EP3704397A1 - Composant pour l'absorption d'énergie de choc - Google Patents

Composant pour l'absorption d'énergie de choc

Info

Publication number
EP3704397A1
EP3704397A1 EP18796873.0A EP18796873A EP3704397A1 EP 3704397 A1 EP3704397 A1 EP 3704397A1 EP 18796873 A EP18796873 A EP 18796873A EP 3704397 A1 EP3704397 A1 EP 3704397A1
Authority
EP
European Patent Office
Prior art keywords
component
fiber
bundles
wall
carbon 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.)
Pending
Application number
EP18796873.0A
Other languages
German (de)
English (en)
Inventor
Bernd Wohlmann
Christian Hunyar
Markus Schneider
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.)
Teijin Carbon Europe GmbH
Original Assignee
Teijin Carbon Europe GmbH
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 Teijin Carbon Europe GmbH filed Critical Teijin Carbon Europe GmbH
Publication of EP3704397A1 publication Critical patent/EP3704397A1/fr
Pending legal-status Critical Current

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
    • F16F7/00—Vibration-dampers; Shock-absorbers
    • F16F7/12—Vibration-dampers; Shock-absorbers using plastic deformation of members
    • F16F7/124—Vibration-dampers; Shock-absorbers using plastic deformation of members characterised by their special construction from fibre-reinforced plastics
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/0405—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres
    • C08J5/042—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres with carbon fibres
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
    • F16F7/00—Vibration-dampers; Shock-absorbers
    • F16F7/003—One-shot shock absorbers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
    • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
    • B60R19/24—Arrangements for mounting bumpers on vehicles
    • B60R19/26—Arrangements for mounting bumpers on vehicles comprising yieldable mounting means
    • B60R19/34—Arrangements for mounting bumpers on vehicles comprising yieldable mounting means destroyed upon impact, e.g. one-shot type
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2363/00—Characterised by the use of epoxy resins; Derivatives of epoxy resins
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
    • F16F2224/00—Materials; Material properties
    • F16F2224/02—Materials; Material properties solids
    • F16F2224/0241—Fibre-reinforced plastics [FRP]
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
    • F16F2234/00—Shape
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
    • F16F2236/00—Mode of stressing of basic spring or damper elements or devices incorporating such elements
    • F16F2236/04—Compression

Definitions

  • the invention relates to a three-dimensional, formed as a body member made of a fiber composite material for arrangement between a first shock element and a second shock element and for the absorption of impact energy due to an acting between the first and second impact element impact stress.
  • the protection of vehicle occupants of a motor vehicle as well as the protection of persons and objects located in the vicinity of the vehicle in collision cases is an important aspect in the design and manufacture of a motor vehicle. It is important in a safe design of a motor vehicle in the event of a collision that a vehicle deceleration or a force acting on the vehicle occupants, while occupant restraint systems develop their effect, do not exceed certain thresholds in the course of the collision.
  • Such a deformation element for example, between a bumper cross member and a frame side member of the
  • Body structure including a body structure carrier or
  • Body structure support failed at an adjusted strength level.
  • Body structure or deformation elements are often designed so that they fail collision energy absorbing in the collision load case of the motor vehicle.
  • Body structural support made of metallic materials are designed so that they deform plastically suitable at a certain level of force over a designated route.
  • pipes made of aluminum provide a strong connection between the bumper cross member and the vehicle.
  • the specific energy absorption (kJ / kg) of metal tubes when compressed is not particularly high.
  • the initial force required for a metal tube to be compressed longitudinally may be too large for many situations.
  • Carbon fiber reinforced plastic or other fiber reinforced plastic hollow sections have been proposed, for example
  • EP 1366960 B1 discloses components for energy absorption or absorption of impact energy from fiber composite materials, in particular composite materials based on carbon fibers.
  • Body structure supports or deformation elements can be produced, for example, by braiding, pultrusion or winding or, as described in EP 1366960 B1, by laminating together several fiber layers, for example multiple layers of fabric, preferably starting from continuous fibers.
  • components for energy absorption have z.T. a layered structure or laminate structure, but can also be prepared from discontinuous fibers according to DE 102014016024 A1 or contain areas with arbitrarily oriented fibers, as described in EP 1366960 B1. Overall, the components described in the aforementioned documents have a complex component structure.
  • JP 06-264949 has a cylindrical shape, wherein the wall of a cylindrical portion is designed so that the wall thickness increases from one end to another end. In the examples, JP 06-264949 goes over
  • Injection molding process prepared elements with a polypropylene matrix were mixed in the glass fibers with a fiber length of 3 mm and in a concentration of 30 wt .-%.
  • EP 3104036 A1 describes structures of fiber composite materials with a thermoplastic matrix for shock absorption or for energy absorption.
  • the structures are usually designed as hollow profiles and may comprise bündiförmige reinforcing fibers.
  • the fibers may be carbon fibers embedded in the thermoplastic matrix.
