DE19608127A1 - Forming a three=dimensional fibre=reinforced composite preform - Google Patents

Forming a three=dimensional fibre=reinforced composite preform

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Publication number
DE19608127A1
DE19608127A1 DE19608127A DE19608127A DE19608127A1 DE 19608127 A1 DE19608127 A1 DE 19608127A1 DE 19608127 A DE19608127 A DE 19608127A DE 19608127 A DE19608127 A DE 19608127A DE 19608127 A1 DE19608127 A1 DE 19608127A1
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Germany
Prior art keywords
fiber
semi
local
finished
layers
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Granted
Application number
DE19608127A
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German (de)
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DE19608127C2 (en
DE19608127B9 (en
Inventor
Klaus Dr Drechsler
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Mercedes Benz Group AG
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Daimler Benz AG
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Application filed by Daimler Benz AG filed Critical Daimler Benz AG
Priority to DE19608127A priority Critical patent/DE19608127B9/en
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Publication of DE19608127C2 publication Critical patent/DE19608127C2/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D65/00—Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
    • B29C70/021—Combinations of fibrous reinforcement and non-fibrous material
    • B29C70/023—Combinations of fibrous reinforcement and non-fibrous material with reinforcing inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/088—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of non-plastics material or non-specified material, e.g. supports
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/302—Details of the edges of fibre composites, e.g. edge finishing or means to avoid delamination
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/543—Fixing the position or configuration of fibrous reinforcements before or during moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/08—Front or rear portions
    • B62D25/14—Dashboards as superstructure sub-units
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/20—Floors or bottom sub-units
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
    • B62D29/041—Understructures

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Composite Materials (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Textile Engineering (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Moulding By Coating Moulds (AREA)
  • Reinforced Plastic Materials (AREA)
  • Body Structure For Vehicles (AREA)

Abstract

The manufacture a three-dimensional fibre reinforced composite component, especially a vehicle floor, based on a main structure of long fibre layers with local reinforcement in high stress areas. The local reinforcements (6) are stitched to the long fibres layers (4) to form a flat integral fibre preform (2) which is then shaped and consolidated under heat and pressure in a tool to form a three dimensional component.

Description

Die Erfindung bezieht sich auf ein Verfahren zum Herstellen eines dreidimensional geformten Faserverbundbauteils, insbesondere eines Kraftfahrzeugbodens, nach dem Oberbegriff des Patentanspruchs 1.The invention relates to a method for producing a three-dimensionally shaped fiber composite component, in particular one Motor vehicle floor, according to the preamble of patent claim 1.

Es ist bekannt, ausgedehntere tragende Wandstrukturen, etwa Kraftfahr­ zeugböden oder ähnliche, dreidimensional geformte Fahrzeugteile, aus Gewichtsgründen aus Langfaserverbundwerkstoff mit örtlichen Verstär­ kungen in den Bereichen erhöhter Belastung herzustellen. Dabei muß bei der Umformung und Konsolidierung des Faserverbundmaterials darauf geachtet werden, daß die Faserstruktur von festigkeitsmindernden Faser­ desorientierungen freigehalten und eine innige Bindung der Faserlagen untereinander und zu den Verstärkungsteilen gewährleistet wird. Um dies sicherzustellen, werden die Langfaserlagen jeweils einzeln oder in dünnen Schichten nacheinander an das Formwerkzeug angeformt und an vor­ gegebenen Stellen des so entstehenden Faserlagenaufbaues werden die örtlichen Verstärkungen beigefügt, bevor das Faserlaminat dann unter Wärme- und Druckeinwirkung konsolidiert wird. Eine solche Herstellungs­ weise ist mit einem so großen Fertigungsaufwand verbunden, daß sie in der Praxis nur in beschränktem Umfang für hochwertige Bauteile in relativ geringen Stückzahlen Verwendung findet, für eine kostengünstige Groß­ serienfertigung aber ungeeignet ist.It is known to have more extensive load-bearing wall structures, such as motor vehicles Tile floors or similar, three-dimensionally shaped vehicle parts Weight reasons from long fiber composite material with local reinforcements in the areas of increased stress. It must be the forming and consolidation of the fiber composite material thereon care is taken that the fiber structure of strength-reducing fiber Disorientations kept free and an intimate bond of the fiber layers with each other and to the reinforcement parts is guaranteed. To do this ensure the long fiber layers are each individually or in thin Layers formed one after the other on the mold and on before  given points of the resulting fiber layer structure local reinforcements added before the fiber laminate is then under Exposure to heat and pressure is consolidated. Such a manufacturing wise is associated with such a large manufacturing effort that it in the Practice only to a limited extent for high-quality components in relative terms small quantities are used for an inexpensive large series production is unsuitable.

