WO2009036820A1 - Procédé de fabrication d'un élément composite fibreux et dispositif associé - Google Patents

Procédé de fabrication d'un élément composite fibreux et dispositif associé Download PDF

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Publication number
WO2009036820A1
WO2009036820A1 PCT/EP2008/004469 EP2008004469W WO2009036820A1 WO 2009036820 A1 WO2009036820 A1 WO 2009036820A1 EP 2008004469 W EP2008004469 W EP 2008004469W WO 2009036820 A1 WO2009036820 A1 WO 2009036820A1
Authority
WO
WIPO (PCT)
Prior art keywords
fiber
curing
fibers
composite component
fiber composite
Prior art date
Application number
PCT/EP2008/004469
Other languages
German (de)
English (en)
Inventor
Karl-Heinz Ilzhöfer
Asmir Salkic
Original Assignee
Daimler Ag
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 Daimler Ag filed Critical Daimler Ag
Publication of WO2009036820A1 publication Critical patent/WO2009036820A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/088—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of non-plastics material or non-specified material, e.g. supports
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29L2031/3005—Body finishings

Definitions

  • the invention relates to a method for producing a fiber composite component, in particular a fiber composite component for a motor vehicle.
  • the invention further relates to a device for producing a fiber composite component, in particular a fiber composite component for a motor vehicle.
  • the fibers be integrated into the component structure in accordance with the flow of force without producing any fiber waste.
  • various textile techniques such as braiding, weaving, sewing, etc., which are used for the production of so-called fiber preforms (preforms) for continuous fiber reinforced composite components.
  • These methods enable the findings of force flux and stress analyzes in a corresponding textile reinforcement structure.
  • the reinforcing fibers are fixed on a embroidery base with an embroidery machine according to the requirements of the analytical component calculation.
  • a disadvantage of this method is that after the Production of the preform the corresponding fiber structure must be impregnated with resin or plastic. This results in an additional process step, which significantly increases the cycle times of the manufacturing process.
  • thermoset materials for the production of the matrix of the fiber composite component so-called for this subsequent impregnation of the fiber structure
  • Infusion method such as RTM (Resin Transfer Molding, S-RIM (Structural Resin Injection Molding), or vacuum injection
  • RTM Resin Transfer Molding, S-RIM (Structural Resin Injection Molding), or vacuum injection
  • the plastic matrix is injected by means of a piston into a corresponding cavity of the fiber composite component and cures under heat and pressure, but the infusion procedures are relative
  • prepregs which are usually referred to as continuous-fiber-reinforced thermoset semifinished products
  • prepregs which are usually referred to as continuous-fiber-reinforced thermoset semifinished products
  • Another disadvantage is that, for example, shell components must be produced over the entire surface of the expensive composite material, although structural properties are required only in some areas.
  • the so-called Tailored Fiber Placement (use of narrow preimpregnated tapes) represents a further development.
  • the restriction regarding component geometry and material usage also applies here. It is therefore an object of the present invention to provide a method for producing a fiber composite component, in particular a fiber composite component for a motor vehicle of the aforementioned type, which ensures optimized fiber material utilization and reduced cycle times of the manufacturing process.
  • An inventive method for producing a fiber composite component, in particular a fiber composite component for a motor vehicle comprises the following steps:
  • Matrix material made of resin and / or matrix fibers on reinforcing fibers or fiber bundles with the formation of fiber material b) Application of the fiber material to a carrier structure simulating the shape of the fiber composite component to produce a preform (30), wherein the arrangement of the fiber material relative to the fiber composite component (20) to be produced c) curing of the fiber material applied to the carrier material to form a fiber composite component.
  • the matrix material is to be understood here as meaning the moldable precursor of the later matrix of the corresponding composite component. These may be liquid curable resins or plastics. Likewise, plastic mixtures of moldable and curable portions are suitable.
  • the matrix fibers act here like the moldable precursor of the later matrix of the corresponding composite component.
  • solid resins which can be applied, for example, as a fine powder, or can be applied to the fiber in solution and dried. Suitable solid resins may be intermediately fusible, so that prior to their curing in step c) a uniform infiltration of the reinforcing fibers can take place.