  • the fibers may preferably be oriented two-dimensionally randomly in a surface plane.
  • reinforcing fibers can be cut, then opened and the opened reinforcing fibers then mixed with a fibrous or particulate thermoplastic.
  • thermoplastic semifinished product a fiber-reinforced thermoplastic semifinished product.
  • One or more such semi-finished layers are stacked on top of each other to form the hollow profile.
  • the layered structure when impacted in a direction parallel to the layers, may result in delamination of the layers, associated with the detachment of large contiguous areas of material, which significantly reduces the specific impact energy impartation, or associated with the buckling of so weakened areas of the component , which leads to the sudden failure of the component and a very low impact energy consumption.
  • the present invention has for its object to provide a structurally simple and easy to manufacture component for absorbing energy in the event of impact load.
  • the component should have a high specific impact load
  • the object is achieved by a three-dimensional, formed as a body member made of a fiber composite material based on carbon fibers for the arrangement between a first shock element and a second shock element and for the absorption of impact energy due to an acting between the first and second shock element impact stress having an impact direction having the component
  • the bundles are distributed substantially uniformly over the wall thickness, when viewed in a direction perpendicular to the first and / or second surface are substantially isotropically aligned and viewed parallel to the first and / or second surface (8, 9), the bundle angle of intersection form with a part of the first and / or second surface (8, 9), wherein the bundles are distributed parallel to the first and / or second surface (8, 9) within the component so that the majority of the cutting angles is within a range , in which the angles of intersection in the West are evenly distributed between 0 ° and 90 ° up to predominantly present
  • the fiber volume fraction of the carbon fibers in the wall is in the range between 35% by volume and 70% by volume
  • the bundles of carbon fibers have a length in the range between 3 mm and 100 mm and
  • the component being obtainable by a process comprising producing a fiber preform from the bundles of carbon fibers, and optionally by subsequently introducing a matrix system into the fiber
  • Fiber preform by injection, infusion infiltration or pressing.
  • the component should be designed as a body in a viewing direction parallel to the longitudinal extent.
  • the term body includes both a profile, semi-profiles or other geometries whose cross-section may vary along the longitudinal axis.
  • the body may be hollow, solid and / or partially filled and / or its longitudinal extent may be subdivided by means of intermediate pieces. Furthermore, the body may have different wall thicknesses, include reinforcing elements and / or have recesses.
  • the body that forms the component may be constructed in one piece (in one piece) or from a plurality of partial bodies.
  • the part bodies may also have different cross sections, be hollow, solid and / or partially filled and different
  • the component can also be referred to as a deformation element.
  • the bundles of carbon fibers may also be referred to as carbon fiber bundles, reinforcing fiber bundles, or bundles only.
  • the component can also be formed without the subsequent incorporation of the components of a matrix system (eg a thermosetting matrix resin).
  • a matrix system eg a thermosetting matrix resin
  • Matrix material (a matrix system) for component manufacturing is not required.
  • the component for example, by activating the
  • Components of the polymer matrix are produced by means of pressure and heat.
  • the polymer matrix (in which the fiber bundles are embedded) consists for the most part of one or more crosslinked polymers. To a lesser extent, the polymer matrix may also comprise partially crosslinked polymers.
  • the polymer matrix can be a predominant proportion of a fully crosslinkable duromer and a small proportion of a thermoplastic
  • Resin system and / or additives.
  • Resin system and / or additives.
  • thermoplastic behaving thermosets used.
  • thermosets used.
  • the polymer matrix consists of a conglomerate of epoxy with thermoplastic portions.
  • Polymer matrix system which consists for the most part of one or more crosslinked polymers (for example, a thermosetting matrix resin).
  • the matrix system preferably hardens.
  • the matrix system (optionally in addition to
  • Part manufacturing can be added) for the most part of one or more crosslinked polymers.
  • the matrix system may comprise fully or at least partially crosslinked polymers.
  • the matrix system can have a predominant proportion of a fully crosslinkable duromer and a small proportion of a thermoplastic resin system and / or additives. It is also possible to use thermoplastically behaving thermosets. In a further embodiment The matrix system consists of a conglomerate of epoxy with thermoplastic components.
  • the component over a wide temperature range advantageously approximately constant
  • the majority of the bundles between the first and / or second surface forms so-called cutting angles with the first and / or second Surface off.
  • the cutting angles of the fiber bundles are in a range in which the cutting angles in the West are uniformly distributed between 0 ° and 90 ° up to an arrangement of the fiber bundles, in which the cutting angles predominantly an angle of greater than 1 °, preferably greater than 2 ° and more preferably greater than 3 °.
  • angles of intersection In the case of a distribution of the fiber bundles, which is predominantly isotropic when considered parallel to the first and / or second surface, the angles of intersection essentially all have a value between 0 ° and 90 °, wherein no value is to be represented much more frequently or less frequently. Lying the
  • the fiber bundles are isotropic in the component and also
  • the wall thickness of the component is is isotropic with respect to the surfaces if the fibers of the fiber bundles have a short length and, in addition, the wall thickness of the component is greater than the fiber length.
