WO2013045114A2

WO2013045114A2 - Fibre-reinforced composite component and method for producing such a composite component

Info

Publication number: WO2013045114A2
Application number: PCT/EP2012/004106
Authority: WO
Inventors: Jens Schaube; Florian Plenk
Original assignee: Gummiwerk Kraiburg Gmbh & Co. Kg
Priority date: 2011-09-29
Filing date: 2012-09-29
Publication date: 2013-04-04
Also published as: DE102011114494A1; WO2013045114A3

Abstract

The invention relates to a composite component (10) comprising at least two layers (12, 14, 16, 18), wherein a first layer (12) consists at least in part of a plastic reinforced with fibres (14) and wherein a second layer (16) consists at least in part of an elastomer. According to the invention, the first layer (12; 22), the second layer (16; 26) and a third layer (18; 28) made of a gel coat or synthetic resin varnish are bonded with each other by mutual crosslinking and curing to form a composite component (10) with high finish quality. The invention also relates to a method for producing such a composite component.

Description

Fiber-reinforced composite component and method for producing such a composite component

The invention relates to a fiber-reinforced composite component having at least one plastic layer and having at least one elastomer layer according to the preamble of patent claim 1 and a method for producing such a composite component according to claim 9.

There are known fiber reinforced plastics (FRP), which are usually less energy-elastic and brittle and therefore can absorb or absorb little energy when vibrations occur due to vibrations, shocks or impacts. If such fiber-reinforced plastics are to be produced with a high surface quality, as is the case, for example, for body shell components or interior trim parts of vehicles, this encounters considerable difficulties. This is due in particular to the undulation of the roving in the tissue. This results in thickness variations of the surrounding resin surrounding the fabric which in turn leads to irregular surfaces due to shrinkage and different thermal expansion coefficients.

A vehicle component is known from WO 2010/083980 A1, in which a bonding agent layer of elastomer and, subsequently, a cover layer of carbon fiber reinforced plastic is applied to a carrier layer of metal or fiber-reinforced synthetic resin. The In this case, the matrix of the cover layer should be made transparent in order to make visible the fibers embedded in the cover layer.

From WO 2006/122749 A1, a composite component is known in which a first, at least partially made of a thermosetting synthetic resin layer and a second, at least partially made of an elastomer layer are joined together by a common heat treatment in one operation. The present invention has for its object to provide a composite component and a method for its production, whose surface has an excellent quality with ease of manufacture.

This object is achieved by the means specified in claim 1 with respect to the device and by the means specified in claim 9 with respect to the method for production. Advantageous embodiments of the invention can be found in the respective subclaims. The invention provides that a first layer of a fiber-reinforced plastic, a second layer of an elastomer and a third layer consisting of a gelcoat or a synthetic resin paint are joined together as a composite component by a common crosslinking or hardening. By using the gelcoat or synthetic resin lacquer layer, which is preferably colored in the desired color, the composite component obtains a smooth surface in a single pass, which also satisfies the high demands of the automotive industry ("Class A visible surface") can thus be made ready for installation without further or at least significantly reduced rework, such as grinding or painting, in one operation. When referring to "layers" in the present invention, they may mean wholly or even partially superimposed or intermeshed strips, pieces or regions of said materials, and a plastic composite component in the sense of the present invention will also be used If one or more layers of the plastic composite component are made of metal or other materials that are not to be designated as plastics, the fiber-reinforced layer and the elastomer layer are jointly co-formed with the cover layer in one operation and then under the influence of energy All of the raw materials involved are coordinated so that they network or harden together.

The first layer is formed as a plastic carrier layer of a fiber reinforced plastic (FRP), a carbon fiber reinforced plastic (CFRP) or a glass fiber reinforced plastic (GRP). The elastomer layer preferably consists of one of the following substances:

of ethylene propylene rubber (EPM), ethylene propylene diene rubber (EPDM), ethylene acrylate rubber (EAM), fluorocarbon rubber (FKM), acrylate rubber (ACM), acrylonitrile butadiene rubber ( NBR), optionally blended with polyvinyl chloride (PVC), hydrogenated nitrile rubber (HNBR), carboxylate nitrile rubber (XNBR), hydrogenated carboxylate nitrile rubber (XHNBR), natural rubber (NR), ethyl vinyl acetate ( EVA), Chlorosulfonyl Polyethylene Rubber (CSM), Chlorinated Polyethylene (CM), Butyl or Halobutyl Rubber, Silicone Rubber (VMQ, MVQ), Fluorosilicone Rubber (FVMQ, MFQ), Chlorohydrin Rubber (CO ), Epichlorohydrin rubber (ECO), polychloroprene rubber (CR), one-component polyurethane (PU) or a combination or a blend of the aforementioned substances. Alternatively, the at least one elastomer layer may also consist of a thermoplastic elastomer (TPE).

