiber composite workpiece with a thermoplastic matrix, with a press mold ( 19 ) with at least one first rigid tool part ( 21 ) and a second rigid tool part ( 28 ), wherein the manufacturing arrangement ( 30 ) is adapted to apply pressure and elevated temperature to a semifinished assembly ( 31 ), which is formed by arranging one or more sections of a semifinished product with a thermoplastic material and reinforcing fibers, and wherein the manufacturing arrangement ( 30 ) an at least partially deformable and / or at least partially preformed cushion ( 36 ; 136 ; 236 ; 336 ), via which by applying force (K) on the tool parts ( 21 . 28 ) the pressure on the semifinished product arrangement ( 31 ) can be applied. Method for welding at least two workpieces ( 101 . 102 ) by means of a welding tool ( 33 ) with at least one first rigid tool part ( 21 ) and a second rigid tool part ( 28 ), wherein at least one of the workpieces ( 101 . 102 ) comprises a thermoplastic material, comprising the steps of: arranging the workpieces ( 101 . 102 ) to each other to form a workpiece assembly ( 103 ); and applying pressure and elevated temperature to the workpiece assembly ( 103 ), wherein the pressure by applying force (K) to the tool parts ( 21 . 28 ) via an at least partially deformable and / or at least partially preformed cushion ( 36 ; 136 ; 236 ; 336 ) between the workpiece assembly ( 103 ) and the first tool part ( 21 ) on the workpiece arrangement ( 103 ) is applied. Welding arrangement ( 35 ) for welding at least two workpieces ( 101 . 102 ), of which at least one has a thermoplastic material, with a welding tool ( 33 ) with at least one first rigid tool part ( 21 ) and a second rigid tool part ( 28 ), wherein the welding arrangement ( 35 ) is designed to withstand pressure and elevated temperature Workpieces ( 101 . 102 ) formed workpiece assembly ( 103 ), and wherein the welding arrangement ( 35 ) an at least partially deformable and / or at least partially preformed cushion ( 36 ; 136 ; 236 ; 336 ), via which by applying force (K) on the tool parts ( 21 . 28 ) the pressure on the workpiece arrangement ( 103 ) can be applied.

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