Aufgabe der Erfindung ist es, das Herstellungsverfahren der eingangs genannten Art so zu gestalten, daß der Fertigungsaufwand wesentlich verringert und dadurch eine kostengünstige Großserienfertigung von räum­ lich geformten, örtlich verstärkten Langfaserverbundbauteilen ermöglicht wird.The object of the invention is the manufacturing process of the beginning mentioned type so that the manufacturing effort is essential reduced and thereby an inexpensive large-scale production of space shaped, locally reinforced long fiber composite components becomes.

Diese Aufgabe wird erfindungsgemäß durch das im Patentanspruch 1 gekennzeichnete Verfahren gelöst.This object is achieved by the in claim 1 identified procedures solved.

Erfindungsgemäß werden die Langfaserlagen und die örtlichen Verstär­ kungen vor der räumlichen Verformung in einem ersten Verfahrensschritt durch automatisiertes Vernähen miteinander zu einer integralen planaren Faserstruktur verbunden, die als Faserhalbzeug gehandhabt werden kann und dann in einem zweiten Verfahrensschritt als Ganzes ähnlich einfach wie bei der spanlosen Kaltverformung von metallischen Blechteilen maschinell in einem Preßformwerkzeug in die endgültige räumliche Bau­ teilgeometrie umgeformt und anschließend konsolidiert wird. Dabei wird durch die gegenseitige textile Bindung der einzelnen Faserlagen und örtlichen Verstärkungsteile sichergestellt, daß das entstehende Faserhalb­ zeug bei der Umformung und Konsolidierung von störenden Faserverschie­ bungen oder anderen Desorientierungen im Faserlagenaufbau freigehalten wird. Aufgrund des geringen Herstellungsaufwandes und der weitgehenden Automatisierbarkeit eignet sich das erfindungsgemäße Verfahren in her­ vorragender Weise für eine kostengünstige Großserienfertigung von quali­ tativ hochwertigen, räumlich geformten Langfaserverbundbauteilen, etwa Bodengruppen im Kraftfahrzeugbau.According to the long fiber layers and the local reinforcements before the spatial deformation in a first process step through automated sewing together to form an integral planar Fiber structure connected, which can be handled as a semi-finished fiber and then similarly simple as a whole in a second process step like the non-cutting cold forming of sheet metal parts mechanically in a press mold in the final spatial construction part geometry is formed and then consolidated. Doing so through the mutual textile binding of the individual fiber layers and  local reinforcement parts ensure that the resulting fiber half testifies to the forming and consolidation of disruptive fiber shifts Exercises or other disorientations in the fiber layer structure are kept clear becomes. Because of the low manufacturing costs and the extensive The method according to the invention is suitable for automation excellent way for an economical mass production of quali high-quality, spatially shaped long fiber composite components, for example Floor groups in motor vehicle construction.

