EP3102393A1

EP3102393A1 - Tape-laying device and method for constructing a laminate

Info

Publication number: EP3102393A1
Application number: EP15702781.4A
Authority: EP
Inventors: Matthias Graf
Original assignee: Dieffenbacher GmbH Maschinen und Anlagenbau
Current assignee: Dieffenbacher GmbH Maschinen und Anlagenbau
Priority date: 2014-02-05
Filing date: 2015-02-05
Publication date: 2016-12-14
Also published as: DE102014101445A1; WO2015118063A1

Abstract

The invention relates to a method for constructing and consolidating a laminate (90) and to an associated tape-laying device (1). The inventive step for the method consists in carrying out the following steps: 1. feeding a tape (93) to be laid, which is provided with binder substances and/or matrix substances, to a laying device (20); 2. laying up the supplied tape (93) by means of the laying device (20) until a tape structure (91) which consists of adjacently-laid and superposed tape (93) and which corresponds to the laminate (90) is obtained; wherein adjacently-laid tape (93) defines a tape layer (92) of a tape structure (91); and 3. controlling the obtaining of a consolidated laminate (90) by: advancing a cross-section (Q) of the tape structure (91) consisting of adjacently-laid and superposed tape layers (92) and/or tape (93) towards an ultrasonic excitation system (30), or vice versa; successive plasticization of the binder and/or matrix substances in all joining zones (95) of all adjacently-laid and superposed tape layers (92) and/or tape (93) of the tape structure (91) that adjoin one another in the cross-section (Q) advanced towards the ultrasonic excitation system (30); and successive bringing together of the plasticized binder and/or matrix substances in all joining zones (95) of all adjacently-laid and superposed tape layers (92) and/or tape (93) of the tape structure (91) that adjoin one another in the cross-section (Q) advanced towards the ultrasonic excitation system (30);

Description

PAPER EQUIPMENT AND METHOD FOR CONSTRUCTING A LAMINATE

The present invention relates to a tape laying apparatus and to a method of constructing and consolidating a laminate for, for example, automotive 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 device for bringing tape to an excitation device 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 together the plasticized binder and / or matrix materials 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.
By "tape" in the context of the present invention is preferably meant any type of sheeted prepreg material, for example between 30 and 150 mm wide prepreg strip material, which is suitable for being laid down 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 further developed, for example, in WO 2009/130087 A1, in order to be able to deposit thermoplastic tapes as well. In this case, an excitation device is mounted on the laying head, which uses the ultrasound, the induction and / or the infrared, and which a tape to be deposited flying in the trigger, for. heated by a coil or roller, shortly before the deposition time locally across its thickness and then locally heated over its thickness tape then presses on a flexible laying roll on the already deposited tape structure flying on and so successively interconnected.
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.
Finally, reference is made to EP 1 315 613 B1, which discloses a method and equipment for producing advanced composite structures, comprising the steps:
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.
On this basis, the present invention seeks to provide an improved tape laying device or an improved method for building and consolidating a laminate for example, automotive components by means of a tape laying device, which or which avoids the disadvantages described above.
According to the invention, this object is achieved by a method for constructing a laminate having the features of patent claim 1 and by a tape laying device for carrying out a method for constructing a laminate having the features of patent claim 7.

ein Heranführen von einem Querschnitt Q der Tapestruktur aus neben- und aufeinander abgelegten Tapelagen und/oder Tapes an eine Ultraschall-Anregungseinrichtung oder umgekehrt;
ein sukzessives Plastifizieren der Binder- und/oder Matrix-Werkstoffe in allen im an die Ultraschall-Anregungseinrichtung herangeführten Querschnitt Q aneinandergrenzenden Fügezonen aller neben- und aufeinander abgelegten Tapelagen und/oder Tapes der Tapestruktur; und
ein sukzessives Zusammenbringen der plastifizierten Binder- und/oder Matrix-Werkstoffe in allen im an die Ultraschall-Anregungseinrichtung herangeführten Querschnitt Q aneinandergrenzenden Fügezonen aller neben- und aufeinander abgelegten Tapelagen und/oder Tapes der Tapestruktur.

