WO2010133216A2

WO2010133216A2 - Method for producing a component made of a composite material

Info

Publication number: WO2010133216A2
Application number: PCT/DE2010/000569
Authority: WO
Inventors: Caren Mueller; Rico Tscharntke
Original assignee: Biostructure Gmbh
Priority date: 2009-05-20
Filing date: 2010-05-19
Publication date: 2010-11-25
Also published as: WO2010133216A3; DE102009022774A1; DE112010002052A5

Abstract

The present invention relates to a method for producing a part (1) made of a composite material made of at least one matrix material (4) and a plurality of fibers (F, FL) embedded therein, wherein the method comprises the following steps: providing a forming cavity (V) for the part (1) to be produced; disposing expandable part components (2, 2*, 20, 21, 200, 200*) in the cavity (V) and fibers (F, FL) at least partially surrounding the expandable part components (2, 2*, 20, 21, 200, 200*); closing the cavity (V) and evacuating the cavity (V) such that the expandable part components (2, 2*, 20, 21, 200, 200*) can expand; expanding the expandable part components (2, 2*, 20, 21, 200, 200*); introducing the at least one matrix material (4) in the form of a fluid into the cavity (V); and removing the part (1) formed of the cured matrix material (4), the expandable part components (2, 2*, 20, 21, 200, 200*), and fiber (F, FL), wherein the expandable part components (2, 2*, 20, 21, 200, 200*) and fibers (F, FL) are embedded in the matrix material (4). In said manner, the expandable part components (2, 2*, 20, 21, 200, 200*) can be disposed within the cavity (V) together with the fibers (F, FL) in a first step, and the desired final fiber courses or fiber structures form only after evacuating the cavity (V), in that the part components (2, 2*, 20, 21, 200, 200*) press the surrounding fibers (F, FL) outward, that is, away from a center point of each of the part components (2, 2*, 20, 21, 200, 200*). Further considerations of the present invention include parts (1) made according to the method according to the invention, and the use of such a part as a diffusion layer (D1-D3, D1 *-D3*) of an isobar tank comprising a plurality of diffusion layers (D1 -D3; D1 *-D3*).

Description

Method for producing a component from a composite material

description

The invention relates to a method for producing a component from a composite material which consists of at least one matrix material and a plurality of fibers embedded therein.

Such a component is lightweight and is said to replace metal, wood, plastic, concrete and other composites without reducing application parameters. This is to be achieved by fibers can be fixed according to a load profile of the component according to any position within the component. Thus, a component is to be created, which is adapted to the intended use of the component occurring loads and compared to alternative designs with the same strength is significantly easier.

EP 0 402 708 A1 discloses a lightweight composite material having a duromer matrix in which fibers are preferably initially present in prefabricated fabric layers and these individual fabric layers are stacked on top of one another and surrounded by the thermoset or duromeric resin.

A disadvantage of the method described in EP 0 402 708 and the components produced therewith is the fact that the creation of three-dimensional support structures is only possible to a limited extent due to the targeted joining of the individual fabric layers. A subsequent, ie after the arrangement of the fabric layer, adaptation of the fiber structure to be created in the interior of the component and in particular a targeted influencing of the fiber profile in all spatial directions is not possible. Page 2

The invention is therefore based on the problem of providing a method which overcomes the disadvantages mentioned above and allows the provision of a component made of a fibrous composite, in which an adaptation of the spatial structure of the fibers during the manufacturing process is possible without access on the fibers from the outside is necessary.

This problem is solved according to the invention with the features of claim 1.

Thereafter, there is provided a method of manufacturing a composite component comprising at least one matrix material and a plurality of fibers embedded therein, the method comprising the steps of:

Providing a mold-giving cavity for the component to be produced,

Arrangement of expandable component components in the cavity and the component components at least partially surrounding fibers,

Closing the cavity and evacuating the cavity so that the components of the component can expand,

Expansion of the expandable component components,

- Introducing the at least one matrix material in the form of a fluid in the cavity and

Removal of the component formed from the hardened matrix material, the component components and fibers, wherein the component components and fibers are embedded in the matrix material.

In particular, cellular structures can be produced with the method according to the invention. This makes it possible to realize insights from bionics and geometry practically and industrially. Furthermore, when constructing a fiber structure within the component, measures can be taken which specifically locally modify the physical properties of the matrix material.

It can be monolithic components manufactured, which are composed of a fiber-reinforced foam. The fibers are here dissipatively in the component before.

In the basic configuration, the component is thus formed from a homogeneous material, which can be freely modified by functional groups in its physical behavior. To build up such a foam fibers and expandable Page 3

Component components and subsequently explained fillers, carrier components and additives are combined in a resin matrix.

Expandable component components can consist of different functional groups in any mixing ratios. They preferably form a core structure for a cellular structure of a fiber foam, of which the .Bauteil consists.

In carrying out the process according to the invention, inter alia, the following components can also be used for the production of the component:

1. Fillers: for influencing the mechanical properties of the component to be produced, which surround at least the component components and / or the fibers in sections; are preferably poured in (loose);

2. Carrier components: to create a supporting structure which is conductive within the component to be produced and at least partially surrounded by component components and fibers; their cores may be surrounded by frictionally bonded fibers, typically characterized by high volume and low weight;

3. Additives: chemical / crystallographic substances which react with the matrix material and which are used to influence the properties of the solidified resin matrix and thus to influence the material properties of the component to be produced;

4. Expander: filled with gas and / or carrier components and gas-tight closed hollow body as expandable component components that increase their volume under relative negative pressure. Typically, they are surrounded or coated with an elastomer or latex.

According to the invention, gas-filled expandable component components or expander can be arranged together with the fibers and carrier components in a first step within the cavity. The expandable component components preferably form the core for building cellular structures within the component.

Only with the evacuation of the cavity, the desired final fiber profiles or fiber structures are formed by the expandable page 4

Component components that push surrounding fibers and carrier components outward, i. they e.g. move away from a mid-point of the respective expander.

In addition, constructively required or functionally desired cavities can be created in the inventive method by appropriately placed and adapted in size and shape expander in the component to be produced.

In a development, the component component or the expander formed with them can be designed such that they can expand only at defined locations and thus not in certain, predetermined spatial directions. Preferably, however, the component components or expander expand in the evacuation of the cavity in all directions almost uniformly.

Accordingly, although the component components and expander may have almost any geometric shape, both are preferably made spherical.

Particularly suitable starting materials for the production of the expanders are elastomers, natural rubber, e.g. Latex, so that the gas trapped in them or in the component component inside it can expand under a relatively low pressure.

Accordingly, expanders are, for example, gas-filled balloons or have gas-storing cores, e.g. Styrofoam, but can also - as already stated above - be enclosed by elastomers carrier components. In particular supported by carrier components expanders allow a stable volume under normal pressure, which allows a more precise structure of the fiber architecture.

Furthermore, the expandable component components with the carrier components form cores of the cellular structures. Such cores can have any spatial dimensions but are always fixed. Fiber filaments connected non-positively to them can bond with filaments of adjacent expandable component components. In this case, fiber filaments can be produced in a specific manner in the form of bonded or mechanically bonded short and long cut fibers and together with fillers. page 5

In addition, the expandable component components can be embedded in fiber layers, fiber hoses, mats, etc. or fillers. They thus form a basis of a spatially cellular structure.

Furthermore, seeds of plants or their replicas can be used as expansion-capable component components. These allow for filling of the matrix material by irradiation with micro or infrared waves, a (second) expansion stage within the component. This can also be done in an embodiment variant as an additional process step after the introduction of the matrix material. Consequently, the expansion of these component components to their final size would take place only within the component produced or at least already having the matrix material. In this way, the desired fiber structures within the component to be produced can optionally be adjusted even better, avoiding undesired voids within the matrix material or pressing excess resin out of the component.

