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
  • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
  • B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
  • B29B11/00—Making preforms
  • B29B11/14—Making preforms characterised by structure or composition
  • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
• • 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
  • B29C70/48—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 and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
• • 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
  • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
  • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
  • B32B3/04—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
• • 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
  • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B29K2105/0872—Prepregs

Definitions

• the invention relates to a process for the multistage preparation of a
• Fiber composite components called, in particular industrial use of the RTM process, resin transfer molding process, common practice. The whole
• Manufacturing process to a usable plastic components consists of several subsequent individual processes. In a first
• Process step near-net shape preforms / semi-finished fiber products are produced, which already have substantially the outer shape of the later plastic component.
• preform process production of a preform
• these preform process are usually several layers of fabric or fiber fabric, usually in two-dimensional form, stacked or possibly joined (sewing, welding, gluing), so that the
• Fiber fabric stack substantially already the necessary outer contours and sometimes already special layers or layer thicknesses or local
• a binder is introduced into the parting planes of the layers, which after reaching a reshaped three-dimensional shape and its activation and curing leads to a fixation of the layers to each other and the corresponding 3D contour (WO 2012 156 523 A1).
• the fabric stacks are transferred to a forming tool and usually under (relatively low) pressure by closing the
• Forming tool as far as the contour of the subsequent molding approximated and cured by activation of the binder (heating and cooling), which is the
• Semi-finished fiber can be inserted close to the final contour in a tool of a press for performing the RTM method itself (WO 2010 103 471 A2). Depending on Demand is the semi-finished fiber still recut or punched at predetermined locations in order to achieve an even more precise contour of the semifinished fiber product (preform) over the later plastic component.
• the mold halves are closed and injected the necessary resin into the cavity of the tool, wherein the resin impregnates the fiber structure of the semifinished fiber, the fibers includes and fixed incorporated into the resin matrix.
• the fiber-reinforced plastic component can be removed from the mold.
• the production of a semi-finished fiber product lays the foundation for success in the production of a semi-finished fiber
• Plastic component It has been found that the state of the art describes a large number of possibilities for producing a preform, which, however, as a rule results in manual or automated production of as level as possible
• Fiber cloth stack exhausted which is finally transferred in a press from its 2D shape into a 3D shape. This can be done in a pre-fixed (eg sewn) or even in a flexible state. The goal is after the
• the essential aim of the preforming or the production of a preform is to obtain a preform which is resistant to bending in order to be fully automated and process-technically safe and reproducible in its quality in the tool of a RTM press after shaping from a limp material or even until further use (reworking, pretreatment, ...) can be transported and stacked.
• Fiber webs are also known in the following process steps: fiber webs or webs are unwound from a roll and made up of a number of different webs or plies, shapes and sizes into a fiber stack as needed. It may be necessary, the outer and possibly inner contour corresponding to a pattern of the preform or the Plastic molding to edit or cut. The pattern is generated from a development of the preform, or the final component. Preferably, the created, substantially flat fiber stack is then by means of a
• Draping device draped, respectively by means of a molded into a three-dimensional preform (WO 2012 062 824 A1, WO 2012 062 825 A1, WO 2012 062 828 A1).
• Preforms are massively stapled to obtain a stable preform that can be safely manipulated insertable into a press mold.
• the compilation of a suitable preform of several partial preforms in a press mold itself can be carried out only in individual cases, since the times of the press opening should be kept as short as possible. It is also necessary for the large-scale production of a large number of partial preforms to provide a corresponding number of cutting, manipulating and draping tools.
• the batt and lay will generally be considered equivalent and will typically be comprised of a plurality of superimposed fiber mats, the nomenclature locating the single preform preform preferably in the prior art and the sequential use of multiple layers to produce a part preform Lings respectively a preform are preferably provided for use in the invention. It is important for the understanding of the invention to know that the layer cover / fiber layer in normally plane orientation in the
• Drape device be inserted, whereas prefabricated part preforms at least already have a certain 3D contouring and if necessary
