WO2009086814A1 - Fiber composite material and method for the production thereof - Google Patents

Fiber composite material and method for the production thereof Download PDF

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Publication number
WO2009086814A1
WO2009086814A1 PCT/DE2009/000003 DE2009000003W WO2009086814A1 WO 2009086814 A1 WO2009086814 A1 WO 2009086814A1 DE 2009000003 W DE2009000003 W DE 2009000003W WO 2009086814 A1 WO2009086814 A1 WO 2009086814A1
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WO
WIPO (PCT)
Prior art keywords
fiber
layer
thermoplastic
fiber composite
composite material
Prior art date
Application number
PCT/DE2009/000003
Other languages
German (de)
French (fr)
Inventor
Karsten Hellmann
Original Assignee
Karsten Hellmann
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Publication date
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Publication of WO2009086814A1 publication Critical patent/WO2009086814A1/en

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Classifications

    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
    • B32B27/285—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42 comprising polyethers
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
    • B32B27/288—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42 comprising polyketones
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0086—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique
    • D06N3/0088—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin
    • D06N3/0093—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin by applying resin powders; by sintering
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/42—Alternating layers, e.g. ABAB(C), AABBAABB(C)
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide fibres
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/51—Elastic
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/546—Flexural strength; Flexion stiffness
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/58—Cuttability

Definitions

  • Fiber composite material and method for its production
  • the invention relates to a fiber composite material comprising at least one fiber material and a thermoplastic plastic material and a method for producing such a fiber composite material.
  • the fiber composite material basically consists of the reinforcing fiber material, which is embedded in a matrix of a plastic material. By mutual interactions of the two components of the fiber composite material receives higher quality properties than each of the two components involved individually.
  • the matrix fixes the reinforcing fibers, transfers and distributes forces and stresses between them and protects them from external mechanical, thermal and chemical influences (environmental influences, resistance to chemicals). Furthermore, it decides on a possible thermal shaping, the heat resistance and recyclability.
  • the fibers are responsible for the strength of the component (tensile strength, flexural strength) and therefore primarily determine the properties of the finished part. They are bound to the matrix by adhesion and / or cohesive forces.
  • fiber material for example, carbon fibers, aramid fibers, nylon fibers or inexpensive glass fibers are used, while thermosetting or elastomeric plastics and thermoplastics are used as the matrix.
  • Fiber-reinforced plastics made of thermoplastic material can be transformed later under heat.
  • fiber materials are hand-draped onto a mold and soaked in a reaction resin. Subsequently, the venting and removal of excess resin by means of roller or brush. Thereafter, the component hardens by the chemical reaction of the resin with the hardener component.
  • the laminate can be compacted by applying a vacuum and excess resin remaining in the laminate can be removed.
  • the ratio of the volume of the fibers to the total volume of a fiber-reinforced material is low, which also leads to a low component quality.
  • the processing of the resin makes high demands on the capabilities of the laminator and occupational safety.
  • preimpregnated fibers that is to say embedded in the matrix, which are also referred to as prepregs, already consist of epitaxial fibers and an uncured thermosetting plastic matrix.
  • the plastic matrix has a slightly sticky, solid consistency and consists of a mixture of resin and hardener, in some cases from an accelerator.
  • the continuous fibers can be in the form of a pure unidirectional layer, as a woven or laid fabric.
  • the semi-finished product created in this way is flexible and can be delivered in web form, in particular wound on reels.
  • As a disadvantage proves the required during transport of the semi-finished adhering to a closed cold chain at about - 18 0 C.
  • the curing then takes place under pressure and heat (autoclave) or under vacuum and heat (oven).
  • thermoplastic fiber-reinforced plastic plates with a defined thickness and fiber orientation are already known.
  • the fiber material is already embedded in the matrix defined by the thermoplastic material, which is heated to melting temperature or above for processing. In this state, the plate material is forced to a new shape and cooled. Due to the inherent stability of the plate material, the three-dimensional drapability can be limited.
  • a fiber composite material is already known from DE 693 09 831 T2, wherein a flexible film of a thermoplastic polymer covers a multifiber filament impregnated with a powder.
  • the powder has as an essential component thermoplastic polymers.
  • the fiber composite material should have a high flexibility, in particular for the formation of highly flexible mats.
  • DE 693 07 995 T2 describes a process for the production of fiber-reinforced thermoplastic compositions in which a fiber is unwound from a bobbin and broken down into individual filaments. The thus opened fiber is then passed through a bed of thermoplastic powder and then reassembled, with a flexible sheath of thermoplastic polymer wrapping the fiber.
  • the invention has for its object to provide a fiber composite material, which allows easy processing as well as a low transport and storage costs. Furthermore, the invention has for its object to provide a method for producing such a fiber composite material.
  • the first object is achieved according to the invention with a fiber composite material according to the features of claim 1.
  • the further embodiment of the fiber composite material can be found in the dependent claims 2 to 11.
  • a fiber composite material in which the fiber composite material has flexible and / or elastic material properties and a layer structure with a first layer formed by the fiber material and at least one further layer formed by the thermoplastic material, wherein the layers form separate planes and on a lie substantially flat contact surface against each other, so that enforcement or penetration of the fiber material is not or not completely.
  • the flexible or elastic material properties of the fiber composite material are retained until they are processed in a shaping process, and thus the handling of the fiber composite material is substantially facilitated.
  • a complete cold chain is not required since the matrix is already in the polymeric state.
  • the flexible or elastic properties of the fiber composite material are achieved, since the fiber material and the thermoplastic material first form separate layers, so penetration or penetration of the fiber material is at least not complete. Rather, the fiber material and the thermoplastic material are flat.
  • the production of the fiber composite material as a semi-finished thereby also allows almost any combination and composition, so that the storage is considerably simplified.
  • a particular advantageous embodiment is achieved in that the first layer is free of thermoplastic constituents of the further layer, so that the flexible or elastic properties of the fiber material as well as those of the thermoplastic material are retained in each case unrestricted. The requirements for warehousing and processing are therefore comparatively low.
  • the fiber composite material can be realized by exactly two layers.
  • a modification of the present invention in which the first layer formed by the fiber material bears a layer of the thermoplastic material on both sides in order to ensure a reliable embedding of the fiber material during the processing process and in particular to avoid areas of insufficient lamination, proves particularly expedient.
  • the further layer formed by the thermoplastic material is designed as a film and thus is not applied directly to the fiber material in the liquid or flowable state.
