DE202014100513U1 - Tape laying device for building a laminate - Google Patents

Abstract

Tape laying device (1) for carrying out a method for constructing and consolidating a laminate (90) for, for example, automotive components, in particular according to one of the preceding claims, characterized by: a) a feed device (10) for feeding with binder and / or matrix Materials provided tape to be deposited (93) to a depositing device (20); b) a depositing device (20) for depositing supplied tape (93) until a tape structure (91) corresponding to the laminate (90) is obtained from juxtaposed and stacked tape (93); wherein juxtaposed tape (93) defines a stacking (92) of a tape structure (91); and c) control means (30) for controlling the obtaining of a consolidated laminate (90) by: - guide means (40) for bringing a cross-section (Q) of the tape structure (91) into juxtaposed and stacked stack layers (92) and / or tapes (93) to an ultrasonic exciter (50) or vice versa; An ultrasound excitation device (50) for a successive plasticizing of the binder and / or matrix materials in all joining zones (95) adjoining each other in the cross section (Q) brought to the ultrasound excitation device (50) of all juxtaposed and stacked layers ( 92) and / or tapes (93) of the tape structure (91); and - a consolidation device (60) for a successive bringing together of the plasticized binder and / or matrix materials in all the cross-section (Q) brought to the ultrasound excitation device (50) adjacent joining zones (95) of all juxtaposed and stacked layers ( 92) and / or tapes (93) of the tape structure (91).

Description

• a) eine Zuführeinrichtung für das Zuführen von mit Binder- und/oder Matrix-Werkstoffen versehenem abzulegenden Tape an eine Ablegeeinrichtung;
• b) eine Ablegeeinrichtung für das Ablegen von zugeführtem Tape; wobei nebeneinander abgelegtes Tape eine Tapelage einer Tapestruktur definiert; und
• c) eine Steuereinrichtung zur Steuerung des Erhalts eines konsolidierten Laminatsdurch: aa) eine Führungseinrichtung für das Heranführen von Tape an eine Anregungseinrichtung oder umgekehrt; bb) eine Anregungseinrichtung für ein Plastifizieren der Binder- und/oder Matrix-Werkstoffe in Fügezonen von an die Anregungseinrichtung herangeführtem Tape; und cc) eine Konsolidierungseinrichtung für ein Zusammenbringen der plastifizierten Binder- und/oder Matrix-Werkstoffe in aneinandergrenzenden Fügezonen aufeinander liegender Tapes.

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

• a) a feeding device for supplying provided with binder and / or matrix materials to be deposited tape to a depositing device;
• b) a depositing device for depositing supplied tape; wherein juxtaposed tape defines a stack of a tape structure; and
• c) a controller for controlling the receipt of a consolidated laminate by: aa) guide means for feeding tape to an exciter or vice versa; bb) an excitation device for plasticizing the binder and / or matrix materials in joining zones of tape brought to the exciting device; and cc) a consolidation device for bringing the plasticized binder and / or matrix materials together in adjoining joining zones of superimposed tapes.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Proceeding from this, the object of the present invention is to provide an improved tape laying device for constructing and consolidating a laminate for, for example, automobile components by means of a tape laying device, which avoids the disadvantages described above.

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

• a) ein Zuführen von mit Binder- und/oder Matrix-Werkstoffen versehenem abzulegenden Tape an eine Ablegeeinrichtung;
• b) ein Ablegen von zugeführtem Tape mittels der Ablegeeinrichtung bis zum Erhalt einer zum Laminat korrespondierenden Tapestruktur aus neben- und aufeinander abgelegtem Tape; wobei nebeneinander abgelegtes Tape eine Tapelage einer Tapestruktur definiert; und
• c) ein Steuern des Erhalts eines konsolidierten Laminats durch: – ein Heranführen von einem Querschnitt Q der Tapestruktur aus nebenund aufeinander abgelegten Tapelagen und/oder Tapes an eine Ultraschall-Anregungseinrichtung oder umgekehrt; – ein sukzessives Plastifizieren der Binder- und/oder Matrix-Werkstoffe in allen im an die Ultraschall-Anregungseinrichtung herangeführten Querschnitt Q aneinandergrenzenden Fügezonen aller neben- und aufeinander abgelegten Tapelagen und/oder Tapes der Tapestruktur; und – ein sukzessives Zusammenbringen der plastifizierten Binder- und/oder Matrix-Werkstoffe in allen im an die Ultraschall-Anregungseinrichtung herangeführten Querschnitt Q aneinandergrenzenden Fügezonen aller neben- und aufeinander abgelegten Tapelagen und/oder Tapes der Tapestruktur.

