EP3860836A2 - Procédés de fabrication d'un composant structural - Google Patents

Procédés de fabrication d'un composant structural

Info

Publication number
EP3860836A2
EP3860836A2 EP19783273.6A EP19783273A EP3860836A2 EP 3860836 A2 EP3860836 A2 EP 3860836A2 EP 19783273 A EP19783273 A EP 19783273A EP 3860836 A2 EP3860836 A2 EP 3860836A2
Authority
EP
European Patent Office
Prior art keywords
layer structure
contour surface
cavity
prepreg
layers
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
EP19783273.6A
Other languages
German (de)
English (en)
Inventor
Julian Kuntz
Markus Kaden
Marvin 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.)
Premium Aerotec GmbH
Original Assignee
Premium Aerotec 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 Premium Aerotec GmbH filed Critical Premium Aerotec GmbH
Publication of EP3860836A2 publication Critical patent/EP3860836A2/fr
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/02—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means
    • B29C33/06—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means using radiation, e.g. electro-magnetic waves, induction heating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/20—Opening, closing or clamping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C43/3642—Bags, bleeder sheets or cauls for isostatic pressing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • B29C70/205—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres the structure being shaped to form a three-dimensional configuration
    • B29C70/207—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres the structure being shaped to form a three-dimensional configuration arranged in parallel planes of fibres crossing at substantial angles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B1/00—Presses, using a press ram, characterised by the features of the drive therefor, pressure being transmitted directly, or through simple thrust or tension members only, to the press ram or platen
    • B30B1/42—Presses, using a press ram, characterised by the features of the drive therefor, pressure being transmitted directly, or through simple thrust or tension members only, to the press ram or platen by magnetic means, e.g. electromagnetic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B15/00—Details of, or accessories for, presses; Auxiliary measures in connection with pressing
    • B30B15/34—Heating or cooling presses or parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0811—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using induction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0822—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using IR radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C2043/3205—Particular pressure exerting means for making definite articles
    • B29C2043/3211—Particular pressure exerting means for making definite articles magnets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C43/3642—Bags, bleeder sheets or cauls for isostatic pressing
    • B29C2043/3655—Pressure transmitters, e.g. caul plates; pressure pads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/20—Making multilayered or multicoloured articles
    • B29C43/203—Making multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/12—Thermoplastic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0003—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular electrical or magnetic properties, e.g. piezoelectric
    • B29K2995/0008—Magnetic or paramagnetic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3076—Aircrafts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B32B2037/1081—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure using a magnetic force

Definitions

  • the present invention relates to a method for producing a
  • Structural component in particular a structural component, which has a curved or double-curved shape or shape.
  • Structural components made of fiber composite material with a large area extension are used. Structural components often also have a dome-shaped or dome-shaped or otherwise spherical shape that is curved in at least two directions. Arched components are used in aircraft construction e.g. used as a pressure frame or as a fuselage shell.
  • the semi-finished fiber products can be considered as having a
  • Matrix material pre-impregnated fiber mats are available. The educated
  • DE 10 2010 050 740 A1 describes a method for producing a structural component, wherein a multiplicity of semifinished layers from one
  • thermoplastic material stacked and selectively are connected to one another in order to fix a position of the semifinished layers relative to one another.
  • Fiber composite components wherein a layer structure, which has reinforcing fiber layers embedded in thermoplastic matrix material, is received between heating mats in the form of metal foils.
  • the layer structure between the heating mats is inductively heated to a forming temperature above the melting point of the
  • a method for producing a structural component is provided.
  • a preformed according to a shape of the structural component to be produced is provided.
  • Layer structure with several layers, each of which has reinforcing fibers embedded in a thermoplastic matrix material.
  • the individual layers are in particular in a non-consolidated or incompletely consolidated or non-pre-consolidated state, i.e. as discrete layers or only partially connected layers, the connection of which is not yet that for the final component has the required quality.
  • Such a layer structure can in particular have an air content of greater than or equal to 2.5 percent by volume.
  • the layer structure is heated in a cavity formed between a contour surface and a system part to a first temperature which is greater than one
  • the layer structure in the cavity is further cooled to a solidification temperature which is, for example, less than that
  • the compression pressure is generated according to the invention by generating a magnetic field directed transversely, preferably perpendicularly to the contour surface, by means of a first magnet device, by means of which a magnetizable field, which is assigned to the system part, is generated
  • the contact part and / or the contour surface can contain or be formed from a magnetizable material, as a result of which the magnetic field contracts the contact part and the contour surface relative to one another.
  • the magnetic material it is also possible for the magnetic material to be coupled to or attached to the contour surface and / or the contact part and thereby to be associated with the contour surface or the contact part.
  • the first magnetic device generates a magnetic field directed transversely, preferably perpendicularly to the contour surface, which interacts with a magnetic field generated by a second magnetic device assigned to the contact part or the contour surface, that the
  • the first magnet device can be a permanent magnet or an electromagnet.
  • the second magnet device can, regardless of the design of the first magnetic device
  • One of the ideas of the invention is therefore to carry out a consolidation of the layer structure formed from thermoplastic fiber composite semifinished products between a contour surface and a contact part, which press the layers of the layer structure together, the required for this
  • Compression pressure by means of a magnetic device e.g. is generated in the form of one or a plurality of electromagnets or permanent magnets, which induces a magnetic field in a magnetic material of a part forming the contour surface and / or the contact part, which causes the contour surface and the contact part to be pressed against the layer structure.
  • Magnetic field achieved, which results in a very even pressure distribution. According to the invention, this can also be achieved by an interaction between a magnetic field generated by a first magnet device and directed transversely to the contour surface and one by a second
  • Magnetic device which is assigned to the contact part or the contour surface, generated magnetic field, whereby the contour surface and the contact part are pressed against the layer structure.
