DE202014100515U1 - Tape laying device for building a laminate - Google Patents

Abstract

A tape laying device (1) for constructing and consolidating a laminate (90) for, for example, automotive components, characterized by: a) a feed device (10) for feeding tape (93) to be deposited with binder and / or matrix materials to a depositing device ( 20); b) a depositing device (20) for depositing supplied tape (93); wherein juxtaposed tape (93) defines a stacking (92) of a tape structure (91); and c) control means (30) for controlling the receipt of a consolidated laminate (90) by: - guide means (40) for feeding tape (93) laid down on the uppermost stack (92) of a previously deposited tape structure (91) an ultrasonic excitation device (50) or vice versa; - An ultrasonic excitation means (50) for a successive plasticizing the binder and / or matrix materials in the adjacent joining zones (95) of the ultrasound excitation means (50) brought up tape (93) and this tape (93) bearing topmost stacking (92) of a previously deposited tape structure (91); and consolidation means (60) for successively contacting the plasticized binder and / or matrix materials in the contiguous joining zones (95) of tape (93) supplied to the ultrasonic exciting means (50) and the tape (93) carrying said tape (93) topmost stacking (92) of a previously deposited tape structure (91); wherein the control device (30) is further arranged such that in at least one sequence during the deposition of tape (93) to be deposited by means of the depositing device (20) onto the uppermost stacking layer (92) of an already deposited tape structure (91) previously deposited next to it (93) is consolidated simultaneously.

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 Laminats durch: 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) a 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 tackiness or weldability of the binder and / or matrix systems in the tape to be deposited or the already deposited tape structure is required.

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

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

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

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

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

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

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

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 11.

• a) ein Zuführen von mit Binder- und/oder Matrix-Werkstoffen versehenem abzulegenden Tape an eine Ablegeeinrichtung;
• b) ein Ablegen von zugeführtem Tape mittels der Ablegeeinrichtung; wobei nebeneinander abgelegtes Tape eine Tapelage einer Tapestruktur definiert; und
• c) ein Steuern des Erhalts eines konsolidierten Laminats durch: aa) ein Heranführen von auf die oberste Tapelage einer bereits abgelegten Tapestruktur abgelegtem Tape an eine Ultraschall-Anregungseinrichtung oder umgekehrt; bb) ein sukzessives Plastifizieren der Binder- und/oder Matrix-Werkstoffe in den aneinandergrenzenden Fügezonen von an die Ultraschall-Anregungseinrichtung herangeführtem Tape und der dieses Tape tragenden obersten Tapelage einer bereits abgelegten Tapestruktur; und cc) ein sukzessives Zusammenbringen der plastifizierten Binder- und/oder Matrix-Werkstoffe in den aneinandergrenzenden Fügezonen von an die Ultraschall-Anregungseinrichtung herangeführtem Tape und der dieses Tape tragenden obersten Tapelage einer bereits abgelegten Tapestruktur; wobei in zumindest einer Abfolge während der Ablage von abzulegendem Tape mittels der Ablegeeinrichtung auf die oberste Tapelage einer bereits abgelegten Tapestruktur zuvor dazu benachbart abgelegtes Tape simultan konsolidiert wird.

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

• a) feeding to be deposited with provided binder and / or matrix materials tape to a depositing device;
• b) depositing supplied tape by means of the depositing device; wherein juxtaposed tape defines a stack of a tape structure; and
• c) controlling the receipt of a consolidated laminate by: aa) bringing tape laid down on the uppermost stack of a previously deposited tape structure to an ultrasound exciter or vice versa; bb) a successive plasticizing of the binder and / or matrix materials in the adjoining joining zones of tape brought to the ultrasonic exciting device and the topmost stacking layer of an already laid down tape structure carrying this tape; and cc) successively bringing together the plasticized binder and / or matrix materials in the adjoining joining zones of tape supplied to the ultrasonic exciting device and the uppermost stacking layer of an already laid down tape structure carrying this tape; wherein in at least one sequence during the storage of tape to be deposited by means of the depositing device on the topmost stack of a previously deposited tape structure previously adjacent stored tape is simultaneously consolidated.