  • the two layers can not only be produced in mutually independent method steps, but can also be combined, if required, in a desired quantity or material thickness.
  • the fiber volume fraction can be varied depending on the requirements of the product to be produced from the fiber composite material.
  • the cutting of the fiber composite material is at the same time easily possible because the fibers are bound by the plastic layer and thereby fiber residues and dust are avoided.
  • thermoplastic synthetic material is produced by extrusion and for this purpose is extruded, for example, onto a silicone paper.
  • the thermoplastic material is then applied as needed and according to the particular requirements of the fiber composite in one or more layers on the fiber material.
  • the fiber volume fraction of the fiber composite material is therefore precisely definable in advance so as to ensure a reproducible component quality.
  • thermoplastic material is applied as a granular solid, in particular as a powder on the fiber material, which by Melting of a surface is connected to the fiber material.
  • an arbitrarily predeterminable amount of the plastic material can be applied to the fiber material and fixed by melting near the surface, so as to obtain the flexibility of the fiber composite material unrestricted by a fiber structure defining connection is first avoided.
  • the powder enclosed between the closed cover layer and the surface of the fiber material is then heated to at least melting temperature, so that a thermoplastic matrix is formed.
  • the fiber composite material has an alternating layer structure comprising at least two layers of the fiber material and at least two layers of the thermoplastic material.
  • the individual layers of each one layer of the fiber material and a layer of the thermoplastic material are initially only loosely on each other, so that the layers are displaceable relative to each other. This avoids wrinkling as well as unwanted delamination, especially in the region of small internal radii of the shaping.
  • the superimposed layers can be compressed by pressure, such as overpressure, vacuum or mechanical pressure, even using suitable release films. An autoclave is not mandatory.
  • the layer structure can be chosen in particular such that the properties of the thermoplastic material of an outer layer differ from at least one inner layer.
  • the outer layer may have a hard surface finish or a high strength while the inner layer is made elastic.
  • the fiber volume fraction can be correspondingly sized differently.
  • the properties on the outer surface of the thermoplastic material may also vary in terms of optical properties, paintability or even UV resistance.
  • thermoplastic material can be superimposed, so as to use, for example, during processing, the flow properties of the thermoplastic material for embedding moldings, in particular flanges, by a positive connection.
  • the layer structure can for this purpose already take place in a mold for the product, wherein the untreated fiber materials and the thermoplastic material are layered separately in the form of a film.
  • the layer structure is formed by different fiber materials and / or thermoplastic plastic materials, wherein the materials in particular have different material properties, quantities and / or dimensions.
  • the layer structure and thus the particular direction-dependent properties of the fiber composite material are freely selectable by also different fiber materials can be coated with the thermoplastic material.
  • the first layer has as essential material components carbon, glass and / or aramid fibers, wherein also different types of bonding can be realized.
  • one-, two- or multi-dimensionally reinforced fiber composite materials can be realized, wherein as one-dimensional reinforcement or unidirectional scrim (UD) such fiber composite material are called whose fibers are oriented only in one direction.
  • UD unidirectional scrim
  • At least one layer comprises as essential material constituents of the thermoplastic synthetic material polypropylene, polyester, polyamide and / or a polyether ketone, for example the polyetheretherketone (PEEK).
  • PEEK polyetheretherketone
  • the layer formed by the thermoplastic material may have an additional solids content, in particular fiber material content.
  • the fiber material can be formed from fibers which have a length of only a few millimeters or else by solid bodies, for example hollow spheres. These can also be provided in partially deviating concentration.
  • the second-mentioned object to provide a method for producing such a fiber composite material comprising at least one fiber material and a thermoplastic material, is realized according to the invention by applying to a first layer formed by the fiber material at least one further layer formed by the thermoplastic material, such that the Layers lie against each other at a substantially flat contact surface and the fiber material is not or not completely penetrated or penetrated by the plastic material.
  • the layer structure can be adapted almost completely to the respective requirements of the product to be produced by, for example, a sectionally different layer structure, in particular Layer thickness selected and the fiber material and the thermoplastic material can be tailored as needed.
  • thermoplastic material can be laminated onto the fiber material, for example, as a film. Furthermore, however, it is particularly expedient if the layer formed by the thermoplastic material is extruded onto the first layer formed by the fiber material.
  • thermoplastic material is applied to the first layer formed by the fiber material and fixed by subsequent heating and applying a compressive force.
  • a maximum of flexibility is achieved, namely that the powdery or present in the form of granules thermoplastic material is not approximately flat adhered to the fiber material, but is trapped only between the fiber material and the closed surface layer.
  • the layer formed by the thermoplastic material is first produced as a film and is laminated to the first layer formed by the fiber material.
  • the film extruded on a silicone paper as a film carrier can have a material thickness of up to several millimeters and is initially stored as a roll product independently of the fiber material. The connection with the fiber material then takes place as needed, so that with a relatively low cost, an individual layer structure can be realized.
  • the invention allows for various embodiments. To further clarify its basic principle, one of them is shown in the drawing and will be described below.
  • the fiber composite material 1 has a layer structure with a first layer 2 formed by a fiber material and with a second layer 3 formed by a thermoplastic plastic material, which each form separate planes and lie against one another on a flat contact surface 4.
  • the elastic properties of the fiber composite material 1 initially remain until the shaping.
  • the processing is considerably simplified as well as the storage.
  • the Layers are each stored wound on a roll 5, 6 and, if necessary, be laminated on the flat contact surface 4.

Abstract

The invention relates to a fiber composite material (1) comprising at least one fiber material and a thermoplastic material, and a method for the production thereof. In order to achieve simple processing and low transport and storage costs, the fiber composite material (1) has a layer construction having a first layer (2) formed by a fiber material and a second layer (3) formed by a thermoplastic material. The layers (2, 3) thereby form separate planes and contact each other at a flat contact surface (4), so that the fiber material is at least not completely interlaced or penetrated by the plastic material. The flexible properties of the fiber composite material (1) thereby remain intact until forming. Processing and storage are thereby significantly simplified. The layers can particularly be wound about a roll (5, 6) for storage.

Description

Faserverbundwerkstoff und Verfahren zu seiner Herstellung Fiber composite material and method for its production
Die Erfindung betrifft einen Faserverbundwerkstoff umfassend zumindest ein Fasermaterial und ein thermoplastisches Kunststoffmaterial sowie ein Verfahren zur Herstellung eines solchen Faserverbundwerkstoffs.The invention relates to a fiber composite material comprising at least one fiber material and a thermoplastic plastic material and a method for producing such a fiber composite material.