A possible procedure for constructing and consolidating a laminate for, for example, automobile components by means of a tape laying device is characterized by:

• a) feeding to be deposited with provided binder and / or matrix materials tape to a depositing device;
• b) depositing of supplied tape by means of the depositing device until obtaining a tape structure corresponding to the laminate of juxtaposed and successively deposited tape; wherein juxtaposed tape defines a stack of a tape structure; and
• c) controlling the receipt of a consolidated laminate by: - bringing a cross-section Q of the tape structure from adjacent and stacked piles and / or tapes to an ultrasonic exciter or vice versa; A successive plasticizing of the binder and / or matrix materials in all the joining zones of adjoining and stacked layers and / or tapes of the tape structure adjacent to one another in the ultrasonic excitation device; and - a successive bringing together of the plasticized binder and / or matrix materials in all in the ultrasonic cross-section Q brought up to the ultrasonic exciter joining zones of all juxtaposed and stacked piles and / or tapes of the tape structure.

By successively plasticizing and consolidating the binder and / or matrix materials in all the joining zones of adjoining and stacked layers and / or tapes of the tape structure that are adjacent to the ultrasonic excitation device Q, a previously corresponding to the laminate , Tapestruktur obtained from juxtaposed and stacked tape advantageously be supplied in total to an ultrasonic excitation device.

By supplying a previously obtained to the laminate, obtained from juxtaposed and successive tape tape structure as a whole ultrasonic excitation and successively plasticized over their cross section Q and consolidated, also large-scale tape structures or laminates of, preferably 30 to 150 mm wide tapes can be advantageous are built with high lay rates and with an interesting speed for serial applications interesting.

Advantageous embodiments and developments, which can be used individually or in combination with each other, are the subject of the dependent claims.

It is thus preferred in a sequence if the successive plasticizing of the binder and / or matrix materials occurs exclusively in the surfaces of the joining zones adjacent to juxtaposed and stacked layers and / or tapes of at least the lowest and uppermost stack layers of the cross section brought to the ultrasound excitation device Q of the tape structure is done.

By the binder and / or matrix materials at least in the side and surface facing away from the juxtaposed and stacked layers and / or tapes of at least lowermost and topmost stacking of the cross-section Q of the tape structure brought to the ultrasonic excitation means not via enamel or flow temperature of the plastic matrix used, can advantageously also large-scale tape structures or laminates of, for example, 30 to 150 mm wide, tapes without unwanted flow processes and fiber shifts constructed and consolidated over its cross-section Q.

The limitation of undesirable flow processes and / or fiber displacements can be increased if, in a preferred sequence, the successive plasticizing of the binder and / or matrix materials is not limited exclusively to the surfaces of the joining zones adjoining one another and stacked layers and / or tapes at least lowermost and uppermost stacking of brought to the ultrasonic excitation device cross-section Q of the tape structure but also in all in between juxtaposed and stacked piles and / or tapes of the tape structure.

Alternatively or cumulatively, depending on the degree desired, namely in the context of the consolidation of individual tapes and / or stackings, or undesired flow processes and / or fiber displacements of individual tapes and / or stackings within the tape structure in a preferred sequence, the successive plasticizing of the binder and / or or matrix materials in stacking layers arranged between topmost and lowest stacking layers of the cross-section Q of the tape structure brought to the ultrasound excitation device, exclusively in the surfaces of the adjoining joining zones and / or across their thickness. In any case, however, the bottom and top layers of a previously deposited tape structure should never be plasticized over the thickness thereof in order not to jeopardize the dimensional stability of the laminate.