  • Preferred resins include lubricious . e_ Phenolic resins, which are thermally cured.
  • matrix fibers are used, this is preferably done in the form of hybrid yarns of reinforcing fibers of matrix fibers.
  • the matrix fibers are suitable for hardening in step c) also harden. If the matrix fibers are used without resin, only intermediately melting fiber types are suitable. These may be precrosslinked polymer fibers which cure completely thermally. If matrix fibers and resin are used, it is also possible to use non-meltable synthetic fibers, which can then be further hardened or crosslinked with the resin.
  • the curing can be carried out thermally and / or photoinitiated, or by cold curing.
  • the thermal curing especially under external pressure, because during or immediately before curing, the resin viscosity drops, or solid resins melt and the resin flows into the spaces formed by the fibers.
  • the thermal curing is carried out by adapted heating, wherein the matrix fibers and / or the resin melt before curing below the curing temperature of the fiber material and thermally crosslink when reaching the curing temperature.
  • the photon initiated curing is preferably used for fiber material with liquid resins.
  • a photonhemi sr.hp pre-crosslinking and then a thermal end crosslinking can be carried out first.
  • the reinforcing fibers or fiber bundles are present together with the precursor of the matrix in a state of excellent formability, which is particularly suitable for the demanding knitting, weaving or knotting process.
  • the reinforcing fiber or fiber bundles already provide the required matrix for the composite body to be molded.
  • the inventive application of the fiber material allows a geometrically optimized application of the fiber material while avoiding fiber waste and optimum fiber utilization.
  • the inventive method is extremely economical in the production of lightweight fiber composite structures, as is avoided by the endkonturtchanging preforms fiber waste, since the fiber material is optimally exploited by a power flow and voltage arrangement and also by the defined, low-defect fiber assembly high quality consistency of the fiber composite parts produced is guaranteed.
  • Resin and matrix fibers from the group of crosslinkable thermosetting and / or elastomeric plastics can be used as the matrix material.
  • Particularly suitable as the resin are the thermal, cold-curing or UV-curing polyesters, polyurethanes, epoxides, phenols or vinyl esters.
  • polyurethanes polyurethanes
  • epoxides phenols or vinyl esters.
  • Vinyl ester polyurethane blends are particularly preferred.
  • step a) applying the plastic by means of a powder, melt or solvent impregnation. This ensures optimal wetting of the fibers or fiber bundles with the resin.
  • solid resin can first be applied in solution to the reinforcing fibers or rovings and then dried to give a gelatinous or solid coating.
  • step b) in method step b) the application of the fiber material by depositing and / or weaving and / or braiding and / or embroidering and / or sewing on the support structure.
  • the support structure may be formed two- or three-dimensional, it may also be removed in a later step from the fiber composite part or remain on the fiber composite component.
  • the said application techniques in particular the mentioned sewing technique causes a defined, low-defect fiber arrangement and thus also contributes to an optimal fiber material utilization with a high quality stability. Furthermore, there is a much higher design freedom compared to the prior art.
  • the support structure is formed in three dimensions, in particular in the form of curved surfaces.
  • the sewing thread essentially ensures only the firm fixation of the fiber material on the carrier structure.
  • the sewing thread may consist of a fusible plastic, which dissolves during thermal curing.
  • the curing of the fiber composite material according to method step c) comprises a pressing, the application of external pressure and / or a heating of the fiber composite material.
  • the preforms produced in process step b) can be pressed and cured in a preferably heated tool.
  • the use of so-called autoclave or microwave devices are conceivable in the curing step.
  • the preform is in an autoclave preferably in a known manner in a protective film wrapped to apply the external pressure surface on the fiber material.
  • Glass fibers, carbon fibers, ceramic fibers, metal fibers, natural fibers or a mixture of at least two of these fiber materials are preferably used as reinforcing fibers.
  • Other suitable reinforcing fibers are aramid fibers or high modulus polyethylene fibers.
  • the support structure may for example consist of a pre-crosslinked, solid at room temperature plastic, wherein the plastic of the support structure may correspond to the plastic of the matrix material.
  • the support structure consists of a pre-crosslinked plastic mold which cures completely in process step c).