By plasticizing and consolidating the binder and / or matrix materials in the adjoining joining zones of tape supplied to the ultrasonic excitation device and the uppermost stacking layer of an already deposited tape structure carrying this tape, it is possible - in at least one sequence - during storage of tape to be deposited by means of the depositing device on the topmost stack of a previously deposited tape structure previously adjacent stored tape are simultaneously consolidated.

By simultaneously consolidating previously deposited tape during the deposition of the tape to be deposited by means of the laying device on the uppermost stack of an already deposited tape structure, large-area tape structures or laminates of preferably 30 to 150 mm wide tapes can advantageously be constructed with high lay rates and with a speed that is interesting for series-compatible applications.

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

So is in a sequence preferred if the successive plasticizing the binder and / or matrix materials exclusively in the surface of the adjoining joining zone of the Ultrasound excitation device brought up tape takes place.

Since the binder and / or matrix materials are not brought above the melting or flow temperature of the plastic matrix used, at least in the side or surface of the ultrasound excitation device facing the ultrasound excitation device, large-area tape structures can advantageously also be used Laminates off, eg 30 to 150 mm wide, tapes without unwanted flow and fiber shifts are built and consolidated.

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 not only occurs exclusively in the surfaces of the adjoining joining zones of tape brought to the ultrasonic excitation device but also in the This tape carrying top stacking an already deposited tape structure is done.

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 at least in the tape carrying topmost stacking an already deposited tape structure across its thickness take place.

In a further development, in a preferred sequence, the successive plasticizing of the binder and / or matrix materials can take place even in tufts below the topmost stacking layer of an already deposited tape structure exclusively in the surfaces of the adjoining joining zones and / or over their thickness. In any case, however, the lowest stacking layer of a previously deposited tape structure should never be plasticized across its thickness in order not to jeopardize the dimensional stability of the laminate.

In 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. Appropriately, the pre-fixing of stored tape with the topmost stack of an already deposited tape structure via a point-shaped ultrasonic welding done in which the binder and / or matrix materials in the tape or the topmost stack locally at least melted and by subsequent cooling each other be fixed. A prefixing has the advantage that the sequences aa) to cc) in a preferred embodiment several times the sequence b), ie a multilayer deposition of tape supplied by the depositor can precede, if - preferably each - on the topmost stack of a previously deposited Tapestruktur stored tape is pre-fixed with the tape carrying this tape top stacking. The successive plasticizing of the binder and / or matrix materials of multi-layer deposited pre-fixed tapes can then be carried out as described above: ie exclusively in the surfaces of the adjoining joining zones and / or over their thickness.

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 sequence corresponding to X (for the number of multi-track handled tapes).

In particular, in one embodiment, it is preferable if, in a sequence, two or more tapes to be deposited simultaneously are stored at a distance from one another by the width B of a tap to be deposited.

This has the advantage that depositing devices and ultrasound excitation devices can be arranged adjacent to one another in a mutually alternating sequence and operate simultaneously:
Thus, in a further preferred sequence following the deposition of first simultaneously spaced tapes, the gaps between tapes deposited at a distance can be filled by depositing further tapes, preferably also simultaneously, to be deposited to form a closed stacking layer.

In particular, however, in a preferred sequence during the deposition of further tapes to be deposited in the gaps left by simultaneously deposited tapes, these adjacent tapes can be simultaneously consolidated.