an introduction of a cross-section Q of the tape structure of juxtaposed and stacked piles and / or tapes to an ultrasonic excitation device or vice versa;
a successive plasticizing of the binder and / or matrix materials in all joining zones Q adjacent to one another in the ultrasound excitation device and adjacent to one another and all of the adjacent layers and / or tapes of the tape structure; and
a successive bringing together of the plasticized binder and / or matrix materials in all joining zones, which are adjacent to each other in the cross-section Q brought to the ultrasound exciter, of all juxtaposed and stacked layers and / or tapes of the tape structure.

In accordance with the invention, the binder and / or matrix materials are successively plasticized and consolidated in all joining zones adjoining one another in the ultrasound excitation device Q of all juxtaposed and stacked layers and / or tapes of the tape structure, one can be previously laminated corresponding tapestry obtained from juxtaposed and stacked tape can advantageously be supplied to an ultrasonic excitation device as a whole.
By supplying a previously obtained to the laminate, obtained from juxtaposed and successive tape tape structure as a whole ultrasonic excitation and successively plasticized over their cross section Q and consolidated, also large-scale tape structures or laminates of, preferably 30 to 150 mm wide tapes can be advantageous are built with high lay rates and with an interesting speed for serial applications interesting.
Advantageous embodiments and developments, which can be used individually or in combination with each other, are the subject of the dependent claims.
Thus, in a sequence of the method, it is preferred if the successive plasticizing of the binder and / or matrix materials occurs exclusively in the surfaces of the joining zones adjacent to juxtaposed and stacked layers and / or tapes of at least the lowest and uppermost stackings of the ultrasound -Anregungseinrichtung brought-up cross-section Q of the tape structure.
By the binder and / or matrix materials at least in the side and surface facing away from the juxtaposed and stacked layers and / or tapes of at least lowermost and topmost stacking of the cross-section Q of the tape structure brought to the ultrasonic excitation means not via enamel - or flow temperature of the plastic matrix used, can advantageously also large-scale tape structures or laminates of, for example 30 to 150 mm wide, tapes without unwanted flow and fiber shifts constructed and consolidated over its cross-section Q.
The limitation of undesired flow processes and / or fiber displacements can be increased if, in a preferred sequence of the process, the successive plasticization of the binder and / or matrix materials not only exclusively in the surfaces of adjacent and stacked piles and / or tapes adjacent Joining zones of at least the lowest and uppermost stacking of brought to the ultrasonic excitation device cross-section Q of the tape structure but also in all in between juxtaposed and stacked piles and / or tapes of Tapestruktur 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 of the process, the successive plasticizing of the binder and / or matrix materials in stacking layers arranged between topmost and bottom stacking layers of the cross-section Q of the tape structure brought to the ultrasound exciter, exclusively in the surfaces of the adjoining joining zones and / or across their thickness. In any case, however, the bottom and top layers of a previously deposited tape structure should never be plasticized over the thickness thereof in order not to jeopardize the dimensional stability of the laminate.
In a preferred embodiment of a sequence of the method, 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 a sufficient intrinsic stability of the deposited tape structure to the advantage, so that the tape structure as a whole also supplied outside the tape laying device arranged ultrasonic excitation and - as described above - can be plasticized and consolidated over its cross-section Q successively.
Preferably, in accordance with the present invention, to increase the layup and consolidation rate, a sequence is preferred in which multiple tapes are simultaneously, i. especially at the same time and multi-lane, be handled. Such a parallelization advantageously multiplies the number of laid tapes per cycle sequence corresponding to X (for the number of multi-track handled tapes).