In a preferred embodiment of a sequence, it is provided to pre-fix the tape deposited on the uppermost stack of an already deposited tape structure with the uppermost stacking layer carrying this tape. Expediently, the prefixing of deposited tape with the uppermost stacking layer of an already deposited tape structure can be effected by point ultrasonic welding, in which the binder and / or matrix materials in the tape or the uppermost stack layer are at least locally melted and fixed together by subsequent cooling , A prefixing has a sufficient intrinsic stability of the deposited tape structure to the advantage, so that the tape structure as a whole also supplied outside the tape laying device arranged ultrasonic excitation and - as described above - can be plasticized and consolidated over its cross-section Q successively.

Preferably, to increase the laying and consolidation rate, a sequence is preferred in which multiple tapes are simultaneously, i. especially at the same time and multi-lane, be handled. Such a parallelization advantageously multiplies the number of laid tapes per cycle sequence corresponding to X (for the number of multi-track handled tapes).

• a) eine Zuführeinrichtung für das Zuführen von mit Binder- und/oder Matrix-Werkstoffen versehenem abzulegenden Tape an eine Ablegeeinrichtung;
• b) eine Ablegeeinrichtung für das Ablegen von zugeführtem Tape bis zum Erhalt einer zum Laminat korrespondierenden Tapestruktur aus neben- und aufeinander abgelegtem Tape; wobei nebeneinander abgelegtes Tape eine Tapelage einer Tapestruktur definiert; und
• c) eine Steuereinrichtung zur Steuerung des Erhalts eines konsolidierten Laminats durch: – eine Führungseinrichtung für das Heranführen von einem Querschnitt Q der Tapestruktur aus neben- und aufeinander abgelegten Tapelagen und/oder Tapes an eine Ultraschall-Anregungseinrichtung oder umgekehrt; – eine Ultraschall-Anregungseinrichtung für ein sukzessives Plastifizieren der Binder- und/oder Matrix-Werkstoffe in allen im an die Ultraschall-Anregungseinrichtung herangeführten Querschnitt Q aneinandergrenzenden Fügezonen aller neben- und aufeinander abgelegten Tapelagen und/oder Tapes der Tapestruktur; und – eine Konsolidierungseinrichtung für ein sukzessives Zusammenbringen der plastifizierten Binder- und/oder Matrix-Werkstoffe in allen im an die Ultraschall-Anregungseinrichtung herangeführten Querschnitt aneinandergrenzenden Fügezonen aller neben- und aufeinander abgelegten Tapelagen und/oder Tapes der Tapestruktur.

A tape laying apparatus for constructing and consolidating a laminate for, for example, automotive components is characterized by:

• a) a feeding device for supplying provided with binder and / or matrix materials to be deposited tape to a depositing device;
• b) a depositing device for depositing supplied tape until a corresponding to the laminate tape structure of juxtaposed and stacked tape; wherein juxtaposed tape defines a stack of a tape structure; and
• c) a control device for controlling the receipt of a consolidated laminate by: - a guide device for bringing a cross-section Q of the tape structure from juxtaposed and stacked piles and / or tapes to an ultrasonic exciter or vice versa; An ultrasound excitation device for a successive plasticizing of the binder and / or matrix materials in all joining zones adjoining each other in the cross-section Q brought to the ultrasound excitation device of all juxtaposed and stacked layers and / or tapes of the tape structure; and - a consolidation device for a successive bringing together of the plasticized binder and / or matrix materials in all brought in the ultrasound excitation device cross-section adjacent joining zones of all juxtaposed and stacked piles and / or tapes of the tape structure.

In a further embodiment of the tape laying device is provided that the depositing device comprises a plurality of guide beams, which simultaneously retracts several tapes, ablängt and deposits, thereby advantageously simultaneous sequences are possible, which increases the laying speed noticeably.

In a further embodiment of the tape laying device is provided that the Laying device and / or the joists and / or a laying table are designed to be slidable at least to the width of one or a group X tapes tapes to the side, so that in subsequent sequences simultaneously retracted several tapes, ablängt and can be filed.

In a further embodiment of the tape-laying device, it is provided that the consolidation device comprises a plurality of large-area ultrasonic excitation devices, which are preferably arranged continuously in a sealing bar device or a pair of rolling elements. The provision of a welding bar device has the advantage that the deposited tape structure can remain on the laying table; the provision of a roller pair device has the advantage that the deposited tape structure with the beginning of their consolidation and the laying table for the construction and consolidation of a new laminate already begins to make free.