  • An example of this could be the use of fiber lengths of 3 mm for a component with a wall thickness of 5 mm.
  • the extension of the component in the longitudinal direction is greater than its extension perpendicular to the longitudinal direction.
  • the component according to the invention leads to a uniform absorption behavior, which can be recognized by the force curve over the deformation path, wherein the peak loads in the initial phase of an impact load are comparatively low.
  • a high specific energy absorption (kJ / kg) can be realized with the component according to the invention in comparison to components or deformation elements made of metallic materials.
  • the component according to the invention thus provides a solution which enables a defined energy absorption to a constant level over an adjustable long deformation distance.
  • the actual energy level can be due to the geometric design of the component (especially by the
  • the layered structure of layers of a laminated one another is compared to deformation elements made of fiber composites. Also compared to deformation elements made of fiber composites, the layered structure of layers of a laminated one another
  • Deformation elements with a layered structure in the event of a failure, at least in part result in a delamination of the layers, ie a peeling or breaking apart of the layers from one another, accompanied by a lower resultant force level.
  • a failure in the present component or deformation element can not take place, as viewed in a direction perpendicular to the thickness of the wall or parallel to the first and / or second surface of the component of the predominant Part of the bundles between an isotropic alignment and an alignment, in the bundles are arranged substantially not a cutting angle greater than 1 ° to the first and / or second surface of the component. This means that there is no layered structure, but a penetration of different levels of the wall of the component by the bundles, so a
  • the bundle and in particular its substantially isotropic distribution, is substantially uniform over the wall thickness
  • the component according to the invention is constructed, at least for the most part, from bundles of carbon fibers, and the orientation of the fiber bundles required according to the invention is the cause of a high specific energy absorption.
  • the impact energy from the continuously acting impact force is dissipated in the failure zone initiated in this way in such a way that it is dissipated
  • the high fiber volume fraction of the carbon fibers in the wall in the range between 35 vol .-% to and 70 vol .-% is the cause of a high specific energy absorption of the component under impact load. It should be noted that at fiber volume fractions below 35 vol .-% the
  • Failure behavior of the component is under shock load dominated by matrix failure, i.
  • the failure behavior is determined by a break or crack in the matrix and thus by an inter-fiber break.
  • Fiber volume fractions above 35% by volume the failure behavior is primarily due to failure at the interface between fiber and matrix, i. determined by a fiber break.
  • the higher failure forces of the latter two failure modes compared to the first failure form generate a high density of degradation energy and thus a high specific dissipated energy and thus a high specific energy absorption in the material.
  • Sufficient distribution of the matrix in the component and wetting on the filament surfaces of the fiber bundles can no longer be guaranteed.
  • the fiber volume fraction is limited by the filament geometry at very high values, since with circular filament cross sections a densest circular packing in the cross-sectional plane along the fiber direction in the fiber bundle can not be exceeded.
  • the fiber volume fraction of the carbon fibers in the wall of the component is in the range from 45% by volume to 65% by volume.
  • the bundles of carbon fibers i. the
  • Carbon fiber filaments and have a length between 3 mm and 100 mm.
  • the length is in the range of 5 mm to 70 mm, and more preferably in the range of 10 mm to 50 mm.
  • the wall of the component according to the invention has a plurality of groups of reinforcing fiber bundles with mutually different lengths, so that overall the length of the reinforcing fiber bundles has a distribution.
  • reinforcing fiber bundles having a length of 20 mm, 30 mm and 50 mm may be combined with each other.
  • the bundles of carbon fibers i. the reinforcing fiber bundles may be made of conventional carbon fiber filament yarns having e.g. 500 to 50,000 fiber filaments exist. However, it is advantageous if each reinforcing fiber bundle consists of 500 to 24,000 reinforcing fiber filaments. To achieve the most homogeneous possible distribution of the reinforcing fiber bundles in the component wall and to achieve the highest possible fiber volume fractions, the number of filaments in the bundles is particularly preferably in the range 500 to 6,000 and most preferably in the range of 1 .000 to 3,000.
  • a multifilament reinforcing yarn may be used as
  • Carbon fiber yarn having a tenacity of at least 5000 MPa measured according to JIS-R-7608 and a tensile modulus of at least 260 GPa measured according to JIS-R-7608.
  • the bundles constituting the wall of the component according to the invention preferably have one Width in the range of 1 mm to 20 mm and more preferably a width in the range of 1 mm and 10 mm. Likewise, it is high for achieving
  • Packing densities of the bundles i. to achieve high fiber volume fractions in the component wall of above 45 vol .-%, further advantageous if the bundles as flat as possible a cross section perpendicular to the extension of
  • the bundles are ribbon-shaped and have a ratio of bundle width to bundle thickness of at least 25.
  • the ratio of bundle width to bundle thickness is particularly preferably in the range from 30 to 150.