Im Rahmen der Erfindung lassen sich sowohl duromere als auch thermo­ plastische Matrixsysteme verwenden. Im Falle eines duromeren Matrix­ systems empfiehlt es sich gemäß Anspruch 2, das Faserhalbzeug anstatt aus Prepregs aus trockenen Langfaserlagen aufzubauen und das Matrix­ system kurz vor dem Einlegen in das Preßformwerkzeug durch Naß­ imprägnieren oder Beifügen einer Harzfolie oder aber erst innerhalb des Preßformwerkzeugs im Wege der Harzinjektion beizugeben. Bei Verwen­ dung eines thermoplastischen Matrixsystems hingegen wird dieses dem Faserhalbzeug gemäß Anspruch 3 vorzugsweise vor dem Vernähen in Form von thermoplastischen Faseranteilen zugemischt.Within the scope of the invention, both thermosetting and thermosetting use plastic matrix systems. In the case of a thermoset matrix systems it is recommended according to claim 2, the semi-finished fiber instead to build from prepregs from dry long fiber layers and the matrix system shortly before insertion into the press mold by wet impregnate or add a resin film or only within the To add the mold by resin injection. When used formation of a thermoplastic matrix system, however, this will Semi-finished fiber according to claim 3 preferably before sewing in the form admixed with thermoplastic fiber.

Gemäß Anspruch 4 werden örtliche Verstärkungsteile in verschiedenartig­ ster textiler Ausbildung, etwa in Form von rippenförmigen Versteifungen, lokalen Aufdoppelungen oder Lasteinleitungselementen und insbesondere örtlichen Sandwichzonen bevorzugt, welche in der Weise hergestellt werden, daß beim Aufbau des Faserhalbzeugs zwischen die Langfaserlagen Abstandsgewebe oder Schaumstoffstücke eingelegt werden, die dann beim Vernähen der Faserlagen nur randvernäht werden. Wahlweise oder zusätz­ lich können, wie gemäß Anspruch 5 bevorzugt, als örtliche Verstärkungs­ elemente aber auch metallische, durch Vernähen an den Langfaserlagen fixierte Versteifungs- oder Befestigungselemente vorgesehen sein.According to claim 4, local reinforcement parts are of different types very textile training, for example in the form of rib-shaped stiffeners, local duplications or load introduction elements and in particular preferred local sandwich zones, which are made in the manner be that when building the semi-finished fiber between the long fiber layers Spacer fabric or pieces of foam are inserted, which then at  Only sew the edge of the fiber layers. Optionally or additionally Lich, as preferred according to claim 5, as a local reinforcement elements but also metallic, by sewing on the long fiber layers fixed stiffening or fastening elements can be provided.

In weiterer, besonders bevorzugter Ausgestaltung der Erfindung wird das Formverhalten des Faserhalbzeugs gemäß Anspruch 6 dadurch verbessert, daß dieses in den Bereichen starker Verformung durch Vernadeln mit einer örtlichen Kurzfaserstruktur versehen wird.In a further, particularly preferred embodiment of the invention, the Improved shape behavior of the semi-finished fiber according to claim 6, that this in the areas of strong deformation by needling with a local short fiber structure is provided.

Im Hinblick auf eine last- und faserverbundgerechte Ausgestaltung wird das Faserhalbzeug ferner nach Anspruch 7 zweckmäßigerweise mit unter­ schiedlichen Fasersorten und -orientierungen gefertigt. Dabei empfiehlt es sich gemäß Anspruch 8, für hochfeste Bauteile als Grundmaterial Carbon­ faserlagen zu verwenden, die zur örtlichen Erhöhung des Elastizitäts- oder Stoßabsorptionsverhaltens in bestimmten Bereichen Glas- oder Aramid­ faseranteile enthalten.With regard to a load and fiber composite design the semi-finished fiber further advantageously according to claim 7 with under different types and orientations of fibers. It recommends doing so itself according to claim 8, for high-strength components as a base material carbon fiber layers to be used to locally increase the elasticity or Shock absorption behavior in certain areas of glass or aramid fiber content included.

Die Erfindung wird nunmehr anhand eines Ausführungsbeispieles in Verbindung mit den Zeichnungen näher beschrieben. Es zeigen in stark schematisierter Darstellung:The invention is now based on an embodiment in Connection described in more detail with the drawings. It show in strong schematic representation:

Fig. 1 ein planares, integrales Faserhalbzeug zur Herstellung eines Kraftfahrzeugbodens mit örtlichen Verstärkungen und ab­ schnittsweise unterschiedlichen Faser-Hauptorientierungen; Figure 1 is a planar, integral semi-finished fiber for the production of a motor vehicle floor with local reinforcements and different main fiber orientations from section.