Typically, a resin is used as a matrix material and cured by a resin injection or infusion process with the fiber (inner) structure to the component. Preferably, the process of the present invention implements parts of a "vacuum assisted resin injection" (VARI) or "resin transfer molding" (RTM) process ("vacuum assisted resin injection" or "resin transfer molding" process) and their advancements in which in each case a negative pressure is built up in a cavity.

As already stated several times, the component to be produced can be equipped by applying the method according to the invention with functional assemblies. These allow, among other things, property modifications of a fiber foam in the component.

The introduction of one or more continuous hoses can also allow the transport of liquids and gases through the component. These can also continue to allow filling with functional gases and liquids or the evacuation of such fluids, resulting in further property extensions for the component to be produced.

The fiber volume fraction between the expandable component parts and fibers and to an outer shape defined by the cavity is due to the pressure Page 6 from the component components or expanders specifically regulated. It is possible to define the amount, size, internal pressure and material of the expandable component parts to adjust the fiber volume fraction.

In this way, among other things, it is possible to create spatially structurally structured components which can be described as monolithic, whose construction can be characterized as bionic (modeled on nature). In addition, geometry complexities can be realized from innovative concepts such as minimized geometry (e.g., tensegrity, tension, and integrity for a particular type of structural system, body geometry).

According to the invention, a targeted adaptation of the fiber profile is ensured by the expandable component components or by their embodiment as expanders, which may optionally also be capable of different expansion by the use of different materials.

Depending on the required load profile and intended use, the fibers can be positioned in the direction of a force occurring in the intended use of the component and are preferably connected three-dimensionally in the entire component to be produced in the method according to the invention.

Preferably, the fiber volume fraction of the component to be produced is between 15-90%.

It is fundamentally irrelevant in the first place whether the fiber structures are to be produced in the nano- or macro-range, because an adjustment of the fiber structure is not only arbitrarily detailed possible by a scaling of the expandable component components, but is also independent of the size or shape of the component to be produced.

In this case, the fibers used in the process according to the invention are understood as meaning, for example, textile fibers, glass fibers, metal fibers or carbon fibers. In addition, microstructured and all organic fibers can be used.

As a cavity, any solid or flexible negative mold is understood, which determines the later outer shape of the component to be produced. It may be this particular Page 7 is a rigid shell, a closed injection mold or a vacuum bag with flexible lateral surfaces.

Furthermore, the fibers may already rest directly on the not yet expanded component components or initially be placed loosely within the cavity. This means that the expandable component components may already be at least partially surrounded by fibers prior to their placement in the cavity, and e.g. are wrapped with fibers.

Alternatively or additionally, ordered or disordered loose fibers can be arranged separately from the expandable component components in the cavity and, for example, the expandable component components can be introduced loosely or in a specific pattern into a fiber material already in the cavity.

In a preferred embodiment, the arrangement of the expandable component components within the cavity is carried out according to a predefined pattern, by the delimited functional areas arise in the finished component, which are each optimized for the loads or forces occurring in the intended use of the component. Accordingly, predefined regions of the component to be produced are combined to form functional groups which serve to absorb defined loads such as impact, tension or rotation. Accordingly, these regions can have fibers in the necessary density and / or orientation, wherein a desired, final fiber profile can be adjusted and adjusted by means of the expandable component components. The component is therefore structurable in itself and almost arbitrarily according to performance parameters.

In order to realize the most homogeneous possible structure within the component, it is preferably provided in the context of the method according to the invention that the fibers are three-dimensionally twisted / sewn together and / or positively connected with each other or with each other. In addition, the component components, expanders and / or fibers can be treated with fillers and additives.

For easier arrangement of the expandable component components in specified patterns within the cavity and for the targeted creation of previously defined

To facilitate structures through the expandable component components and the fibers, the expandable component components in a page 8

Embodiment arranged in at least one prefabricated Faserumhüllung and / or on a fiber surface. This fiber cladding or fiber surface is in each case made of fibers, in particular of fiber filaments, fiber rovings, fiber layers, individual fiber mats or at least one fiber hose.

In an embodiment based thereon, expandable component components are arranged within at least one fiber sheath formed from a fiber tube or a fiber sheath consisting of a plurality of individual chambers. This fiber sheath is placed within the cavity and thus already constitutes a basic structure for the fiber structure to be realized within the component to be produced, before the cavity is evacuated and the matrix material is introduced.

Alternatively or additionally, it can be provided that expandable component components are arranged on a substantially flat, spread-out fiber surface with fiber material which is wound in such a way that the components arranged thereon are located inside the wound-up fiber surface and the wound-up fiber surface is arranged in the cavity before the matrix material is introduced into the cavity.

In other words, the entire inner and outer structure of the component is unwound into the fiber surface. For structural construction, the fiber surface is provided with expandable component parts, e.g. partly in the form of expanders and optionally with functional ingredients, e.g. Fillers and / or additives, coated and then rolled until the fiber surface is in the form of a coil. This is introduced into the cavity, which is closed and evacuated. In the process, the component components or expander expand and press the outer layer of the wound fiber surface against the inner walls of the cavity and establish the structure present within the fiber surface.

Likewise, expandable component components can be arranged on a fiber surface, which, regardless of whether this is wound or not, consists of individual surface-connected fiber mats.

In order to define more load-bearing and shaping support structures within the component to be produced, which are not exclusively dependent on the expandable component components and thus can be adapted more specifically to the loads occurring, fillers in the cavity are preferably before the evacuation of the cavity Page 9 arranged, which surround the expandable component components at least in sections.

By means of the added fillers, the fiber volume fraction can be regulated and the specification of the physical properties of the matrix controlled. Thus, an expansion of the component components within the cavity takes place in a through the

Fiber material and the fillers reduced volume, so that the fillers, any

Carrier components and fibers are compressed by the expanding component components or expander. By subsequently introduced matrix material are then already by the expandable component components, fibers and

Fillers formed supporting structures fixed in the component.

The fillers may furthermore be introduced into / on the prefabricated fiber sheathings and / or at least partially surround the prefabricated fiber sheathings. Likewise, fillers may be introduced into interstices or chambers of a fiber surface discussed above, the interstices being formed by area of the fiber surface in which the fiber mats making up the fiber surface are not interconnected.

Furthermore, fillers may be added to the resin matrix prior to injection / infusion.

Fillers are for example fiber-needle, plate or particulate and / or mineral substances, in particular carbon fibers, glass fibers, glass beads, amorphous silica, asbestos, calcium silicate, calcium metasilicate, magnesium carbonate, kaolin, calcined kaolin, chalk, powdered Quartz, mica, barium sulfate, feldspar, aramid fibers, potassium titanate fibers, acicular wollastonite, talc, boehmite, bentonite, montmorillonite, vermicullite, hectorite or laponite, etc. Particles of rubber, metal powders, dyes, pigments and their binders and adhesion promoters, organic fillers such as wood flour can be used.

The fillers to be applied may, for example, also be carbon nanotubes ("CNTs") contained in a solvent, or micorbalons, etc., which are sprayed onto the expandable component components, fibers and / or fillers. Page 10

With such carbon nanotubes, additional reinforcement effects can be achieved and the component to be produced can additionally be provided with greater strength locally or over a large area.

The bond between fibers and resin matrix or matrix material takes place physically. Adhesive forces connect fibers and matrix. In addition, surface defects of the fibers and the therein e.g. resinous matrix material for increased friction between fibers and matrix. These properties can be regulated by the fillers, the surface structure of the fibers and the viscosity of the resin.