  • Ratio of bundle width to bundle thickness, in terms of their length and in terms of the number of reinforcing fiber filaments can be realized particularly high packing densities of the reinforcing fiber bundles and thus particularly high fiber volume fractions in the component wall.
  • the bundles arranged in the wall of the component have different lengths and different numbers of filaments in addition to a flat cross-section. This leads to particularly high fiber volume fractions in the wall of the component.
  • Impact energy i. As a deformation or crash element, a uniform material behavior over as large a range as possible
  • thermoplastics with higher glass transition temperatures for example thermoplastics of the PAEK family, such as e.g. Polyether ether ketones (PEEK), etc.
  • PEEK Polyether ether ketones
  • the high processing temperatures due to the high melting temperatures mean considerable consequential costs.
  • Thermoplastics with a melting point above 250 ° C are not suitable.
  • the bundles are embedded in the component and the carbon fibers constituting the bundles in a polymer matrix, which consists for the most part of one or more partially or fully crosslinked polymers.
  • the polymer matrix preferably comprises at least 60% by volume, based on the matrix fraction, and particularly preferably at least 75% by volume, of one or more partially or fully crosslinked polymers.
  • Other constituents of the polymer matrix may be, for example, thermoplastics in order to increase the impact strength of the component or other additives, for example the
  • the polymer matrix has a matrix material based on acrylate or methacrylate.
  • the carbon fibers are included in the wall of the component
  • the wall is at least predominantly composed of bundles of carbon fibers, within which the carbon fibers
  • constituent carbon fiber filaments are arranged parallel to each other, wherein the bundles and the carbon fibers constituting the bundles are embedded in a polymer matrix, which consists for the most part of one or more crosslinked polymers. This means that in fact the bundle structure is preserved in the finished component.
  • the carbon fibers are stretched in the bundles, whereby a high level of Drucksteif ig values for the component according to the invention can be achieved.
  • This property of the component according to the invention is in the application of advantage, since at a shock load of the component or the deformation element, which is a failure of the component to form a crash zone, the material lying below the crash zone must withstand the compressive forces and must not fail.
  • This high pressure stiffness is necessary, since it keeps the deformation in the support zone, which has not yet been damaged by failure (crushing), and thus prevents premature failure of the component by kinking or buckling. If the compressive stiffness in relation to the crash failure stress is comparatively low, otherwise the component would have to be made very thick or, in the worst case, it always fails due to kinking or buckling.
  • a stretched configuration of the carbon fibers in the component is understood to mean that the carbon fibers are not curled or bent on their own and a change in the
  • Reinforcing fibers were oriented and undulated by the flow of the viscous matrix during the manufacture of the SMC component during the filling process.
  • the fiber bundles are not aligned along a straight line, but have in comparison to a significant curvature.
  • the strong flow of the matrix and fibers during the filling process creates an inhomogeneous fiber distribution.
  • the carbon fiber bundles according to the invention are distributed homogeneously over the component cross-section. Homogeneous distribution is understood here to mean that the fluctuation of the fiber volume fraction is less than ⁇ 10% by volume for each sample of the component having a size of at least half the fiber bundle length of the component (eg for a cylindrical sample of 25 mm diameter and 2 mm Thickness with a component wall thickness of 2 mm and a fiber bundle length of 50 mm).
  • the bundles are already deposited in the production of the preform essentially in the final geometry. During the injection and infusion process, only the flowable components will be added to the polymer matrix. A shift in the Carbon fiber bundle is excluded due to the fixation of the preform. Over this, the carbon fiber bundles retain their stretched orientation. This achieves high compressive stiffness values and avoids undesired failure at weak points, such as resin-rich zones or particularly severely deformed areas of the component.
  • the component can be produced in a simple manner by first producing from the bundles of carbon fibers a fiber preform, often also referred to as a preform.
  • the already near-net shape fiber preform is inserted into a tool which has the negative or positive near net shape of the component. If the reinforcing fiber bundles already have enough matrix material, the addition of further matrix material is not necessary.
  • the matrix material can be activated, for example, for component production with pressure and heat.
  • additional matrix material matrix system
  • the matrix material i. the not fully or partially cured matrix resin, are introduced into the tool and thus in the fiber preform via infusion, infiltration, injection or pressing. Subsequently, with full or partial crosslinking of the polymeric matrix material (for example by curing a thermosetting matrix resin), the component is formed.
  • the production of the fiber preform can be carried out inexpensively and in a simple manner according to the method, as described, for example, in EP 2727693 B1, to the relevant disclosure of which reference is expressly made.
  • the method of EP 2727693 B1 comprises the following steps:
  • Carbon fibers are used, in which the carbon fibers are provided with a binder.
  • This binder is a material by means of which e.g. by a heat activation and subsequent cooling of the
  • Fiber preform can be brought into a stable state, the one
  • the binder may then be a fiber preparation commonly applied to the filaments of the carbon fibers to provide improved processability and fiber closure, ie at least partially bonding the filaments together.