Ein Faserverbundwerkstoff wird in der Praxis bereits vielfach eingesetzt und zählt somit zum Stand der Technik. Der Faserverbundwerkstoff besteht dabei grundsätzlich aus dem verstärkenden Fasermaterial, das in eine Matrix aus einem Kunststoffmaterial eingebettet ist. Durch gegenseitige Wechselwirkungen der beiden Komponenten erhält der Faserverbundwerkstoff höherwertige Eigenschaften als jeder der beiden einzeln beteiligten Komponenten.A fiber composite material is already widely used in practice and thus belongs to the state of the art. The fiber composite material basically consists of the reinforcing fiber material, which is embedded in a matrix of a plastic material. By mutual interactions of the two components of the fiber composite material receives higher quality properties than each of the two components involved individually.
Die Matrix fixiert die Verstärkungsfasern, überträgt und verteilt Kräfte und Spannungen zwischen ihnen und schützt sie vor äußeren mechanischen, thermischen und chemischen Einflüssen (Umwelteinflüsse, Beständigkeit gegenüber Chemikalien). Weiterhin entscheidet sie über eine mögliche thermische Formgebung, die Wärmeformbeständigkeit und Recyclingfähigkeit.The matrix fixes the reinforcing fibers, transfers and distributes forces and stresses between them and protects them from external mechanical, thermal and chemical influences (environmental influences, resistance to chemicals). Furthermore, it decides on a possible thermal shaping, the heat resistance and recyclability.
Die Fasern sind verantwortlich für die Festigkeit des Bauteils (Zugfestigkeit, Biegefestigkeit) und bestimmen daher vorrangig die Eigenschaften des Fertigteils. Sie sind durch Adhäsionsund / oder Kohäsionskräfte an die Matrix gebunden.The fibers are responsible for the strength of the component (tensile strength, flexural strength) and therefore primarily determine the properties of the finished part. They are bound to the matrix by adhesion and / or cohesive forces.
Als Fasermaterial werden beispielsweise Kohlenstofffasern, Aramidfasern, Nylonfasern oder auch kostengünstige Glasfasern eingesetzt, während als Matrix duroplastische oder elastomere Kunststoffe sowie Thermoplaste verwendet werden. Faserverstärkte Kunststoffe aus thermoplastischem Kunststoffmaterial lassen sich unter Hitze nachträglich umformen. Bei dem Handlaminierverfahren werden Fasermaterialien von Hand auf eine Form drapiert und mit einem Reaktionsharz getränkt. Anschließend erfolgt die Entlüftung und Entfernung von Harzüberschuss mittels Rolle oder Pinsel. Danach härtet das Bauteil durch die chemische Reaktion des Harzes mit der Härterkomponente aus. Zur Erhöhung des Faservolumenanteils kann das Laminat durch Anlegen eines Vakuums verdichtet und noch im Laminat befindlicher Harzüberschuss entfernt werden.As fiber material, for example, carbon fibers, aramid fibers, nylon fibers or inexpensive glass fibers are used, while thermosetting or elastomeric plastics and thermoplastics are used as the matrix. Fiber-reinforced plastics made of thermoplastic material can be transformed later under heat. In the hand lamination process, fiber materials are hand-draped onto a mold and soaked in a reaction resin. Subsequently, the venting and removal of excess resin by means of roller or brush. Thereafter, the component hardens by the chemical reaction of the resin with the hardener component. To increase the fiber volume fraction, the laminate can be compacted by applying a vacuum and excess resin remaining in the laminate can be removed.
Das Verhältnis des Volumens der Fasern zum Gesamtvolumen eines faserverstärkten Materials ist dabei jedoch gering, was zu einer ebenfalls geringen Bauteilqualität führt. Zudem stellt die Verarbeitung des Harzes hohe Ansprüche an die Fähigkeiten des Laminierers sowie den Arbeitsschutz.However, the ratio of the volume of the fibers to the total volume of a fiber-reinforced material is low, which also leads to a low component quality. In addition, the processing of the resin makes high demands on the capabilities of the laminator and occupational safety.
Demgegenüber bestehen bereits vorimprägnierte, also in die Matrix eingebettete Fasern, die auch als Prepreg bezeichnet werden, aus Eπdlosfasern und einer ungehärteten duroplastischen Kunststoffmatrix. Die Kunststoffmatrix hat eine leicht klebrige, feste Konsistenz und besteht aus einer Mischung von Harz und Härter, in manchen Fällen noch aus einem Beschleuniger. Die Endlosfasern können als reine unidirektionale Schicht, als Gewebe oder Gelege vorliegen. Das so geschaffene Halbzeug ist flexibel und ist bahnförmig, insbesondere auf Rollen gewickelt, lieferbar. Als nachteilig erweist sich jedoch die beim Transport des Halbzeuges erforderliche Einhaltung einer geschlossenen Kühlkette bei ca. - 18 0C. Die Aushärtung erfolgt dann unter Druck und Hitze (Autoklav) oder unter Vakuum und Hitze (Wärmeschrank).In contrast, preimpregnated fibers, that is to say embedded in the matrix, which are also referred to as prepregs, already consist of epitaxial fibers and an uncured thermosetting plastic matrix. The plastic matrix has a slightly sticky, solid consistency and consists of a mixture of resin and hardener, in some cases from an accelerator. The continuous fibers can be in the form of a pure unidirectional layer, as a woven or laid fabric. The semi-finished product created in this way is flexible and can be delivered in web form, in particular wound on reels. As a disadvantage, however, proves the required during transport of the semi-finished adhering to a closed cold chain at about - 18 0 C. The curing then takes place under pressure and heat (autoclave) or under vacuum and heat (oven).
Weiterhin sind auch bereits thermoplastische faserverstärkte Kunststoffplatten mit definierter Dicke und Faserausrichtung bekannt. Dabei ist das Fasermaterial bereits in die durch das thermoplastische Kunststoffmaterial definierte Matrix eingebettet, die zur Verarbeitung bis auf Schmelztemperatur oder darüber erwärmt wird. In diesem Zustand wird das Plattenmaterial unter Zwang in eine neue Form gebracht und abgekühlt. Durch die Eigenstabilität des Plattenmaterials kann die dreidimensionale Drapierbarkeit eingeschränkt sein.Furthermore, thermoplastic fiber-reinforced plastic plates with a defined thickness and fiber orientation are already known. In this case, the fiber material is already embedded in the matrix defined by the thermoplastic material, which is heated to melting temperature or above for processing. In this state, the plate material is forced to a new shape and cooled. Due to the inherent stability of the plate material, the three-dimensional drapability can be limited.