  • the first magnet device can be arranged on the contact part or the contour surface, the magnetic field generated by the first magnet device extending through the layer structure. Accordingly, the first magnet device can be opposite the magnetizable material or opposite the second
  • Magnet device can be arranged. This creates a spatially strongly bundled, but generates a magnetic field that is distributed over the contour surface or the system part and that generates the compression pressure. By extending the magnetic field through the layer structure, a favorable flow of force is achieved and a flat distribution of the compression pressure is improved.
  • the plant part and / or the contour surface can contain an inductively heatable material and the heating of the
  • Layer build up by inductive heating can also be carried out using infrared radiation.
  • Inductive heating i.e. heating through
  • AC voltage offers the advantage that the contour surface and / or that
  • the contact part and / or the contour surface can in particular have a material that can be heated inductively, in particular an electrically conductive material, e.g. a metal material like
  • Infrared radiation can advantageously be generated with little design effort.
  • the cavity is evacuated by means of a vacuum device.
  • Layer structure can be present, sucked out of the layer structure. This prevents pore formation in the structural component and thereby increases the mechanical strength of the structural component. Furthermore, the vacuum can Support generation of compression pressure. This further speeds up the process.
  • the system part can be formed, for example, by a vacuum film, i.e. an elastically or plastically deformable, flat film, e.g. made of a silicone material or a similar material.
  • a vacuum film i.e. an elastically or plastically deformable, flat film, e.g. made of a silicone material or a similar material.
  • a method for producing a structural component is provided.
  • a layer structure which has been preformed in accordance with a shape of the structural component to be produced and has a plurality of layers, each of which has reinforcing fibers embedded in a thermoplastic matrix material.
  • the individual layers are particularly in a non-consolidated or non-pre-consolidated state, i.e. as discrete layers.
  • Such a layer structure can in particular have an air content of greater than or equal to 2.5 percent by volume.
  • Layer structure is heated in a cavity formed between a contour surface and a system part to a first temperature that is greater than one
  • the melting point of the thermoplastic matrix material is, the plant part and / or the contour surface containing an inductively heatable material and the heating being carried out inductively, that is to say by generating alternating magnetic fields by means of an alternating electrical voltage, which induce eddy currents in the inductively heatable material.
  • a compression pressure is applied by evacuating the cavity and the layer structure in the cavity is cooled to a solidification temperature which is, for example, lower than the melting point of the thermoplastic matrix material.
  • the plant part and / or the contour surface therefore contain a material which can be heated inductively, in particular an electrically conductive material, for example a metal material such as structural steel, stainless steel, invar steel, aluminum, copper or the like, a semiconductor material, a ferrimagnetic material
  • the plant part can be formed by a vacuum film, i.e. an elastically or plastically deformable, surface-extending film, e.g. made of a silicone material or a similar material.
  • a vacuum film i.e. an elastically or plastically deformable, surface-extending film, e.g. made of a silicone material or a similar material.
  • the contact part is formed by a second shaped plate. Accordingly, this is designed as a flat metal plate, for example a curved metal plate, which is adapted to the shape of the component to be produced.
  • the molded sheet has a low heat capacity, but still offers a certain mechanical stability. As a result, the cavity can be heated quickly and with little energy expenditure.
  • the compression pressure is by means of Magnetic force is applied, a particularly good area distribution of the compression pressure can be achieved.
  • a seal is arranged between the first shaped plate and the contour surface, which seals the cavity hermetically.
  • the seal can, for example, from a
  • Silicone material or another elastic, sealing material can be formed. The application of the
  • At least one stiffening profile or reinforcing profile which is a thermoplastic, can be placed on a layer of the layer structure lying opposite to the contour surface
  • Stiffening profile is generated. Since this takes place at the same time as the consolidation, the process is further accelerated.
  • the contour surface is provided by a first surface of a mold half.
  • the mold half has a surface section which forms the contour surface and a base section which supports or supports this surface section.
  • the base section can in particular be designed in block form or as a support frame. This provides a particularly dimensionally stable contour surface, what the laying down of the layer structure is facilitated, for example with regard to the position tolerance of the individual layers relative to one another.
  • the contour surface can also be provided by an inner surface of a first mold plate which is supported by the first mold half. Similar to the second shaped sheet, the first shaped sheet is designed as a surface-extending, adapted to the shape of the component to be manufactured, e.g. curved metal plate. An opposite side surface of the first molding sheet, which is opposite to the inner surface, is formed by the base section of the
  • the separation of the mold half and the first mold sheet offers the advantage that the heat capacity of the parts forming the cavity is further reduced, so that the cavity can be heated and cooled quickly and with little energy expenditure, and the mold half does not have to be as resistant to temperature.
  • the base section or the mold half as a whole can be produced from a cheap plastic material or cheap metal and the compression pressure can nevertheless be applied by means of magnetic force, which further reduces the tool costs.
  • a thermally insulating layer is optionally arranged between the first shaped plate and the mold half. This has the advantage that the mold half is exposed to smaller temperature fluctuations and is consequently less deformed by thermal expansion.
  • the above-mentioned seal can, for example, if the contact part is formed by a first shaped plate, between the first and the second, which provides the contour surface
  • Form sheet to be arranged.
  • This provides a hermetically sealed cavity between two thin mold plates, which can be evacuated in a simple and efficient manner. This improves, for example, the quality of the component produced, since possible air pockets are prevented and, if the compression pressure is applied by evacuating the cavity, the application of the compression pressure is additionally facilitated.
  • the individual layers of the layer structure each have at least one semifinished product that has a plurality of prepreg tapes that extend along one another, each in
  • thermoplastic matrix material embedded, unidirectionally arranged reinforcing fibers and comprises a plurality of connecting strands containing a thermoplastic material.