In a further preferred embodiment, it is provided that the sealing bar device is formed from a multiplicity of side-by-side sliding shoes, which in particular with regard to consolidation parameters are each designed separately by means of a separate control device or the control device.

Such a shoe, which can be found in individual or cumulative features of its embodiment detached from the present invention application, is characterized in particular by a zone with short in movement or sliding direction contact length for coupling ultrasonic energy in the tape structure of tufts and / or tape and by a at least one side in movement or sliding direction G subsequent long zone for cooling the tape structure of tufts and / or tapes.

In particular, it has proven useful to design the contact surface of the zone of a sliding shoe for coupling ultrasound energy in the sliding direction G simply curved or circular segment-shaped, so that the contact surface is greatly reduced almost to a linear blade (similar to a circular segment-shaped blade).

Alternatively or cumulatively, the contact force, the sliding speed and / or the ultrasound intensity can be controlled constant or variable by means of a separate control device or in particular as a function of the material properties and / or the temperature and / or thickness of an already deposited tape structure made of layers / or tapes, wherein in particular the surface pressure on the US-coupling zone and the subsequent cooling zone can be controlled differently sized.

Finally, in a development, a sliding shoe is preferred, which is equipped, for example, at its rear end with moving sensors, for example by means of preferably obliquely coupled ultrasound (transmitter and receiver) the consolidation of the tape structure checks for their quality and parameters of the controller for an adaptive control Consolidation, in particular by means of changing the US intensity and / or the speed and / or the contact force provides.

Advantageously, the present invention permits the construction and consolidation of a laminate with high lay rates and speed of interest for production applications.

Insofar as it advantageously leaves the structure as well as the successive consolidation of laid tape structures on one and the same laying table, a release of individual tapes or stackings as a result of encountered in the prior art separation of construction on the one hand and consolidating tape structures laid on the other hand is reliably avoided.

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

These and other features and advantages of the invention will be explained in more detail with reference to the embodiments of construction and consolidation of a laminate illustrated in the drawings.

They show schematically:

1 to 11 the individual steps for building and consolidating a laminate by means of a single-lane Tapelegevorrichtung according to the invention;

12 to 21 the individual steps for building and consolidating a laminate by means of a multi-track tape laying device according to the invention;

22 a recorded by means of a tape laying device according to the invention tapestry of juxtaposed and successive tape;

23 the consolidation of the tapestry structure 22 by means of a welding bar device of a tape laying device according to the invention;

24 Details of a trained from a plurality of variably controllable sliding shoes Schweißbalkeneinrichtung a Tapelegevorrichtung according to the invention;

25 a sliding shoe 24 in an enlarged side view; and

26 the consolidation of the tapestry structure 22 by means of a roller pair device of a tape laying device according to the invention.

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

• a) eine Zuführeinrichtung 10 für das Zuführen von mit Binder- und/oder Matrix-Werkstoffen versehenem abzulegenden Tape 93 an eine Ablegeeinrichtung 20;
• b) eine Ablegeeinrichtung 20 für das Ablegen von zugeführtem Tape 93 bis zum Erhalt einer zum Laminat 90 korrespondierenden Tapestruktur 91 aus nebenund aufeinander abgelegtem Tape 93; wobei nebeneinander abgelegtes Tape 93 eine Tapelage 92 einer Tapestruktur 91 definiert; und
• c) eine Steuereinrichtung 30 zur Steuerung des Erhalts eines konsolidierten Laminats 90 durch: – eine Führungseinrichtung 40 für das Heranführen von einem Querschnitt (Q) der Tapestruktur 91 aus neben- und aufeinander abgelegten Tapelagen 92 und/oder Tapes 93 an eine Ultraschall- Anregungseinrichtung 50 oder umgekehrt; – eine Ultraschall-Anregungseinrichtung 50 für ein sukzessives Plastifizieren der Binder- und/oder Matrix-Werkstoffe in allen im an die Ultraschall-Anregungseinrichtung 50 herangeführten Querschnitt Q aneinandergrenzenden Fügezonen 95 aller neben- und aufeinander abgelegten Tapelagen 92 und/oder Tapes 93 der Tapestruktur 91; und – eine Konsolidierungseinrichtung 60 für ein sukzessives Zusammenbringen der plastifizierten Binder- und/oder Matrix-Werkstoffe in allen im an die Ultraschall-Anregungseinrichtung 50 herangeführten Querschnitt Q aneinandergrenzenden Fügezonen 95 aller neben- und aufeinander abgelegten Tapelagen 92 und/oder Tapes 93 der Tapestruktur 91.