In carrying out the method according to the invention, the introduction of the matrix material preferably takes place after the evacuation of the cavity so that already expanded component components are present when the matrix material, for example a resin, is supplied. Furthermore, the negative pressure can be regulated during and after the filling of the resin. However, it can also be provided that an expansion of the component components is realized only after the complete or partial filling of the cavity with matrix material. In such a case, therefore, the component components would at least partially already be within a liquid matrix material as they expand.

For further targeted influencing of the material properties of the component to be produced, the method according to the invention can be supplemented by a gas injection into the component before and / or after hardening of the matrix material. This is understood to mean, for example, that gas is injected locally into the expanded expander. This is a third way to regulate the cavity pressure and thus the fiber volume fraction.

In particular, these expander can be used by their physical connection to the outside of the component even after curing functionally for the transport or storage of substances.

In order to influence the material properties of the component to be produced, additives are applied to the component components, to fibers and fillers in one embodiment prior to introduction of the matrix material into the cavity.

In this context, additives are understood as meaning, in particular, additives which influence the crystallization of the matrix material, for example of a resin. By chemical Page 11

Reaction they affect the shape and size of the crystals of the erstarten resin matrix. These influence physical parameters of the resin such as hardness hardness temperature resistance, chemical reactivity, porosity etc.

Part of the present invention is, inter alia, that the properties of the resin matrix in the monolithic component in a single casting can be controlled dynamically targeted. By spraying or generally applying the additives to the preform, the additives are already at the location of the desired property in the component. However, this can be applied in all fiber composite techniques.

Thus, it is possible to influence a matrix of resin from the matrix material by incorporating additives but also localized fillers (crystallization, density, length of the polymer chains and their unfolding, physical and chemical behavior, duration and position of the glass transition point). By applying additives and / or introducing fillers, moreover, the resin matrix can be varied dynamically as it flows into the cavity in terms of its behavior in the component to be produced. These additives / fillers are applied to the preform, i. in particular, the fiber architecture or the already arranged in the cavity components of the composite, applied before evacuation. Thus, a progressing resin front of the introduced matrix material absorbs the additives at design-determined positions and locally determines the properties of the resin solidified there. This makes the component relatively complex with e.g. defined mechanical properties. With additives, however, the resin can still be foamed in the marketplace at specified points.

As the matrix material, a resin can be used. In particular, the matrix material may comprise a duromer, an elastomer or a thermoplastic. The matrix material may also comprise a biopolymer which is essentially obtained from renewable raw materials.

As a thermoset mainly epoxy (EP) resins, unsaturated polyester (UP) resins and vinyl ester (VE) resins are used. In addition, depending on the application phenol (PF) resins, polyamides and bismaleimides can be used.

Uncrosslinked polymers are vulcanized with sulfur to elastomers, which can be used in particular for the production of the expander. The starting material is rubber, which, inter alia, in the form of natural rubber, isoprene rubber Page 12 and butadiene rubber is used. In addition to the spatially crosslinked elastomers, there are the thermoplastic elastomers. Used are, for example, styrene-butadiene-styrene triblock copolymers, polyurethanes, elastomer thermoplastic blends (eg EPDM / PP, NR / PP).

In the field of thermoplastics, semi-crystalline materials such as polypropylene (PP), polyamide (PA) and amorphous thermoplastics such as polystyrene (PS), polycarbonate (PC) are used. Particularly suitable as the matrix are polypropylene (PE), the saturated polyesters, polybutylene terephthalate (PBT) and polyethylene terephthalate (PET) and polyamides (PA). High heat-resistant thermoplastic matrix materials include polysulfone (PSU), polyethersulfone (PES), polyphenylene sulfide (PPS), as well as polyetheretherketone (PEEK) and polyetherimide (PEI).

Examples of suitable starting materials are preferably the natural fats and oils of rapeseed, sunflower, soy, flax, hemp, castor, coconuts, oil palms,

Oil palm kernels and olive trees. Other suitable starting materials are those by the

Polymerization or Olygomerization of fatty acids by radical polymerization or thermal treatment accessible dimer and trimer fatty acids and their

Subsequent products given.

For the preparation of oleochemical thermosets, the following classes of compounds are particularly suitable:

• epoxidized fats and oils

Amine fatty substances (meth) acrylate-functional fatty substances, preferably prepared by esterification of (meth) acrylic acid with hydroxide functionalized fats and oils, or by ring-opening reaction of epoxidized fatty substances with olefinically unsaturated carboxylic acids such as (meth) acrylic acid, crotonic acid, itaconic acid, maleic acid or their mixture.

The most important representatives of the epoxidized fats and oils are the expoxidized linseed and soybean oil and the epoxidized rapeseed oil as well as the epoxidized sunflower oil.

Typically, the expandable component components or the expanders made from or with them include elastomers, polyamides, or latex, or are made from the foregoing materials to define their expandability. Page 13

Another aspect of the present invention is a component made according to the proposed method of the invention.

Conceivable are components for vehicle construction, i. the automotive industry, rail vehicle construction, aircraft construction, the manufacture of body parts and interior fittings. Furthermore, an inventive component in the construction industry for insulation materials and structural elements, in window construction for the construction of window frames, door frames and doors, in the furniture industry for the production of panels, multi-shell wall systems, furniture parts and furniture, in the electrical / energy industry for the production of computers , Home appliances, hi-fi, PA enclosures, blades and rotor blades of blowers or wind turbines. The production of machine parts and panels are procedurally feasible. Also, the inventive method for the production of components and bodies whose applications are under water and in space.

In the field of recreational activities and sports components of the invention sports equipment, boats, gliders, racing, tubs and basins, bicycle frames, miniature golf courses, bars, surfboards but also masts for example. Electricity, sailboats and wind turbines, planking be made.

In mechanical engineering, they can be used for the production of gears or gear parts and in waste management for the production of waste containers.

In plant construction tanks, pumps, pipe elements can be manufactured.

In the packaging industry, the components according to the invention can be used for the production of bottles, hollow bodies, molded parts and technical packaging.

Furthermore, such a component can be used as a container or case or in scaffolding and stage construction.

Also, the components of the invention in agriculture for the production of containers, feed silos, plant pots and in safety technology for the production of protective helmets and -Protektoren use, in medicine for the production of Protesen. Carrying and supporting, in the leisure and wellness industry, in trade fair construction. Page 14

A further aspect of the present invention is therefore also the use of a component made of a composite material according to the method of the invention for providing therewith at least one diffusion layer for an isobaric tank for storing a gaseous fluid, e.g. Hydrogen, produce.

Such an isobaric tank has at least a first and a second diffusion layer and a jacket, wherein the first diffusion layer in the interior of the isobaric tank completely encloses a first cavity for receiving the fluid, the second diffusion layer completely encloses a second cavity in which the first cavity is completely accommodated and the shell completely encloses the second diffusion layer to seal the isobaric tank from an exterior space. Furthermore, the first and second diffusion layers are permeable to the fluid from a threshold value for the pressure applied to the respective diffusion layer by the gaseous fluid received in the isobaric tank.

In this way, a multi-layer Isobarentank can be constructed, which is filled with the gas to be stored at high pressure. Although it is quite possible to fill the outermost cavity of the isobaric tank, in which several other cavities are located, with the fluid under the highest pressure. Thus, the fluid would diffuse through the individual diffusion layers from outside to inside. However, it is preferred to provide an innermost (first) cavity with the fluid at a highest pressure and to allow the fluid to partially escape into the next cavity through the (first) diffusion layer surrounding this innermost cavity when a certain threshold is reached. Thus, a relief of the innermost cavity and there is a back pressure in the next, adjacent (second) cavity created.

Of course, it is possible to have a plurality of similar or different, i. Provide permeable diffusion layers at different pressures.