eine Führungseinrichtung für das Heranführen von einem Querschnitt Q der Tapestruktur aus neben- und aufeinander abgelegten Tapelagen und/oder Tapes an eine Ultraschall-Anregungseinrichtung oder umgekehrt;
eine Ultraschall-Anregungseinrichtung für ein sukzessives Plastifizieren der Binder- und/oder Matrix-Werkstoffe in allen im an die Ultraschall-Anregungseinrichtung herangeführten Querschnitt Q aneinandergrenzenden Fügezonen aller neben- und aufeinander abgelegten Tapelagen und/oder Tapes der Tapestruktur; und
eine Konsolidierungseinrichtung für ein sukzessives Zusammenbringen der plastifizierten Binder- und/oder Matrix-Werkstoffe in allen im an die Ultraschall-Anregungseinrichtung herangeführten Querschnitt aneinandergrenzenden Fügezonen aller neben- und aufeinander abgelegten Tapelagen und/oder Tapes der Tapestruktur.

a guide device for bringing a cross-section Q of the tape structure from adjacent and stacked stack layers and / or tapes to an ultrasonic excitation device or vice versa;
an ultrasound excitation device for a successive plasticizing of the binder and / or matrix materials in all the joining zones of adjoining and stacked stack layers and / or tapes of the tape structure adjoining each other in the cross section Q brought to the ultrasound excitation device; and
a consolidation device for a successive bringing together of the plasticized binder and / or matrix materials in all brought in the ultrasound excitation device cross-section adjacent joint zones of all juxtaposed and stacked piles and / or tapes of the tape structure.

In a further embodiment of the tape laying device is provided that the depositing device comprises a plurality of guide beams, which simultaneously retracts several tapes, ablängt and deposits, thereby advantageously simultaneous sequences are possible, which increases the laying speed noticeably.
In a further embodiment of the tape-laying device, 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 comprises a plurality of large-area ultrasonic excitation devices, which are preferably arranged continuously in a sealing bar device or a pair of rolling elements. The provision of a welding bar device has the advantage that the deposited tape structure can remain on the laying table; the provision of a roller pair device has the advantage that the deposited tape structure with the beginning of their consolidation and the laying table for the construction and consolidation of a new laminate already begins to make free.
In a further preferred embodiment, it is provided that the sealing bar device is formed from a multiplicity of side-by-side sliding shoes, which in particular with regard to consolidation parameters are each designed separately by means of a separate control device or the control device.
Such a shoe, which can be found in individual or cumulative features of its embodiment detached from the present invention application, is characterized in particular by a zone with short in movement or sliding direction contact length for coupling ultrasonic energy in the tape structure of tufts and / or tape and by a at least one side in the direction of movement or sliding G subsequent long zone for cooling the tape structure of tufts and / or tapes.
In particular, it has proven useful to design the contact surface of the zone of a sliding shoe for coupling ultrasound energy in the sliding direction G simply curved or circular segment-shaped, so that the contact surface is greatly reduced almost to a linear blade (similar to a circular segment-shaped blade).
Alternatively or cumulatively, the contact force, the sliding speed and / or the ultrasound intensity can be controlled constant or variable by means of a separate control device or in particular as a function of the material properties and / or the temperature and / or thickness of an already deposited tape structure made of layers / or tapes, wherein in particular the surface pressure on the US-coupling zone and the subsequent cooling zone can be controlled differently sized.
Finally, in a development, a sliding shoe is preferred, which is equipped, for example, at its rear end with moving sensors, for example by means of preferably obliquely coupled ultrasound (transmitter and receiver) the consolidation of the tape structure checks for their quality and parameters of the controller for an adaptive control Consolidation, in particular by means of changing the US intensity and / or the speed and / or the contact force provides.
Advantageously, the present invention permits the construction and consolidation of a laminate with high lay rates and speed of interest for production applications.
Insofar as it advantageously leaves the structure as well as the successive consolidation of laid tape structures on one and the same laying table, a release of individual tapes or stackings as a result of encountered in the prior art separation of construction on the one hand and consolidating tape structures laid on the other hand is reliably avoided.
The present invention is particularly suitable for industrial construction and consolidation of a laminate for, for example, automotive components, which are converted to the final component by a thermoforming process or in conjunction with a flowable fiber composite material in the extrusion or injection molding process.
These and other features and advantages of the invention will be explained in more detail with reference to the embodiments of construction and consolidation of a laminate illustrated in the drawings.
They show schematically:
Fig. 1 to 11, the individual process steps for building and consolidating a laminate by means of a single-track tape applicator device according to the invention;
FIGS. 12 to 21 show the individual method steps for constructing and consolidating a laminate by means of a multi-track tape dispensing device according to the invention;
FIG. 22 shows a tape structure of a tape laying device according to the invention, made up of juxtaposed and stacked tape; FIG.
FIG. 23 shows the consolidation of the tape structure from FIG. 22 by means of a welding bar device of a tape laying device according to the invention;
FIG. 24 details of a sealing bar device of a tape laying device according to the invention formed from a plurality of variably controllable sliding shoes; FIG.
FIG. 25 shows a sliding shoe from FIG. 24 in an enlarged side view; FIG. and
Fig. 26 shows the consolidation of the tape structure of Fig. 22 by means of a pair of rolls of a tape laying apparatus according to the invention.
In the following description of preferred embodiments, like reference numerals designate like components.