  • Preparations are often based on epoxy resins or polyurethane resins.
  • the polymer matrix (in which the fiber bundles are embedded) preferably represents the binder or the preparation for the carbon fiber bundles.
  • an increased content is required for producing the fiber preform for the component according to the invention, preferably in the range of 2 Wt .-% to 14% by weight and particularly preferably in the range of 3 wt .-% to 7 wt .-%, based on the total weight of the binder provided with carbon fiber yarn.
  • Suitable binders here are thermoplastic or unhardened or partially cured thermoset polymers or even polymer compositions of these polymers.
  • thermoplastic polymers are, for example, polyethyleneimine, polyetherketone, polyetheretherketone, polyphenylene sulfide, polysulfone, polyethersulfone, polyether ether sulfone, aromatic polyhydroxyethers, thermoplastic polyurethane resins or mixtures of these polymers.
  • uncured or partially cured thermoset polymers come from any suitable thermoplastic polymers.
  • Fiber preform ie usually at room temperature, prevail, are not sticky. However, at elevated temperatures the binder (s) should be tacky and result in good adhesion of the fiber bundles made therefrom.
  • Such reinforcing fiber yarns or Strands of reinforcing fibers are described, for example, in WO 2005/095080, the disclosure of which is expressly referred to here.
  • the local filament yarns are infiltrated with a binder composed of several different epoxy resins, these epoxy resins differ in a defined manner with respect to their properties such as epoxy value and molecular weight and with respect to their concentration.
  • WO 2013/017434 the disclosure of which is incorporated herein by reference, describes prepreg impregnated with a binder
  • the polymer matrix used in the component and / or the matrix system used a fracture toughness, which increases by a maximum of 100% at a
  • the polymer matrix used in the component may be the polymer matrix of the reinforcing fiber bundles and / or the matrix system optionally additionally added for the production of the component.
  • the component is, as stated, in a viewing direction parallel to
  • the training as a body is a self-supporting and against buckling loads stable structure. In this way, the impact energy over the deformation can be uniformly dissipated and a buckling of the component, creating another
  • the body when viewed parallel to the longitudinal direction of the component to a profile, more preferably to a
  • Wave profile, a zig-zag profile, an angle profile or a profile, which has a mixture of the aforementioned profiles act. However, it can also be any, even irregular profiles.
  • the inner and / or outer cross-section of the body has a wave shape, a zig-zag shape, an angle shape, a curve or a mixture of the aforementioned shapes.
  • the component may have as a body a closed hollow profile, which has a cavity extending between the first and second ends, wherein the first end and the second end are connectable to the first and the second impact element, and wherein the hollow profile has an outer and an inner cross-section and the first surface facing away from the cavity and the second surface facing the cavity.
  • hollow profiles are preferred in which the inner and / or the outer cross section has a circular, elliptical, square or rectangular contour or a polygonal contour. Examples of such hollow profiles are as in EP 3104036 A1 or in the
  • the component may have more than a first and a second end.
  • the component may have three or more ends.
  • Simplification is reported below from a first and a second end, without restricting the component to it.
  • the wall thickness of the component according to the invention over the extension in the longitudinal direction is constant (see Figure 2c). In a further preferred embodiment, the wall thickness of the component increases from the first to the second end of the component (see Figure 2d).
  • a hollow profile as the body of the component can preferably the inner and / or the outer Cross section along the extension to be constant in the longitudinal direction.
  • the inner and / or outer cross-section may increase in a region between the first and second ends from the first to the second end of the composite component.
  • a wall is obtained with a wall thickness constant from the first to the second end of the component.
  • the cross-sectional area of the wall over the extension of the component in the longitudinal direction is constant.
  • a constant wall thickness can be obtained if the inner and outer cross-sections increase in the same way from the first to the second end along the longitudinal extension. In this case, however, the cross-sectional area of the wall increases over the extension of the component in the longitudinal direction from the first to the second end of the component.
  • Further advantageous embodiments of the component according to the invention are those in which the wall thickness increases in a region between the first and the second end from the first to the second end of the component.
  • the wall of the component is made thicker and / or thinner only in some areas.
  • Subregions whose wall is thicker within the subregion may have ribs, for example.
  • Subregions whose wall is thinner within the subregion can be, for example, trigger regions which can be used to introduce force.
  • the component is constructed from a plurality of partial bodies.
  • the component may consist of two body shells that
  • the component can be used individually or with several components as an absorption element for impact energy.
  • the components used may be the same or different and / or in Row next to each other, one above the other and / or arranged concentrically around a center.
  • this component in the case that the component is a closed hollow profile as a body, this component is constructed from two partial profiles, which are interconnected in the longitudinal direction to form the hollow profile.
  • Such sub-profiles for example in the form of half-shells, are in a particularly simple manner via a process for producing a
  • the sub-profiles in the longitudinal direction on the side flanges, via which the sub-profiles are interconnected.
  • the connection can preferably be effected by means of an adhesive, for example by means of a 2-component construction adhesive.