Fig. 2 einen Schnitt längs der Linie II-II der Fig. 1 im Bereich einer Aufdoppelung; FIG. 2 shows a section along the line II-II of FIG. 1 in the region of a doubling;

Fig. 3 einen Schnitt längs der Linie III-III der Fig. 1 im Bereich eines metallischen Befestigungselements; Fig. 3 is a section along the line III-III of Figure 1 in the region of a metal fastener.

Fig. 4 einen Schnitt längs der Linie IV-IV der Fig. 1 im Bereich einer Sandwichzone; Fig. 4 shows a section along the line IV-IV of Figure 1 in the region of a sandwich zone.

Fig. 5 eine Imprägniervorrichtung für das Faserhalbzeug und ein nachgeschaltetes Preßformwerkzeug zum Umformen und Kon­ solidieren; und Figure 5 is an impregnation device for the semi-finished fiber and a downstream press mold for forming and con solidating. and

Fig. 6 die Faserverbund-Bodengruppe im fertiggestellten Zustand. Fig. 6, the fiber composite floor assembly in the finished state.

Fig. 1 zeigt ein Faserhalbzeug 2 für eine Kraftfahrzeug-Bodengruppe, welches aus einer Vielzahl von eben übereinandergelegten, textilen Ge­ webezuschnitten 4 aufgebaut ist und eine multiaxiale Faserorientierung besitzt, wobei die einzelnen, in Fig. 1 strichpunktiert berandeten Bereiche des Faserhalbzeugs 2 jeweils unterschiedliche Faser-Vorzugsrichtungen haben. So werden für den mittleren Bereich des Faserhalbzeugs 2, der in der fertigen Bodengruppe den Bodentunnel bildet, vorwiegend Gewebe­ lagen mit einer in Längsrichtung unidirektionalen Faserorientierung 4A gewählt, während die seitlichen Randbereiche, die die Schweller ergeben, hauptsächlich aus Gewebelagen mit einer sich kreuzenden, zur Längs­ richtung des Faserhalbzeugs 2 unter ±45° geneigten Faserorientierung 4B und die dazwischenliegenden Abschnitte des Faserhalbzeugs 2, also die pedal-, sitz- und kofferraumseitigen Bodenteile des herzustellenden Bau­ teils, vornehmlich aus Gewebelagen mit einer in Querrichtung unidirek­ tionalen Faserrichtung 4C aufgebaut sind. Fig. 1 shows a semi-finished fiber 2 for a motor vehicle floor assembly, which is constructed from a large number of just superimposed, textile Ge 4 and has a multiaxial fiber orientation, the individual regions of the semi-finished fiber 2 with dash-dotted lines in FIG. 1 each having different fibers - have preferred directions. For the central area of the semi-finished fiber 2 , which forms the floor tunnel in the finished floor assembly, predominantly fabrics with a longitudinally unidirectional fiber orientation 4 A were selected, while the lateral edge areas that give the sills mainly consist of fabric layers with a crossing, to the longitudinal direction of the semi-finished fiber 2 inclined at ± 45 ° fiber orientation 4 B and the intermediate sections of the semi-finished fiber 2 , i.e. the pedal, seat and trunk-side floor parts of the construction to be manufactured, mainly composed of fabric layers with a cross-directional unidirectional fiber direction 4 C. are.

