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
  • B29C70/06—Fibrous reinforcements only
  • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
  • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
  • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/06—Fibrous reinforcements only
  • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
  • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/28—Shaping operations therefor
  • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
  • B29C70/545—Perforating, cutting or machining during or after moulding
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
  • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
  • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2250/00—Layers arrangement
  • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/02—Synthetic macromolecular fibres
  • B32B2262/0261—Polyamide fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/02—Synthetic macromolecular fibres
  • B32B2262/0261—Polyamide fibres
  • B32B2262/0269—Aromatic polyamide fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/02—Synthetic macromolecular fibres
  • B32B2262/0276—Polyester fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/10—Inorganic fibres
  • B32B2262/101—Glass fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/10—Inorganic fibres
  • B32B2262/103—Metal fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/10—Inorganic fibres
  • B32B2262/106—Carbon fibres, e.g. graphite fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2479/00—Furniture
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2605/00—Vehicles
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
  • Y02T50/00—Aeronautics or air transport
  • Y02T50/40—Weight reduction
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
  • Y10T428/24033—Structurally defined web or sheet [e.g., overall dimension, etc.] including stitching and discrete fastener[s], coating or bond

Definitions

• the invention relates to a reinforcing process for core composites, characterized in that the introduction of a through-hole in the core material is carried out separately from the introduction of the reinforcing structure.
• the invention is suitable for reinforcing core composite structures.
• the core composite structure may preferably be made of fiber-plastic composite with outer layers of textile semifinished products (eg, fabrics, scrims, mats, etc.), a core material (eg, polymeric foam), and a polymeric matrix material (thermoplastic or thermoset).
• Core composites are layered structures consisting of relatively thin top and bottom cover layers as well as a relatively thick core layer of low bulk density.
• the transverse eg tensile and tensile stiffness and strength in the z-direction, shear stiffness and strength in the xz and yz plane, peel resistance between the cover layer and the core, fail-safe behavior
• the mechanical properties of core composite structures in the direction of the plate plane eg stiffness and strength
• the mechanical properties of core composite structures in the direction of the plate plane can be significantly increased with the aid of reinforcing elements penetrating in the thickness direction.
• the principle of optimized density distribution in structural foam or in high-strength, lightweight composite materials is z. B. realized in sandwich panels with a shear-resistant composite of a foam core with both sides tensile cover layers. There are several ways to create a permanent bond. Depending on the stress z. B. glued or armored.
• the reinforcement is the reinforcement of one object by another, which has a higher compressive or tensile strength.
• 6,187,411 describes sewing in the two-side sewing method, in which an upper thread is inserted from a cover layer of the core composite with a needle into the layer structure and held in the vicinity of the other cover layer by a lower thread in the layer structure. This results in the withdrawal of the needle from the layer structure a loop.
• a sewing method for reinforcing foams is disclosed, which after the production of a through hole by means of a needle, the fiber bundles is pulled through the foam material and then cut flush or applied to the surface and optionally glued. During further processing, this leads to slipping out of the fibers from the cover layer, which greatly reduces composite strength but also leads to surface undulation.
• US 5624622 discloses reinforcing a foam core composite by warp stitching or lock stitch sewing.
• the thread is entrained when the needle penetrates. During the insertion into the foam, the thread extends over the entire length parallel to the needle. The hole size of the puncture hole is thus determined by the needle diameter and the thickness of the thread.
• the core hole diameter and the fiber volume content of the sewing thread in the core hole can be determined by microscopic examinations.
• experimental studies on using the lockstitch sewing technology and using a sewing needle with a diameter of 1, 2 mm and an aramid yarn with a line weight of 62 g / km sewn core composite structures that the diameter of the resulting resin column in the core material (approx 1.7 mm) is greater than the determined core hole diameter of one impregnated core composite structure with a single puncture.
• the reason for this is that adjacent cell walls in the area of the sewing needle diameter are destroyed by the piercing of the sewing needle. In these now open pores with an average diameter of approx. 0.7 mm, resin can penetrate in the subsequent infiltration process (Fig. A).
• Figure A Mechanism of the resulting resin column using lockstitch sewing technology and the dependence of the suture volume content within a core hole on the number of sutures in the core hole
• the resulting diameter in the polymeric core material when using more conventional production methods depends mainly on the sewing needle diameter used, the cross-sectional area of the sewing thread and on the pore diameter of the polymeric rigid foam used. Since sewing needle and sewing thread at the same time penetrate into the core composite structure in all previously known reinforcement methods, an unfavorable ratio of incorporated cross-sectional area of the reinforcement elements to the size of the core hole diameter always occurs. High fiber volume contents in the core hole diameter, similar to the fiber volume content of the outer layers (> 50%), can thus not be achieved with conventional reinforcement methods.
• the aim must be to strive for the highest possible fiber volume content of the reinforcement in the core hole diameter.