By combining with the colored for the respective purpose third layer finished composite components can be produced inexpensively. After joint shaping and curing, the composite components according to the invention are in a ready-to-use condition and no longer necessarily have to be additionally painted, although an optional coating is possible. As a result, body shell components, such as doors, fenders, hoods, trunk lids, roof modules, spoilers or the like can be made in finished form and matching color and mounted directly to the vehicle.

The structure of the composite component of the fiber-reinforced layer, the elastomer layer and the cover layer is preferably as follows: a) According to a first alternative, first the supply of the third layer in a preferably provided with a release agent form, in particular by spraying the Gelcoats or Kunstharzlacks, b ) then feeding the second layer by applying an uncrosslinked elastomer layer (eg, by laying a green rubber or TPE film) on the third layer;

c) then feeding the first layer of fiber reinforced plastic to the second layer, in particular as a pre-soaked prepreg, or as a dry web, mat or mat which is then infiltrated with synthetic resin in an intermediate step;

d) joining the first layer, the second layer and the third layer by co-curing under energization. e) According to a second alternative, between the third layer and the second layer, a further plastic layer, in particular reinforced with carbon fibers, is inserted, which then also with the others Layers is connected by a common curing or crosslinking while supplying energy.

As a result of the softer elastomeric layer, both vibration absorption in the composite component according to the invention and vibration isolation by the composite component according to the invention can be achieved. In addition, the elastomeric layer effectively protects the composite component of the invention against impacting objects, such as a car body component of a vehicle from stone chipping, hail, bird strike, falling tools, as well as from scratches or abrasion. For interior trim parts, optically and / or haptically pleasing surface layers can be produced.

The composite component according to the invention has the following further advantages:

• easy processing

• short cycle times

• low energy consumption

• multi-component processing and thus the reduction of

installation expenses

• Combination of three materials (hard-soft-hard composite)

• Diverse coloring with effects and therefore design freedom

The optional introduction of flame-retardant elastomer layers impedes fire propagation.

A particularly advantageous use of a composite component according to the invention is that the composite component is used as energy-absorbing component. In general, use as a stable, vibration-damping lightweight component is advantageous. Here, for example, use as interior trim or body shell component of vehicles or as a housing for high quality Consumer goods, such as computers or notebooks or the like possible, this list is only exemplary and not conclusive.

At a minimum, only a first layer or inserted or embedded strips, pieces or regions of a fiber-reinforced plastic and a second layer of an elastomer are provided in conjunction with the third layer of a gelcoat or synthetic resin lacquer. For certain applications, a multi-layer structure is advantageous, wherein advantageously each of a plastic layer and an elastomer layer alternate with each other. In this case, advantageously, an outer layer or both outer layers can be formed by gelcoat or synthetic resin paint.

Further advantages of the invention are: The separate production of a resin-based reinforcement is no longer necessary.

The structure of the entire composite component is done in a continuous operation at the same workplace.

A use of adhesion promoters is not necessary.

- Less time required for the production, thereby significant cost reduction.

The production of an electrically dissipative variant is possible without significantly higher material costs by embedding conductive threads, strips or fabric.

- Completely new constructions are possible:

• Energy-absorbing components in lightweight construction

• Composite components with integrated surface protection against scratches, abrasion, hail, stone chipping or other impacting objects

· Components with reduced fracture or splinter inclination

deformation • Flame-retardant composite parts by incorporation of incombustible elastic layers (eg metal or metal hydroxide particles or halogenated paraffins as aggregates in the elastomer). Hereinafter, embodiments of the invention are described with reference to the drawing. In detail shows:

1 shows the basic structure of a composite component with three layers, a first layer of a fiber-reinforced plastic, an elastomer layer arranged above it as a second layer and a third layer of gelcoat or synthetic resin lacquer forming the outer layer, and an alternative to FIG the second and the third layer still another fiber-reinforced plastic layer is provided.

In Fig. 1, a composite component 10 according to the invention is shown schematically in its structure. In this case, the composite component 10 has a first layer 12, a second layer 16 arranged thereon and a third layer 18 adjoining upwards thereon as a cover layer or outer layer.

When referring to the figure description of "on top" or "upwards", it is to be noted that in Figures 1 and 2 the cover layer or outer layer 18 is below, as in the case of manufacture in a form not shown When using the finished composite component 10, the cover layer or outer layer 18 forms its outer visible side.

The first layer 12 is formed as a plastic carrier layer made of a reinforced with fibers 14 plastic (FRP), a carbon fiber reinforced plastic (CFRP) or a glass fiber reinforced plastic (GRP). As material for the Fiber reinforcement 14, which is used in the form of loose fibers, a woven, laid or pulp, are preferably glass fibers, nylon, polyester, carbon fibers, viscose, aramid fibers or metal fibers as well as fibers from natural, renewable raw materials into consideration.