Aus der DE 693 09 831 T2 ist bereits ein Faserverbundwerkstoff bekannt, wobei eine flexible Folie aus einem thermoplastischen Polymer ein mit einem Pulver imprägniertes Multifaser- Filament abdeckt. Das Pulver weist dabei als wesentlichen Bestandteil thermoplastische Polymere auf. Hierdurch soll der Faserverbundwerkstoff eine hohe Flexibilität insbesondere zur Bildung hochflexibler Matten aufweisen. Weiterhin beschreibt die DE 693 07 995 T2 ein Verfahren zur Herstellung von faserverstärkten thermoplastischen Zusammensetzungen, bei dem von einer Spule eine Faser abgewickelt und in einzelne Filamente zerlegt wird. Die so geöffnete Faser wird dann durch ein Bett mit einem thermoplastischen Pulver geführt und anschließend wieder zusammengesetzt, wobei eine flexible Hülle aus einem thermoplastischen Polymer die Faser umhüllt.A fiber composite material is already known from DE 693 09 831 T2, wherein a flexible film of a thermoplastic polymer covers a multifiber filament impregnated with a powder. The powder has as an essential component thermoplastic polymers. As a result, the fiber composite material should have a high flexibility, in particular for the formation of highly flexible mats. Furthermore, DE 693 07 995 T2 describes a process for the production of fiber-reinforced thermoplastic compositions in which a fiber is unwound from a bobbin and broken down into individual filaments. The thus opened fiber is then passed through a bed of thermoplastic powder and then reassembled, with a flexible sheath of thermoplastic polymer wrapping the fiber.
Der Erfindung liegt die Aufgabe zugrunde, einen Faserverbundwerkstoff zu schaffen, welcher eine einfache Verarbeitung ebenso wie einen geringen Transport- und Lagerhaltungsaufwand ermöglicht. Weiterhin liegt der Erfindung die Aufgabe zugrunde, ein Verfahren zur Herstellung eines solchen Faserverbundwerkstoffes zu schaffen.The invention has for its object to provide a fiber composite material, which allows easy processing as well as a low transport and storage costs. Furthermore, the invention has for its object to provide a method for producing such a fiber composite material.
Die erstgenannte Aufgabe wird erfindungsgemäß mit einem Faserverbundwerkstoff gemäß den Merkmalen des Anspruchs 1 gelöst. Die weitere Ausgestaltung des Faserverbundwerkstoffs ist den Unteransprüchen 2 bis 11 zu entnehmen.The first object is achieved according to the invention with a fiber composite material according to the features of claim 1. The further embodiment of the fiber composite material can be found in the dependent claims 2 to 11.
Erfindungsgemäß ist also ein Faserverbundwerkstoff vorgesehen, bei dem der Faserverbundwerkstoff flexible und/oder elastische Materialeigenschaften und einen Schichtaufbau mit einer ersten durch das Fasermaterial gebildeten Schicht und mit zumindest einer weiteren durch das thermoplastische Kunststoffmaterial gebildeten Schicht aufweist, wobei die Schichten separate Ebenen bilden und an einer im Wesentlichen ebenen Kontaktfläche gegeneinander liegen, sodass eine Durchsetzung oder Durchdringung des Fasermaterials nicht oder nicht vollständig erfolgt. Hierdurch wird es erfindungsgemäß erreicht, dass die flexiblen oder elastischen Materialeigenschaften des Faserverbundwerkstoffs bis zur Verarbeitung in einem Formgebungsprozess erhalten bleiben und somit die Handhabung des Faserverbundwerkstoffs wesentlich erleichtert wird. Eine lückenlose Kühlkette ist dabei insbesondere nicht erforderlich, da die Matrix bereits im polymeren Zustand vorliegt. Die flexiblen oder elastischen Eigenschaften des Faserverbundwerkstoffs werden erreicht, da das Fasermaterial und das thermoplastische Kunststoffmaterial zunächst separate Schichten bilden, eine Durchsetzung oder Durchdringung des Fasermaterials also zumindest nicht vollständig erfolgt. Vielmehr liegen das Fasermaterial und das thermoplastische Kunststoffmaterial flach aufeinander. Die Herstellung des Faserverbundwerkstoffs als Halbzeug gestattet dadurch zudem eine nahezu beliebige Kombination und Zusammensetzung, sodass die Bevorratung erheblich vereinfacht ist. Dabei wird eine besondere vorteilhafte Ausgestaltung dadurch erreicht, dass die erste Schicht frei von thermoplastischen Bestandteilen der weiteren Schicht ist, sodass die flexiblen oder elastischen Eigenschaften des Fasermaterials ebenso wie diejenigen des thermoplastischen Kunststoffmaterials jeweils für sich genommen uneingeschränkt erhalten bleiben. Die Anforderungen an die Lagerhaltung sowie die Verarbeitung sind dadurch vergleichsweise gering.According to the invention, therefore, a fiber composite material is provided in which the fiber composite material has flexible and / or elastic material properties and a layer structure with a first layer formed by the fiber material and at least one further layer formed by the thermoplastic material, wherein the layers form separate planes and on a lie substantially flat contact surface against each other, so that enforcement or penetration of the fiber material is not or not completely. In this way, it is achieved according to the invention that the flexible or elastic material properties of the fiber composite material are retained until they are processed in a shaping process, and thus the handling of the fiber composite material is substantially facilitated. In particular, a complete cold chain is not required since the matrix is already in the polymeric state. The flexible or elastic properties of the fiber composite material are achieved, since the fiber material and the thermoplastic material first form separate layers, so penetration or penetration of the fiber material is at least not complete. Rather, the fiber material and the thermoplastic material are flat. The production of the fiber composite material as a semi-finished thereby also allows almost any combination and composition, so that the storage is considerably simplified. In this case, a particular advantageous embodiment is achieved in that the first layer is free of thermoplastic constituents of the further layer, so that the flexible or elastic properties of the fiber material as well as those of the thermoplastic material are retained in each case unrestricted. The requirements for warehousing and processing are therefore comparatively low.