eine Führungseinrichtung 40 für das Heranführen von einem Querschnitt (Q) der Tapestruktur 91 aus neben- und aufeinander abgelegten Tapelagen 92 und/oder Tapes 93 an eine Ultraschall-Anregungseinrichtung 50 oder umgekehrt;
eine Ultraschall-Anregungseinrichtung 50 für ein sukzessives Plastifizieren der Binder- und/oder Matrix-Werkstoffe in allen im an die Ultraschall-Anregungseinrichtung 50 herangeführten Querschnitt Q aneinandergrenzenden Fügezonen 95 aller neben- und aufeinander abgelegten Tapelagen 92 und/oder Tapes 93 der Tapestruktur 91; und
eine Konsolidierungseinrichtung 60 für ein sukzessives Zusammenbringen der plastifizierten Binder- und/oder Matrix-Werkstoffe in allen im an die Ultraschall-Anregungseinrichtung 50 herangeführten Querschnitt Q aneinandergrenzenden Fügezonen 95 aller neben- und aufeinander abgelegten Tapelagen 92 und/oder Tapes 93 der Tapestruktur 91.

1 to 11

guide means 40 for guiding a cross-section (Q) of the tape structure 91 of juxtaposed and stacked stack layers 92 and / or tape 93 to an ultrasonic excitation device 50 or vice versa;
an ultrasound excitation device 50 for a successive plasticizing of the binder and / or matrix materials in all joining zones 95 adjoining one another in the cross section Q brought to the ultrasound excitation device 50 of all juxtaposed and stacked layers 92 and / or tapes 93 of the tape structure 91; and
a consolidation device 60 for a successive bringing together of the plasticized binder and / or matrix materials in all joined in the ultrasound excitation means 50 cross-section Q adjacent joining zones 95 all juxtaposed and stacked stacking layers 92 and / or tapes 93 of the tape structure 91st