  • thermoplastic material of the connecting strands can do the same
  • thermoplastic material such as that contained in the prepreg tapes
  • the connecting strands and the prepreg tapes are connected to form a textile fabric in which each of the connecting strands crosses several of the prepreg tapes, the connecting strands and the prepreg tapes in a first end area of the sheet and a second end area of the sheet material lying opposite to it, each integrally bonded along a connecting line are interconnected. Accordingly, the entire layer can be formed by such a semifinished product or several of these semifinished products have a semifinished product to be provided in the form of a textile fabric which consists of prepreg tapes with unidirectional fibers and
  • the textile structure that is to say a structure composed of intersecting strands, offers the advantage that the semi-finished product has anisotropic deformation properties.
  • the textile structure allows the prepreg tapes to slide along one another, which prevents wrinkling when deforming.
  • Wrinkle formation is further prevented by the fact that a cohesive
  • connection of the strands i.e. a material connection between Prepreg tapes and thermoplastic connecting strands are only provided along connecting lines lying opposite one another, the prepreg tapes and the connecting strands on the rest
  • the unidirectional thermoplastic prepreg tapes are elongated, single-ply tape material, in which continuous, unidirectional reinforcing fibers are embedded in a thermoplastic matrix material.
  • Prepreg tapes of this type have the advantage that they are easily deformable but are not very susceptible to the formation of undulations.
  • the connecting strands each have a first end section and a second end section lying opposite thereto
  • a respective layer of the layer structure is formed by thermoplastic connection of at least the first end sections of the connecting strands of a first semi-finished product with prepreg strips of a respective further semi-finished product.
  • the second end sections of the connecting strands of the further semifinished product can also be used
  • Prepreg tapes of the first semi-finished product are connected thermoplastic.
  • a welding process e.g. Ultrasonic welding can be used.
  • the layers of the layer structure are formed by semi-finished products, which have a multiplicity of prepreg tapes, each of which is in a thermoplastic matrix material have embedded, unidirectionally arranged reinforcing fibers, the prepreg tapes being arranged to form a multiaxial scrim, which comprises a plurality of superimposed layers of prepreg tapes, the
  • Prepreg tapes run parallel to one another within a layer, and the layers are connected relative to one another at individual points.
  • the layers are preferably connected at discrete locations arranged in a periodically repeating pattern.
  • the layers can be sewn, knitted or interwoven, e.g. by means of a variety of a thermoplastic
  • Plastic strands 30 containing connecting strands are sewn.
  • a multilayer semifinished product is accordingly used to form the layer structure, the individual layers being formed from parallel prepreg strips and the individual layers being connected only at points by the connecting strands.
  • connection points can be provided along parallel lines. Due to the punctiform connection of the layers and the parallel extension of the prepreg tapes and thus the reinforcing fibers within the individual layers, the individual layers can slide relative to one another and the fibers within the individual layers can slide relative to one another, thereby creating a
  • the layer structure is provided by depositing prepreg tapes by means of a depositing head, the individual prepreg tapes being fixed in their position relative to one another when they are deposited.
  • the prepreg tapes can in particular each have unidirectionally arranged reinforcing fibers embedded in a thermoplastic matrix material.
  • the layers are formed using an AFP method, "AFP" as an abbreviation for the expression "automated fiber placement".
  • the depositing head can have, for example, a roller or roller which presses the prepreg strips onto the contour surface or creates an already formed location.
  • An actuator for example in the form of a manipulator of an industrial robot, can be provided for moving the roller.
  • the contour surface is optionally heated to a storage temperature which is below the melting temperature of the thermoplastic
  • Matrix material In order to fix the prepreg tapes, they can be locally heated to the melting temperature by the deposit head at the moment of deposit, so that the individual prepreg tapes locally fuse with one another after being deposited.
  • the optional heating of the contour surface causes the
  • Temperature difference, which the laying head must generate, is advantageously reduced, and thermal stresses in the prepreg bands are prevented.
  • the layer structure is formed in such a way that the reinforcing fibers are arranged in one layer along a direction and in different layers in different directions
  • the layers are stacked one on top of the other in such a way that the prepreg tapes or the reinforcing fibers of two adjacent layers or layers each extend in different directions. This improves the mechanical strength of the structural component.
  • the contour surface has a curved geometry.
  • a “curved component” or a “curved shape” is generally understood to mean a geometric body that has at least a first one
  • an arched Body here understood to mean an at least partially dome-shaped, spherical, parabolic or bowl-shaped body.
  • a vertex of the arched shape of the component can, for example, by the center of gravity of one of the body forming the arched shape
  • the vertex can be on a
  • directions and axes which relate to the course of physical structures, a course of an axis, a direction or a structure “along” another axis, direction or structure is understood here to mean that these, in particular the tangents resulting in a respective location of the structures at an angle of less than or equal to 45 degrees, preferably less than 30 degrees and
  • a course of an axis, a direction or a structure “transverse” to another axis, direction or structure is understood here to mean that these, in particular, the tangents which result in a respective location of the structures each run at an angle of greater than or equal to 45 degrees, preferably greater than or equal to 60 degrees and particularly preferably perpendicular to one another.
  • Reinforcing fibers here can generally be thread-shaped or thread-shaped fibers, such as carbon, Glass, ceramic, aramid, boron, mineral, natural or plastic fibers or mixtures of these.
  • a “melting point” or a “melting temperature” in relation to a thermoplastic material is understood here to mean a temperature above which the material is in a flowable, viscous state. Above the
  • Melting temperature can be a component made of thermoplastic material with another component made of thermoplastic material, which is also above the
  • Melting temperature is present, cohesively connected, in particular fused.