If a permissible maximum pressure is reached in an outermost cavity adjoining the jacket of the isobaric tank, the fluid contained therein is compressed from this outermost cavity back into the innermost cavity. A removal of the gas or gaseous fluid stored in the isobaric tank is then preferably carried out at the outermost cavity of the isobaric tank. Page 15

Through the use of a component for the diffusion layers of the isobaric tank, which is produced by the method according to the invention, the permissible diffusion between the adjoining cavities via the respective diffusion layer can be adjusted specifically. About component components and the matrix, the material properties of the diffusion layer, the permeability of a diffusion layer is already set during production.

However, the active principle of the isobaric tank described here is not necessarily bound to the use of a component for one of the diffusion layers, which was produced by the method according to the invention.

Further features and advantages of the invention will become apparent in the following description of exemplary embodiments with reference to the figures.

Show it:

1 is a flowchart which schematically illustrates the sequence of a method according to the invention;

2 shows an exemplary embodiment of a component produced by the method according to the invention;

Fig. 3 shows schematically a fiber tube in the expansible

Component components and fillers were filled;

4A-4D show various views of a fiber architecture to be arranged in a cavity, which is wound up, in which inter alia, expandable component components and functional assemblies are located in their interior, in various stages of the method;

Fig. 5A schematically several, provided with individual chambers

Fiber cladding, are to be filled in the expandable component components and fillers, within a cavity for the component to be produced; Page 16

FIG. 5B a detail of a fiber surface consisting of a plurality of hexagonal fiber mats with expandable component components and fillers; FIG.

6A-6B are sectional views of two embodiments of an isobaric tank according to the invention with a plurality of diffusion layers.

FIG. 1 shows schematically a possible sequence of the method according to the invention for producing a component from a composite material, in which fibers are embedded within a matrix material, for example a resin.

First, in a first step A, a cavity is provided, in which the components forming the component to be produced are arranged or introduced. The outer shape defined by the cavity determines the later final shape of the component to be produced. Such a cavity may, for example, be a matrix provided with a solid core or a simple hollow shape without an inner core. Likewise, however, it is also possible to use a cavity in the form of a flexible (vacuum) bag or a combination of outer form and vacuum bag.

Within the provided cavity, a fiber architecture is built up within the cavity in the subsequent steps. This is characterized by an arrangement of fibers, fiber rovings, fiber fabrics, fiber hoses and / or mats or tiles and the arrangement of expandable component components and fillers in the cavity according to design specifications for the component to be manufactured, as provided in a step B of Figure 1 is. In this case, the said components to be arranged in the cavity, in particular the expansion-capable component components, can be in the form of the expander and carrier components already explained in the introduction. The expandable component components may already be individually surrounded by fibers. But they can also be used in already introduced in the cavity fibers that are loose or disordered or targeted within the cavity aligned or arranged.

In principle, the fiber material may also be loose and present as rovings, yarns, tubes, knitted fabrics, knits, prepegs.

Arranged in the cavity, the introduced components thus form fiber-reinforced structures, which in the context of an embodiment variant of the invention Page 17

In turn, process can be additionally connected with fibers from micro to endless.

The aim is to surround the expandable component components or the expander with ordered and / or disordered fibers, so that the fibers within the cavity can be specifically aligned with a subsequent expansion of the component components or expander or at least the already built in the cavity shape stabilized and fixed.

The expander are preferably designed as filled with gas and / or carrier components hollow body made of an elastomer, so that in an evacuation of the cavity by the resulting negative pressure, an expansion of such hollow body can take place.

In order to be able to define desired, later support structures in a simple manner already in the arrangement of the expandable component components and the fibers within the cavity, at least some of the component components may already be surrounded in advance with fibers. More load-bearing support structures are primarily formed by surrounding with fibers selectively expanded component components and possibly additionally filled and non-expandable carrier components. Such carrier components are preferably such that they allow a frictional connection of their surface and fibers.

By way of example, expandable component components are inserted into a fiber tube formed from interwoven individual fibers before an arrangement of the component components takes place within the cavity.

Such an exemplified fiber tube can thus be designed within the cavity along a desired course. Such a profile of a fiber tube, for example, be rectilinear within the cavity, so that a kind of pressure rod is realized within the component to be produced. In this case, this pressure rod is formed by the fibers of the fiber tube embedded within the later-introduced matrix material and the components accommodated therein (in particular expanders, carrier components and fillers explained below) and, with the support structure provided with it, provides a larger (tensile) area along its course. Strength within the finished component. Page 18

To realize within the component to be produced and thus within the cured matrix material, the carrying capacity and load capacity of the component not exclusively on the introduced fibers and the expandable component components and to provide greater rigidity of the support structure to be created, are in a step B.2 additionally Fillers added to the cavity.

While the expansion-capable component components are preferably positioned or placed within the cavity, in one embodiment of the method according to the invention it is entirely possible to introduce additional fillers, at least partially surrounding the component components, loosely into the cavity in order to produce the fiber architecture.

Likewise fillers can be arranged in prefabricated Faserumhüllungen, such as a fiber hose described above (see also Figure 3), together with the expandable component components. The expandable

Component components always cause a displacement of the fibers and the fillers against each other and in the direction of the outer walls defining the cavity. In such

Fibers arranged expansionsfähigen component components form after hardening of the introduced matrix material prestressed support structures in the manufactured component.

As further noted under optional process step B.2 of Figure 1, the fillers may include crosslinking agents, or additional crosslinking agents may be added to the fillers. In this context, such crosslinking agents are substances which can also be referred to as additives. The additives added to the fillers can thus specifically (chemically) influence the crosslinking properties of the resin matrix.

In addition, such crosslinking agents are also intended for the crosslinking of fibers which form lateral surfaces of fiber cladding or fiber surfaces. Although individual fibers can always be connected to each other mechanically, for example by sewing, twisting or weaving together. However, it is also possible to use the cross-linking agents in a simple manner to achieve a three-dimensional coupling of the fibers in the component at the chemical level. Page 19

For further targeted influencing of the material properties of the component to be produced, additives can in principle be introduced into the cavity in process step B.2 during the production of the fiber architecture. In a variant of the method, additives of this type, for example materials which are in a solvent and influence the crystallization of the resin matrix, can preferably be sprayed or applied onto component components already surrounded by fibers.

As additives serve e.g. volatile solvents e.g. Toluene Toluene, common name after IUPAC also toluene, methylbenzene, phenylmethane, called by the IUPAC nomenclature methylbenzene, is a colorless, characteristic smelling, volatile liquid that resembles benzene in many of its properties. Toluene is an aromatic hydrocarbon, often replacing the toxic benzene as a solvent.

Before the cavity with the created fiber architecture located therein is hermetically sealed and evacuated, as is subsequently provided in method step C of FIG. 1, an air turbulence may be previously provided according to method step B.3. By such Luftverwirbelung present loose fibers are mechanically linked together within the cavity.

In the subsequent evacuation of the cavity, it is provided according to the invention that the expander expand and thus define the desired inner support structure consisting of expansion-capable component components as well as fibers, fillers and additives within the cavity. The shape of the expander stabilizes the fiber architecture and provides the necessary in-mold pressure.

Subsequently, in a subsequent method step D, the matrix material, for example a resin, in particular a duromer, an elastomer or a thermoplastic, is introduced into the cavity by infusion or injection. In this case, the matrix material can be heated to increase the viscosity. Possible and known methods in this context are, for example, "Vacuum Assisted Resin Injection" (VARI) [vacuum assisted resin injection] or "Resin Transfer Molding" (RTM) [resin transfer molding] and their further developments.