Aus Festigkeits- und Gewichtsgründen sind die Gewebelagen 4 aus Carbonfasern hergestellt, denen in bestimmten Bereichen, wo ein örtlich erhöhtes Elastizitäts- oder Stoßabsorptionsverhalten gefordert wird, Glas- bzw. Aramidfaseranteile zugemischt sind. Bei Verwendung eines thermo­ plastischen Matrixsystems enthalten die Gewebe 4 ferner thermoplastische Faseranteile in gleichförmiger Verteilung. Kommt hingegen - wie bei dem nachfolgend beschriebenen Ausführungsbeispiel - ein duromeres Matrix­ system zur Anwendung, so wird das Faserhalbzeug 2 aus trockenen Ge­ webelagen 4 aufgebaut. Statt dessen können gewünschtenfalls aber auch vorimprägnierte Gewebezuschnitte, sog. Prepregs, verwendet werden.For reasons of strength and weight, the fabric layers 4 are made of carbon fibers, to which glass or aramid fiber components are mixed in certain areas where a locally increased elasticity or shock absorption behavior is required. When using a thermoplastic matrix system, the fabrics 4 also contain thermoplastic fiber components in a uniform distribution. If, on the other hand, a duromer matrix system is used, as in the exemplary embodiment described below, the semi-finished fiber 2 is constructed from dry fabric layers 4 . If desired, however, pre-impregnated fabric blanks, so-called prepregs, can also be used instead.

Komplettiert wird das Faserhalbzeug 2 durch örtliche, lastspezifisch ge­ staltete Verstärkungsteile 6, die an den Stellen erhöhter mechanischer Beanspruchung der Bodengruppe zwischen oder auf den Gewebelagen des Faserhalbzeugs 2 angeordnet werden. So wird das Faserhalbzeug 2 z. B. im Bereich des Sitzbodenteils mit in Längsrichtung rippenförmig verlaufenden Fasergestricken 6.1 zur Erhöhung der lokalen Biegesteifigkeit und am kofferraumseitigen Ende mit textilen Vorformlingen 6.2 zur örtlichen Kraft­ einleitung belegt, und im Bereich des Pedalbodenteils sind den Gewebe­ lagen Aramidstreifen 6.3 zur Verbesserung des Stoßabsorptions- und Zähigkeitsverhaltens beigefügt. Weiterhin wird die Mittelzone des Faser­ lagenaufbaues 4 durch eine Aufdoppelung 6.4 aus Faserlagen, die eine quasi-isotrope, in Längsrichtung und unter ±45° verlaufende Faserorien­ tierung 4D besitzen, örtlich verstärkt (Fig. 2), und im Bereich des Sitz­ bodenteils werden im Faserlagenaufbau 4 metallische Anschlußelemente 6.5 für spätere Schraubverbindungen eingebettet (Fig. 3). Wie für den kofferraumseitigen Abschnitt des Faserhalbzeugs 2 und im einzelnen in Fig. 4 dargestellt, können ferner zwischen die Gewebelagen 4 Schaum­ stoffeinlagen oder Abstandsgewebe 6.6 eingefügt werden, um der fertigen Bodengruppe eine örtliche Sandwichstruktur zu verleihen.The semi-finished fiber 2 is completed by local, load-specific designed reinforcing parts 6 , which are arranged at the points of increased mechanical stress on the floor assembly between or on the fabric layers of the semi-finished fiber 2 . So the semi-finished fiber 2 z. B. in the area of the seat bottom part with rib-shaped knitting fibers 6.1 in the longitudinal direction to increase the local bending stiffness and at the end of the trunk with textile preforms 6.2 for local force introduction, and in the area of the pedal bottom part the fabrics were aramid strips 6.3 to improve the shock absorption and toughness behavior attached. Furthermore, the central zone of the fiber layer structure 4 is locally reinforced by a doubling 6.4 of fiber layers, which have a quasi-isotropic, in the longitudinal direction and at ± 45 ° fiber orientation 4 D ( Fig. 2), and in the area of the seat bottom part 4 metallic connection elements 6.5 embedded in the fiber layer structure for later screw connections ( FIG. 3). As shown for the trunk-side section of the semi-finished fiber 2 and in detail in Fig. 4, 4 foam inserts or spacer fabric 6.6 can also be inserted between the fabric layers 4 to give the finished floor assembly a local sandwich structure.