  • Fig. 1 is a schematic sectional view of a layer structure
  • Fig. 2 is a sectional view of a layer structure, which is arranged in a cavity, during a method according to one
  • Embodiment of the present invention shows a sectional view of a layer structure which is arranged in a cavity during a method according to a further exemplary embodiment of the present invention
  • Fig. 4 shows a sectional view of a layer structure which is arranged in a cavity during a method according to a further exemplary embodiment of the present invention
  • Fig. 5 is a plan view of a semi-finished product for use in a
  • Fig. 7 is a schematic sectional view of a prepreg tape for
  • Fig. 8 is a schematic sectional view of a connecting strand
  • Fig. 9 is a schematic sectional view of a connecting strand
  • FIG. 10 shows a plan view of a layer for producing a layer structure for a method according to an exemplary embodiment of the present invention, the layer being formed from two semi-finished products according to FIG. 5;
  • Fig. 1 1 is a schematic partial sectional view of a semi-finished product for
  • Embodiment of the present invention shows the formation of a layer of a layer structure according to an exemplary embodiment of a method of the present
  • FIG. 13 shows a schematic exploded view of a layer structure composed of a plurality of layers for use in a method according to an exemplary embodiment of the present invention
  • 14 shows a perspective view of a method using an exemplary embodiment of the present invention
  • FIG. 15 shows a sectional view of a layer structure, which is arranged in a cavity, during a method according to a further exemplary embodiment of the present invention.
  • Fig. 16 is a plan view of the arrangement shown in Fig. 15.
  • the same reference numerals designate identical or functionally identical components, unless stated otherwise.
  • FIG. 14 shows an example of a curved structural component B in the form of a
  • the structural component B can in particular have a circular peripheral edge E.
  • the structural component B can, for example, be dome-shaped or dome-shaped and thus curved in several directions of curvature.
  • 14 shows an apex P of the curved shape of the structural component B, which is given by an intersection of lines of symmetry S1, S2 of the structural component B.
  • Fig. 1 shows a sectional view of a layer structure 100 as the starting product of a method for producing a structural component B, e.g. of the structural component B shown in Fig. 14.
  • the layer structure 100 has several, e.g.
  • the layers 110 are generally formed as two-dimensionally extending layers, each of which has reinforcing fibers 21 (not shown in FIG. 1) embedded in a thermoplastic matrix material 20 (not shown in FIG. 1).
  • the layers 110 are arranged one above the other or stacked one on top of the other and can in particular lie flat against one another.
  • the layer structure 100 as a whole is preformed, that is
  • the layer structure 100 shown as an example in FIG. 1 has an arched, in particular dome-shaped or dome-shaped shape.
  • the structural component B shown in FIG. 14 can be produced with this layer structure 100, for example.
  • the individual layers 110 are at a first connection point 120, which is in the region of the
  • Vertex P of the arched shape to be produced is located, thermoplastic bonded, e.g. by ultrasonic welding.
  • the thermoplastic bonded e.g. by ultrasonic welding.
  • connection point should be selected in such a way that there is no or only a very small one in the corresponding area during a subsequent deformation
  • the locations 1 10 can alternatively or additionally also be connected in a thermoplastic manner at further connection points 121 apart from the apex P, for example also by
  • the layer structure 100 can generally be done by sequential deposition and
  • the individual layers 1 10 are formed, the depositing and forming optionally taking place simultaneously.
  • the individual layers 1 10 can for example be stacked and shaped as flat semi-finished products 1.
  • the individual layers 110 can be produced by laying down a multiplicity of prepreg bands 2, e.g. by means of an AFP process, which is explained below by way of example with reference to FIG. 12.
  • the semifinished product 1 has a multiplicity of prepreg strips 2 and a multiplicity of connecting strands 3.
  • the prepreg tape 2 has a plurality of reinforcing fibers 21 which extend in one direction or unidirectionally.
  • the reinforcing fibers 21 can be present, for example, as fiber bundles.
  • the reinforcing fibers 21 are in one
  • the prepreg tapes 2 are realized as narrow, strip-shaped tapes. As shown in FIG. 7, the prepreg tapes 2 can have a width b2, for example in a range between 1 mm and 15 mm, and a length I2, for example in a range between 0.5 m and 100 m.
  • the figures 8 and 9 show examples of possible configurations of FIGS.
  • connecting strands 3 can each consist of a thermoplastic material or have a thermoplastic material.
  • 8 shows, by way of example, a reinforcement strand 3 in cross section, which is made of a thermoplastic material 30
  • the film strip 33 can be realized with a rectangular cross section.
  • FIG. 9 shows, by way of example, a reinforcing strand 3 in cross section, which is designed as a thread 34 consisting of thermoplastic material 30.
  • the thread 34 can be formed from a plurality of twisted filaments 35 which form an approximately circular cross section of the thread 34.
  • the reinforcing strands 3 contain the same thermoplastic material that is used as the matrix material of the prepreg tapes.
  • the prepreg strips 2 and the connecting strands 3 are woven together and thereby form a textile, single-ply flat structure 4.
  • the connecting strands 3 extend transversely to the prepreg bands 2, each of the
  • Connecting strands 3 crosses several of the prepreg strips 2.
  • each connecting strand 3 runs in sections on opposite sides of the prepreg strips 2.
  • the prepreg strips 2 run along one another and do not cross one another within the flat structure 4. 5 are the
  • the prepreg strips 2 extend in a first direction R1 and the connecting strands 3 extend in a direction transverse to that first direction R1 extending second direction R2.
  • a first prepreg tape 2A which is outermost in relation to the second direction R2 and an extreme second prepreg tape 2B which is situated opposite to the first prepreg tape are integrally connected to the connecting strands 3 in FIG. 5.
  • the connecting strands 3 are in the region of a first end section 31 with the first prepreg tape 2A and in the region of a second end section 32, which is opposite to the first end section 31 with respect to the second direction R2 second prepreg tape 2A integrally connected.
  • the first and the second prepreg tape 2A, 2B each define opposite edges of the textile fabric 4.
  • each of the connecting strands 3 can be integrally connected to the first and the second prepreg tape 2A, 2B.
  • the connecting strands 3 and the prepreg strips 2 are integrally connected to one another in a first end region 41 of the flat structure 4 and in a second end region 42 of the flat structure 4 lying opposite this, along a connecting line 5A, 5B.
  • the connecting lines 5A, 5B each run along the first direction R1 or along the first and second prepreg bands 2A, 2B.
  • the integral connection can be produced, for example, by ultrasonic welding.