1 , for the construction of a laminate 90, fiber tapes 93, which are first to be deposited by means of a feed device 10, are removed from a reel or reel 11, cut to the required length (see FIG positioned by means of this over the laying table 61 of a consolidation device 60. As shown in Fig. 3 shows the depositing device 20 then moves to the width B of a tape 93 to the right and back to the feeder 10, and engages - as shown in Fig. 4 - from the local coil 11 a newly deposited tape 93 in order to already deposited tape 93 adjacent positioning on the laying table 61 ( Fig. 5 ).
The tape laying apparatus 1 shown in FIG. 6 improves the sequence described so far that this 1 provides a second feeder 10 in addition to roll 11 in the end area of the first tapes 93 to be deposited, so that the depositing apparatus 20 moves only laterally and already new tape 93 during the return stroke can take off.
This sequence is necessary for each tape 93 to be deposited until a first stacking layer 92 is deposited on the laying table 61 ( FIG. 7 ). In order to adequately fix the tapes 93 of the first stacking layer 92 on the laying table 61, the latter 61 can be designed to be vacuumable (not shown).
As shown in FIG. 8 , further tapes 93 are deposited on a top stacking layer 92 thus formed 92 of a deposited tape structure and pre-fixed to each other via spot welding by means of ultrasonic welding heads 71 (position fixing), so that the tapes 93 after positioning and / or Do not move unintentionally first pressing or stand up by residual stresses. So far as the storage of tapes 93 on the top stacking 92 of an already deposited tape structure 91, a prefixing device 70 is preferred, which dot-shaped ultrasonic welding heads 71 comprises for pre-fixing of stored tape 93 with the top stacking 92 an already deposited tape structure 91 by means of welds 72nd
In order to keep the design effort of the device 1 simple, the prefixing device 70 and / or its ultrasonic welding heads 71 can be part of the depositing device 20 (cf., previous figures ).
9 shows the storage of further tapes 93 on the uppermost stacking layer 92 of an already laid down tapestry 91 analogously to FIGS. 3 to 5, that is to say without a second feed device 10 in the end region of deposited tapes 93; FIG. 10 shows the deposit of further tapes 93 on the uppermost stacking 92 of an already deposited tapestry 91 analogous to FIG. 6, ie with a second feeder in the end region of deposited tapes 93 or stackings 92 formed therefrom . FIG. 11 finally shows, comparable to that shown in FIG 7 shows the situation for two stacked layers 92 placed on one another.
FIGS. 12 to 21 show the individual method steps for constructing and consolidating a laminate 90 by means of a multi-track tape applicator 1 according to the invention, which is preferred given the required increase in laying rates.
In contrast to the tape dispensing device 1 shown in FIGS. 1 to 11, the tape dispensing device 1 shown in FIGS. 12 to 21 has a multi-track feed device 10 and a multi-track dispenser 20.
FIGS. 13 to 20 now show the multi-track sequences analogous to FIGS. 2 to 11.
Regardless of whether a first portion of a tape structure 91 is obtained in a single-lane (Fig. 1 to 11) or multi-lane (Figs. 12 to 20) sequence, as shown in Fig. 21, another 91 may be added to this first portion of a tape structure Sections of a tape structure 91 are created.
FIG. 22 shows a tape structure 91 deposited by means of a tape laying device 1 according to the invention from adjacent and successively deposited tape 93.
FIG. 23 shows the consolidation of the tape structure from FIG. 22 by means of a welding bar device 53 of a tape laying device 1 according to the invention. After completion of a single or multi-track laying process pre-fixed tape structures 91 are fed to a subsequent process. In this subsequent process, the pre-fixed tapes 93 and / or stacking layers 92 of a deposited tape structure 91 are "clocked" stepwise under an ultrasonic welding bar device 53, which is equipped with a plurality of large-scale ultrasonic excitation devices 30, which are arranged in juxtaposed sliding shoes 80 and the tape structure 91 from stacking layers 92 and / or tapes 93 successively, largely over the entire surface, consolidated.
The necessary heat is achieved by a high-frequency mechanical vibration, which arises between the components by molecular and boundary surface friction.
The group of friction welding ultrasonic welding is characterized by very low welding times and high efficiency. Usually high-frequency alternating current is generated by means of a generator and transmitted via a shielded cable to an ultrasonic transducer, the so-called converter, which generates mechanical ultrasonic frequency therefrom with the aid of the piezoelectric or magnetostrictive effect. These vibrations are transmitted to the sonotrode via an amplitude transformation piece. Different applications require different designs of sonotrodes, which are usually made of steel, aluminum or titanium. The amplitude of the oscillation and the impedance matching are influenced by the shape and mass of the amplitude transformation piece.
FIG. 24 shows details of a sealing bar device 54 of a tape dispensing device 1 according to the invention formed from a plurality of ultrasonically adjustable sliding shoes 80 which can be controlled in a variable manner. It can be seen that the plurality of side-by-side sliding shoes 80, in particular with regard to consolidation parameters, are each designed to be controllable separately by means of a separate or control device 30. Depending on the degree desired, namely in the context of the consolidation of individual tapes 93 and / or stacking layers 92, or undesired flow processes and / or fiber displacements of individual tapes 93 and / or stacking layers 92 can within the tapestry 91 in a preferred sequence of the method, the successive plasticizing the Binder and / or matrix materials in between the top and bottom stacking 92 arranged stacking layers 92 of the brought to the ultrasonic exciter 50 cross-section Q of the tape structure 91 exclusively in the surfaces 96 of the adjoining joining zones 95 and / or across the thickness of time. In any case, however, the lowermost and uppermost stacking layers 92 of a previously deposited tape structure 91 are never plasticized across their thickness in order not to jeopardize the dimensional accuracy of the laminate 90.