• the invention thus understands the transition between a layer layer and a resulting part preform (3D contoured) essentially as flowing.
• the object of the invention is to provide a method, an apparatus and a preform in which with the multi-stage production of a
• Preform is to achieve an improvement in the transitions between the layers of the sub-preforms or within the preform. In a possible extension of the object, it should be made possible to essentially dispense with the production of partial preforms or to allow the number of necessary partial preforms in an optimized production process of a
• the solution of the task for the method comprises the following method steps:
• At least one layer layer and / or a partial preform is inserted by means of the transport device in a draping form
• the layer or layers are transformed by means of Drapierstempeln along the contour of Drapierform,
• the solution for the device is that for the multi-stage production of a three-dimensional preform from at least two layered and / or
• Part preforms in the course of the production of fiber-reinforced molded parts with at least one draping device and at least one transport device for the layer covers and / or partial preforms, wherein the draping device at least comprises a drape shape for the fiber fabric and movable to Drapierform
• Drapierstempel for reshaping and / or fixing the Schichtgelege and / or Operavorformlingen corresponding to the contour of the Drapierform, and wherein in the
• Drapierstempel is arranged at least one means for activating the binder, wherein the Drapierstempel and the transport device so with a
• Control device of the device are operatively connected, that they are suitable in a predetermined sequence, preferably different Schichtgelege and / or
• a first solution for a preform is that at least one abutting edge between the layered layers and / or the partial preforms a Step edge is arranged, which preferably has a reinforcing overlap with at least one further agent.
• the preform is manufactured by a method according to one or more of the method claims and / or in a device according to one or more of the device claims.
• the impact edge formation respectively the formation of the
• Fiber mat blank of a fiber fabric is located adjacent and fully absorbing the above and below fiber layers absorb the loads. As a result, fiber bends are avoided, which is known to lead to a strong reduction in component strength.
• the drape shape may be substantially
• the laminate layer or a fiber mat blank can be heated and placed in the draping mold and then cooled by the draping mold and / or the draping dies so that the binder hardens.
• the layer cover and / or the preforms are preheated to or above the melting temperature of the applied binder and are inserted into the draping mold in the hot state.
• Fasermattenzuites is inserted with a movable transport tray with or without a conveyor belt in the drapery form.
• the layer coverings and / or the partial preforms are or are provided on at least one abutting edge with a step edge.
• the step edges are preferably made of different fiber mat blanks in the production of the layer cover or in the course of draping the layer cover or partial preforms in the draping device.
• the layer coverings to be inserted and / or the preforms differ in their spatial arrangement in the draping form and / or in their spatial extent from one another.
• at least one fiber mat blank or a layer covering is introduced in the draping device such that it has at least two further layer layers and / or
• At least one draping stamp will lift off again after each forming of a layered fabric or a pre-premort.
• at least one Drapierstempel remain for fixing in contact with the layer layer or the preform.
• the step edges and / or the abutting edges are wetted with binder at the contact points between the layered layer and / or a fiber mat blank and / or a partial preform.
• one is compared to one
• suitable means are provided for monitoring the abutment edges and / or for forming the step edges and / or for arranging the layer layers in the draping device
• Device used and / or in particular the subsequent Schichtgegege or partial preforms to be applied are positioned by means for monitoring the position of the stationary and the moving step edges and / or the abutting edges.
• Drape stamp by means of predetermined, preferably cutting or draping,
• Means be suitable in the course of Drapiervorganges on the layer layer and / or on the partial preforms on at least one edge to form a step edge.
• Means be suitable in the course of Drapiervorganges on the layer layer and / or on the partial preforms on at least one edge to form a step edge.
• a preferred further embodiment is in the device a
• Cutting device for producing different fiber mat blanks and an associated transport device for the production of the layer layer arranged.
• Transport device for arranging a fiber mat blank or a
• Schichtgeleges be arranged in the draping device for connecting further Schichtgelege and / or Operavorformlinge by overlapping the abutting edge or the step edge.
• in the device preferably in the draping device, means for wetting the step edges and / or the
• Abutting edges with binder at the contact points between the layered and / or a fiber mat blank and / or a part preform be arranged.
• Fiber mat blank a layered layer and / or a partial preform
• Part preforms be arranged, in particular with means for monitoring the position of the stationary and the moving step edges and / or the abutting edges.