  • first end section 31 of the connecting strands 3 protrudes or protrudes beyond the first prepreg band 2A and the second end section 32 of the connecting strands 3 extends beyond the second prepreg band 2B, and thus, and thus forms a protruding tab.
  • the first end section 31 of the connecting strands 3 protrudes or protrudes beyond the first prepreg band 2A and the second end section 32 of the connecting strands 3 extends beyond the second prepreg band 2B, and thus, and thus forms a protruding tab.
  • the connecting strands 3 each protrude beyond the connecting lines 5A, 5B.
  • the prepreg strips 2 and the connecting strands 3 are interwoven and thereby form a textile, single-ply flat structure 4.
  • the connecting strands 3 extend transversely to the prepreg bands 2, each of the
  • Connecting strands 3 crosses several of the prepreg strips 2.
  • each connecting strand 3 runs in sections on opposite sides of the prepreg strips 2.
  • the prepreg strips 2 can also intersect.
  • the connecting strands 3 are shown by way of example as foil strips 33.
  • the connecting strands 3 in the area of a first end section 31 and in the area of a second end section 32, which is opposite to the first end section 31 with respect to the second direction R2, are each materially bonded to one of the prepreg strips 2 connected.
  • the connecting strands 3 and the prepreg strips 2 are integrally connected to one another in a first end region 41 of the flat structure 4 and in a second end region 42 of the flat structure 4 lying opposite to this, along a connecting line 5A, 5B.
  • Fig. 6 it is shown as an example that the connecting lines 5A, 5B each along
  • the cohesive connection can, for example, by
  • the first end section 31 extends over the first Connection line 5A and the second end portion 32 protrudes beyond the second connection line 5B and thus forms a projecting tab.
  • Figs. 5 and 6 exemplarily shown semifinished products 3 allow the prepreg tapes to slide against each other due to their textile structure, thereby reducing the risk of wrinkles when the semifinished product is deformed.
  • FIG. 10 shows an example of the production of a single layer 110 from several of the semi-finished products 1 shown in FIG 12 thermoplastic or cohesively connected, eg by ultrasonic welding.
  • the second end sections 32 of the connecting strands 3 of the further semifinished product 12 are further thermoplastic bonded to prepreg tapes 2 of the first semifinished product 1 1, for example also by ultrasonic welding.
  • the first end sections 31 of the connecting strands 3 of the first semifinished product 1 1 overlap the outermost second prepreg band 2B of the second semifinished product 12 and the second end sections 32 of the connecting strands 3 of the first
  • Semi-finished products 12 overlap the outermost first prepreg tape 2A of the first
  • Semi-finished product 1 The semi-finished product 1 shown in FIG. 6 can be connected in the same way to other such semi-finished products 1.
  • a plurality of layers 110 can be stacked on top of one another and formed.
  • the individual layers 110 can also be cut to size (not shown) in order to produce a desired peripheral shape.
  • a semi-finished product 1 can also be used, as is shown in FIGS. 5 and 6 is shown, each form a layer 1 10, if necessary after performing a cut (not shown).
  • the semi-finished product 1 shown schematically and by way of example in FIG. 11 is constructed in several layers.
  • the prepreg tapes 2 are arranged to form a surface-extending multiaxial fabric 6, which comprises a plurality of layers 60 of prepreg tapes 2 lying one above the other. As is shown schematically in FIG. 11, the prepreg strips 2 extend parallel to one another within a respective layer 60. In adjacent layers 60 the extend
  • FIG. 11 shows only two layers or layers 60.
  • the individual layers 60 are connected relative to one another at individual locations or at points, preferably at discrete locations arranged in a periodically repeating pattern.
  • the layers 60 can be sewn using the connecting strands 3 described above. For reasons of clarity, this is shown in FIG. 11 only at a single point.
  • the connecting strand 3 wraps around two intersecting prepreg strips 2 at an intersection.
  • the connecting strand 3 is preferably designed as a thread 34.
  • the prepreg strips 2 can slide against one another within a layer 60 and the layers 60, as a result of which the risk of creasing during the shaping of the semifinished product 1 is reduced.
  • one or more semi-finished products 1, as is shown by way of example in FIG. 11, can be stacked on top of one another and formed.
  • the semi-finished products 1 can also be cut to size (not shown) in order to produce a desired circumferential shape.
  • Fig. 12 shows schematically a provision of the layer structure 100 by depositing prepreg tapes 2 by means of a depositing head 410.
  • the prepreg tapes 2 can, in particular, be designed as exemplified in FIG. 7 and already explained above.
  • the depositing head 410 has one or more rollers (not shown) and can be moved along a contour surface 150a by means of a movement device 420.
  • the contour surface 150a can in particular be through a first surface 310a of a mold half 310 or through a
  • Inner surface 210a of a shaped plate 21 1 may be formed, which will be described in detail below.
  • the movement device 420 is only shown symbolically as a block in FIG. 12 and can be, for example, by a
  • the movement device 420 moves the depositing head 410 along predetermined movement paths along the contour surface 150a and the at least one roll places the prepreg tape 2, which e.g. is unrolled from a storage drum (not shown) to which
  • Contour surface 150a The individual prepreg tapes 2 are placed parallel to one another or next to one another within a layer 110, as is shown schematically in FIG. 12. Furthermore, the prepreg strips 2 are fixed in their position 1 10 relative to one another, e.g. by locally heating the prepreg strips 2 to a temperature which is higher than the melting temperature of the matrix material 20. This results in a cohesive connection of the at least locally
  • prepreg tapes 2 are deposited in the manner described on a layer 110 already formed.
  • FIG. 13 schematically shows an exploded view of a layer structure 100.
  • the reinforcing fibers 21 run inside a layer 110 preferably along a direction R1 10.
  • the reinforcing fibers 21 extend from layers 110 lying against one another of the layer structure 100 in intersecting directions R1 10.