1 to 11 show the steps to build and consolidate a laminate 90 by means of a single-lane Tapelegevorrichtung 1 according to the invention, which is characterized by:

• a) a feeder 10 for feeding with tape and / or matrix materials provided to be deposited tape 93 to a depositing device 20 ;
• b) a depositing device 20 for depositing supplied tape 93 until you get a laminate 90 corresponding tapestry structure 91 from side by side and successively laid down tape 93 ; where juxtaposed tape 93 a stack 92 a tapestry structure 91 Are defined; and
• c) a control device 30 for controlling the receipt of a consolidated laminate 90 by: - a guide device 40 for introducing a cross-section (Q) of the tape structure 91 from juxtaposed and stacked pile layers 92 and / or tapes 93 to an ultrasonic excitation device 50 or the other way around; - An ultrasonic excitation device 50 for a successive plasticizing of the binder and / or matrix materials in all of the ultrasonic excitation means 50 brought cross-section Q adjacent joining zones 95 all juxtaposed and stacked pile layers 92 and / or tapes 93 the tapestry structure 91 ; and - a consolidation facility 60 for a successive bringing together of the plasticized binder and / or matrix materials in all to the ultrasonic excitation device 50 brought cross-section Q adjacent joining zones 95 all juxtaposed and stacked pile layers 92 and / or tapes 93 the tapestry structure 91 ,

As in 1 is shown, so is to build a laminate 90 first by means of a feeder 10 to be deposited fiber tapes 93 for example, from a spool or reel 11 subtracted, cut to the required length (see. 2 ) and after feeding to a depositing device 20 by means of this over the Legetisch 61 a consolidation facility 60 positioned. As 3 shows drives the depositing device 20 then the width B of a tape 93 to the right and back to the feeder 10 , and attacks - as in 4 shown - from the local coil 11 a new tape to be deposited 93 in order to already stored tape 93 adjacent positioning on the laying table 61 ( 5 ).

In the 6 illustrated tape laying device 1 improves the sequence described so far that this 1 in the end of the first tapes to be deposited 93 a second feeder 10 besides roll 11 provides, so that the depositing device 20 only moved laterally and already on the return stroke new tape 93 can take off. This sequence is for each tape to be deposited 93 as long as necessary until a first stacking 92 on the laying table 61 is stored ( 7 ). To the tapes 93 the first stacking 92 on the laying table 61 to fix sufficiently, this can 61 be formed vacuumable (not shown).

As in 8th are shown on a topmost stack thus formed 92 a dropped tape structure 91 more tapes 93 filed and punctiform welding by means of ultrasonic welding heads 71 prefixed to each other (position fixation), so that the tapes 93 Do not move accidentally after positioning and / or first pressing or stand up by residual stresses. So far as the filing of tapes 93 on the topmost stack 92 an already deposited tape structure 91 takes place, is a prefixing device 70 preferred, which dot-shaped ultrasonic welding heads 71 includes for pre-fixing stored tape 93 with the topmost stack 92 an already deposited tape structure 91 by means of welds 72 ,

To do the design effort of the device 1 Easy to hold, can the prefixing device 70 and / or their ultrasonic welding heads 71 Part of the depositing device 20 be (see previous figures).

9 shows the filing of more tapes 93 on the topmost stack 92 an already deposited tape structure 91 analogous 3 to 5 So without a second feeder 10 in the end area of stored tapes 93 ; 10 shows the filing of more tapes 93 on the topmost stack 92 an already deposited tape structure 91 analogous 6 . So with a second feeder in the end of deposited tapes 93 or from it formed Tapelagen 92 , 11 finally shows comparable to the one in 7 shown situation, the situation for two successive stackings 92 ,

12 to 21 show the steps to build and consolidate a laminate 90 by means of a multi-track tape-laying device 1 according to the invention, which is preferred when required increase of laying rates.