Der Faserverbundwerkstoff kann durch genau zwei Schichten realisiert werden. Als besonders zweckmäßig erweist sich hingegen eine Abwandlung der vorliegenden Erfindung, bei welcher die durch das Fasermaterial gebildete erste Schicht beidseitig jeweils eine Schicht des thermoplastischen Kunststoffmaterials trägt, um so eine zuverlässige Einbettung des Fasermaterials während des Verarbeitungsprozesses sicherzustellen und dabei insbesondere Bereiche unzureichender Laminierung zu vermeiden.The fiber composite material can be realized by exactly two layers. On the other hand, a modification of the present invention in which the first layer formed by the fiber material bears a layer of the thermoplastic material on both sides in order to ensure a reliable embedding of the fiber material during the processing process and in particular to avoid areas of insufficient lamination, proves particularly expedient.
Weiterhin erweist es sich gemäß einer weiteren Ausgestaltung als besonders zweckmäßig, wenn die weitere durch das thermoplastische Kunststoffmaterial gebildete Schicht als Folie ausgeführt ist und somit nicht unmittelbar im flüssigen oder fließfähigen Zustand auf das Fasermaterial aufgebracht wird. Hierdurch können die beiden Schichten nicht nur in voneinander unabhängigen Verfahrensschritten hergestellt, sondern auch bedarfsweise in einer gewünschten Menge bzw. Materialstärke kombiniert werden. Auf diese Weise kann beispielsweise der Faservolumenanteil in Abhängigkeit der Anforderungen an das aus dem Faserverbundwerkstoff herzustellende Erzeugnis variiert werden. Das Zuschneiden des Faserverbundwerkstoffs ist zugleich problemlos möglich, weil die Fasern durch die Kunststoffschicht gebunden sind und dadurch Faserreste und Staub vermieden werden.Furthermore, it proves to be particularly expedient according to a further embodiment, when the further layer formed by the thermoplastic material is designed as a film and thus is not applied directly to the fiber material in the liquid or flowable state. As a result, the two layers can not only be produced in mutually independent method steps, but can also be combined, if required, in a desired quantity or material thickness. In this way, for example, the fiber volume fraction can be varied depending on the requirements of the product to be produced from the fiber composite material. The cutting of the fiber composite material is at the same time easily possible because the fibers are bound by the plastic layer and thereby fiber residues and dust are avoided.
Hierzu eignet sich besonders eine Variante des erfindungsgemäßen Faserverbundwerkstoffs, bei dem die durch das thermoplastische Kunststoffmaterial gebildete Schicht im Extrusionsverfahren hergestellt ist und hierzu beispielsweise auf ein Silikonpapier extrudiert wird. Das thermoplastische Kunststoffmaterial wird dann bedarfsweise und entsprechend der jeweiligen Anforderungen an den Faserverbundwerkstoff in einer oder mehreren Schichten auf das Fasermaterial aufgebracht. Der Faservolumenanteil des Faserverbundwerkstoffs ist somit vorab genau definierbar, um so eine reproduzierbare Bauteilqualität sicherzustellen.Particularly suitable for this purpose is a variant of the fiber composite material according to the invention, in which the layer formed by the thermoplastic synthetic material is produced by extrusion and for this purpose is extruded, for example, onto a silicone paper. The thermoplastic material is then applied as needed and according to the particular requirements of the fiber composite in one or more layers on the fiber material. The fiber volume fraction of the fiber composite material is therefore precisely definable in advance so as to ensure a reproducible component quality.
Eine andere, ebenfalls besonders zweckmäßige Ausgestaltung wird dann erreicht, wenn die durch das thermoplastische Kunststoffmaterial gebildete Schicht als ein körniger Feststoff, insbesondere als ein Pulver auf das Fasermaterial aufgebracht ist, welches durch Schmelzen einer Oberfläche mit dem Fasermaterial verbunden ist. Hierdurch kann zugleich eine beliebig vorbestimmbare Menge des Kunststoffmaterials auf das Fasermaterial aufgebracht und durch oberflächennahes Schmelzen fixiert werden, um so die Flexibilität des Faserverbundwerkstoffs uneingeschränkt zu erhalten, indem eine die Faserstruktur festlegende Verbindung zunächst vermieden wird. Bei der Formgebung des Erzeugnisses wird dann das zwischen der geschlossenen Deckschicht und der Oberfläche des Fasermaterials eingeschlossene Pulver zumindest bis auf Schmelztemperatur erwärmt, sodass sich eine thermoplastische Matrix ausbildet.Another, also particularly advantageous embodiment is achieved when the layer formed by the thermoplastic material is applied as a granular solid, in particular as a powder on the fiber material, which by Melting of a surface is connected to the fiber material. In this way, at the same time an arbitrarily predeterminable amount of the plastic material can be applied to the fiber material and fixed by melting near the surface, so as to obtain the flexibility of the fiber composite material unrestricted by a fiber structure defining connection is first avoided. During the shaping of the product, the powder enclosed between the closed cover layer and the surface of the fiber material is then heated to at least melting temperature, so that a thermoplastic matrix is formed.
Eine besonders praxisnahe Ausführungsform der Erfindung wird auch dadurch erreicht, dass der Faserverbundwerkstoff einen abwechselnden Schichtaufbau zumindest umfassend zwei Schichten des Fasermaterials und zumindest zwei Schichten des thermoplastischen Kunststoffmaterials aufweist. Dabei liegen die einzelnen Lagen aus jeweils einer Schicht des Fasermaterials und einer Schicht des thermoplastischen Kunststoffmaterials zunächst nur lose aufeinander, sodass die Lagen relativ zueinander verschiebbar sind. Dadurch wird eine Faltenbildung ebenso wie eine unerwünschte Delaminierung insbesondere im Bereich kleiner Innenradien der Formgebung vermieden. Die übereinander liegenden Lagen können durch Druck, beispielsweise Überdruck, Vakuum oder einen mechanischen Druck, auch unter Verwendung geeigneter Trennfolien verdichtet werden. Ein Autoklav ist nicht zwingend erforderlich.A particularly practical embodiment of the invention is also achieved in that the fiber composite material has an alternating layer structure comprising at least two layers of the fiber material and at least two layers of the thermoplastic material. The individual layers of each one layer of the fiber material and a layer of the thermoplastic material are initially only loosely on each other, so that the layers are displaceable relative to each other. This avoids wrinkling as well as unwanted delamination, especially in the region of small internal radii of the shaping. The superimposed layers can be compressed by pressure, such as overpressure, vacuum or mechanical pressure, even using suitable release films. An autoclave is not mandatory.
