EP0413714A1 - Procede et installation de traitement en grande serie de materiaux composites renforces par des fibres de haute performance - Google Patents

Procede et installation de traitement en grande serie de materiaux composites renforces par des fibres de haute performance

Info

Publication number
EP0413714A1
EP0413714A1 EP89904805A EP89904805A EP0413714A1 EP 0413714 A1 EP0413714 A1 EP 0413714A1 EP 89904805 A EP89904805 A EP 89904805A EP 89904805 A EP89904805 A EP 89904805A EP 0413714 A1 EP0413714 A1 EP 0413714A1
Authority
EP
European Patent Office
Prior art keywords
molding
temperature
phase
zone
fibers
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP89904805A
Other languages
German (de)
English (en)
Inventor
Jürgen KÖSTER
Manfred Geiger
Gerhard Von Der Heyd
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
MOBIK SPORTGERAETE VERTRIEBS GBR
Original Assignee
Mobik Sportgerate Vertriebs GbR
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mobik Sportgerate Vertriebs GbR filed Critical Mobik Sportgerate Vertriebs GbR
Publication of EP0413714A1 publication Critical patent/EP0413714A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/002—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor characterised by the choice of material
    • B29C51/004—Textile or other fibrous material made from plastics fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/18—Thermoforming apparatus
    • B29C51/20—Thermoforming apparatus having movable moulds or mould parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/261—Handling means, e.g. transfer means, feeding means
    • B29C51/262—Clamping means for the sheets, e.g. clamping frames
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts

Definitions

  • the invention relates to a process for the large-scale, cycle-wise molding of consolidated high-performance fiber composite materials (HFVW) based on thermoplastic (hereinafter also preliminary material) into three-dimensional molded parts by means of a closed production system, the discontinuous characteristic of certain thermoplastic materials Behavior of the material depending on the temperature to be used to control the process.
  • the primary material is preferably moved by means of a conveyor system through a tunnel-like device from a pick-up station to a pick-up station.
  • the invention also relates to a plant for carrying out the method.
  • the processes which are suitable for large series, work with cycle times in the range of 1 minute for quantities of often more than 1000 pieces / day.
  • the material and workpiece are created at the same time (simultaneous process) and in an appropriately designed tool ('in situ process').
  • the remote Manufacturing processes are correspondingly complex in nature with numerous, in some cases even workpiece-dependent, at least both chemical and physical parameters.
  • the parameters of pressure and temperature in these processes are also predominantly the same and determined by the chemical processes as well as the viscosity and shrinkage: higher temperatures are almost always accompanied by higher pressures.
  • short cycle times can only be achieved with low-viscosity base materials (components) and with high mold filling pressures, which in turn require corresponding closing pressures (for sealing). Avoiding burrs and sprues are typical manufacturing problems for these processes.
  • the forces to be applied determine the design of the system; they often reach 300 bar (RRIM 70 bar) or 50 meganewtons for medium to large molded parts.
  • the cycle times for the finished molded part are in the range of 5 minutes, occasionally less (low surface requirements). A shortening of the cycle times leads to higher rates of rejects and rework (process risk) due to the process complexity.
  • Exemplary methods are SMC, GMT, RTM, XMC, BMC, RRIM, MMC.
  • the position of the reinforcing fibers and their protection is of secondary importance in the process control (isotropy characteristic).
  • the speed of the processes is limited by the orientation of the fibers; The same applies to the deformation, which is aimed at aligning the fibers in the direction of the force flow while protecting the individual fibers as much as possible, two important aspects of these 'anisotropic' processes (see FIG. 1)).
  • low plant costs and the cost of changing grades as well as tooling costs should lead to low processing costs and flexible Process control. This should be limited to two, if possible only one, parameter (temperature).
  • the cycle time is essentially determined by the forming time
  • the process parameters are limited to pressure and temperature, the process control even limited to the temperature if possible,
  • the low pressures allow a correspondingly smaller dimensioning of the system and, in particular, of the tools. Both are important prerequisites for flexible and inexpensive processes.
  • concentration of the process control on the temperature parameter simplifies and secures the process; it also promotes a high degree of automation.
  • the plant and the method for producing the primary material are not the subject of this invention. However, such a system can be combined with the system according to the invention. Panels, pipes, panels, sandwich panels are possible as semi-finished products.
  • the consolidated high-performance Serverbundmaterial (primary material) consists of high-strength (organic, inorganic, metallic) fibers or fiber bundles (rovings) in a form-supporting, (supporting) thermoplastic matrix, which at temperatures above the ambient temperature as often as desired and without changing the chemical physical properties becomes plastic.
  • This applies to certain metals 'Metal Matrix Composites' - MMC's
  • certain plastics 'Plastic Matrix Composites' - PMC's.
  • very low form forces can be used in the area of the softening temperature or crystallite melting temperature of the matrix.
  • the molding times are then in the range of seconds, molding pressures below 1 bar.
  • the deformation can be repeated any number of times.
  • the technical / physical properties of the composite are largely retained, provided that fiber breaks are avoided.
  • fe depends on various parameters such as polarity of the material, degree of molecular orientation, molecular weight, crosslinking, crystallinity, crystal orientation.
  • the degree of crystallinity can be changed by the rate of heating and cooling as well as by the temperature of the deformation.
  • the adaptation of the material properties by changing the speed of temperature change and the deformation temperature is an essential part of this invention.
  • the method according to the invention provides for the high-performance fiber composite materials to be reshaped within an area with the lowest mechanical strength and greatest extensibility of the matrix material, as shown in FIGS. 3 and 4, for example. Furthermore, by controlling a particular one Temperature profile over the tool as well as the mold frame generates a higher crystallinity at previously defined locations of the molded part and thus achieves a higher mechanical strength at this location (FIG. 5).