After curing of the thus created component in which the fibers, fillers, etc. and expandable component components are embedded within the matrix, the component produced is removed from the cavity in a final step E. About the additives used and the shaping effect of Page 20

Expander is thereby created within the component made of the composite material a stabilizing and in particular three-dimensionally networked support structure, which is adapted to the loads occurring at a proper use of the manufactured component.

In addition to the components mentioned, other functional components can also be incorporated in the production of the fiber architecture prior to closing the cavity (step C of the embodiment of FIG. 1). Such functional components may be, for example, any pipes or even electronic components such as sensors.

FIG. 2 shows a component 1 produced by the process according to the invention in the form of a mast, which is shown in cross-section in FIG. The component 1 is substantially cylindrical and has a circular base.

Within the cross-section schematically shown are fiber-surrounded expanders (component components) 20 and 21 as well as particulate fillers 3 embedded in an additive-provided cured matrix material.

A single expander (or even a single component component 20) is centrally located within a cavity, not shown, so that it forms an amplified center of the component 1 to be produced.

Decentralized, smaller expandable component components 21 were arranged along a circular path around this central expander 20 in order to form a stabilizing core within the component 1 together with the central expander 20 with the additionally introduced carrier components and fillers 3. In this case, the individual expander and component components 20, 21 each along a

Longitudinal direction of the component 1 extend and each have a length which corresponds to almost a total length of the component 1. However, it is preferred if in each case a plurality of central expanders 20 and a plurality of

Component components 21 along the longitudinal direction of the component 1 are arranged one behind the other, wherein a central expander 20 is each surrounded by a plurality of expandable component components 21 and / or fillers.

The thus along the longitudinal direction of the component 1 extending rigid structures with the expanders 20 and other expandable component components Page 21

21 are in this case designed for the increased in the interior of the component 1 occurring loads. In other words, the expander 20 and expansion-capable component components 21 and the surrounding carrier components and fillers 3 have been arranged within the component 1 just in functional areas 6.0 and 6.1 according to a predefined pattern to the produced component 1 targeted to these functional areas with an adapted physical To provide behavior.

The functional groups formed thereby are surrounded by supporting cell structures, which in turn are built up from expanders, carrier components, fibers and fillers. Around a central functional group with the expander 20, cell structures are constructed in such a way that forces acting on each spatial dimension counteract a large number of neutral lines.

FIG. 3 shows a prefabricated fiber sheath in the form of a fiber tube 5 into which expandable component components 2 and surrounding fillers 3 have been introduced.

Such a fiber tube 5 is arranged as already fully formed Faserumhüllung in a cavity and thus allows a comparatively easy-to-hand specification of a desired fiber structure or - together with the accommodated within the fiber tube 5 expandable component components 2 and the fillers 3 - the direct specification of a defined Support structure within the component to be produced.

The fiber tube 5 of Figure 3 here consists of interwoven fibers F, which are then pressed upon expansion of the possibly filled with gas spherical expander or component components 2 to the outside, as indicated by the arrows for an expander 2.

The orientation of the fibers F on or within a lateral surface of the fiber tube 5 can in principle be carried out in various ways. FIG. 3 illustrates two different variants. In a variant (shown in FIG. 3 at the right end of the fiber tube 5 shown), the individual fibers F of the fiber tube 5 all run parallel to each other and transversely to the direction of extension of the fiber tube 5. The individual fibers F thus form a fiber structure 50 ^* in the form of a Unidirectional Geleges. In a subsequent expansion of Page 22

Component component or of the expander 2 and the associated increase in surface area of the component component or of the expander 2, the individual fibers F and the fiber structure 50 ^{* are} significantly charged to train in the fiber direction and thus biased.

A force acting perpendicular to the fiber direction in the pressure rod force leads to a bulge and thus to an increase in the diameter of the ball-like or cylindrical shape. This deformation counteract the loaded on train fibers until collapse. The optimum performance parameters of the fibers are exploited spatially. This makes it possible to translate a compressive load for the tensile optimized fibers.

A further improvement can be produced by Multiaxialgelege, as they are also illustrated in Figure 3 (at a left end of the illustrated fiber tube 5). In this case, a plurality of fiber layers extend as fiber structures 50, 51 and 52, each with parallel individual fibers F at different angles to one another. In other words, the fiber tube 5 is defined here by a plurality of fiber bundles of individual fibers F, wherein the individual fiber bundles defining the fiber structures 50 - 52 are each inclined relative to one another or run along different directions.

Independently of the formation of the fiber structures 50 - 52, 50 ^* within the fiber tube 5, a defined functional component can already be created in the fiber architecture of the component to be produced with such a fiber sheath in which already expandable component components 2 and / or fillers 3 are arranged. This functional assembly then forms the desired and adjustable expansion of the component components 2 a desired support structure in a functional area of the finished component, which is adapted to the loads occurring during normal use.

FIGS. 4A to 4D show, in different views and at different stages, a further embodiment variant for the arrangement of expansion-capable component components and fillers with fibers F prior to the arrangement within a cavity.

In this case, almost the entire inner structure of the component to be produced is unwound in a fiber mat, which then with expandable component components and If necessary, fillers and additives are coated and subsequently wound up again inside the cavity and surrounded with matrix material.

In FIG. 4B, a fiber mat designed as a fiber base surface 6 is first of all shown in a state in which the fiber base surface 6 is opened by folding it upwards

Folding line L outgoing was once opened by a delivery state shown in Figure 4A delivery. A lateral surface 60 thus visible in FIG. 4B forms in the later coiled state of the fiber base surface 6 (see FIG

4D) an outer surface of the wound-up fiber base surface 6, in the interior of which the components arranged thereon (fibrous material, expandable

Component components 200, fillers 3 and optionally additives) are included.

FIG. 4C shows the fiber base surface 6 in a further unwound state resulting from the unfolding of the fiber base surface 6 starting from the state of FIG. 4B. The thus processed length and width of the newly spread fiber base 6 thus exceeds many times the dimensions of the unwound surface of the component to be produced.

In FIG. 4C, the sections of the fiber base 6 still wound up in FIG. 4B are thus also visible, which are designated as functional regions 61. These

Functional regions 61 of the fiber base surface 6 are formed by shoulders, recesses and / or cuts in the fiber base surface 6 consisting of fibers F. The specific configuration of the functional regions 61 of the fiber base 6 takes place on the basis of design specifications, in particular on the basis of expected or calculated forces acting on the component to be manufactured during its intended use.

The arrangement of the expandable component components 200 and any fillers and additives on the unfolded or unwound functional areas 61 is further carried out on the basis of the force flows occurring within the finished component along predetermined patterns 201 and 202.

Subsequently, the fiber base 6 is rewound or rolled up. In this case, the fiber materials arranged in the functional areas 61 and expandable component components 200 as well as any fillers and additives are then wrapped or rolled in, so that a coil formed by the fiber base surface 6 is formed, in the interior of which Page 24 components are present and each separated by the individual winding layers of the fiber base 6 from each other.

The coiled fiber base 6 is shown in Figure 4D in a cross section. This wound-up fiber base surface 6 is then introduced into the cavity and optionally surrounded with further fibers, expandable component components and / or fillers. With the evacuation of the cavity, the expandable component components 200 expand and so define the final shape of the internal structure of the component to be manufactured prior to the introduction of the matrix material.

In a further development of the method illustrated by FIGS. 4A-4D, provision may additionally be made for the finished roll of the fiber base 6 (see FIG. 4D) to be raised in a targeted manner by the expansion of the component component 200 substantially along the fold line L. For this purpose, for example, the lateral surface 60 of the wound-up fiber base surface 6 with the components located therein adjoin an outer wall of the cavity and thus compress the lateral surface 60 during expansion of the expandable component components 200 against this outer wall or against the cavity itself. As a result, as a result of the further expansion of the expandable component component 200, the inner layers of the fiber base surface 6 are pressed upwards or downwards, that is to say essentially perpendicular to the outer surface 60. Thus, the inner structure of the wound fiber base 6 is directed to or is pressed outwards.