In contrast to the in the 1 to 11 shown tape laying device 1 has the in the 12 to 21 illustrated tape laying device 1 a multi-lane feeder 10 as well as a multi-lane depositing device 20 on.

The 13 to 20 now show the multi-track sequences analogous to the 2 to 11 ,

Regardless of whether a first section of a tape structure 91 in a single-lane ( 1 to 11 ) or multilane ( 12 to 20 ) Sequence can be obtained - as in 21 shown - on this first section of a tape structure 91 further sections of a tape structure 91 be created.

22 shows one by means of a tape laying device 1 deposited according to the invention Tapestruktur 91 from juxtaposed and stacked tape 93 ,

23 shows the consolidation of the tape structure 22 by means of a welding bar device 53 a tape device 1 according to the invention. After completion of a single or multi-track laying process are prefixed tape structures 91 fed to a subsequent process. In this follow-up process are the pre-fixed tapes 93 and / or stackings 92 a dropped tape structure 91 gradually under an ultrasonic welding bar device 53 "Clocked through", which with a variety of large-scale ultrasonic excitation equipment 30 equipped, in juxtaposed sliding shoes 80 are arranged and the tape structure 91 from stackings 92 and / or tapes 93 successive, largely full-scale, consolidated.

The necessary heat is achieved by a high-frequency mechanical vibration, which arises between the components by molecular and boundary surface friction.

The group of friction welding ultrasonic welding is characterized by very low welding times and high efficiency. Usually high-frequency alternating current is generated by means of a generator and transmitted via a shielded cable to an ultrasonic transducer, the so-called converter, which generates mechanical ultrasonic frequency therefrom with the aid of the piezoelectric or magnetostrictive effect. These vibrations are transmitted to the sonotrode via an amplitude transformation piece. Different applications require different designs of sonotrodes, which are usually made of steel, aluminum or titanium. The amplitude of the oscillation and the impedance matching are influenced by the shape and mass of the amplitude transformation piece.

24 shows details of one of several variably controllable ultrasonic sliding shoes 80 trained welding bar device 54 a tape device 1 according to the invention. It can be seen that the large number of side by side sliding shoes 80 in particular with regard to consolidation parameters in each case separately by means of a separate or the control device 30 are formed controllable. Depending on the degree desired, namely in the context of the consolidation of individual tapes 93 and / or stackings 92 , or unwanted flow processes and / or fiber shifts of individual tapes 93 and / or stackings 92 can do so within the tapestry structure 91 in a preferred sequence, the successive plasticizing of the binder and / or matrix materials in between top and bottom stacking 92 arranged piles 92 the to the ultrasonic excitation device 50 brought cross section Q of the tape structure 91 exclusively in the surfaces 96 the adjoining joining zones 95 and / or across their thickness. In any case, however, the lowest and highest stacking 92 an already deposited tape structure 91 never plasticized over the thickness to the dimensional stability of the laminate 90 not to endanger.

In this process, referred to as consolidation, according to the invention, the joining parameters (ie the binder and / or matrix materials) are preferred exclusively in all contact surfaces 95 two stackings 92 heated to plasticizing. Missing at a joining zone 95 between two pile layers 92 , a connection stays off (in the 23 and 26 as contact areas 97 in). On the other hand, the compounds, that is, as far as possible full-surface bonding or welding due to plasticization of the binder and / or matrix materials in, for example, all surfaces 96 of tape to be deposited 93 with the binder and / or matrix materials in joining zones 95 the topmost stackage 92 an already deposited tape structure 91 , arises in such a way that the near-surface binder and / or matrix materials in the molten or flowable state of aggregation due Plastification completely connect and ideally polymer chains are partially looped and / or form covalent bonds.