  • the connection can also be effected by means of a clamping, screwing, welding and / or riveting surrounding the flanges on the outside, or by means of an auxiliary construction enclosing the flanges, as described for example in EP 3104036 A1.
  • the sub-profiles are positively and / or non-positively connected.
  • the component has a region for initiating the impact energy at its at least first and / or second end.
  • the impact force or impact energy in the often referred to as a crash element component is first introduced into a located at the end of the crash element area for initiating the impact energy, the so-called trigger area, for example, a chamfer the cross-sectional area (chamfer) can be.
  • the trigger area for example, a chamfer the cross-sectional area (chamfer) can be.
  • the exact geometric design of this area has proven to be less important. He does, however, have one Reduction of the wall thickness or the cross-sectional area of the wall include and is primarily a breaking point for a targeted failure.
  • an increased tension acts, as the same force acts on less material in the area of the bevelled tips, and the material fails.
  • the wall of the present component is composed at least predominantly of bundles of carbon fibers, within which the carbon fiber filaments constituting the carbon fibers are arranged parallel to one another.
  • the wall may additionally comprise at least one layer of unidirectionally oriented long fibers, wherein the at least one layer on at least one of
  • Surfaces or inside the wall can be arranged and extend between the first and the second end of the component.
  • Layers of unidirectionally oriented long fibers can be achieved in the application, for example, a further stabilization of the component against buckling.
  • the long fibers extend from the first to the second end of the component. At more than two ends extend the
  • Long fibers preferably between at least two ends of the component. Such long fibers preferably have fibers with a length of more than 10 mm and a width of more than 3 mm.
  • the wall has on the first and / or second surface reinforcing elements which extend in the direction of the longitudinal direction of the component.
  • Reinforcement elements may e.g. have the shape of ribs or lamellae which are applied to the surface, for example by adhering separately produced elements (see also Figure 2).
  • the reinforcing elements may also be made of fiber composite material, but they may also be elements of, for example, metallic materials. In the case that the reinforcing elements made of fiber composite material, the
  • Reinforcement also integral with the component or the wall of the component connected and made together with the wall.
  • tapes of unidirectional fibers such as unidirectional prepregs, may be laminated to the wall of the fiber preform and cured after injection of the matrix material together with the matrixed fiber preform to the component.
  • the reinforcing elements consist of the same bundles of carbon fibers, which were also used for the formation of the wall of the component.
  • a permanently bearing element is integrated into the component, which is connectable to the first and the second impact element. This permanently bearing element is not destroyed in the event of a shock load together with the component, but
  • the permanently supporting element may be a steel tube which is telescopically displaced in the component in the event of a crash or in the event of a shock load. It is also possible that several permanently supporting elements are integrated into the component.
  • FIG. 1 schematically shows a comparison of the voltage-path curves between components not according to the invention and an exemplary embodiment of the component according to the invention in a crash.
  • FIGS. 2, 2a, 2b, 2c and 2d schematically illustrate possible embodiments of the component.
  • FIGS. 1 and 3 to 11 show various crash data in curves for exemplary embodiments of the component.
  • the x-axis represents the distance measured in mm.
  • the y-axis indicates the force measured in kN.
  • FIG. 1 shows a comparison of the pressure or stress-displacement characteristics of an aluminum component (curve A) in comparison to components made of fiber-reinforced plastics.
  • the X-axis describes the path in mm, the Y-axis the pressure or the stress in MPa.
  • Fiber-reinforced plastics is a non-inventive example of a thermoplastic with carbon fibers (curve B) and a component, according to an embodiment of the invention (curve C), wherein the carbon fibers having a mean cutting length of the fiber bundles of 50 mm in an isotropic fiber bundle distribution in the component templates.
  • Both components made of fiber-reinforced plastic had the same geometry and were constructed from half-shells.
  • the aluminum component consisted of a tube with a 66 mm inner diameter and 2 mm wall thickness. The geometries of the components were coordinated so that the results are comparable. It can be seen that the amplitude variation with respect to the path of the aluminum component is much greater than that of the
  • the initial voltage amplitude of the failing component according to an embodiment of the invention is substantially lower. This has the consequence that at lower initial forces already kinetic energy in
  • Deformation energy is converted and so, for example, the following
  • Vehicle structures or vehicle occupants are protected against the action of high forces.
  • FIG. 2 shows an exemplary embodiment of a component 1 which is used for
  • the component 1 has a first end E1 and a second end E2 and, for example, a semicircular Cross-section, wherein the cross section changes along the longitudinal direction L.
  • the component 1 may have a rib 2 (or a plurality of ribs), which may be provided on a first surface 8, for example.
  • the rib can be made in one piece from the component 1 or attached as a further element on the component 1.
  • the rib 2 can be formed by the deposition of one or more slivers on the component 1.
  • the component 1 may further preferably have recesses 3, such as holes. Through these recesses 3, advantageously, the weight of the component 1 can be reduced, without the length or width of the
  • the component flaps or covers 5 may be provided which divide the component 1 in its longitudinal extent L.