With the expansion of the expandable component components 200 and the fiber base surface 6, which is spirally wound on average in section, it is thus possible to create a load-bearing structure within the component to be produced which, despite its complexity, is relatively easy to manufacture.

Again, always structurally required or functionally desired cavities can be created within the manufactured component by appropriately placed and resized expander 200.

FIGS. 5A and 5B further illustrate an embodiment variant for the method according to the invention, in which prefabricated fiber structures

Find use. This process variant is used to produce shell-like Page 25

Conventionally sandwiched components using the method described herein.

In one embodiment (not shown in FIGS. 5A and 5B), a centered hexagon in which all edge lengths and rays are of equal length to the center span a surface that does not want to be deformed into the third spatial dimension. This deformation would trigger a complex tensile-pressure behavior, which the hexagonal fiber structure defies. This area is a homeostatic area. The variant embodiment of the method according to the invention provides a hybrid fiber architecture according to these basic geometric rules

Available.

The hexagonal mat consists of at least two fiber mats as the outer layer. An application-oriented mix of expandable component components, fillers and additives is applied over a wide area. The cutting takes place with individual fibers, rovings and yarns and forms the basic geometric structure. By sewing, the chambers are fixed with their contents. With the help of the fabric holder, a CNC sewing machine, the diagonal sewing system and the robot-assisted single- and double-sided sewing technology, high accuracy and reproducibility of the products are achieved. The sewing machine parameters, such as needle geometry, needle thickness, sewing thread tension and sewing speed, affect the mechanical properties of the end product, as well as the nature of an optional fiber material entrained on the outer sides.

After curing of the matrix creates a two-dimensional surface structure. The hexagonal mats can be used for the construction of arched surfaces. For this purpose, the angle of suturing is modified or the tension of the entrained fiber material is changed in order to adapt the shape of the triangles dynamically to the curved surfaces in the sense of triangulation of surfaces.

If the tips of the triangles do not meet in a common center, as illustrated in FIG. 5B, a structure is built according to the principle of action of a geodesic dome. Preferably, furthermore, a shingle-like structure (not shown) is selected, that is to say the seams do not have to be designed vertically.

Shown schematically in FIG. 5A is a cavity V, in which a plurality of (in the present case two shown) fiber sheathings 5 * are arranged. These fiber sheaths 5 ^* are Page 26 cylindrical and each have a hexagonal base. This hexagonal base is divided into six sections by six substantially identical triangles, each forming a triangular base for the six six chambers 5a-5f located within the fiber sheaths 5 ^* . The individual chambers 5a-5f of the fiber cladding 5 ^* are bounded in each case by three chamber walls W1, W2 and W3, so that the individual chambers 5a-5f are open at the two end faces of the cylindrical fiber cladding 5 ^* .

A chamber 5a-5f is preferably made of a single fiber mat which forms the individual chamber walls W1-W3 by corresponding folding and stitching along seams N. The seams N preferably also connect the chambers 5a-5f with one another in order to form the individual fiber sheathings 5 ^* .

In the respective hollow chambers 5a - 5f, before or after their arrangement within the cavity V, the expandable component components as well as any fillers and optionally additional fibers (not shown here) are arranged. By projecting loose fiber bundles or loose fibers F _L , with which the individual chambers 5a - 5f are sewn together, also a connection to another adjacent Faserumhüllung 5 ^{* is} possible. In this way, adjoining fiber sheathings 5 ^* are non-positively connected to each other by twisting, stitching or interweaving and thus produce a complex, three-dimensional load-bearing structure within the component to be produced from fibers F, F _L , fillers and expandable component components.

By projecting loose fiber bundles or loose fibers F _L , with which the individual fiber mats of the chambers 5a - 5f are sewn together, also a connection to another adjacent fiber mat and / or fiber sheath 5 * is possible. In this way, adjoining fiber mats and / or fiber sheaths 5 * are non-positively connected to each other by twisting, sewing or weaving.

By embedding the expandable component components and the likewise cylindrical, ie in this case prismatic stitching of the fiber sheath 5 *, the structures to be produced within the matrix material and thus the component to be produced can be made extremely stable, since in an expansion of the possibly in the chambers 5a - 5f pre-tension the sutures N respectively. Thus, each chamber wall W1, W2, W3 both radially after Pressed on the outside 27, as well as by the associated with her and also outwardly depressed chamber wall W2, W3; W1, W3 or W1, W2 prevented. In addition, a chamber wall W1, which defines a part of an outer surface, would be pressed outward as well as such an expansion of the chamber wall W1 would be counteracted by an adjacent chamber wall W1-W3 of an adjacent fiber sheath 5 ^* .

Moreover, it is possible to interlock carrier components connected to one another with fibers F, F _L with one another and with the fiber mats and / or fiber sheathings 5 ^* , even if the (outer) seam N of a fiber mat follows a triangular pattern. As a result of the intermediate spaces formed along the seam N, mutually moved carrier components can be connected to one another directly or indirectly during expansion of the expandable component components. For example, a connection of adjacent and in different chambers 5a - 5f befindlicher carrier components via the adjoining them and frictionally connectable to them fiber F, F _L. A support structure formed by the expandable component components or at least stabilized within the component to be produced can thus be created along the N.

It is thus possible to make room parquets of individual chambers 5a - 5f with the fiber sheaths 5 ^* , wherein the size of the triangular base of the chambers 5a - 5f can be varied by adjusting the seams N. This results in complex three-dimensional fiber structures within the finished component, which are not characterized by a layered laminate structure, but can still be adapted comparatively easily to desired force flows.

FIG. 5B illustrates another prefabricated fiber structure in the form of a fiber surface 7. This fiber surface 7 is made of several mutually hexagonal sewn fiber mats 7a - 7d. The individual fiber mats 7a-7d are each connected to at least one further fiber mat 7a-7f at the corners of the regular hexagon formed by them so that there is a gap between each of three interconnected fiber mats 7a, 7b and 7c or 7b, 7c and 7d 8 is formed.

In these spaces 8 expansion component components 2 and 200 can be filled or arranged according to the preceding figures, in particular a complex geometric support structure with fibers, fillers and Page 28 to create expandable component components within the component to be produced.

In particular, a fiber surface 7 according to FIG. 5B is suitable for creating shell-like components in which at least one of the fiber surfaces 7 or also a plurality of fiber surfaces 7 are arranged to create a complex three-dimensional fiber structure within the cavity.

In order to improve the connection of individual fiber surfaces 7 and the components applied to the fiber surface 7 (for example expandable component components 2, 2 ^* , 200 and 200 ^* , fillers 3, 3 ^* and additives), the individual fiber mats 7a-7d extend along the hexagonal one Form defining edges and along the seam N fibers F _L , which can produce a frictional connection, for example by twisting, sewing or weaving to other fibers F, F _L. This applies in particular to fibers which have additionally been arranged around the individual expansion-capable component components 2, 2 ^* , 200 or 200 ^* (not shown here). The chambers are designed to be open to allow direct contact of the fiber filaments and to be fixed as the matrix hardens.

FIGS. 6A and 6B illustrate two exemplary embodiments for using a component which has been produced from a composite material according to a method according to the invention. Thus, FIGS. 6A and 6B each show a section through an isobaric tank T or T ^* , which has a plurality of individual diffusion layers D1-D3 or D1 ^* -D3 ^* produced according to the invention.