Das so aufgebaute textile Gebilde wird anschließend, wie in Fig. 1 durch das Bezugszeichen 8 angedeutet, zusammen mit den örtlichen Verstär­ kungsteilen 6 maschinell unter Beibehalt der planaren Schichtung zu dem integralen Faserhalbzeug 2 vernäht, wodurch sämtliche Verstärkungsteile 6 und Gewebezuschnitte 4 zueinander und in ihrer Faserorientierung sicher fixiert werden, so daß sich das Faserhalbzeug 2 als Ganzes ohne die Gefahr störender Faserverschiebungen oder anderer Fehlorientierungen problemlos transportieren, lagern und schließlich in die endgültige dreidimensionale Bauteilgeometrie umformen und konsolidieren läßt. Einzelne Verstär­ kungsteile, wie etwa die metallischen Befestigungselemente 6.5 oder die Abstandsgewebe 6.6 werden natürlich nur randseitig mitvernäht.The thus constructed textile structure is then, as indicated in Fig. 1 by the reference numeral 8, together with the local Verstär kung share 6 machined while maintaining the planar lamination to the integral semifinished fiber 2 sewn, whereby all the reinforcement members 6 and fabric sections 4 to each other and in their Fiber orientation are securely fixed, so that the semi-finished fiber 2 as a whole can be transported, stored and finally reshaped and consolidated into the final three-dimensional component geometry without the risk of disruptive fiber displacements or other incorrect orientations. Individual reinforcement parts, such as the metal fasteners 6.5 or the spacer fabric 6.6 are of course only sewn along the edge.

In einem Zwischenschritt wird das Faserhalbzeug 2 noch an den Stellen stärkerer räumlicher Formänderung vernadelt, so daß die Langfaserlagen örtlich eine Kurzfaserstruktur erhalten, wie dies in Fig. 1 durch die Ver­ nadelungszonen 10 angedeutet ist. In an intermediate step, the semi-finished fiber 2 is needled even at the points of greater spatial change, so that the long fiber layers locally receive a short fiber structure, as indicated in FIG. 1 by the needling zones 10 .

Das duromere Matrixsystem wird dem Faserhalbzeug 2 entweder im Wege der Harzinjektion innerhalb des Preßformwerkzeugs 12 (Fig. 5) oder aber an einer diesem vorgeschalteten Imprägnierstation 14 zugegeben, wo das Faserhalbzeug 2 beidseitig mit einer über Preßwalzen 16 angedrückten Harzfolie 18 belegt und/oder mittels einer Sprühvorrichtung 20 mit Flüssig­ harz imprägniert wird, bevor es als Ganzes in das Preßformwerkzeug 12 eingelegt und beim Schließen desselben in die räumliche Bauteilgeometrie umgeformt und dann unter Druck- und Wärmeeinwirkung konsolidiert wird.The thermosetting matrix system is added to the semifinished fiber product 2 either by way of resin injection within the compression mold 12 ( FIG. 5) or at an impregnation station 14 connected upstream thereof, where the semifinished fiber product 2 is coated on both sides with a resin film 18 pressed on by press rollers 16 and / or by means of a Spray device 20 is impregnated with liquid resin before it is inserted as a whole into the compression mold 12 and when it is closed it is reshaped into the spatial component geometry and then consolidated under the action of pressure and heat.

In Fig. 6 ist die auf diese Weise fertiggestellte Kraftfahrzeug-Bodengruppe mit Abgastunnel 22, Schwellern 24, Pedalboden 26, Sitzboden 28 und kofferraumseitiger Abschlußwand 30 einschließlich der örtlichen Verstär­ kungsteile 6 und der entsprechenden Faser-Vorzugsrichtungen dargestellt.In Fig. 6 the finished motor vehicle floor assembly with exhaust tunnel 22 , sills 24 , pedal floor 26 , seat floor 28 and trunk-side end wall 30 including the local reinforcement parts 6 and the corresponding fiber preferred directions is shown.