  • the cover 5 can be designed so that they extend from one wall to the other wall and thus form a closure or they can extend only within the component 1, without the cover 5 has a contact with the other (opposite) wall side.
  • the lid or flaps 5 can advantageously stabilize the component 1 and, for example, prevent kinking of the body 1 in the event of a shock.
  • the body 1 has a half-round profile 7, wherein the first end E1 has a smaller diameter than the second end E2.
  • the component 1 can be connected to other parts.
  • the other parts may, for example, be further components 1 for the absorption of impact energy (of the same type or another type) or impact elements.
  • the component 1 can be brought into positive and / or non-positive connection with the other parts, wherein an irreversible connection is preferred.
  • FIG. 2 a shows an embodiment of the component 1 as used for example 1.
  • FIG. 2b schematically shows a section of the component 1. Shown is a part of a wall of the component 1 with the first surface 8. Fiber bundles for Formation of the component 1 are substantially isotropic when viewing a perpendicular S to the first surface 8. Furthermore, the fiber bundles when viewing a parallels W to the first surface 8 cut angle to the surfaces 8, 9th
  • FIG. 2 c schematically illustrates an exemplary embodiment of the component 1 in a simplified manner.
  • an external cross section 1 1 of FIG. 2 c schematically illustrates an exemplary embodiment of the component 1 in a simplified manner.
  • an external cross section 1 1 of FIG. 2 c schematically illustrates an exemplary embodiment of the component 1 in a simplified manner.
  • an external cross section 1 1 of FIG. 2 c schematically illustrates an exemplary embodiment of the component 1 in a simplified manner.
  • an external cross section 1 1 of FIG. 2 c schematically illustrates an exemplary embodiment of the component 1 in a simplified manner.
  • an external cross section 1 1 of FIG. 2 c schematically illustrates an exemplary embodiment of the component 1 in a simplified manner.
  • an external cross section 1 1 of FIG. 2 c schematically illustrates an exemplary embodiment of the component 1 in a simplified manner.
  • an external cross section 1 1 of FIG. 2 c schematically illustrates an exemplary embodiment of the component 1 in a simplified manner.
  • FIG. 2d schematically shows a further embodiment of the component 1 in a simplified manner. In this embodiment remains the
  • FIG. 12 shows an X-ray image of a component with stretched fiber bundles.
  • the component should preferably be at least 20% of the fiber bundles in FIG. 12
  • a body according to an embodiment of the invention as a crash component as shown in Figure 2a, produced.
  • the component was tested in a dynamic impact test.
  • preforms were first produced so-called preforms.
  • a carbon fiber yarn (Tenax HTS40 X030 12k 800 tex) with disability (according to the writings WO 2005/095080, WO 2013/017434) was divided into fiber bundles in the transverse and longitudinal direction. The fiber bundles were given a length of 50 mm and a width between 1 mm and 5 mm.
  • Fiber bundles were formed into near-net shape preforms.
  • the fiber bundles are applied to a preform tool, which already for the most part depicts the geometry of the end component.
  • the method of application (manually or by means of a controlled track, e.g., a robot) is of minor importance as long as a uniform application of the bundles is produced.
  • a fiber order is set to a
  • the preform tool can be designed with many small holes, which are acted upon by a suction flow. In this way, the fiber bundles are sucked in and fixed at the respective point.
  • this structure is heated and the binder unfolds its adhesive effect. Under certain circumstances, the structure can be compacted by an additional force perpendicular to the respective surface. After the binder has cooled again, the entire preform but also the individual fiber bundles are fixed at their local locations.
  • the preforms were fixed in a steel mold by a resin infusion process (Resin
  • Trigger introduced in the form of a circumferential 45 ° bevel.
  • the component thus fabricated was attached to a flat, non-compliant steel baffle plate so that the longitudinal axis was perpendicular to the plate and the force application point faced outward. Subsequently, a carriage, which had a mass of 61 kg and a flat steel baffle plate in the direction of the component, so at 10 m / s on the component driven that it was destroyed along its longitudinal axis.
  • Comparative Example 1 of Table 1 is a component of carbon fibers with a cut length of 50 mm, wherein the component was produced according to the description of Example 1, with the difference that polyamide 6 was used as the matrix material.
  • a component has the disadvantage that the initial amplitude is substantially higher than for a component according to an exemplary embodiment of the invention.
  • thermoplastic matrix systems show a temperature-dependent crash behavior, which is not desirable.
  • components with a high proportion of thermoplastics tend to absorb water, which reduces the life of such components due to swelling of the components. It can easily be seen that the shortening of the service life, especially at the end of the life cycle, influences and reduces the crash properties of the component.
  • thermoplastic matrix The temperature dependence of components with a thermoplastic matrix is shown in FIG. 11.
  • the X-axis of Figure 1 1 describes the path in mm
  • the Y-axis describes the force in kN.