In FIG. 6A, a cylindrical hollow space H1, H2 or H3, each of which is completely defined by the respective diffusion layer D1, D2 or D3 and respectively by the corresponding diffusion layer D1, D2 or D3, is created from the individual diffusion layers D1, D2 and D3 D3 is completely surrounded. In this case, a cavity H1, which is defined by the (first) diffusion layer D1, forms an innermost cavity of the isobaric tank T, which lies within the respective larger cavities H2 and H3. The next larger cavity H2, which is defined by the (second) diffusion layer D2, is accordingly within the next larger cavity H3, which is defined by the outermost (third) diffusion layer D3.

The isobaric tank T is designed for storage or storage of a gaseous fluid, for example of hydrogen, which is preferably in the innermost cavity H1 Page 29 is filled under high pressure. The individual diffusion layers D1, D2 and D3 are produced by means of the method according to the invention. Due to the possible with the inventive method specific adjustment of the material properties based on the expandable component components are the diffusion layers D1, D2 and D3 from a certain (possibly different from each other) threshold or limit value for a pressure on the respective diffusion layer D1, D2 or D3 is applied, designed to be permeable to the fluid received. In other words, the individual diffusion layers D1, D2 and D3 are open to diffusion at a certain pressure value.

Thus, upon reaching a (first) pressure threshold within the cavity H1, the gaseous fluid received therein may at least partially diffuse through the diffusion layer D1 into the adjacent cavity H2 so as to provide relief to the cavity H1. Thus, part of the gaseous fluid to be stored within the isobaric tank T is also present in the cavity H2 at a pressure. If this pressure in the second cavity H2 increases by further diffusion through the diffusion layer D1 beyond a further (second) threshold, which is defined for the diffusion layer D2, then the gaseous fluid can move from the cavity H2 via the diffusion layer D2 into the next larger one Reach cavity H3.

Depending on the application, this illustrated principle of diffusing through the individual diffusion layers D1-D3 of an isobaric tank T can be supplemented almost arbitrarily by further diffusion layers, so that such an isobaric tank has more than the three diffusion layers D1-D3 shown. The outermost diffusion layer (the diffusion layer D3 in FIG. 6A) is separated by a jacket from an outer space of the isobaric tank T, which completely encloses the outermost diffusion layer (here D3) and seals against the outside space. However, such a jacket is not shown in FIGS. 6A and 6B.

In accordance with the isobaric tank T of FIG. 6A, FIG. 6B also shows a multilayer isobaric tank T ^* , which has three diffusion layers DT-D3 * of different sizes. The diffusion layers D1 ^* , D2 ^* and D3 ^* are identical in their properties to the diffusion layers D1, D2 and D3 of the isobaric tank T, but have a different shape. Thus, the diffusion layers D1 ^* -D3 ^* do not enclose a cylindrical cavity with a circular base, but in each case a cuboid cavity HT, H2 * or H3 ^* . Here again, the size of the individual cavities is valid: H3 ^* > H2 ^* > H1 ^* . Page 30

In addition to the relationships already explained in FIG. 6A, FIG. 6B illustrates, with the exemplary diffusion directions S ₁₂ and S _23, the diffusion of the gaseous fluid within the isobaric tank T ^* when the individual set (pressure) threshold values of the diffusion layers D 1 ^* , D 2 ^* and D3 * can be achieved. This is further illustrated by the pressures P ₁ , p ₂ and p ₃ in the cavities H1 ^* , H2 ^* and H3 ^{* which are} plotted in FIG. 6B, p ₁ > p ₂ > p _{3 being} valid in this exemplary embodiment. Accordingly, extraction of the gas stored within the isobaric tank T ^* (or the isobaric tank T) at the outermost cavity H3 * (or H3) is preferred, while the gaseous fluid under the largest compression within the innermost cavity H1 ^* (or H1 ) is present.

Via a compression line K and a corresponding delivery device for the fluid, upon reaching a critical pressure p ₃ within the outermost cavity H ₃ *, delivery of fluid from the cavity H ₃ ^* to the innermost (first cavity H 1 ^* ) of the isobaric tank T ^{* takes} place ,

The example of application of FIGS. 6A and 6B also illustrates the advantages of the method according to the invention, in which specific functionalities, in particular diffusibility and the targeted conduction of components, fillers and additives within a fiber structure for a component produced from a composite material are easily achieved Force flows, recorded and can be adjusted during the manufacture of the component.

By filling the expansion-capable component components or the filling with them within the component of specifically left cavities with gas or a subsequent evacuation of such a gas, the thermal conductivity of the component to be produced can be adjusted comparatively easily and in almost any degree of detail.

Due to the variable expansion of the expandable component components, a desired fiber structure or architecture can be scaled from the nano to the macro range. Nevertheless, inexpensive and commercially available materials and methods for introducing the matrix material can be used during the manufacturing process of the component. Conventional methods for the production of (lightweight) components made of composite materials, such as the bonding of Page 31 spherically shaped half-shells, as usually realized in airfoils of aircraft or rotor blades for wind turbines, can be replaced by the application of the method according to the invention, since the components to be manufactured can be manufactured inexpensively in one piece.

Page 32 List of Reference Signs

1 component

2, 2 ^* (spherical) component component / expander

20 (central) component part / expander 200, 200 ^* component component / expander

201, 202 arrangement pattern

21 (decentralized) component component / expander 3, 3 * filler / additive

4 matrix material

5 fiber tube 5 ^* fiber sheath 5a, 5b, 5c, 5d, 5e chamber

50 * fiber structure

50, 51, 52 fiber structure

6 Fiber basis 6.1, 6.2 Functional range

60 lateral surface

61 functional area

7 fiber surface 7a, 7b, 7c, 7d fiber mat

8 gap D1 ^* , D2 ^* , D3 ^* diffusion layer D1, D2, D3 diffusion layer F fiber (s)

F _L (loose) fiber (s)

H1 ^* , H2 *, H3 ^* cavity

H1. H2, H3 cavity

K compression line

L folding line

N seam

Pi, P2, Pa pressure

S ₁₂ , S ₂₃ diffusion direction

T, T * isobaric tank

V cavity

W1, W2, W3 chamber wall

_{* * * * ** * * * *}

Claims

Page 33 claims

A method of manufacturing a composite component (1) comprising at least one matrix material (4) and a plurality of fibers (F, FL) embedded therein, said method comprising the steps of:

Providing a mold-giving cavity (V) for the component (1) to be produced,

Arrangement of expandable component components (2, 2 ^* , 20, 21, 200,

200 ^* ) in the cavity (V) and of the expansion-capable component components (2, 2 ^* , 20, 21, 200, 200 ^* ) at least partially surrounding fibers (F, F _L ),

Closing the cavity (V) and evacuating the cavity (V) in such a way that the expandable component parts (2, 2 ^* , 20, 21, 200, 200 ^* ) can expand,

Expanding the expandable component components (2, 2 ^* , 20, 21, 200, 200 ^* ),

- Introducing the at least one matrix material (4) in the form of a fluid in the cavity (V) and

- Removal of the hardened matrix material (4), the

Component components (2, 2 *. 20, 21, 200, 200 ^* ) and fibers (F, F _L ) formed component (1), wherein the component components (2, 2 ^* , 20, 21, 200, 200 *) and fibers (F, F _L ) are embedded in the matrix matrix (4).

2. The method according to claim 1, characterized in that the expansion-capable component components (2, 2 ^* , 20, 21, 200, 200 ^* ) already before their arrangement in the cavity (V) at least partially surrounded by fibers (F, F _L ) and / or fibers (F, F _L ) are arranged separately from the expandable component components (2, 2 ^* , 20, 21, 200, 200 *) in the cavity (V).