  • FIG. 13 only symbolically shows a reinforcing fiber 21 as a broken line in two layers 110.
  • the layer structure 100 is brought to a first temperature in a cavity 205 which is greater than a melting point of the
  • thermoplastic matrix material 20 heated and cooled with the application of a compression pressure in the cavity 205 to a solidification temperature, which is, for example, less than the melting point of the thermoplastic matrix material 20, and thus consolidated.
  • the cavity 205 is between a contour surface 150a and one
  • Plant part 220 is formed, as shown in FIGS. 2 to 4 is shown schematically.
  • the contour surface 150a generally has a geometry or shape corresponding to the shape of the structural component B.
  • Figs. 2 to 4 is the
  • Contour surface 150a is convexly curved and has a curved geometry for producing the structural component B shown by way of example in FIG. 14. 15 shows an example of a concavely curved contour surface.
  • FIG. 2 shows an example of a tool arrangement W which has a first shaped plate 21 1, which forms the contour surface 150 a, and a second shaped plate 221 as the contact part 220.
  • the contact part 220 or the second shaped plate 221 and the first shaped plate 21 1 are closed relative to one another
  • a cavity 205 is formed between the contour surface 150a and an inner surface 220a of the contact part 220, which is the contour surface 150a is facing in the closed position.
  • a seal 215 can be arranged between the first and the second shaped plate 21 1, 221, which hermetically seals the cavity 205 in the closed position.
  • a vacuum film (not shown) can also be provided as the contact part 220.
  • the first shaped plate 21 1 can optionally be supported by a mold half 310, as is the case with the tool arrangement W shown by way of example in FIG. 3. Furthermore, the contour surface 150a can also be formed on a mold half 310 instead of on the first shaped plate 21 1, as is shown by way of example in FIG. 4 for a further tool arrangement W. This only one-sided support of the cavity 205 or the first shaped plate 21 1 is a
  • Energy expenditure for heating the layer structure and for cooling the layer structure during consolidation is very low, or the time required for these steps is reduced with high dimensional stability of the cavity 205.
  • the shaped sheets 21 1, 221 are each in the form of flat plate-shaped components with an in
  • the first shaped plate 21 1 has an inner surface 210a, which forms the contour surface 150a, and one
  • the second shaped plate 221 has an inner surface 220a which, in particular, corresponds to the shape of the structural component B to be produced or is complementary to the inner surface 210a of the first
  • Shaped sheet 21 1 can be formed.
  • the inner surface 220a of the one shown in FIGS. 2 to 4 shown second mold plates 221 is concavely curved and has a curved geometry. 2 and 3, the shaped sheets 21 1, 221 in particular dome-shaped.
  • the shaped sheets 21 1, 221 can each be formed from a metal material such as stainless steel or Invar steel.
  • Figs. 3 and 4 each show tool arrangements with an optional mold half 310.
  • the mold half 310 has one
  • the surface section 312 has a first surface 310a, which can be designed, for example, as a three-dimensional surface to be described.
  • the first surface 310a serves to support the first mold plate 21 1.
  • the first surface 310a can, for example, be convexly curved and arched.
  • the first surface 310a of the mold half 310 forms the contour surface 150a on which the layer structure 100 is deposited.
  • the first surface 310a has a shape corresponding to the shape of the component B to be produced. 4 is the first
  • the base portion 314 supports or supports the surface portion 312
  • Base section 314 can, in particular, be designed in the form of blocks or cuboids, as is shown by way of example in FIG. 3.
  • Surface section 312 and base section 314 can in particular be made in one piece.
  • the base section 314 can also be realized as a support frame or structure, as shown by way of example in FIG. 4.
  • the surface section 312 can in particular be designed in the form of a plate.
  • the support structure 314 shown by way of example in FIG. 4 has a plurality of feet 315 which are distributed around a circumference of the surface section 312 and are attached to the latter.
  • the support structure 314 can have stiffening ribs 316, which on one opposite to the first surface 310a of the second surface 310b of the surface section 312 are attached.
  • the layer structure 100 is located in the cavity 205 formed between the shaped sheets 21 1, 221.
  • the cavity 205 is hermetically sealed by means of the optional seal 215.
  • the contour surface 150a is formed in FIG. 2 by the inner surface 210a of the first shaped plate 21 1.
  • the second shaped plate 221 forms the contact part 220.
  • the contact part 220 can also be formed by a vacuum film (not shown).
  • the stiffening profiles 130 can have, for example, a double-T-shaped cross section, as is shown by way of example in FIG. 2, and contain a thermoplastic material.
  • the stiffening profiles 130 can be formed from a fiber-reinforced thermoplastic material.
  • the first and the second shaped plate 21 1, 221 are brought into the closed position, as shown in FIG. 2.
  • the second shaped plate 221 is provided with recesses 223, through which a web of the stiffening profile 130 extends.
  • the second shaped plate 221 can be formed, for example, in two parts, a first part having the recesses 223 in the form of slots which are open on one side and are closed by a second part.
  • a seal is optionally available between the web and the respective recess (not shown) arranged.
  • the stiffening profiles 130 can also be inserted into enveloping bulges or depressions (not shown) of the second shaped plate 221. This improves the tightness of the cavity 205.
  • the stiffening profile 130 is generally pressed against the layer structure 100 in the cavity 205 by means of the contact part 220.
  • the cavity 205 is
  • Vacuum device 230 which is connected in a fluidically conductive manner to the cavity 205, is evacuated.
  • a force F is applied to the mold plates 21 1, 221, which pulls the mold plates 21 1, 221 together relative to one another, so that the layer structure 100 is subjected to a compression pressure and the optional stiffening profiles 130 are pressed onto the layer structure 100.
  • the evacuation also removes air that may be contained in the layer structure 100 from the layer structure.
  • the layer structure 100 is heated in the cavity 205 to a first temperature which is greater than a melting point of the
  • thermoplastic matrix material 20 As a result, the matrix material 20 of the individual layers 110 of the layer structure 100 melts
  • Stiffening profile 130 and the layer structure 100 is achieved.