  • the curve D describes the crash behavior of a component constructed according to Comparative Example 1 at -30 ° C.
  • the curve E describes the crash behavior of a component constructed according to Comparative Example 1 at -20 ° C, the F curve at 50 ° C and the G curve at 90 ° C.
  • Such a temperature range is common especially for components as crash elements in the automotive sector.
  • a consistent failure behavior which is largely independent of the temperature, can therefore with thermoplastics as the main
  • Matrix material can not be achieved.
  • Comparative Example 2 of Table 1 is an aluminum tube, as it was already used for the experiment of Figure 1.
  • Example 2 is an aluminum tube, as it was already used for the experiment of Figure 1.
  • Example 2 a component was made from preforms containing fiber bundles of length 25 mm and width of 1 mm to 5 mm. In contrast to Example 1, consequently fiber lengths of 25 mm were used instead of 50 mm.
  • the wall thickness of the component corresponded to that of
  • Example 1 The component was destroyed as indicated in Example 1. This resulted in a force curve shown similar to Figure 3 with a force plateau at (55 +/- 5) kN. The absorbed energy per mass of the component material was 72 J / g. The course of the force-displacement curve and the specific
  • Example 1 components were made from preforms containing fiber bundles of length 50 mm and width of 1 mm to 5 mm. Unlike in Example 1, however, two components were manufactured, the one
  • Wall thickness of 3 mm or 4 mm had.
  • the components were destroyed as indicated in Example 1 and the results worked up as indicated in Example 1.
  • the absorbed energy per mass of the component material was 70 J / g for 3 mm wall thickness and 73 J / g for 4 mm wall thickness.
  • Example 1 components were made from preforms containing fiber bundles of length 50 mm and width of 1 mm to 5 mm with a wall thickness of 2 mm. The components were as in Example 1
  • Example 1 components were made from preforms, which fiber bundles of length 50 mm and the width of 1 mm to 5 mm at a Wall thickness of 2 mm had.
  • the fiber volume fraction of the components according to Example 5 was once 40% and once 45%.
  • the components were destroyed as described in Example 1 and the data prepared as described for Example 1.
  • the force profiles of the curves were shown in FIG. 9 for 40% fiber volume fraction and FIG. 10 with 45% fiber volume fraction with a force plateau at (45 +/- 10) kN for a fiber volume fraction of 40% and at (45 +/- 5) kN for a fiber volume fraction of 45%.
  • the energy absorbed per mass of the component material was 64 J / g for a fiber volume fraction of 40% and 61 J / g for a fiber volume fraction of 45%. While at 40% fiber volume fraction, the fluctuations in the plateau region of the force-displacement curve were still relatively large, 45% already formed

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Abstract

L'invention concerne un composant servant d'élément de collision constitué d'un matériau composite renforcé par des fibres, dont la paroi est constituée au moins en majeure partie de faisceaux de fibres de carbone. À l'intérieur des faisceaux de fibres, les filaments de fibres de carbone sont parallèles les uns aux autres et les faisceaux sont incorporés dans une matrice polymère. Les faisceaux sont répartis uniformément à l'intérieur de la paroi du composant et orientés sensiblement de manière isotrope, vus perpendiculairement à une première et/ou à une deuxième surface.
EP18796873.0A 2017-10-30 2018-10-26 Composant pour l'absorption d'énergie de choc Pending EP3704397A1 (fr)

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EP17199076 2017-10-30
PCT/EP2018/079466 WO2019086348A1 (fr) 2017-10-30 2018-10-26 Composant pour l'absorption d'énergie de choc

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US20210156445A1 (en) 2019-11-26 2021-05-27 GM Global Technology Operations LLC Corrugated hollow structures and two-step molding of corrugated hollow structures

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JP3246041B2 (ja) 1993-03-15 2002-01-15 株式会社豊田自動織機 エネルギー吸収部材
JP3362441B2 (ja) * 1993-04-09 2003-01-07 東レ株式会社 エネルギー吸収部材
DE19522575C2 (de) * 1994-06-27 1999-06-10 Lw Composite Gmbh & Co Aufprallvorrichtung für Fahrzeuge
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CA2562141C (fr) 2004-03-31 2012-05-29 Markus Schneider File impregne d'une resine epoxy et son utilisation pour la production d'une preforme
AU2011335297B2 (en) * 2010-12-02 2014-10-02 Toho Tenax Europe Gmbh Uni-directional fibre preform having slivers and consisting of reinforcing fibre bundles, and a composite material component
TWI565844B (zh) 2011-07-29 2017-01-11 東邦特耐克絲歐洲股份有限公司 預浸漬樹脂之撓性增強纖維紗線
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DE102014016024A1 (de) 2014-10-29 2016-05-04 Daimler Ag Fahrzeug mit Energieabsorptionseinheit

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CN111328366A (zh) 2020-06-23
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WO2019086348A1 (fr) 2019-05-09
JP7428651B2 (ja) 2024-02-06

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