• a) eine Zuführeinrichtung für das Zuführen von mit Binder- und/oder Matrix-Werkstoffen versehenem abzulegenden Tape an eine Ablegeeinrichtung;
• b) eine Ablegeeinrichtung für das Ablegen von zugeführtem Tape; wobei nebeneinander abgelegtes Tape eine Tapelage einer Tapestruktur definiert; und
• c) eine Steuereinrichtung zur Steuerung des Erhalts eines konsolidierten Laminats durch: aa) eine Führungseinrichtung für das Heranführen von auf die oberste Tapelage einer bereits abgelegten Tapestruktur abgelegtem Tape an eine Ultraschall-Anregungseinrichtung oder umgekehrt; bb) eine Ultraschall-Anregungseinrichtung für ein sukzessives Plastifizieren der Binder- und/oder Matrix-Werkstoffe in den aneinandergrenzenden Fügezonen von an die Ultraschall-Anregungseinrichtung herangeführtem Tape und der dieses Tape tragenden obersten Tapelage einer bereits abgelegten Tapestruktur; und cc) eine Konsolidierungseinrichtung für ein sukzessives Zusammenbringen der plastifizierten Binder- und/oder Matrix-Werkstoffe in den aneinandergrenzenden Fügezonen von an die Ultraschall-Anregungseinrichtung herangeführtem Tape und der dieses Tape tragenden obersten Tapelage einer bereits abgelegten Tapestruktur; wobei die Steuereinrichtung weiterhin dergestalt eingerichtet ist, dass – in zumindest einer Abfolge – während der Ablage von abzulegendem Tape mittels der Ablegeeinrichtung auf die oberste Tapelage einer bereits abgelegten Tapestruktur zuvor dazu benachbart abgelegtes Tape simultan konsolidiert wird.

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

• a) a feeding device for supplying provided with binder and / or matrix materials to be deposited tape to a depositing device;
• b) a depositing device for depositing supplied tape; wherein juxtaposed tape defines a stack of a tape structure; and
• c) a control device for controlling the receipt of a consolidated laminate by: aa) a guide device for bringing tape laid down onto the uppermost stack of a previously deposited tape structure to an ultrasound exciter or vice versa; bb) an ultrasound excitation device for a successive plasticizing of the binder and / or matrix materials in the adjoining joining zones of tape brought to the ultrasound excitation device and the uppermost stacking layer of an already deposited tape structure carrying this tape; and cc) consolidation means for successively contacting the plasticized binder and / or matrix materials in the contiguous joining zones of tape fed to the ultrasonic exciting means and the topmost stacking layer of an already deposited tape structure carrying said tape; wherein the control device is further configured such that - in at least one sequence - during the storage of tape to be deposited by means of the depositing device on the topmost stack of a previously deposited tape structure previously adjacent stored tape is simultaneously consolidated.

In one 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 particular, it is preferred if two or more adjacent guide beams are arranged spaced apart from each other by the width B of a tap to be deposited. This has the advantage that the two or more guide beams of the depositing device can be arranged in multiple alternating sequence adjacent to ultrasonic excitation devices of the consolidation devices and work simultaneously.

In a further embodiment of the tape-laying device, it is provided that the laying device and / or the laying beams and / or a laying table are designed to be displaceable sideways at least by the width of one or a group X, so that several tapes are drawn in at the same time in subsequent sequences. can be cut off and stored.

In a further embodiment of the tape-laying device, it is provided that the consolidation device is formed by large-area ultrasound excitation devices, which are preferably arranged in a sliding shoe adjacently arranged to each horizontal bar and which, in particular with regard to consolidation parameters, are designed to be separately controllable by means of a separate or 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 the direction of movement or sliding G subsequent long zone for cooling the tape structure of tufts and / or tapes.

In particular, it has been proven 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, so that the contact surface is almost reduced 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.

Advantageously, by leaving the structure as well as the successive consolidation of laid tape structures on one and the same laying table, loosening of individual tapes or piles is a consequence of separation in the art On the one hand, on the one hand, and the consolidation of laid tape structures, on the other hand, process reliability is avoided.

The present invention is particularly suitable for the 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.