In this process, referred to as consolidation, according to the invention, the joining parameters (ie the binder and / or matrix materials) are preferably heated exclusively in all the contact surfaces 95 of two stacking layers 92 until they have been plasticized. If there is no joining zone 95 between two stacking layers 92, a connection remains (marked in FIGS. 23 and 26 as a contact clearance area 97). On the other hand, the compounds, that is, as far as possible full-surface bonding or welding due to plasticization of the binder and / or matrix materials in, for example, all surfaces 96 of tape 93 to be deposited with the binder and / or matrix materials in joining zones 95 of the uppermost Tapelage 92 an already deposited tape structure 91, arises such 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 entwined and / or form covalent bonds.
FIG. 25 shows an ultrasonic sliding shoe 80 from FIG. 24 in an enlarged side view. The illustrated shoe 80, 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 81 in the movement or sliding direction G short contact length 83 for coupling ultrasonic energy into the tape structure 91 from Tapelagen 92 and / or tape 93 and by at least one side in the direction of movement or sliding G subsequent long zone 82 for cooling the tape structure 91 of Tapelagen 92 and / or tapes 93. It has proven particularly useful, the contact surface 83 of the zone 81 of a shoe 80 for coupling of ultrasonic energy in the sliding direction G simply curved or circular segment-shaped, so that the contact surface 83 is greatly reduced almost to a linear blade ("similar to a circular segment-shaped blade"). Alternatively or cumulatively, the contact pressure, the sliding speed and / or the ultrasound intensity can be controlled constant or variable by means of a separate or control device 30, in particular depending on the material properties and / or the temperature and / or thickness of an already deposited tape structure 91 Tapelagen 92 and / or tapes 93, in particular, the surface pressure on the US-coupling zone 81 and the subsequent cooling zone 82 may be controlled differently sized. Finally, in an embodiment, an ultrasound gliding shoe 80 is preferred, which, for example, at its rear end, equipped with moving sensors (not shown), for example, by means of preferably obliquely coupled ultrasound (transmitter and receiver) checks the consolidation of the tape structure 91 on their quality and providing parameters to the controller 30 for adaptive control of the consolidation, such as, in particular, by changing the US intensity and / or the speed and / or the contact pressure.
Finally, FIG. 26 shows the consolidation of the tape structure from FIG. 22 by means of a roller pair device 54 of a tape laying device 1 according to the invention. The use of an ultrasonically impinged pair of rollers is of particular interest in the manufacture of tailored blanks 91, in particular of constant thickness. The pair of rollers can be arranged, for example, on one longitudinal side of the laying table 61 and thus alternatively to the previously described consolidation by means of a welding bar device 53 via individual arranged in the rollers of the roller pair means 54 ultrasonic excitation means 30 in the cycle, a - substantially full-surface - welding by means of a continuous pass the tapestry 91 from juxtaposed and stacked stacking layers 92 and / or tapes 93, in particular when deducted from the laying table 61, achieved by the ultrasonically impinged pair of rollers.
By according to the invention, the binder and / or matrix materials are successively plasticized and consolidated in all the joining zones 95 adjoining each other in the cross-section Q brought to the ultrasound excitation device 50 and of all stacked layers 92 and / or tapes 93 of the tape structure 91 previously obtained to laminate 90, obtained from juxtaposed and stacked tape 93 tape structure 91 advantageously a total of an ultrasonic excitation device 50 are supplied.
By supplying a tape structure 91 corresponding to the laminate 90 and obtained from juxtaposed and stacked tape 93 as a whole to an ultrasonic excitation device 50 and successively plastifying and consolidating over its cross-section Q, large-area tape structures 91 or laminates 90, preferably 30 to 150 mm wide, tapes 93 are advantageously constructed with high laying rates and consolidated with an interesting speed for series-compatible applications.
Advantageously, the present invention permits the construction and consolidation of a laminate 90 at high lay rates and speed of interest for production applications.
Insofar as it advantageously leaves the structure as well as the successive consolidation of laid tape structures 91 on one and the same laying table 61, detachment of individual tapes 93 or stackings 92 as a result of separation of structure on the one hand and consolidation of laid tape structures 91 on the other hand is reliably avoided ,
The present invention is particularly useful for industrial construction and consolidation of a laminate 90 for, for example, automotive components that are formed into the final component by a thermoforming process or in conjunction with a flowable fiber composite material in the extrusion or injection molding process.
LIST OF REFERENCE NUMBERS
1 tape device
10 feeder
11 bobbin, roll
20 depositing device
30 control device
40 guide device
50 excitation device
53 Welding bar device
54 roller pair device
60 consolidation facility
61 Legetisch
70 prefixing device
71 Ultrasonic welding head
72 spot weld
80 sliding shoe
81 Einkopplungszone of the sliding block 80th
82 cooling zone of the sliding block 80
83 contact surface of the coupling zone 81
90 laminate
91 Tapestruktur
92 stacking
93 tape
95 joining zones
96 Surface of the joining zones
97 area sections
Q cross section
B width of a tape 93
X Number of multi-track tapes 93a, 93b, 93c, 93d, ...
G sliding direction