  • Plastic of the support structure is preferably chemically related to the matrix material.
  • the cured support material typically remains as a flat and unreinforced fabric in the finished component.
  • the carrier structure can also be removed after curing of the fiber material in a further process step.
  • a functional part is integrated into the fiber composite component when sewing, embroidering or weaving.
  • metallic connecting parts can act for attachment to a vehicle body.
  • cables or media lines can be sewn on and integrated into the fiber structure.
  • the invention additionally relates to a fiber composite component, in particular a fiber composite component for a motor vehicle, produced by a method according to the invention described above.
  • Preferred components are trim parts of the vehicle interior.
  • An apparatus according to the invention for producing a fiber composite component in particular a fiber composite component for a motor vehicle, has at least one application station for applying matrix material made of resin to individual fibers or fiber bundles or rovings, at least one fabrication station for applying the fiber material to a form of the fiber composite component_s__nachbi.l.dende-
  • Carrier structure for producing a preform wherein the arrangement of the fiber material based on the fiber composite component to be produced kraftfluß- and voltage optimized and takes place at least one curing station for curing the fiber composite material applied to the carrier material.
  • the fiber bundles may be pure reinforcing fibers or hybrid yarns of reinforcing and matrix fibers.
  • the device according to the invention is an optimized fiber material utilization and a reduced cycle time of the manufacturing process for producing a
  • the resin can be selected from the group comprising thermosetting and elastomeric liquid or solid resins.
  • the application station has at least one impregnation nozzle and / or at least one resin or liquid resin bed.
  • the resin can be applied in liquid form or powder form to the fibers and fiber bundles.
  • the material may be contained in solid form, such as a powder or individual fibers, with the fibers and fiber bundles to be coated being passed through the resin bed.
  • the packaging station has at least one weaving and / or embroidery and / or sewing device.
  • the packaging station or the weaving and / or embroidery and / or sewing device may have a programmable control device, so that the prepreg fibers or fiber bundles are deposited on the carrier structure in accordance with the requirements of a component calculation calculated in advance and correspondingly stored in the control device can be.
  • the curing device has at least one pressurizable and / or heatable tool, at least one autoclave or at least one microwave device, IR irradiation device or UV irradiation device. The devices mentioned allow the necessary curing of the preforms to the resulting fiber composite components.
  • the fiber material consists of glass fibers, carbon fibers, or carbon fibers or carbon fibers, ceramic fibers, metal fibers, natural fibers or a mixture of at least two of these fiber materials.
  • the figure shows a schematic representation of a device 10 for producing a fiber composite component 20, in particular a fiber composite component for_e.in
  • the apparatus 10 comprises an application station 12 for applying resin matrix material to reinforcing fiber bundles.
  • the fiber bundle is wound up on a discharge gate 32 with at least one coil and is fed to a resin bed 18 containing the matrix material.
  • the coated rovings are fed to a finishing station 14.
  • the finishing station 14 serves to apply the coated fiber material to a carrier structure made of resin-impregnated cardboard, simulating the shape of the fiber composite component 20. This results in a preform 30 which has the pre-impregnated fiber material, wherein the fiber bundles have been applied to the end contour-faithful preform 30 in a way that is optimized in terms of flux and voltage.
  • the Applying the fiber material takes place in the illustrated embodiment by means of a sewing device 22 with a sewing head 26.
  • the sewing device 22 is controlled by a programmable controller 24.
  • the control of the sewing device 22 takes place in accordance with previously calculated and determined optimal flow structures of the fibers and fiber bundles, taking into account the shape of the fiber composite component to be produced 20.
  • the support structure is formed in the illustrated embodiment as a three-dimensional structure.
  • the carrier structure is removed from the finished fiber composite component 20 in a subsequent process step, not shown.
  • the support structure can also be a surface component and firmly connect to the preform 30 to the fiber composite component 20.
  • the apparatus 10 further includes a curing station 16 for curing the preform 30.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Reinforced Plastic Materials (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