  • the heating takes place inductively.
  • the system part 220 and / or the contour surface 150a contain an inductively heatable material, e.g. one electric
  • the first or the second shaped plate 21 1, 221 or both shaped plates 21 1, 221 can each be made of stainless steel or invar steel. If the system part 220 is designed as a vacuum film, this can also have a network made of an inductively heatable material. If the contour surface 150a by a first
  • the molded part 310 is shown as an example, the molded part 310, in particular the
  • Surface section 312 have an inductively heatable material,,, or be formed from this. It is conceivable, for example, that the contact part 220 and / or the part forming the contour surface 150a have a non-inductively heatable carrier material, e.g. a plastic material in which inductively heatable particles or structures e.g. a network that are embedded. As shown schematically in FIG. 2, a heating device 250 is in the form of a for inductive heating
  • Induction heater 252 is provided which is one or more
  • the induction coils 253 are supplied with an alternating electrical voltage by means of an alternating current source 254.
  • Induction coils 252 can be powered by an alternating current in the low frequency range, e.g. in a range between 50 Hz and 300 Hz, in the medium frequency range, e.g. in a range between 200 Hz and 100 kHz, or in
  • the layer structure 100 in the cavity 205 is cooled to a solidification temperature that is, for example, less than the melting point of the thermoplastic matrix material 20 is.
  • the compression pressure is applied in FIG. 2 exclusively by the evacuation of the cavity 205 by means of the pump 230. To cool the
  • the induction heating device 252 is switched off. Due to the low heat capacity of the shaped sheets 21 1, 221, the cavity 205 cools down quickly and the matrix material 20 solidifies within a short time. Optionally, the induction heater 252 may be slow or gradually reduced in performance to maintain a certain cooling rate. The cavity 205 can optionally also be cooled. Optionally, this can be
  • System part 220 and / or the contour surface 150a are also a thermally insulating medium (not shown) in order to reduce the outflow of energy when heating.
  • the layer structure 100 is located in the cavity 205 formed between the shaped sheets 21 1, 221.
  • the cavity 205 is hermetically sealed by means of the optional seal 215.
  • the contour surface 150a is formed in FIG. 2 by the inner surface 210a of the first shaped plate 21 1.
  • the second shaped plate 221 forms the contact part 220.
  • the contact part 220 can also be formed by a vacuum film (not shown).
  • the first shaped plate 21 1 is formed by the first surface 310a of the shaped part 310 or by the
  • the cavity 205 is optionally evacuated by means of a pump or vacuum device 230, which is connected to the cavity 205 in a fluidly conductive manner.
  • the evacuation draws air, which may be contained in the layer structure 100, out of the layer structure.
  • a force F is applied to the shaped sheets 21 1, 221 on the shaped sheets 21 1, 221 in such a way that the layer structure 100 is pressed together between the shaped sheets 21 1, 221 or is subjected to a compression pressure. 3, this force F is generated by generating a magnetic field directed transversely to the contour surface 150a, which is coupled into a magnetizable material assigned to the contact part 220 and / or into a magnetizable material assigned to the contour surface 150a.
  • the first and / or the second shaped plate 21 1, 221 has or are formed from a magnetizable material, as a result of which the magnetizable material is assigned to the shaped plates 21 1, 221.
  • one of the shaped sheets 21 1, 221 or both shaped sheets 21 1, 221 can be formed from stainless steel or Invar steel.
  • the contact part 220 and / or the contour surface 150a can be formed from a magnetizable material, as a result of which the magnetisable material is assigned to the contact part 220 or the contour surface 150a, respectively.
  • the magnetizable material can also be assigned to the contour surface 150a or the contact part 220 by being attached to the contact part 220 and / or the contour surface 150a.
  • the mold half 310 or the surface section 312 of the mold half 310 can be formed from a magnetizable material.
  • a first magnet device 240 is provided. 3, the first magnet device 240 is implemented, for example, in the form of an electrical magnet device with a plurality of electrical induction coils 241.
  • the first magnetic device 240 is set up to generate a magnetic field and can therefore also have one or more permanent magnets instead of the induction coils 241.
  • the first magnetic device 240 generally has one or more magnetic field generators which are used to generate a magnetic field are set up.
  • the following statements regarding induction coils 241 therefore generally apply to magnetic field generators.
  • the induction coils 241 are distributed along the contour surface 150a. For this purpose, the induction coils 241
  • the induction coils 241 may be arranged in the area of the mold half 310 or be integrated into this, as is shown by way of example in FIG. 3.
  • the induction coils 241 may be distributed along the contour surface 150a by arranging them on the part of the contact part 220.
  • Induction coils 241 are arranged on an outer surface 220b of the contact part 220 opposite to the inner surface 220a (not shown). By applying an electrical voltage to the coils 241, a magnetic field is induced in the magnetizable material, which the
  • Contour surface 150a and the contact part 220 that is to say in FIG. 3 the mold plates 21 1, 221 pull together or press together relative to one another and thereby compress the layer structure 100.
  • Magnetic device (not shown in FIG. 3) can be assigned to the contour surface 150a or the contact part 220.
  • the second magnet device can also be implemented as an electrical magnet device, as was described above for the first magnet device 240. It is also conceivable that the second magnet device is formed by one or more permanent magnets.
  • the first magnet device 240 can be arranged on the contact part 220 or the contour surface 150a and the second magnet device is arranged on the other of the contact part 220 and the contour surface 150a.
  • a magnetic field can be generated by the magnetic devices, which interacts with the magnetic field of the other magnetic device and extends through the layer structure 100, so that the contact part 220 and the part forming the contour surface 150a are attracted to one another.
  • the layer structure 100 in the cavity is heated to the first temperature and the layer structure is cooled down to the solidification temperature with the application of the compression pressure for consolidation.
  • Insulation layer 31 1 largely prevents heating of the mold half 310 during heating.