  • the heating component the semi-finished product is heated from the room temperature at the beginning of the system to the material-specific mold temperature at the beginning of the mold component; in the molding component, the raw material is shaped into a molding by means of different molding processes; in the cooling component, the molded part is cooled to a temperature below the softening or crystallization temperature, with precisely prescribed heating or cooling gradients having to be observed in each case.
  • the components must be arranged consecutively, since even small temperature differences compared to the optimal mold temperature, be it within the process or within the workpiece, lead to significantly higher mold pressures
  • the encapsulation of the system increases the thermal efficiency and consequently reduces the process risk.
  • a mold frame is of further essential importance in the method according to the invention and the plant corresponding to it.
  • the fibers of the composite material are arranged in predetermined directions, e.g. B. in the form of a fabric or in the form of a scrim.
  • Several layers of such fabrics can also be arranged in a composite with different Chen fiber types.
  • the fibers perform the function of force transmission in front of the matrix; it is therefore important to protect and align them.
  • the fibers When shaping, the fibers must be able to move freely against each other as far as possible without being pushed over one another (wrinkling). Especially with several layers.
  • the form force should be low and should be evenly distributed over the entire surface of the primary material and the molded part.
  • this mold frame which is designed differently depending on the shape of the molded part and thus has the function of a second tool. It has controllable flow obstacles or is temperature-controlled in zones in such a way that certain fiber areas are delayed in their movement compared to other fiber areas during textile shaping.
  • the molding frame is integrated in a suitable manner in the transport device.
  • thermoplastic plastics ammorphic consistency Fig. 3
  • crystalline consistency Fig.
  • FIG. 5 shows a schematic view of the system or device according to the invention, which also serves to illustrate the method according to the invention
  • FIG. 6 shows a second exemplary embodiment of a system according to the invention
  • FIG. 12 schematically in the upper part a top view of the finished molded part, for example a case shell, a side view of the case shell being shown in the lower part of FIG. 12.
  • the entire system or device consists of a tunnel 1, in which a heating zone 2, a molding zone 3
  • the method therefore provides for a heating phase, a molding phase and a cooling phase.
  • a conveyor system 5 runs through the entire system. This conveyor system 5 conveys the primary material 7, starting from a receiving station 9 through the entire system to a removal station 10, in which the finished, already cooled molded part 11 is removed.
  • the primary material 7 is a consolidated high-performance fiber composite material.
  • the preliminary material 7 therefore already has a consolidated state when it arrives in the receiving station 9, i. H. the original layered structure was pressed with the fibers, so that the fibers are surrounded by a matrix.
  • the matrix is formed by a thermoplastic material, which, as already mentioned, can be a thermoplastic or a metal, preferably aluminum.
  • the expression "high performance” indicates that the fiber material is present in the starting material in an amount greater than 50% by volume.
  • the expression "high performance” is also intended to mean that the fibers are directed and endless in order to be able to take over the force in the material composite through a conductive function in front of the matrix (anisotropy feature).
  • a molding frame 8 is now preferably provided and, as shown in FIG. 5, arranged on the receiving station 9.
  • the molding frame consists of an upper and lower half 8a, 8b which can also be referred to as an upper part and lower part. Recesses are provided in the mold frame 8 according to the desired shape of the molded part to be produced.
  • the mold frame 8 is transported together with the primary material 7 from the conveyor system 5, starting from the receiving station 9, into the heating zone 2 in order to be heated there to the material-specific mold temperature.
  • the molding frame then travels together with the primary material 7 into the molding zone 3 and from there to the cooling zone 4, and after the finished, filled molding 11 has been removed from the molding frame 8, the latter is carried out quickly and as far as possible without further temperature loss via a channel 12 to the receiving station 9 returns in order to be occupied with primary material 7 there again.
  • the conveyor system 5 can be designed in the heating and cooling zone 2, 4 in such a way that with a cycle time determined by the molding time in the molding zone 3, different dwell times in the heating and cooling zone 2, 4 are made possible.
  • the primary material 7 is formed into a molded part 11, which is already shown removed from the molding frame 8 in the removal station 10.
  • the primary material is deformed in a manner known per se, taking advantage of the discontinuous behavior of the mechanical properties of the thermoplastic used in the molding zone 3, the deformation temperature of the primary material being preferably used in the deformation to control the process in such a way that the lowest possible deformation pressure must be exerted on the primary material located in the molding zone 3.