3. The method according to any one of claims 1 or 2, characterized in that the arrangement of the expandable component components (2, 2 ^* , 20, 21, 200, 200 ^* ) Within the cavity (V) according to a predefined pattern (201, 202) takes place through which in the finished component (1) delimitable functional areas (6.1, 6.2, 61) arise, each for the intended use of the component ( 1) occurring loads are optimized.

4. The method according to any one of the preceding claims, characterized in that the fibers (F, F _L ) are three-dimensionally interconnected with each other or with each other.

5. The method according to any one of the preceding claims, characterized in that the expandable component components (2, 2 ^* , 20, 21, 200, 200 ^* ) in at least one prefabricated fiber sheath (5, 5 ^* ) and / or on a fiber surface (6 7), each of which is made of fibers (F ₁ F _L ), in particular of fiber rovings, fiber rims, fiber mats (7a-7d) or at least one fiber hose (5),

6. The method according to claim 5, characterized in that expandable component components (2, 2 ^* ) within at least one of a fiber tube (5) formed fiber sheath (5, 5 *) are arranged.

7. The method according to claim 5 or 6, characterized in that a fiber surface (7) on which the expandable component components (2, 2 ^* , 20, 21, 200, 200 *) are arranged, from individual interconnected fiber mats (7a - 7a). 7d).

8. The method according to any one of claims 5 to 7, characterized in that at least the expansion-capable component components (2, 2 ^* , 20, 21, 200, 200 ^* ) are arranged on a substantially flat, spread-out fiber surface (6), such is wound with the components arranged thereon inside the wound-up fiber surface (6), and the wound up

Fiber surface (6) in the cavity (V) is arranged before the matrix material (4) is introduced into the cavity (V).

9. The method according to any one of the preceding claims, characterized in that prior to the evacuation of the cavity (V) fillers (3, 3 ^* ) for influencing the

Characteristics of the component to be produced (1) are arranged in the cavity (V), Page 35 surrounding the expansion-capable component components (2, 2 *, 20, 21, 200, 200 *) and / or fibers (F, F _L ) at least in sections.

10. The method according to any one of claims 5 or 6 and the claim 9, characterized in that fillers (3, 3 ^* ) in the prefabricated Faserumhüllungen (5,

5 ^* ) are introduced and / or fillers (3, 3 ^* ) at least partially surrounded the prefabricated fiber sheaths (5, 5 *).

11. The method according to claim 7 and one of claims 9 or 10, characterized in that expandable component components (2, 2 ^* , 20, 21, 200,

200 *) and fillers (3, 3 ^* ) in chambers (8) of the fiber surface (7) are introduced, wherein the chambers (8) by sewing fibers (F, FL) are formed in particular of fiber surfaces (7).

12. The method according to any one of claims claim 9 to 11, characterized in that the expanded component components (2, 2 ^* , 20, 21, 200, 200 ^* ) and at least partially surrounding fillers (3, 3 ^* ) and / or Fibers (F, F _L ) after curing of the matrix material (4) form a defined support structure within the finished component (1).

13. The method according to any one of claims 9 to 12, characterized in that the component components (2, 2 *. 20, 21, 200, 200 ^* ), fibers (F, F _L ), carrier components and / or fillers (3, 3 ^* ) are treated with at least one additive so that a targeted and locally controllable influence on the crosslinking of the matrix material (4) takes place.

14. The method according to any one of the preceding claims, characterized in that at least a portion of the expandable component components (2, 2 ^* , 20, 21, 200, 200 ^* ) are non-positively connected to fibers (F, F _L ).

15. The method according to any one of the preceding claims, characterized in that the introduction of the matrix material (4) after the evacuation of the cavity (V), and / or that an additional expansion of component components (2, 2 ^* , 20, 21, 200 , 200 ^* ) and / or expandable fillers (3, 3 ^* ) after introduction of the matrix material (4). Page 36

16. The method according to any one of the preceding claims, characterized in that before the evacuation of the cavity (V) carrier components for creating a within the produced component (1) forces conductive support structure in the cavity (V) are arranged.

17. The method according to any one of the preceding claims, characterized in that the expandable component components (2, 2 ^* , 20, 21, 200, 200 *) are at least partially formed by gas-tight and filled with gas and / or carrier components hollow body.

18. The method according to claim 17, characterized in that the hollow bodies are surrounded by an elastomer or latex.

19. The method according to any one of the preceding claims, characterized in that for influencing the material properties of the produced component (1) before introducing the matrix material (4) in the cavity (V) additives to the component components (2, 2 ^* , 20, 21 , 200, 200 *), on fibers (F, F _L ) carrier components (2, 2 ^* , 20, 21, 200, 200 ^* ) and / or on fillers (3, 3 ^* ) are applied to the at least one Matrix material (4) react chemically.

20. The method according to any one of the preceding claims, characterized in that contained in a solvent carbon nanotubes ("carbon nanotubes") on the expandable component components (2, 2 *, 20, 21, 200, 200 ^* ), on fibers (F, F _L ), carrier components and / or fillers (3, 3 ^* ) are sprayed on.

21. The method according to any one of the preceding claims, characterized in that the matrix material (4) comprises a resin, in particular a duromer, an elastomer or a thermoplastic.

22. The method according to claim 21, characterized in that the matrix material (4) comprises a biopolymer, which is obtained substantially from renewable raw materials.

23. The method according to any one of the preceding claims, characterized in that the fiber volume fraction in the produced component (1) by the at

Evacuation of the cavity (V) expanding components (2, 2 ^* , 20, 21, 200, 200 *) is specifically regulated. Page 37

24. The method according to any one of the preceding claims, characterized in that the fiber volume fraction of the component to be produced (1) is between 15-90%.

25. A method for producing a component (1) from a composite material which consists of at least one matrix material (4) and a plurality of fibers (F, FL) embedded therein, the method comprising the following steps:

- Providing a shape giving cavity (V) for the component to be produced

(D.

Arrangement of fibers (F, F _L ) within the cavity (V),

Applying additives and / or fillers to the chamfers (F, F _L ) which react with the matrix material (4) during the introduction of the at least one matrix material (4) and / or locally influence the properties of the component to be produced, and

- introducing the at least matrix material (4) in the form of a fluid into the

Cavity (V) and

26. The method according to claim 25, characterized in that contained in a solvent carbon nanotubes ("carbon nano tubes") are sprayed onto the fibers (F, F _L ).

27. Component of a composite material, which is produced according to a method according to one of claims 1 to 26.

An isobaric tank (T, T ^* ) for storing a gaseous fluid having at least a first and a second diffusion layer (D1-D3, D1 ^* - D3 ^* ) and a cladding, said first diffusion layer (D1, D1 ^* , D2 , D2 ^* ) inside the isobar tank (T, T ^* ) completely encloses a first cavity (H1, H1 *, H2, H2 ^* ) for receiving the fluid, the second diffusion layer (D2, D2 ^* , D3, D3 ^* ) encloses one second cavity (H2, H2 ^* , H3, H3 *) completely encloses, in which the first

Cavity (H1, H1 ^* , H2, H2 *) is completely accommodated, and the shell completely encloses the second diffusion layer (D2, D2 ^* , D3, D3 ^* ) to the isobaric tank (T, Page 38

T ^* ) with respect to an outer space, wherein the diffusion layer (D1-D3, D1 ^* -D3 ^* ) in each case from a threshold (p1, p2, p3) at the respective diffusion layer (D1-D3; Dr the isobaric tank (T, T *) received gaseous fluid is permeable ar.

29. Use of a component according to claim 27 for manufacturing a diffusion layer (D1-D3, D1 * - D3 ^* ) for an isobaric tank according to claim 28.

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