25 shows an ultrasonic slider 80 out 24 in an enlarged side view. The illustrated shoe 80 , which can be used in individual or cumulative features of its embodiment, detached from the present invention, is characterized in particular by a zone 81 with in the direction of movement or sliding G short contact length 83 for coupling ultrasonic energy into the tape structure 91 from stackings 92 and / or tape 93 and by a at least one side in the direction of movement or sliding G subsequent long zone 82 for cooling the tape structure 91 from stackings 92 and / or tapes 93 , It has proven particularly useful, the contact surface 83 the zone 81 a sliding shoe 80 for coupling of ultrasonic energy in the sliding direction G simply curved or circular segment-shaped, so that the contact surface 83 strongly reduced almost to a line-shaped runner ("similar to a circular segment-shaped runner"). Alternatively or cumulatively, by means of a separate or the control device 30 the contact force, the sliding speed and / or the ultrasound intensity are controlled constant or variable, in particular depending on the material properties and / or the temperature and / or thickness of a previously deposited tape structure 91 from stackings 92 and / or tapes 93 , in particular, the surface pressure on the US coupling zone 81 and the subsequent cooling zone 82 can be controlled differently sized. Finally, in an embodiment, an ultrasonic sliding shoe 80 preferably, which is equipped, for example at its rear end, with moving sensors (not shown), for example by means of preferably obliquely coupled ultrasound (transmitter and receiver), the consolidation of the tape structure 91 on your quality checks and parameters of the control device 30 for an adaptive control of the consolidation, in particular by means of changing the US intensity and / or the speed and / or the contact pressure.

26 Finally, the consolidation of the tapestry shows 22 by means of a roller pair device 54 a tape device 1 according to the invention. The use of an ultrasonically impinged pair of rollers is particularly useful in the production of tape structures (tailored blanks) 91 with particular constant thickness of interest. The pair of rollers can, for example, on one longitudinal side of the Legetisches 61 be arranged and so alternative to the consolidation described above by means of a welding bar device 53 about individual in the rollers of the roller pair device 54 arranged ultrasonic excitation devices 30 in the cycle, a - largely full-surface - welding by means of a continuous passage of the tape structure 91 from juxtaposed and stacked pile layers 92 and / or tapes 93 , especially when deducting from the laying table 61 to achieve by the ultrasonically impinged pair of rollers.

In accordance with the invention, the binder and / or matrix materials in all parts of the ultrasonic excitation device 50 brought cross-section Q adjacent joining zones 95 all juxtaposed and stacked pile layers 92 and / or tapes 93 the tapestry structure 91 can be gradually plasticized and consolidated, one previously to the laminate 90 corresponding, made of juxtaposed and successive tape 93 obtained tapestry structure 91 advantageous overall an ultrasonic excitation device 50 be supplied.

By going to the laminate first 90 corresponding, made of juxtaposed and stacked tape 93 obtained tapestry structure 91 a total of an ultrasonic excitation device 50 supplied and successively plasticized and consolidated over its cross-section Q, can also large-scale tape structures 91 or laminates 90 out, preferably 30 to 150 mm wide, tapes 93 can advantageously be constructed with high laying rates and consolidated with an interesting speed for serial applications.

The present invention advantageously permits the construction and consolidation of a laminate 90 with high lay rates and with an interesting speed for serial applications.

As far as they are advantageous the structure as well as the successive consolidation of laid tape structures 91 on one and the same laying table 61 is a loosening of individual tapes 93 or stackings 92 as a result of prior art separation of construction on the one hand and consolidation of laid tape structures 91 on the other hand, reliably avoided.

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

LIST OF REFERENCE NUMBERS

1

 Tape laying device

10

 feeding

11

 Coil, roll

20

 laying device

30

 control device

40

 guide means

50

 exciter

53

 Welding beam means

54

 Rolling pair of device

60

 consolidation means

61

 Legetisch

70

 Vorfixier facility

71

 Ultrasonic welding head

72

 WeldingSpot

80

 shoe

81

Coupling zone of the sliding shoe 80

82

Cooling zone of the shoe 80

83

Contact surface of the coupling zone 81

90

 laminate

91

 Tape structure

92

 Tape position

93

 Tape

95

 joining zones

96

 Surface of the joining zones

97

 surface sections

Q

 cross-section

B

Width of a tap 93

X

Number of multi-track tapes 93a . 93b . 93c . 93d , ...