  • the primary material in the heating zone 2 is heated to the forming temperature in such a way that the primary material has the forming temperature through and through.
  • the temperature of the raw material outlet from the heating zone 2 is exactly the same as the temperature at the inlet to the molding zone 3, so that a closed or encapsulated production system is formed.
  • the temperature of the molded part which has not yet cooled is preferably accurate at the beginning of the cooling zone 4 equal to the temperature at the exit of the molding zone 3.
  • the pressure exerted on the primary material located in the forming zone is controlled depending on the temperature in such a way that a minimal forming energy is required for the forming.
  • FIG. 5 illustrates the case of deep drawing.
  • Fig. 7 shows the deformation by low pressure
  • Fig. 8 by gas pressure
  • Fig. 9 hydromechanical.
  • the tool 13 can consist of a soft material, such as, for example, silicone rubber.
  • the units generating the pressure are preferably arranged outside the tunnel-like device (tunnel) 1 as shown at 14.
  • tunnel-like device tunnel-like device 1
  • two separate pressure-generating units are provided, one for a tool holder 15 and the other for a hold-down 16.
  • the pressure-generating units can be controlled independently of one another depending on the workpiece, for example in such a way that the hold-down 16 first holds down the holder frame 8 before the tool holder 15 carries out the deformation.
  • This arrangement according to the invention simplifies the (therefore temperature-independent) design of the pressure-generating system and simplifies the tool change.
  • the entire system is designed, as far as the pressures are concerned, that pressure-sensitive materials such as sandwich panels with structural cores (honeycomb) or foam cores can also be processed.
  • pressure-sensitive materials such as sandwich panels with structural cores (honeycomb) or foam cores can also be processed.
  • the heating is preferably carried out by warm air, but otherwise also by any other method, preferably with targeted fine control of the temperature in the preferably also heatable mold frame 8.
  • the pressure can be generated in a variety of ways, for example hydraulically, pneumatically, electromagnetically, mechanically or hydromechanically.
  • the molding frame 8 preferably performs a multiple function: the primary material, shown in plan view in FIG. 11, is fiber-oriented by the molding frame 8 in a certain direction of rotation (for example 0 ° / 90 ° or + 45 °) stored. Due to the special design of certain parts of the mold frame, cf. 10 the retention zones Rz, the necessary relative movement of the fibers in the warp direction and the weft direction to each other is promoted. For this purpose, it may be expedient to temper these retention zones Rz differently from the other mold frame 8 (delay due to different viscosity of the matrix of the primary material).
  • the lower half 8b of the mold frame 8 is at the same time designed as a decorative ring.
  • Tool and mold frame complement each other in their function in the deformation of the primary material.
  • 11 shows the primary material with the retention zones. In the Threads or fibers ending in these retention zones are delayed in relation to the other threads, so that the relative movement starts.
  • 12 shows a molded part, for example a case shell, as can be molded by a molded frame 8 of the type shown.
  • FIG. 6 shows another embodiment of the system according to the invention, using a different embodiment of the mold frame, which is identified here by the reference symbols 80a, 80b.
  • the upper half 80a of the mold frame is attached to the hold-down device 16 in order to accelerate the loading of the system and also to accelerate the removal of the molded part 11.
  • the mold frame 8 (FIG. 5) or the lower part 80b of the mold frame 80 (FIG. 6) is suitably integrated into the conveyor system 5, in particular in such a way that other mold frames are placed on the conveyor system when changing types and tools can be.
  • the conveyor system 5 is also designed so flexible that as little "empty parts" run through the system when the system is interrupted.
  • the molded part is cooled in the cooling zone 4 in such a controlled manner that it retains its shape and the matrix has the desired consistency.
  • FIG. 7 shows the vacuum process, in which the molding frame 8 rests on a frame 17, which is either arranged stationary in the molding zone 3 or is designed to be movable as part of the conveyor system 5.
  • the negative pressure applied within the frame 17 leads to the molding process being range of the mold temperature "automatically", ie as soon as the matrix of the primary material has reached the material-specific physical forming temperature.
  • a hold-down 18 bears against the mold frame 8 during the application of the negative pressure.
  • Fig. 8 shows the overpressure process.
  • the hold-down device 18 seals the system at the same time, so that when the physical properties of the matrix corresponding to the pressure of the gas are reached, the deformation automatically starts again.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Textile Engineering (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Moulding By Coating Moulds (AREA)
  • Reinforced Plastic Materials (AREA)