Der Schichtaufbau kann dabei insbesondere derart gewählt werden, dass die Eigenschaften des thermoplastischen Kunststoffmaterials einer äußeren Schicht gegenüber zumindest einer inneren Schicht abweichen. Beispielsweise kann die äußere Schicht eine harte Oberflächenbeschaffenheit oder eine hohe Festigkeit aufweisen, während die innere Schicht elastisch ausgeführt ist. Hierzu kann der Faservolumenanteil entsprechend unterschiedlich bemessen werden. Weiterhin können die Eigenschaften an der äußeren Oberfläche des thermoplastischen Kunststoffmaterials auch hinsichtlich der optischen Eigenschaften, der Lackierfähigkeit oder auch der UV-Beständigkeit variieren.The layer structure can be chosen in particular such that the properties of the thermoplastic material of an outer layer differ from at least one inner layer. For example, the outer layer may have a hard surface finish or a high strength while the inner layer is made elastic. For this purpose, the fiber volume fraction can be correspondingly sized differently. Furthermore, the properties on the outer surface of the thermoplastic material may also vary in terms of optical properties, paintability or even UV resistance.
Selbstverständlich können dabei zumindest in Teilbereichen mehrere Schichten des thermoplastischen Kunststoffmaterials aufeinander gelegt werden, um so beispielsweise bei der Verarbeitung die Fließeigenschaften des thermoplastischen Kunststoffmaterials zur Einbettung von Formkörpern, insbesondere Flanschen, durch eine formschlüssige Verbindung zu nutzen. Der Schichtaufbau kann hierzu bereits in einer Form für das Erzeugnis erfolgen, wobei die unbehandelten Fasermaterialien und das thermoplastische Kunststoffmaterial in Form einer Folie getrennt aufeinander geschichtet werden. Weiterhin erweist es sich als besonders praxisgerecht, wenn der Schichtaufbau durch verschiedene Fasermaterialien und/oder thermoplastische Kunststoffmaterialien gebildet ist, wobei die Materialien insbesondere unterschiedliche Materialeigenschaften, Mengen und/oder Abmessungen aufweisen. Hierdurch sind der Schichtaufbau und damit die insbesondere auch richtungsabhängigen Eigenschaften des Faserverbundwerkstoffs frei wählbar, indem sich auch unterschiedliche Faserwerktstoffe mit dem thermoplastischen Kunststoff material beschichten lassen.Of course, at least in some areas several layers of the thermoplastic material can be superimposed, so as to use, for example, during processing, the flow properties of the thermoplastic material for embedding moldings, in particular flanges, by a positive connection. The layer structure can for this purpose already take place in a mold for the product, wherein the untreated fiber materials and the thermoplastic material are layered separately in the form of a film. Furthermore, it proves to be particularly practical if the layer structure is formed by different fiber materials and / or thermoplastic plastic materials, wherein the materials in particular have different material properties, quantities and / or dimensions. As a result, the layer structure and thus the particular direction-dependent properties of the fiber composite material are freely selectable by also different fiber materials can be coated with the thermoplastic material.
Als Fasermaterial weist dabei beispielsweise gemäß einer besonderen Ausführungsform die erste Schicht als wesentliche Materialbestandteile Carbon-, Glas und/oder Aramidfasern aufweist, wobei auch verschiedene Bindungsarten realisiert werden können. Grundsätzlich können so ein-, zwei- oder mehrdimensional verstärkte Faserverbundwerkstoffe realisiert werden, wobei als eindimensionale Verstärkung oder unidirektionales Gelege (UD) solche Faserverbundwerkstoff werden bezeichnet, deren Fasern nur in eine Richtung orientiert sind.As a fiber material, for example, according to a particular embodiment, the first layer has as essential material components carbon, glass and / or aramid fibers, wherein also different types of bonding can be realized. Basically, one-, two- or multi-dimensionally reinforced fiber composite materials can be realized, wherein as one-dimensional reinforcement or unidirectional scrim (UD) such fiber composite material are called whose fibers are oriented only in one direction.
Hierbei ist es besonders praxisnah, wenn zumindest eine Schicht als wesentliche Materialbestandteile des thermoplastischen Kunststoffmaterials Polypropylen, Polyester, Polyamid und/oder ein Polyetherketon, beispielsweise das Polyetheretherketon (PEEK), aufweist.In this case, it is particularly practical if at least one layer comprises as essential material constituents of the thermoplastic synthetic material polypropylene, polyester, polyamide and / or a polyether ketone, for example the polyetheretherketone (PEEK).
Weiterhin kann die durch das thermoplastische Kunststoffmaterial gebildete Schicht einen zusätzlichen Feststoffanteil, insbesondere Fasermaterialanteil, aufweisen. Das Fasermaterial kann hierzu aus Fasern, die nur eine Länge von wenigen Millimetern aufweisen, oder auch durch Festkörper, beispielsweise Hohlkugeln, gebildet sein. Diese können zudem auch in partiell abweichender Konzentration vorgesehen sein.Furthermore, the layer formed by the thermoplastic material may have an additional solids content, in particular fiber material content. For this purpose, the fiber material can be formed from fibers which have a length of only a few millimeters or else by solid bodies, for example hollow spheres. These can also be provided in partially deviating concentration.
Die zweitgenannte Aufgabe, Verfahren zur Herstellung eines solchen Faserverbundwerkstoffs umfassend zumindest ein Fasermaterial und ein thermoplastisches Kunststoffmaterial zu schaffen, wird erfindungsgemäß dadurch realisiert, dass auf eine erste durch das Fasermaterial gebildete Schicht zumindest eine weitere durch das thermoplastische Kunststoffmaterial gebildete Schicht aufgebracht wird, derart dass die Schichten an einer im wesentlichen ebenen Kontaktfläche aneinander liegen und das Fasermaterial von dem Kunststoffmaterial nicht oder nicht vollständig durchsetzt oder durchdrungen wird. Hierdurch kann der Schichtaufbau nahezu uneingeschränkt an die jeweiligen Anforderungen an das herzustellenden Erzeugnis angepasst werden, indem eine beispielsweise auch abschnittsweise unterschiedlicher Schichtaufbau, insbesondere Schichtstärke ausgewählt und das Fasermaterial und das thermoplastisches Kunststoffmaterial so bedarfsgerecht konfektioniert werden kann.The second-mentioned object, to provide a method for producing such a fiber composite material comprising at least one fiber material and a thermoplastic material, is realized according to the invention by applying to a first layer formed by the fiber material at least one further layer formed by the thermoplastic material, such that the Layers lie against each other at a substantially flat contact surface and the fiber material is not or not completely penetrated or penetrated by the plastic material. As a result, the layer structure can be adapted almost completely to the respective requirements of the product to be produced by, for example, a sectionally different layer structure, in particular Layer thickness selected and the fiber material and the thermoplastic material can be tailored as needed.