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

24 Details of a shoe from the 1 to 23 in an enlarged side view.

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; 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: aa) eine Führungseinrichtung 40 für das Heranführen von auf die oberste Tapelage 92 einer bereits abgelegten Tapestruktur 91 abgelegtem Tape 93 an eine Ultraschall-Anregungseinrichtung 50 oder umgekehrt; bb) eine Ultraschall-Anregungseinrichtung 50 für ein sukzessives Plastifizieren der Binder- und/oder Matrix-Werkstoffe in den aneinandergrenzenden Fügezonen 95 von an die Ultraschall-Anregungseinrichtung 50 herangeführtem Tape 93 und der dieses Tape 93 tragenden obersten Tapelage 92 einer bereits abgelegten Tapestruktur 91; und cc) eine Konsolidierungseinrichtung 60 für ein sukzessives Zusammenbringen der plastifizierten Binder- und/oder Matrix-Werkstoffe in den aneinandergrenzenden Fügezonen 95 von an die Ultraschall-Anregungseinrichtung 50 herangeführtem Tape 93 und der dieses Tape 93 tragenden obersten Tapelage 92 einer bereits abgelegten Tapestruktur 91; wobei die Steuereinrichtung 30 weiterhin dergestalt eingerichtet ist, dass – in zumindest einer Abfolge – während der Ablage von abzulegendem Tape 93 mittels der Ablegeeinrichtung 20 auf die oberste Tapelage 92 einer bereits abgelegten Tapestruktur 91 zuvor dazu benachbart abgelegtes Tape 93 simultan konsolidiert wird.

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 ; 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: aa) a management facility 40 for bringing on the topmost stack 92 an already deposited tape structure 91 discarded tape 93 to an ultrasonic excitation device 50 or the other way around; bb) an ultrasonic excitation device 50 for a successive plasticizing of the binder and / or matrix materials in the adjoining joining zones 95 from to the ultrasonic exciter 50 brought up tape 93 and this tape 93 carrying top stacking 92 an already deposited tape structure 91 ; and cc) a consolidator 60 for a successive bringing together of the plasticized binder and / or matrix materials in the adjoining joining zones 95 from to the ultrasonic exciter 50 brought up tape 93 and this tape 93 carrying top stacking 92 an already deposited tape structure 91 ; the control device 30 is further configured such that - in at least one order - while filing abzulegendem tape 93 by means of the depositing device 20 on the topmost stack 92 an already deposited tape structure 91 Previously stored next tape 93 is consolidated simultaneously.

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 , It can be seen, as in this and other sequences during the storage of tape to be deposited 93 by means of the depositing device 20 on the topmost stack 92 an already deposited tape structure 91 Previously stored next tape 93 is consolidated simultaneously. This is in addition to the depositing device 20 a consolidation facility 60 arranged, which is an ultrasonic excitation device 50 includes. By means of the ultrasonic excitation device 50 a successive plasticizing of the binder and / or matrix materials takes place in the adjoining joining zones 95 from to the ultrasonic exciter 50 brought up tape 93 and this tape 93 carrying top stacking 92 an already deposited tape structure 91 , Simultaneously, the consolidation facility provides 60 for a successive bringing together of the plasticized binder and / or matrix materials in the adjoining joining zones 95 from to the ultrasonic exciter 50 brought up tape 93 and this tape 93 carrying top stacking 92 an already deposited tape structure 91 ,

10 shows a status with continued sequence, here - analog 6 - Again, a second feeder 10 in the end area of stored tapes 93 and / or stackings 10 is provided. 11 finally shows comparable to the one in 7 shown situation, the situation for two stacked and already consolidated piles 92 ,

12 to 23 show the steps to build and consolidate a laminate 90 by means of a multi-track tape-laying device 1 according to the invention. 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 along with multi-track consolidation facility 60 on.

The 13 to 23 now show the multi-track sequences analogous to the 2 to 11 , In particular, in this embodiment, a Tapelegevorrichtung 1 preferably according to the invention by a depositing device 20 Made of a variety of beams 21 which advantageously at the same time, and preferably in parallel and uniaxially, several tapes 93a . 93b . 93c . 93d . 93e , ... moves in, possibly as in 13 shown in different lengths, cuts and drops. By this parallelization is advantageous, the number of laid tapes 93a . 93b . 93c . 93d . 93e , ... per measure corresponding to X (for the number of multi-track handled tapes 93a . 93b . 93c . 93d . 93e , ...) multiplied, where in the figures, the multi-track with X = 5 is shown.

Thus the simultaneous feeding, lengths and / or laying of several tapes 93a . 93b . 93c . 93d . 93e , ... can be done without collision, are preferably two or more adjacent beams 21 around the width B of a tap to be deposited 93a . 93b . 93c . 93d . 93e , ... arranged spaced from each other. The joists 21 and with it the parallel and at the same time stored tapes 93a . 93b . 93c . 93d . 93e , ..., so they each have a distance from each other of a tape width B.