L'invention concerne un procédé et un dispositif de fabrication d'un élément composite fibreux destiné notamment à un véhicule à moteur, le procédé comprenant les étapes suivantes: a) appliquer du matériau matriciel en plastique sur un matériau fibreux composé de fibres individuelles ou de faisceaux de fibres; b) appliquer le matériau fibreux sur une structure porteuse imitant la forme de l'élément composite fibreux pour créer une préforme (30), la disposition du matériau fibreux relativement à l'élément composite fibreux (20) à fabriquer étant optimisée en termes de flux de force et de tension; c) faire durcir le matériau composite fibreux appliqué sur le matériau support. L'invention porte également sur un dispositif de fabrication d'un élément composite fibreux destiné notamment à un véhicule à moteur.
PCT/EP2008/004469 2007-09-17 2008-06-04 Procédé de fabrication d'un élément composite fibreux et dispositif associé WO2009036820A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
DE102007044218.3 2007-09-17
DE102007044218 2007-09-17
DE102007054087.8 2007-11-13
DE102007054087A DE102007054087B4 (de) 2007-09-17 2007-11-13 Verfahren zur Herstellung eines Faserverbundbauteils und Vorrichtung hierfür

Publications (1)

Publication Number Publication Date
WO2009036820A1 true WO2009036820A1 (fr) 2009-03-26

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Application Number Title Priority Date Filing Date
PCT/EP2008/004469 WO2009036820A1 (fr) 2007-09-17 2008-06-04 Procédé de fabrication d'un élément composite fibreux et dispositif associé

Country Status (2)

Country Link
DE (1) DE102007054087B4 (fr)
WO (1) WO2009036820A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR3026669A1 (fr) * 2014-10-02 2016-04-08 Deutsches Zentrum Fur Luft- Und Raumfahrt E V
CN111372759A (zh) * 2017-12-13 2020-07-03 宝马股份公司 纤维增强的车辆车身

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102010012719A1 (de) 2010-03-25 2011-09-29 Daimler Ag Legekopfkompaktvorrichtung, Legeanlage und Verfahren zur Herstellung einer Preform
DE102010033287A1 (de) 2010-08-04 2012-02-09 Daimler Ag Verfahren zur Herstellung eines geformten Faserverbundbauteils für ein Kraftfahrzeug
EP3758922B1 (fr) * 2018-02-27 2024-05-15 Eovidar AB Procédé de fabrication de produits en fibre composite

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DE4121866A1 (de) * 1991-07-02 1993-01-14 Peter Pelz Formteil mit einem kern aus kunststoff und einer glasfaser-beschichtung sowie verfahren zum herstellen eines solchen formteils
US5851459A (en) * 1997-03-31 1998-12-22 Chen; Jason Method for manufacturing cranks for bicycles
US20020144767A1 (en) * 2001-04-06 2002-10-10 Johnson David W. Method of clinching the top and bottom ends of Z-axis fibers into the respective top and bottom surfaces of a composite laminate
EP1473132A2 (fr) * 2003-05-02 2004-11-03 The Boeing Company Couches intermédiaires à haute porosité pour le renforcement de composites moulés à base de tissu et de liquide
US20050167030A1 (en) * 1999-06-21 2005-08-04 Pella Corporation Method of making a reinforcing mat for a pultruded part
EP1724098A1 (fr) * 2005-05-20 2006-11-22 Carbo Tech Composites GmbH Procédé de fabrication d'un produit laminé composite et produit composite fabriqué par le procédé de lamination

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DE3226290C2 (de) * 1982-07-14 1985-09-12 Messerschmitt-Bölkow-Blohm GmbH, 8000 München Anordnung zum gesteuerten Ablegen von Fasern auf eine Form
NL1000598C2 (nl) * 1995-06-20 1996-12-23 Dsm Nv Antiballistisch vormdeel en een werkwijze voor de vervaardiging van het vormdeel.
DE102005023320A1 (de) * 2005-05-17 2006-11-30 Gummiwerk Kraiburg Gmbh & Co. Kg Verbundbauteil aus wärmehärtenden Harzen und Elastomeren, Verfahren zur Herstellung und Verwendung eines solchen Verbundteils

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4121866A1 (de) * 1991-07-02 1993-01-14 Peter Pelz Formteil mit einem kern aus kunststoff und einer glasfaser-beschichtung sowie verfahren zum herstellen eines solchen formteils
US5851459A (en) * 1997-03-31 1998-12-22 Chen; Jason Method for manufacturing cranks for bicycles
US20050167030A1 (en) * 1999-06-21 2005-08-04 Pella Corporation Method of making a reinforcing mat for a pultruded part
US20020144767A1 (en) * 2001-04-06 2002-10-10 Johnson David W. Method of clinching the top and bottom ends of Z-axis fibers into the respective top and bottom surfaces of a composite laminate
EP1473132A2 (fr) * 2003-05-02 2004-11-03 The Boeing Company Couches intermédiaires à haute porosité pour le renforcement de composites moulés à base de tissu et de liquide
EP1724098A1 (fr) * 2005-05-20 2006-11-22 Carbo Tech Composites GmbH Procédé de fabrication d'un produit laminé composite et produit composite fabriqué par le procédé de lamination

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR3026669A1 (fr) * 2014-10-02 2016-04-08 Deutsches Zentrum Fur Luft- Und Raumfahrt E V
CN111372759A (zh) * 2017-12-13 2020-07-03 宝马股份公司 纤维增强的车辆车身
CN111372759B (zh) * 2017-12-13 2024-04-02 宝马股份公司 纤维增强的车辆车身

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DE102007054087B4 (de) 2012-05-03

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