Claims

Method for constructing and consolidating a laminate (90) for, for example, automobile components by means of a tape laying device (1), characterized by:

a) feeding to be deposited with binder and / or matrix materials to be deposited tape (93) to a depositing device (20);

b) depositing supplied tape (93) by means of the depositing device (20) until a tape structure (91) corresponding to the laminate (90) is obtained from tape (93) deposited next to and on top of one another; wherein juxtaposed tape (93) defines a stacking (92) of a tape structure (91); and c) controlling the receipt of a consolidated laminate (90) by:

- An approach of a cross section (Q) of the tape structure (91) of juxtaposed and stacked stacking layers (92) and / or tapes (93) to an ultrasonic excitation means (30) or vice versa;

a successive plasticizing of the binder and / or matrix materials in all the cross-section (Q) brought to the ultrasound excitation device (30) adjoining joining zones (95) of all juxtaposed and stacked stacking layers (92) and / or tapes (93 ) the tape structure (91); and

a successive bringing together of the plasticized binder and / or matrix materials in all joining zones (95) adjoining each other in the cross-section (Q) brought to the ultrasonic excitation device (30) of all stacked layers (92) and / or tapes ( 93) of the tape structure (91).
The method of claim 1, wherein in a sequence of the method, the successive plasticizing of the binder and / or matrix materials exclusively in the surfaces (96) adjacent to the juxtaposed and stacked piles (92) and / or tapes (93) Joining zones (95) of at least the bottom and top stacking layer (92) of the ultrasound excitation device (50) brought up cross section (Q) of the tape structure (91).
The method of claim 1 or 2, wherein in a sequence of the method successive plasticizing the binder and / or matrix materials exclusively in the surfaces (96) of the adjoining joining zones (95) of all juxtaposed and stacked stack layers (92) and / or tapes (93) of the ultrasound excitation device (50) brought up cross section (Q) of the tape structure (91) takes place.
Method according to one of the preceding claims, wherein in a sequence of the method, the successive plasticizing of the binder and / or matrix materials in between top and bottom stacking layer (92) arranged stacking layers (92) of the ultrasound excitation means (50) brought up Cross-section (Q) of the tape structure (91) exclusively in the surfaces (96) of the adjoining joining zones (95) and / or across the thickness takes place.
Method according to one of the preceding claims, wherein in a sequence of the method on the topmost stacking (92) of a previously deposited tape structure (91) stored tape (93) with this tape (93) carrying topmost stacking (92), in particular via a punctiform ultrasonic welding, prefixed.
Method according to one of the preceding claims, in which a plurality of tapes (93a, 93b, 93c, 93d, 93e, ...) are handled simultaneously in a sequence of the method.
Tape laying device (1) for carrying out a method for constructing and consolidating a laminate (90) for, for example, automobile components, in particular according to one of the preceding claims, characterized by :