As in 15 can be seen following the filing of first deposited tapes 93a . 93b . 93c . 93d . 93e , ... the gaps 94 between two tapes 93a . 93b , ... to a closed stack 92 refilled. This is characterized by a tape laying device 1 preferably according to the invention by a depositing device 20 and / or joists 21 and / or laying table 61 from which at least the width B of a tap to be deposited 93a are displaceable to the side. This can be done after the first tap is removed 93a or the first X-tapes 93a . 93b . 93c . 93d . 93e , ... and moving sideways by one tap width B in the next bar another tapes 93a or other X-tapes (with eg X = 5) 93a . 93b . 93c . 93d . 93e , ... on the laying table 61 put down and the gaps 94 from the first bar to a closed stack 93 fill up, which then the top stacking 92 an already deposited tape structure 91 corresponds to 16 ).

As in 17 can be seen in the connection first on the top stacking 92 an already deposited tape structure 91 filed and pre-fixed tapes 93a . 93b . 93c . 93d . 93e , ... the remaining gaps 94 between two tapes 93a . 93b , ... to a closed stack 92 filled, ie stored and prefixed analogously in the manner described above.

In the subsequent sequence ( 19 ) are followed by a leading up with the top tier 92 an already deposited tape structure 91 pre-fixed tapes 93a . 93b . 93c . 93d . 93e , ... or from it formed Tapelage 93 to an ultrasonic excitation device 30 or the other way around.

By means of an ultrasonic excitation device 50 Then, a successive plasticizing of the binder and / or matrix materials in the adjoining joining zones 95 from to the ultrasonic exciter 50 brought up tape 93 and this tape 93 carrying top stacking 92 an already deposited tape structure 91 ,

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.

At the in 19 ff. illustrated embodiment of the tape laying device 1 According to the invention, a consolidation device has 60 proven, which a variety of large-scale ultrasonic excitation 50 includes the distance between two joists 21 For example, in a shoe 80 , are arranged. In particular, for the economic implementation of, preferably full-surface, welding has proven an embodiment in which each exactly one ultrasonic excitation devices 50 is attached to a track and this 50 in a width B of the tape 93 held ultrasound sliding shoe 80 arranged by lowering, pressing and axial process over the entire Tapelänge is performed.

Between the preferred X beams 21 are therefore preferred, for example, X ultrasonic excitation devices 50 arranged. These can be moved individually or, if necessary, coupled in the leg axis. After laying the first X laps on tapes 93a . 93b . 93c . 93d . 93e , ... and the lateral offset of a tap width B, so may be preferred within a lay cycle and during the next X tapes 93a . 93b . 93c . 93d . 93e , ... to fill in the gaps 94 be laid, the previously laid tape strips 93a . 93b . 93c . 93d . 93e , ..., via the ultrasonic excitation equipment 50 , full surface with the topmost stacking 92 the already underlying tape structure 91 be plasticized and connected.

The ultrasound exciters 50 generated ultrasonic vibrations are thereby, preferably under the pressure of the sliding shoes 80 , on top of the pile with the top 92 an already deposited tape structure 91 to be connected first tapes 93a . 93b . 93c . 93d . 93e , ... transfer. These heat up and begin to soften, increasing the damping coefficient. The increase in the damping coefficient leads to higher internal friction, which accelerates the temperature increase.

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 ; 93 . 93a . 93b . 93c . 93d . 93e , ... heated to plasticizing. Missing at a joining zone 95 between two pile layers 92 , remains a connection (in the figures as Kontaktfreiflächen 97 in). The compounds, however, ie the 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 to plasticization completely connect and ideally polymer chains are partially looped and / or form covalent bonds.

Are - such as in 19 shown - the first tapes 93a . 93b . 93c . 93d . 93e , ... with the top stacking layer 92 an already deposited tape structure 91 fully consolidated, can be found in the in 21 shown return of the sliding shoes 80 at the same time the tapes laid on the gap 93a ... the stacking 93 be successively subjected to ultrasonic vibrations and under the pressure of the sliding shoes 80 with the upper stacking layer 92 an already deposited tape structure 91 get connected.