Das thermoplastische Kunststoffmaterial kann hierzu beispielsweise als eine Folie auf das Fasermaterial kaschiert werden. Weiterhin ist es jedoch besonders zweckmäßig, wenn die durch das thermoplastische Kunststoffmaterial gebildete Schicht auf die erste durch das Fasermaterial gebildete Schicht extrudiert wird.For this purpose, the thermoplastic material can be laminated onto the fiber material, for example, as a film. Furthermore, however, it is particularly expedient if the layer formed by the thermoplastic material is extruded onto the first layer formed by the fiber material.
Ein anderes, ebenfalls besonders Erfolg versprechendes Verfahren wird dadurch geschaffen, dass die durch das thermoplastische Kunststoffmaterial gebildete Schicht auf die erste durch das Fasermaterial gebildete Schicht aufgebracht und durch nachfolgendes Erhitzen und Aufbringen einer Druckkraft fixiert wird. Hierdurch wird ein Höchstmaß an Flexibilität erreicht, indem nämlich das pulverförmige oder in Form eines Granulates vorliegende thermoplastische Kunststoffmaterial nicht etwa flächig an dem Fasermaterial anhaftet, sondern lediglich zwischen dem Fasermaterial und der geschlossenen Oberflächenschicht eingeschlossen ist.Another, also particularly promising method is created by the layer formed by the thermoplastic material is applied to the first layer formed by the fiber material and fixed by subsequent heating and applying a compressive force. As a result, a maximum of flexibility is achieved, namely that the powdery or present in the form of granules thermoplastic material is not approximately flat adhered to the fiber material, but is trapped only between the fiber material and the closed surface layer.
Als ebenfalls besonders praxisgerecht erweist es sich auch, wenn die durch das thermoplastische Kunststoffmaterial gebildete Schicht zunächst als Folie hergestellt wird und auf die erste durch das Fasermaterial gebildete Schicht kaschiert wird. Die beispielsweise auf ein Silikonpapier als Folienträger extrudierte Folie kann dabei eine Materialstärke bis zu mehreren Millimetern aufweisen und wird dabei zunächst unabhängig von dem Fasermaterial als Rollenware gelagert. Die Verbindung mit dem Fasermaterial erfolgt dann bedarfsweise, sodass mit einem vergleichsweise geringen Aufwand ein individueller Schichtaufbau realisiert werden kann.It also proves to be particularly practical if the layer formed by the thermoplastic material is first produced as a film and is laminated to the first layer formed by the fiber material. The film extruded on a silicone paper as a film carrier, for example, can have a material thickness of up to several millimeters and is initially stored as a roll product independently of the fiber material. The connection with the fiber material then takes place as needed, so that with a relatively low cost, an individual layer structure can be realized.
Die Erfindung lässt verschiedene Ausführungsformen zu. Zur weiteren Verdeutlichung ihres Grundprinzips ist eine davon in der Zeichnung dargestellt und wird nachfolgend beschrieben. Diese zeigt in einer Prinzipskizze einen Faserverbundwerkstoff 1 mit flexiblen Materialeigenschaften, welcher beispielsweise als Rollenware herstellbar ist. Der Faserverbundwerkstoff 1 hat einen Schichtaufbau mit einer durch ein Fasermaterial gebildeten ersten Schicht 2 und mit einer durch ein thermoplastisches Kunststoffmaterial gebildeten zweiten Schicht 3, die jeweils separate Ebenen bilden und an einer ebenen Kontaktfläche 4 gegeneinander liegen. Hierdurch bleiben die elastischen Eigenschaften des Faserverbundwerkstoffs 1 zunächst bis zur Formgebung erhalten. Die Verarbeitung wird dadurch ebenso wie die Lagerhaltung erheblich vereinfacht. Insbesondere können die Schichten jeweils auf einer Rolle 5, 6 aufgewickelt gelagert werden und bedarfsweise an der ebenen Kontaktfläche 4 aufeinander kaschiert werden. The invention allows for various embodiments. To further clarify its basic principle, one of them is shown in the drawing and will be described below. This shows in a schematic diagram a fiber composite material 1 with flexible material properties, which can be produced, for example, as a roll. The fiber composite material 1 has a layer structure with a first layer 2 formed by a fiber material and with a second layer 3 formed by a thermoplastic plastic material, which each form separate planes and lie against one another on a flat contact surface 4. As a result, the elastic properties of the fiber composite material 1 initially remain until the shaping. The processing is considerably simplified as well as the storage. In particular, the Layers are each stored wound on a roll 5, 6 and, if necessary, be laminated on the flat contact surface 4.

Claims

PATENTANSPRÜCHE
1. Faserverbundwerkstoff (1) umfassend zumindest ein Fasermaterial und ein thermoplastisches Kunststoffmaterial, dadurch gekennzeichnet, dass der Faserverbundwerkstoff flexible und/oder elastische Materialeigenschaften und einen Schichtaufbau mit einer ersten durch das Fasermaterial gebildeten Schicht (2) und mit zumindest einer weiteren durch das thermoplastische Kunststoffmaterial gebildeten Schicht (3) aufweist, wobei die Schichten (2, 3) separate Ebenen bilden und an einer im Wesentlichen ebenen Kontaktfläche (4) gegeneinander liegen, sodass eine Durchsetzung oder Durchdringung des Fasermaterials nicht oder nicht vollständig erfolgt.1. fiber composite material (1) comprising at least one fiber material and a thermoplastic plastic material, characterized in that the fiber composite material flexible and / or elastic material properties and a layer structure with a first formed by the fiber material layer (2) and at least one further by the thermoplastic material wherein the layers (2, 3) form separate planes and lie against one another on a substantially planar contact surface (4), so that enforcement or penetration of the fiber material does not take place or does not take place completely.
2. Faserverbundwerkstoff (1 ) nach Anspruch 1 , dadurch gekennzeichnet, dass die erste Schicht (2) frei von thermoplastischen Bestandteilen der weiteren Schicht (3) ist.2. fiber composite material (1) according to claim 1, characterized in that the first layer (2) is free of thermoplastic constituents of the further layer (3).