  • the heating can, for example, by means of
  • the heating device 250 can be designed as an infrared radiator 251, which is arranged on the part of the system part 220.
  • a further infrared radiator (not shown) can optionally be arranged on the side of the contour surface 150a.
  • the infrared radiator 251 is set up to generate thermal radiation in order to heat the cavity 205.
  • the heating can also be carried out inductively as described with reference to FIG. 2.
  • the cavity 205 can continue to be evacuated both during heating and during cooling.
  • the compression pressure is also by means of a
  • Magnetic device 240 generated magnetic field applied, as described above with reference to FIG. 3.
  • the contour surface 150a is formed by the first surface 310a of the mold half 310.
  • the heating device 250 is
  • Induction heating device 252 is formed and the cavity is heated inductively, as described above.
  • the tool arrangement W shown in FIG. 15 differs from the tool arrangement W shown in FIG. 3 in particular in the arrangement and design of the magnet device 240 as an electrical magnet device.
  • the first shaped sheet 21 1 is assigned a magnetizable material in that the shaped sheet 21 1 itself has a magnetizable material.
  • the induction coils 241 are connected to a flat support structure 242 and are distributed over the support structure 242, for example in a lattice-like manner, as is shown by way of example in FIG. 16.
  • the support structure 242 is elastically deformable and can in particular be formed from a flexible material, such as rubber, silicone or the like. This ensures an even pressure distribution even in the case of inaccurate shapes.
  • the support structure 242 can be locally fiber or wire reinforced to prevent damage such as bursting. Due to the flexibility of the support structure 242, the magnet device 240 can also be used for different shapes.
  • Induction coils 241 as repeating, same elements are the same elements.
  • the cushions 243 can be formed from a flexible material and can be coated with a flowable medium such as e.g. Air, water, oil, sand or the like filled.
  • the soft cushions 243 below the induction coils 241 transmit the pressure evenly in the event of shape inaccuracies and possibly also laterally.
  • a rigid plate element 244 can also be arranged between a respective induction coil 241 and the support structure 242, which further improves the pressure distribution.
  • the magnetic device 240 can be used with the
  • Carrier structure 241 is placed on the outer surface 220b of the contact part 220 will.
  • the induction coils 241 of the magnet device 240 are energized, preferably with a direct current. As a result, they induce a magnetic field, so that the magnet device 240 and the first shaped plate 21 1 are attracted to one another and the layer structure 100 is pressed together between the shaped plates 21 1, 221.
  • the heating device 250 can optionally be designed as an induction heating device 252, which heats the first shaped plate 21 1.
  • the induction heating device 252 is integrated in the molded part 310.
  • the induction coils 241 of the magnet device 240 can also be used as induction heating. For this, these are marked with a
  • the coils 253 of the heating device 250 can also be used as coils generating a magnetic field.
  • the heating device 250 forms a second magnet device assigned to the contact surface 150a.
  • the pressure for pressing the layer structure 100 can thus essentially be generated by the attractive forces between the induction coils 241 of the magnet device 240 and the coils 253 of the heating device 250, since the coils 241, 253 correspondingly pass on the resulting forces to the elements in between. This makes a particularly large one
  • thermoplastic matrix material 20 thermoplastic matrix material

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Health & Medical Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Toxicology (AREA)
  • Oral & Maxillofacial Surgery (AREA)
  • Thermal Sciences (AREA)
  • Textile Engineering (AREA)
  • Moulding By Coating Moulds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

L'invention concerne des procédés de fabrication d'un composant structural (B). Les procédés comprennent respectivement la fourniture d'une structure en couches (100) préformée comprenant une pluralité de couches (110) qui possèdent chacune des fibres de renforcement (21) enrobées dans un matériau de matrice thermoplastique (20), le chauffage de la structure en couches (100) dans une cavité (205) formée entre une surface de contour (150a) et une partie d'appui (220) à une première température qui est supérieure au point de fusion du matériau de matrice thermoplastique (20), et le refroidissement de la structure en couches (100) dans la cavité (205) à une température de solidification qui est inférieure, par exemple, au point de fusion du matériau de matrice thermoplastique (20), en appliquant une pression de compression. Selon un procédé, la pression de compression est produite en générant un champ magnétique orienté transversalement à la surface de contour (150a) au moyen d'un dispositif magnétique (240), ledit champ magnétique contractant ou comprimant la partie d'appui (220) et la surface de contour (150a) l'une par rapport à l'autre. Selon un procédé supplémentaire, un chauffage inductif de la cavité (205) est effectué.
EP19783273.6A 2018-10-04 2019-10-02 Procédés de fabrication d'un composant structural Pending EP3860836A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102018217017.7A DE102018217017A1 (de) 2018-10-04 2018-10-04 Verfahren zur herstellung eines strukturbauteils
PCT/EP2019/076736 WO2020070204A2 (fr) 2018-10-04 2019-10-02 Procédés de fabrication d'un composant structural

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EP3860836A2 true EP3860836A2 (fr) 2021-08-11

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US (1) US20220161508A1 (fr)
EP (1) EP3860836A2 (fr)
DE (1) DE102018217017A1 (fr)
WO (1) WO2020070204A2 (fr)

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DE102018217018A1 (de) * 2018-10-04 2020-04-09 Premium Aerotec Gmbh Halbzeug und verfahren zur herstellung eines strukturbauteils
DE102020105023A1 (de) 2020-02-26 2021-08-26 Airbus Operations Gmbh Vorrichtung und Verfahren zum Herstellen eines faserverstärkten Bauteils
CN115891217B (zh) * 2022-10-24 2024-01-05 北京科技大学 一种磁场取向磁微针增强复合材料层间性能的方法与装置

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US20220161508A1 (en) 2022-05-26
DE102018217017A1 (de) 2020-04-09
WO2020070204A3 (fr) 2020-05-28
WO2020070204A2 (fr) 2020-04-09

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