• the high resin content in the Core hole diameter for an increase in weight, which is not tolerated especially in aerospace.
• the invention is based on the object of improving the mechanical properties of core composite structures by introducing reinforcing elements in the thickness direction of the core composite structure (z direction), with a high fiber volume content of the reinforcement in the core hole diameter.
• the weight should not be greatly increased.
• reinforcement of core composites takes place by a) introducing a through-hole in the core material separated from the introduction of the reinforcement structure, b) retrieving the reinforcement structure after inserting the through-hole with the aid of a hook, gripper or needle and is introduced into the core composite structure by an upward and rotational movement or upward movement of a slider-secured gripper, hook or needle; c) after insertion of the through-hole and subsequent introduction of the reinforcement structure, the needle the gripper or the hook with or without slide (gripper system) and without or with simultaneous rotation in sewing direction to the next puncture hole is passed, wherein the next puncture the reinforcing structure on the needle, the hook or the gripperrousg Concentr and after piercing the core material the reinforcing material below eriger side, wherein it by the upward and rotational movement of the gripper, hook or needle or the upward movement of the / secured with a slider gripper, hook or needle leads to an entanglement between the top and bottom reinforcing structure.
• a closable hook needle for example provided with a flap or a slider used, so can be dispensed with the rotational movements.
• This novel sewing technique can also be used for preforming as well as for attaching additional component components (eg stringers, frames, etc.) to the core composite structure.
• Shifting of the cover layer can be prevented, which usually meant that the pins have slipped out of the cover layer.
• the resulting ondulation of the cover layer can also be prevented by the method according to the invention.
• the permanent bond of the cover layers with the core material now also allows easy transport of the composite material.
• the use of foams, felts, or other fibrous webs results in improved thermal and / or acoustic insulation properties.
• the core composite structure can be impregnated with a thermosetting or thermoplastic matrix material in a liquid composite molding process. According to the invention core composites are obtained.
• Drawing 1 illustrates the sewing process.
• a hook, gripper or needle (gripper system) (1) with the reinforcing material (3) such as sewing thread or roving is used for reinforcing core composites ( Figure I).
• Hook, gripper or needle (1) are guided with the Am istsmaterial (3) with simultaneous rotational movement by 180 ° to the next puncture site ( Figure I and II). If hooks, needles or grippers are secured with a slide, the rotary motion can be dispensed with.
• Hook, gripper or needle (1) are introduced to introduce a through hole in the core material (2) or optionally by one or more cover layers and the core material (Figure III). In this case, the reinforcing material is not carried along. The reinforcing material slides past the hook, needle or gripper ( Figure IV) and remains on top of the core material.
• Needle, hook or gripper get below the reinforcing material, which is then then introduced by an upward and rotational movement in the core composite structure (Figure IV).
• Figure IV Are hook, needle or gripper secured with a slider, so can be dispensed with the rotational movement in the upward movement again.
• Hook, gripper or needle without slide are guided with a rotary movement in sewing direction to the next puncture site ( Figure I).
• Hook, gripper or needle with slide are guided in the sewing direction to the next puncture site without any rotational movement.
• the material to be sewn or the reinforcing unit is transported on to the next puncturing position and the reinforcing process is then repeated there.
• the reinforcing structure By retracting the reinforcing structure, it can be an additional Widening of the resulting from the piercing of the gripper system Kernloch- come diameter, whereby a high fiber volume content can be realized.
• the reinforcing elements are introduced by train in the core composite structure or only in the core material, there is a very good alignment and no buckling of the reinforcing structure. With the help of this Arm istsvons the introduced reinforcing elements may also have a deviating from 0 ° to the z-axis angle, z. B. +/- 45 ° with pure transverse force stress.
• the through holes can be introduced into the foam under any angular position. The orientation of the through holes can be adapted to the particular shape of the foam material to be reinforced as well as the expected load situation during use.
• the core material used may be a polymeric rigid foam (eg PMI, PVC, PEI, PU, EPP, PES, PS, etc.). But other foams, which are commonly used as core material, can be used. Likewise, fibers and other fiber fabrics can be used.
• the core material may have a thickness, for example, of 1 to 150 mm, a width of approximately 1250 mm, and a length of approximately 2500 mm.
• the top and bottom textile cover layers may be the same or different and made of polyamide, polyester, carbon, glass, nylon, metal, aramid or basalt fibers or other reinforcing materials. The thickness of a single textile cover layer layer may be the same or different and, for example, between 0.1 mm and 5.0 mm.
• thermoplastics or thermosets can be used as a polymeric matrix material.
• the reinforcing structure can consist either of textile reinforcing structures (eg sewing threads, rovings) or of rod-shaped elements (eg pins of unidirectional fiber-plastic composite, unreinforced plastic or metal, etc.).
• fiber bundles are understood to mean rovings made from a large number of individual fibers or monofilaments, individual fibers themselves and also threads which have been formed by twisting of individual fibers or fiber bundles.
• Typical diameters of the reinforcing structure may be 0.1 mm to 2.0 mm. For a good bond of reinforcement and Kernmatehal the core material or the entire sandwich system can be infiltrated with resins.
• a vacuum is applied to one side of the core material or the sandwich system to suck in a resin located on the other side.
• the amount of resin introduced should be as small as possible in order to achieve an optimum balance between strength and weight.
• the optimization is mainly done by reducing the amount of resin while increasing the fiber content per puncture hole.