3. Faserverbundwerkstoff (1) nach den Ansprüchen 1 oder 2, dadurch gekennzeichnet, dass die durch das Fasermaterial gebildete erste Schicht beidseitig jeweils eine Schicht des thermoplastischen Kunststoffmaterials trägt.3. fiber composite material (1) according to claims 1 or 2, characterized in that the first layer formed by the fiber material carries on both sides in each case a layer of the thermoplastic material.
4. Faserverbundwerkstoff (1) nach zumindest einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die weitere durch das thermoplastische Kunststoffmaterial gebildete Schicht (3) als Folie ausgeführt ist.4. fiber composite material (1) according to at least one of the preceding claims, characterized in that the further formed by the thermoplastic material layer (3) is designed as a film.
5. Faserverbundwerkstoff (1) nach zumindest einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die durch das thermoplastische Kunststoffmaterial gebildete Schicht (3) im Extrusionsverfahren hergestellt ist.5. fiber composite material (1) according to at least one of the preceding claims, characterized in that the layer formed by the thermoplastic material layer (3) is produced by extrusion.
6. Faserverbundwerkstoff (1) nach zumindest einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass die durch das thermoplastische Kunststoffmaterial gebildete Schicht als ein körniger Feststoff, insbesondere als ein Pulver auf das Fasermaterial aufgebracht ist, welches durch Schmelzen einer Oberfläche mit dem Fasermaterial verbunden ist.6. fiber composite material (1) according to at least one of claims 1 to 3, characterized in that the layer formed by the thermoplastic material is applied as a granular solid, in particular as a powder on the fiber material, which is connected by melting a surface with the fiber material.
7. Faserverbundwerkstoff (1 ) nach zumindest einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass der Faserverbundwerkstoff einen abwechselnden Schichtaufbau zumindest umfassend zwei Schichten des Fasermaterials und zumindest zwei Schichten des thermoplastischen Kunststoffmaterials aufweist.7. fiber composite material (1) according to at least one of the preceding claims, characterized in that the fiber composite material has an alternating layer structure comprising at least two layers of the fiber material and at least two layers of the thermoplastic material.
8. Faserverbundwerkstoff (1) nach zumindest einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass der Schichtaufbau durch verschiedene Fasermaterialien und/oder thermoplastischen Kunststoffmaterialien gebildet ist, wobei die Materialien insbesondere unterschiedliche Materialeigenschaften, Mengen und/oder Abmessungen aufweisen.8. fiber composite material (1) according to at least one of the preceding claims, characterized in that the layer structure is formed by different fiber materials and / or thermoplastic plastic materials, the materials in particular have different material properties, quantities and / or dimensions.
9. Faserverbundwerkstoff (1 ) nach zumindest einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die erste Schicht (2) als wesentliche Materialbestandteile Carbon-, Glas und/oder Aramidfasern aufweist.9. fiber composite material (1) according to at least one of the preceding claims, characterized in that the first layer (2) as essential material constituents carbon, glass and / or aramid fibers.
10. Faserverbundwerkstoff (1 ) nach zumindest einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass zumindest eine Schicht (3) als wesentliche Materialbestandteile des thermoplastischen Kunststoffmaterials Polypropylen, Polyester, Polyamid und/oder ein Polyetherketon, beispielsweise das Polyetheretherketon (PEEK), aufweist.10. fiber composite material (1) according to at least one of the preceding claims, characterized in that at least one layer (3) as essential material components of the thermoplastic material polypropylene, polyester, polyamide and / or a polyether ketone, for example, the polyetheretherketone (PEEK) having.
11. Faserverbundwerkstoff (1 ) nach zumindest einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die durch das thermoplastische Kunststoffmaterial gebildete Schicht (3) einen zusätzlichen Feststoffanteil, insbesondere Fasermaterialanteil, aufweist.11. fiber composite material (1) according to at least one of the preceding claims, characterized in that the layer formed by the thermoplastic material layer (3) has an additional solids content, in particular fiber material content.
12. Verfahren zur Herstellung eines Faserverbundwerkstoffs umfassend zumindest ein Fasermaterial und ein thermoplastisches Kunststoffmaterial nach zumindest einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass auf eine erste durch das Fasermaterial gebildete Schicht zumindest eine weitere durch das thermoplastische Kunststoffmaterial gebildete Schicht aufgebracht wird, derart dass die Schichten an einer im wesentlichen ebenen Kontaktfläche aneinander liegen und das Fasermaterial von dem Kunststoffmaterial nicht oder nicht vollständig durchsetzt oder durchdrungen wird. 12. A method for producing a fiber composite material comprising at least one fiber material and a thermoplastic material according to at least one of the preceding claims, characterized in that on a first layer formed by the fiber material at least one further layer formed by the thermoplastic material material is applied, such that the layers lie against each other at a substantially flat contact surface and the fiber material is not or not completely penetrated or penetrated by the plastic material.
13. Verfahren nach Anspruch 12, dadurch gekennzeichnet, dass die durch das thermoplastische Kunststoffmaterial gebildete Schicht auf die erste durch das Fasermaterial gebildete Schicht extrudiert wird.13. The method according to claim 12, characterized in that the layer formed by the thermoplastic material is extruded onto the first layer formed by the fiber material.
14. Verfahren nach Anspruch 12, dadurch gekennzeichnet, dass die durch das thermoplastische Kunststoffmaterial gebildete Schicht auf die erste durch das Fasermaterial gebildete Schicht aufgebracht und durch nachfolgendes Erhitzen und Aufbringen einer Druckkraft fixiert wird.14. The method according to claim 12, characterized in that the layer formed by the thermoplastic material is applied to the first layer formed by the fiber material and fixed by subsequent heating and applying a compressive force.
15. Verfahren nach zumindest einem der Ansprüche 12 bis 14, dadurch gekennzeichnet, dass die durch das thermoplastische Kunststoffmaterial gebildete Schicht zunächst als Folie hergestellt wird und auf die erste durch das Fasermaterial gebildete Schicht kaschiert wird. 15. The method according to at least one of claims 12 to 14, characterized in that the layer formed by the thermoplastic material is first prepared as a film and is laminated to the first layer formed by the fiber material.
PCT/DE2009/000003 2008-01-07 2009-01-06 Fiber composite material and method for the production thereof WO2009086814A1 (en)

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