a) a feed device (10) for supplying provided with binder and / or matrix materials to be deposited tape (93) to a depositing device (20);

b) a depositing device (20) for depositing supplied tape (93) until a tape structure (91) corresponding to the laminate (90) is obtained from juxtaposed and stacked tape (93); wherein juxtaposed tape (93) defines a stacking (92) of a tape structure (91); and c) control means (30) for controlling the obtaining of a consolidated laminate (90) by:

- A guide means (40) for the introduction of a cross section (Q) of the tape structure (91) of juxtaposed and stacked stacking layers (92) and / or tapes (93) to an ultrasonic excitation means (50) or vice versa;

an ultrasound excitation device (50) for a successive plasticizing of the binder and / or matrix materials in all joining zones (95) adjoining each other in the cross section (Q) brought to the ultrasound excitation device (50) of all juxtaposed and stacked layers ( 92) and / or tapes (93) of the tape structure (91); and - a consolidation device (60) for a successive bringing together of the plasticized binder and / or matrix materials in all in cross section (Q) brought to the ultrasound exciter (50) adjacent joining zones (95) of all juxtaposed and stacked piles ( 92) and / or tapes (93) of the tape structure (91).
Tape laying device (1) according to claim 7, characterized in that the depositing device (20) comprises a plurality of guide beams (21) which at the same time retracts, cuts and deposits a plurality of tapes (93a, 93b, 93c, 93d, 93e, ...).
Tape laying device (1) according to claim 7 or 8, characterized in that the depositing device (20) and / or the laying bars (21) and / or a laying table (41) at least the width of one or a group (X) tapes to be deposited (93 ) are designed to be displaced to the side.
Tape laying device (1) according to any one of claims 7 to 9, characterized in that the consolidation device (40) comprises a plurality of large-area ultrasonic excitation means (50), which are preferably arranged continuously in a welding bar means (53) or a roller pair means (54).
Tape laying device (1) according to claim 10, characterized in that the welding bar means (53) is formed of a plurality of juxtaposed sliding shoes (80), which in particular with respect to consolidation parameters each separately by means of a separate or the control device (30) are formed controllable.
Tape laying device (1) according to claim 11, characterized in that each sliding shoe (80) has a zone (81) with a short contact length (83) in the direction of movement or sliding (G) for coupling ultrasonic energy into the tape structure (91) Toppagen (92) and / or tape (93) and at least one side in the direction of movement or sliding (G) subsequent long zone (82) for cooling the tape structure (91) of Tapelagen (92) and / or tapes (93).
Tape laying device (1) according to any one of claims 7 to 12, characterized in that the contact surface (83) of the zone (81) of a sliding shoe (80) for coupling of ultrasonic energy in the sliding direction (G) is simply curved or circular segment-shaped, so that the contact surface (83) is reduced to almost a line-shaped runner.
Tape laying device (1) according to any one of claims 7 to 13, characterized in that by means of a separate or the control device (30) the contact pressure, the sliding speed and / or the ultrasonic intensity is controlled constant or variable, in particular depending on the material properties and / or the temperature and / or thickness of an already deposited tape structure (91) of stacking layers (92) and / or tapes (93), wherein in particular the surface pressure on the US-coupling zone (81) and the subsequent cooling zone (82) are controlled differently sized ,
Tape laying device (1) according to any one of claims 7 to 14, characterized in that the sliding shoe (80), for example at its rear end, is provided with moving sensors (84) which, for example, by means of preferably obliquely coupled ultrasound, consolidate the tape structure (91 ) checks for quality and provides parameters to the control means (30) for adaptive control of the consolidation, such as, in particular, by changing the US intensity and / or the speed and / or the contact pressure.