Claims (8)

1. Verfahren zum Herstellen eines dreidimensional geformten Faserverbundbauteils, insbesondere eines Kraftfahrzeugbodens, bestehend aus einer aus übereinander liegenden Langfaserlagen aufgebauten Grundstruktur und an dieser in den Bereichen erhöhter Belastung angebrachten, örtlichen Verstärkungsteilen, dadurch gekennzeichnet, daß die Langfaserlagen (4) im unverformten Zustand zusammen mit den örtlichen Verstärkungsteilen (6) zu einem planaren, integralen Faser­ halbzeug (2) vernäht werden und anschließend das Faserhalbzeug als Ganzes in einem Preßformwerkzeug (12) unter Druck- und Wärme­ einwirkung in die dreidimensionale Bauteilgeometrie umgeformt und zum fertigen Faserverbundbauteil konsolidiert wird. 1. A method for producing a three-dimensionally shaped fiber composite component, in particular a motor vehicle floor, consisting of a basic structure constructed from superimposed long fiber layers and attached to this in the areas of increased stress, local reinforcement parts, characterized in that the long fiber layers ( 4 ) in the undeformed state together with local reinforcements (6) semi-finished product to a planar, integral fiber (2) are sewed and then the semifinished fiber product as a whole in a press-molding die (12) under pressure and heat converted in the three-dimensional component geometry and is consolidated to the finished fiber composite component. 2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß das Faserhalbzeug (2) im trockenen Zustand vernäht und durch Naßimprägnieren vor dem Einlegen in das Preßformwerkzeug (12) oder im Wege der Harzinjektion innerhalb des Preßformwerkzeugs matrixdurchtränkt wird.2. The method according to claim 1, characterized in that the semi-finished fiber ( 2 ) is sewn in the dry state and is soaked in the matrix by wet impregnation before insertion into the compression mold ( 12 ) or by way of resin injection within the compression mold. 3. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß das Faserhalbzeug (2) als Matrix thermoplastische Faseranteile enthält.3. The method according to claim 1, characterized in that the semi-finished fiber ( 2 ) contains thermoplastic fiber components as a matrix. 4. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, daß die örtlichen Verstärkungen (6) in Form von rippen- oder streifen­ förmigen Versteifungselementen (6.1; 6.3), lokalen Aufdoppelungen (6.4), örtlich zwischen die Langfaserlagen (4) eingefügten, als Sand­ wichkern wirkenden Einlagen (6.6) oder Lasteinleitungselementen (6.2) aus textilem Material vorgefertigt werden.4. The method according to any one of the preceding claims, characterized in that the local reinforcements ( 6 ) in the form of rib or strip-shaped stiffening elements ( 6.1 ; 6.3 ), local doublings ( 6.4 ), inserted locally between the long fiber layers ( 4 ) as Pre-fabricated inserts ( 6.6 ) or load transfer elements ( 6.2 ) made of textile material are prefabricated. 5. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, daß als örtliche Verstärkungen (6) metallische, durch Vernähen an den Langfaserlagen fixierte Versteifungs- oder Befestigungselemente (6.5) vorgesehen werden. 5. The method according to any one of the preceding claims, characterized in that as local reinforcements ( 6 ) metallic, stiffening or fastening elements ( 6.5 ) fixed by sewing on the long fiber layers are provided. 6. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, daß das Faserhalbzeug (2) in den Bereichen starker Verformung durch örtliches Vernadeln (10) mit einer Kurzfaserstruktur versehen wird.6. The method according to any one of the preceding claims, characterized in that the semi-finished fiber ( 2 ) is provided with a short fiber structure in the areas of strong deformation by local needling ( 10 ). 7. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, daß das Faserhalbzeug (2) mit unterschiedlichen Fasersorten und -orien­ tierungen gefertigt wird.7. The method according to any one of the preceding claims, characterized in that the semi-finished fiber ( 2 ) is made with different types and types of fibers. 8. Verfahren nach Anspruch 7, dadurch gekennzeichnet, daß das Faserhalbzeug aus Carbonfasern mit örtlichen Glas- und/oder Aramidfaseranteilen besteht.8. The method according to claim 7, characterized in that the semi-finished product made of carbon fibers with local glass and / or Aramid fiber shares.
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