Due to the proposed structure of a preferred Tapelegevorrichtung invention 1 , Tapelegen and consolidation are split into two separate process steps, which can be advantageous but time-saving synchronously performed.

2 shows the result of successively consolidated joining zones 25 two stackings 92 Like previously described.

As far as the laminate to be built 90 more stackings 93 As previously described, these may be applied, pre-fixed and consolidated as required. Likewise, the laminate can 90 - as in 23 presented - of course, be expanded in its width. For this purpose, the depositing device moves 20 and / or the joists 21 and / or the laying table 41 by a distance 2xXxB and the process described above is repeated until the entire width of the component to be laid is laid, in which respect and to avoid repetition reference is made to the previous description.

24 finally shows details of a shoe 80 from the 1 to 23 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 , In particular, the contact area has proven itself 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.

According to the invention, the binder and / or matrix materials in the adjoining joining zones 95 from to the ultrasonic excitation device 50 brought up tape 93 and this tape 93 carrying top stacking 92 an already deposited tape structure 91 plasticized and consolidated, can - in at least one order - during the storage of tape to be deposited 93 by means of the depositing device 20 on the topmost stack 92 an already deposited tape structure 91 Previously stored next tape 93 be consolidated simultaneously.

By - in at least one order - during the storage of tape to be deposited 93 by means of the depositing device 20 on the topmost stack 92 an already deposited tape structure 91 Previously stored next tape 93 can be simultaneously consolidated, also large-scale tape structures 91 or laminates 90 from, 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.

By favoring the construction 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

21

 individually working beam

30

 control device

40

 guide means

50

 exciter

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

94

Gap between two discarded tapes 93

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 . 93e , ...

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 building and consolidating a laminate ( 90 ) for, for example, automotive components, characterized by: a) a feed device ( 10 ) for feeding binder and / or matrix materials to be deposited ( 93 ) to a depositing device ( 20 ); b) a depositing device ( 20 ) for depositing supplied tape ( 93 ); where juxtaposed tape ( 93 ) a stack ( 92 ) of a tape structure ( 91 ) Are defined; and c) a control device ( 30 ) for controlling the obtaining of a consolidated laminate ( 90 ) by: - a management device ( 40 ) for bringing on the topmost stack ( 92 ) of a previously deposited tape structure ( 91 ) stored tape ( 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 the adjoining joining zones ( 95 ) from to the ultrasound excitation device ( 50 ) ( 93 ) and this tape ( 93 ) carrying topmost stack ( 92 ) of a previously deposited tape structure ( 91 ); and - a consolidation facility ( 60 ) for a successive bringing together of the plasticized binder and / or matrix materials in the adjoining joining zones ( 95 ) from to the ultrasound excitation device ( 50 ) ( 93 ) and this tape ( 93 ) carrying topmost stack ( 92 ) of a previously deposited tape structure ( 91 ); the control device ( 30 ) is further arranged such that in at least one sequence during the storage of tape to be deposited ( 93 ) by means of the depositing device ( 20 ) on the topmost stack ( 92 ) of a previously deposited tape structure ( 91 ) previously stored adjacent tape ( 93 ) is consolidated simultaneously. 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 two or more adjacent guide beams ( 21 ) each by the width of a tap to be deposited ( 93a . 93b . 93c . 93d . 93e , ...) are arranged at a distance from each other. Tape laying device ( 1 ) according to one of claims 1 to 3, characterized in that the depositing device ( 20 ) and / or the laying bars ( 21 ) and / or a laying table ( 41 ) at least around the width (B) of one or a group (X) of tapes to be deposited ( 93a ) are designed to be displaced to the side. Tape laying device ( 1 ) according to one of claims 1 to 4, characterized in that the consolidation device ( 60 ) by large-scale ultrasound excitation devices ( 50 ), which preferably in one to each horizontal beam ( 21 ) adjacently arranged sliding shoe ( 80 ), which, in particular with regard to consolidation parameters, are arranged separately in each case 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 claim 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 a previously 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.

Images