G

 sliding

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

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

Claims (9)

Tape laying device ( 1 ) for carrying out a method for constructing and consolidating a laminate ( 90 ) for, for example, automotive components, in particular according to one of the preceding claims, characterized by: a) a feed device ( 10 ) for feeding binder and / or matrix materials to be deposited ( 93 ) to a depositing device ( 20 ); b) a depositing device ( 20 ) for depositing supplied tape ( 93 ) until a laminate is obtained ( 90 ) corresponding tapestry structure ( 91 ) from juxtaposed and stacked tape ( 93 ); where juxtaposed tape ( 93 ) a stack ( 92 ) of a tape structure ( 91 ) Are defined; and c) a control device ( 30 ) for controlling the obtaining of a consolidated laminate ( 90 ) by: - a management device ( 40 ) for the introduction of a cross-section (Q) of the tape structure ( 91 ) of juxtaposed and stacked layers ( 92 ) and / or tapes ( 93 ) to an ultrasound excitation device ( 50 ) or the other way around; An ultrasonic excitation device ( 50 ) for a successive plasticizing of the binder and / or matrix materials in all of the ultrasound excitation devices ( 50 ) brought cross-section (Q) adjoining joining zones ( 95 ) of all juxtaposed and stacked pile layers ( 92 ) and / or tapes ( 93 ) of the tape structure ( 91 ); and - a consolidation facility ( 60 ) for successively bringing the plasticized binder and / or matrix materials into contact with the ultrasound excitation device ( 50 ) brought cross-section (Q) adjoining joining zones ( 95 ) of all juxtaposed and stacked pile layers ( 92 ) and / or tapes ( 93 ) of the tape structure ( 91 ). Tape laying device ( 1 ) according to claim 1, characterized in that the depositing device ( 20 ) a plurality of horizontal beams ( 21 ), which at the same time several tapes ( 93a . 93b . 93c . 93d . 93e , ...) feeds, cuts and deposits. Tape laying device ( 1 ) according to claim 1 or 2, characterized in that the depositing device ( 20 ) and / or the laying bars ( 21 ) and / or a laying table ( 41 ) at least by the width of one or a group (X) tapes to be deposited ( 93 ) are designed to be displaced to the side. Tape laying device ( 1 ) according to one of claims 1 to 3, characterized in that the consolidation device ( 40 ) a plurality of large-scale ultrasound excitation devices ( 50 ), which are preferably continuous in a welding bar device ( 53 ) or a roller pair device ( 54 ) are arranged. Tape laying device ( 1 ) according to claim 4, characterized in that the welding bar device ( 53 ) of a plurality of juxtaposed sliding shoes ( 80 ), which in particular with regard to consolidation parameters in each case separately by means of a separate or the control device ( 30 ) are formed controllable. Tape laying device ( 1 ) according to claim 5, characterized in that each sliding shoe ( 80 ) a zone ( 81 ) in the movement or sliding direction (G) short contact length ( 83 ) for coupling ultrasound energy into the tape structure ( 91 ) from piles ( 92 ) and / or tape ( 93 ) and a at least one side in the direction of movement or sliding (G) subsequent long zone ( 82 ) for cooling the tape structure ( 91 ) from piles ( 92 ) and / or tapes ( 93 ). Tape laying device ( 1 ) according to one of claims 1 to 6, characterized in that the contact surface ( 83 ) of the zone ( 81 ) of a sliding shoe ( 80 ) for coupling of ultrasound energy in the sliding direction (G) is simply curved or circular segment-shaped, so that the contact surface ( 83 ) is reduced almost to a linear runner. Tape laying device ( 1 ) according to one of claims 1 to 7, characterized in that by means of a separate or the control device ( 30 ) the contact force, the sliding speed and / or the ultrasound intensity is controlled constant or variable, in particular as a function of the material properties and / or the temperature and / or thickness of an already deposited tape structure ( 91 ) from piles ( 92 ) and / or tapes ( 93 ), in particular the surface pressure on the US coupling zone ( 81 ) and the subsequent cooling zone ( 82 ) are sized differently. Tape laying device ( 1 ) according to one of claims 1 to 8, characterized in that the sliding shoe ( 80 ), for example at its rear end, with moving sensors ( 84 ) equipped, for example, by means of preferably obliquely coupled ultrasound, the consolidation of the tape structure ( 91 ) checks on their quality and parameters of the control device ( 30 ) for an adaptive control of the consolidation, in particular by means of changing the US intensity and / or the speed and / or the contact pressure.

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