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• Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Composite Materials (AREA)
• Mechanical Engineering (AREA)
• Textile Engineering (AREA)
• Moulding By Coating Moulds (AREA)
• Laminated Bodies (AREA)
• Fencing (AREA)
• Sewing Machines And Sewing (AREA)
• Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
• Lining Or Joining Of Plastics Or The Like (AREA)

Applications Claiming Priority (2)

Publications (1)

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ID=40011030

Family Applications (1)

Country Status (10)

Cited By (1)

Families Citing this family (23)

Family Cites Families (20)

• 2007
  • 2007-10-25 DE DE102007051422A patent/DE102007051422A1/de not_active Withdrawn
• 2008
  • 2008-08-18 JP JP2010530367A patent/JP2011502558A/ja active Pending
  • 2008-08-18 US US12/738,643 patent/US8474388B2/en not_active Expired - Fee Related
  • 2008-08-18 CA CA2703110A patent/CA2703110C/en not_active Expired - Fee Related
  • 2008-08-18 EP EP08803072A patent/EP2203298A1/de not_active Withdrawn
  • 2008-08-18 WO PCT/EP2008/060782 patent/WO2009053129A1/de active Application Filing
  • 2008-08-18 BR BRPI0818817 patent/BRPI0818817A2/pt not_active IP Right Cessation
  • 2008-08-18 KR KR20107008909A patent/KR101479805B1/ko not_active IP Right Cessation
  • 2008-09-03 CN CN2008102148934A patent/CN101417518B/zh not_active Expired - Fee Related
  • 2008-10-22 TW TW097140430A patent/TWI451010B/zh not_active IP Right Cessation

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