• the device is particularly suitable for carrying out the method, but can also be operated independently.
• All combinations shown in the figure description are all alone and independently and in any combination usable.
• individual sentences or subsets are also to be evaluated as independent characteristics. Further advantageous measures and embodiments of the subject matter of the invention will become apparent from the dependent claims and the following description with the drawing.
• Figure 2 shows a possible example of a composite preform of three
• Partial preforms with overlap or a bumped edge (dotted part preform) of the prior art Partial preforms with overlap or a bumped edge (dotted part preform) of the prior art
• FIGS. 6 to 10 show a similar component on a schematic component contour
• FIG. 1 shows a plant for the production of fiber-reinforced molded parts 19 in an RTM press 15 using preformed preforms 17 as
• the fiber mat blanks 22 can then by means of a suitable transport device (which in FIG.
• a glue application device 13 and where appropriate provided with binder as needed, before they are assembled into a fiber fabric 1.
• fiber mats 10 which already contain a suitable binder, so that could be dispensed with this step.
• the finished fiber layer 1 can then be tempered by a heating device 2 and preferably raised to a temperature which at least corresponds to the melting temperature of the binder. Of course, this step can also take place only in the draping device 3 itself. Subsequently, the fiber fabric 1 is brought into a draping device 3 and formed there by suitable means along the contour of the drape form 18.
• the fiber fabric 1 undergoes cooling and solidifies to a preform 17 which can usually be stacked without problems on a stack 16 or inserted in component-specific intermediate carriers for transport before it is in a RTM Press 15 is pressed into a reinforced molding 19.
• Production of a preform is no longer only a fiber fabric 1 is used, which is formed in the drapery device 3, but that at least two
• Layers A, B ... (in the example to E) are used, from which after the forming in the draping device 3, a preform 17 is created.
• FIG. 2 shows a possible example of a composite preform 17 consisting of three layered layers A, B, C or A, B, C with an overlap by layer cover C or a bump edge 7 (dotted layer cover C) according to the prior art, wherein according to the prior art Kunststoff prefabricated preforms 9 as
• FIGS. 3 to 5 the sequence of a possible positioning of the layered layers A to E is shown in section of a fictitious preform
• Part preforms are shown, wherein first according to Figure 3 two, preferably parallel inserted and draped, outer layer layer A and B after draping as Operavorformlinge (if cured) have a step edge 4, wherein in Figure 4, the central arrangement of another layered fabric with corresponding counter-rotating step edge a connected between the three
• Layered A, B, C respectively produced the preforms, wherein the step edge of the layer layer is configured in accordance with the other way around to produce the Shuftung.
• the layer layer C may have a region C "which may later be used for overlapping.
• the layer cover D or E overlapping the interconnections and the interconnecting layers can be replaced by means of fiber mats or partial preforms
• FIGS. 6 to 10 show a similar sequence according to FIGS. 3 to 5 on a schematic component contour (in this case a base trough of a motor vehicle) in plan view.
• an empty draping form 18 (according to FIG. 6) is laid in two layer layers A, B (FIG. 7) and fixed or shaped in the draping form 18 by means of the draping stamps (not shown). Due to the arrangement of different fiber mats in the course of production, there is already a step edge 4 to the layered A, B or this is in the course of forming, for example, outside at the edge of Drapierform the layer layer A, B, fixed and while it is inside down in the draping form 18 flows, the step edge 4 is formed.
• Step edge 4 can be supported by the respective many and appropriately arranged Drapierstempel 5.
• a step edge is also recognizable at the upper and lower ends of the layers A, B.
• a further layer layer C with a corresponding reciprocal step edge is now centrally placed in the drape form and / or actively draped with the drapery stamps to the layered layers A, B.
• the Layer cover C have a further structure C "for a subsequent overlap function or impact edge.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Composite Materials (AREA)
• Robotics (AREA)
• Reinforced Plastic Materials (AREA)
• Moulding By Coating Moulds (AREA)
• Casting Or Compression Moulding Of Plastics Or The Like (AREA)
• Laminated Bodies (AREA)
• Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)

Applications Claiming Priority (2)

Publications (1)

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• 2013
  • 2013-03-25 DE DE102013103039.4A patent/DE102013103039A1/de not_active Withdrawn
• 2014
  • 2014-03-25 JP JP2016504644A patent/JP2016515481A/ja active Pending
  • 2014-03-25 EP EP14712014.1A patent/EP2978576A1/de not_active Withdrawn
  • 2014-03-25 WO PCT/EP2014/056004 patent/WO2014154720A1/de active Application Filing
  • 2014-03-25 CN CN201480018397.5A patent/CN105073365A/zh active Pending
  • 2014-03-25 US US14/779,958 patent/US20160059498A1/en not_active Abandoned
  • 2014-03-25 KR KR1020157030606A patent/KR20150135455A/ko not_active Application Discontinuation

Non-Patent Citations (2)

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