Abstract

Procédé de façonnage de préformés tridimensionnels en grande série, en continu et en cadence avec des matériaux composites renforcés par des fibres à base de matériaux thermoplastiques en tant que matrice. En tant que matériau de base, on utilise des matériaux composites consolidés renforcés par des fibres de haute performance. Par matériaux consolidés on entend des matériaux composites déjà stratifiés et renforcés par des fibres, composés de fibres pouvant présenter des compositions diverses comprimées avec la matrice. Par matériau de haute performance on entend un matériau de base qui comprend de préférence un pourcentage supérieur à 50 % de fibres alignées et sans fin.
EP89904805A 1988-04-22 1989-04-20 Procede et installation de traitement en grande serie de materiaux composites renforces par des fibres de haute performance Withdrawn EP0413714A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE3813694A DE3813694A1 (de) 1988-04-22 1988-04-22 Verfahren und anlage zur grossseriellen verarbeitung von hochleistungs-faserverbundwerkstoffen
DE3813694 1988-04-22

Publications (1)

Publication Number Publication Date
EP0413714A1 true EP0413714A1 (fr) 1991-02-27

Family

ID=6352709

Family Applications (1)

Application Number Title Priority Date Filing Date
EP89904805A Withdrawn EP0413714A1 (fr) 1988-04-22 1989-04-20 Procede et installation de traitement en grande serie de materiaux composites renforces par des fibres de haute performance

Country Status (7)

Country Link
EP (1) EP0413714A1 (fr)
JP (1) JPH03504700A (fr)
KR (1) KR900700272A (fr)
AU (1) AU636566B2 (fr)
BR (1) BR8907388A (fr)
DE (1) DE3813694A1 (fr)
WO (1) WO1989010253A1 (fr)

Families Citing this family (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5290167A (en) * 1990-10-08 1994-03-01 Sumitomo Heavy Industries, Ltd. Method of manufacturing three-dimensional parts using sheets of thermoplastic resin high-performance fiber-reinforced composite material and apparatus therefor
DE9109287U1 (de) * 1991-07-27 1992-09-03 Verpaco AG, Hünenberg Formwerkzeug zur Herstellung von Kunststoffbechern
DE9216080U1 (de) * 1992-11-26 1993-08-26 Reiss International GmbH, 88069 Tettnang Tiefziehteil
DE19922799B4 (de) * 1999-05-18 2014-06-12 Bayerische Motoren Werke Aktiengesellschaft Verfahren zur Herstellung eines Kunststoffformteils
DE10330919A1 (de) * 2003-07-03 2005-01-27 Deutsches Zentrum für Luft- und Raumfahrt e.V. Verfahren und Vorrichtung zur Herstellung eines Faserverbundwerkstoff-Bauteils
DE102005052440A1 (de) * 2005-11-03 2007-05-10 Christian Gahle Verfahren zum Herstellen von zwei- oder dreidimensional warm umgeformten Werkstücken aus Holz-Kunststoff-Verbundwerkstoff
DE102011119223A1 (de) 2011-11-22 2013-05-23 Daimler Ag Herstellvorrichtung zu einer Herstellung eines faserverstärkten Kraftfahrzeugbauteils
DE102012000772A1 (de) * 2012-01-18 2013-07-18 GM Global Technology Operations LLC (n. d. Gesetzen des Staates Delaware) Sitzschale eines Kraftfahrzeugs und Verfahren zur Herstellung derselben
EP3135707A1 (fr) 2015-08-26 2017-03-01 LANXESS Deutschland GmbH Compositions de polyamide
DE102017105450A1 (de) * 2017-03-14 2018-09-20 Dieffenbacher GmbH Maschinen- und Anlagenbau Verfahren und Anlage zum Konsolidieren von Faserverbundstrukturen
WO2021146223A1 (fr) * 2020-01-15 2021-07-22 Cytec Industries Inc. Mise en forme mécanique automatisée de matériaux composites

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Publication number Priority date Publication date Assignee Title
US3765998A (en) * 1971-01-11 1973-10-16 Allied Chem Shapable fiber-reinforced low molecular weight polyethylene terephthalate
US3850723A (en) * 1971-09-20 1974-11-26 Ppg Industries Inc Method of making a stampable reinforced sheet
DE2614986A1 (de) * 1976-04-07 1977-12-29 Kannegiesser H Kg Vorrichtung zur verformung von aus kunststoffen geschaeumten platten
EP0195562B1 (fr) * 1985-03-21 1992-10-28 Imperial Chemical Industries Plc Procédé de fabrication d'articles moulés en matériaux composites renforcés
GB8507312D0 (en) * 1985-03-21 1985-05-01 Ici Plc Producing shaped articles
FR2600936B1 (fr) * 1986-07-07 1989-02-24 Cofim Procede et dispositif pour la realisation de preformes pour pieces en materiaux composites

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO8910253A1 *

Also Published As

Publication number Publication date
WO1989010253A1 (fr) 1989-11-02
DE3813694A1 (de) 1989-11-02
AU3449089A (en) 1989-11-24
AU636566B2 (en) 1993-05-06
JPH03504700A (ja) 1991-10-17
BR8907388A (pt) 1991-04-23
KR900700272A (ko) 1990-08-13

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