The second layer 16 consists of an elastomer layer arranged on the first layer 12, which can optionally also be provided with an insert of fibers or fabric material. The subsequent to the second layer 16 cover layer or outer layer 18 consists of a gelcoat or synthetic resin lacquer layer with the color properties adapted for the particular application. For example, silicic acid to increase the abrasion resistance of the outer layer 18 is preferably admixed with the gelcoat consisting of, for example, unsaturated polyester (UP).

The second layer 16 formed as an elastomer layer preferably consists of one of the following materials: ethylene-propylene rubber (EPM), ethylene-propylene-diene rubber (EPDM), ethylene-acrylate rubber (EAM), fluorocarbon rubber (FKM ), Acrylate rubber (ACM), acrylonitrile-butadiene rubber (NBR), optionally blended with polyvinyl chloride (PVC), hydrogenated nitrile rubber (HNBR), carboxylate-nithl rubber (XNBR), hydrogenated carboxylate-nitrile rubber (XHNBR), Natural Rubber (NR), Ethyl Vinyl Acetate (EVA), Chlorosulfonyl Polyethylene Rubber (CSM), Chlorinated Polyethylene (CM), Butyl or Halobutyl Rubber, Silicone Rubber (VMQ, MVQ), Fluorine - Silicone rubber (FVMQ, MFQ), chlorohydrin rubber (CO), epichlorohydrin rubber (ECO), polychloroprene rubber (CR), one-component polyurethane (PU) or a combination or a blend of the aforementioned substances. Alternatively, the at least one elastomer layer may also consist of a thermoplastic elastomer (TPE). For this purpose, in particular TPE-S (also "TPS" = styrene block copolymers, such as SBS, SEBS, SEPS, SEEPS or MBS, for example, the product Thermolast® the KRAIBURG TPE GmbH & Co. KG), TPE-V (also "TPV" = dynamically vulcanized thermoplastics), TPE-A (also "TPA" = thermoplastic copolyamides) or TPE-E (also "TPC" = thermoplastic copolyesters) into consideration ,

The elastomer layer contains - if it does not consist of TPE - a crosslinking system which, depending on the elastomer used at least one crosslinker from the group of peroxides, amines and / or bisphenols and allows a reaction with the resin of the carrier layer. As an alternative to a heat treatment for a crosslinking of the elastomer layer 16 with the synthetic resin of the carrier layer 12 and the gelcoat or synthetic resin coating layer 18, another crosslinking treatment, for example with ultraviolet irradiation (UV light), may also be carried out. On top of a first elastomeric layer, further elastomeric layers, if necessary of different strength and hardness, may be applied, which are assembled to bond to the respective underlying elastomeric layer. The at least one elastomer layer particularly preferably consists of rubber-based materials. Alternatively or in addition to reinforcement with fibers 14, it is also possible to use a metal powder as an insert in at least one of the layers 12, 16 or 18. As a result, specific physical properties of the composite component 10 can be selectively generated, such as its strength, flexibility and elasticity, its spring and damping behavior, its electrical conductivity or its flammability.

In the embodiment according to FIG. 2, the layers of a composite component 20 corresponding to FIG. 1 are provided with a higher reference number. In contrast to FIG. 1, between the second layer 26 (elastomer layer) and the third layer 28 (outer layer of gelcoat or synthetic resin lacquer) there is a further layer 27 of a thermosetting synthetic resin provided with a fabric or fiber insert 271. This layer 27 is preferably formed as prepreg impregnated with synthetic resin, but can also be applied as a dry tissue and then infiltrated with synthetic resin. The fabric 271 is for example particularly preferably formed from carbon fibers. In this case, it may be desirable to make the outer layer 18 of gel coat or synthetic resin paint transparent or at least translucent, so that the carbon fibers are visible on the visible side and give the composite component 20 a high-tech character with a high-quality appearance

The production of the component according to the invention preferably takes place in a mold with the following method steps:

If necessary, the mold is provided with an anti-sticking agent, but may also be self-adhesive (for example by Teflon® surfaces).

Next, the gelcoat or synthetic resin paint layer as outer layer 18 or 28 is preferably produced by spraying in the mold.

In the second exemplary embodiment according to FIG. 2, a carbon fiber mat 271 is preferably applied to the outer layer 28 as prepreg pre-impregnated with synthetic resin or alternatively applied as a dry carbon fiber mat 271 and passed through in an intermediate step

Resin infusion impregnated with synthetic resin; in the first embodiment shown in Figure 1 eliminates this additional

Resin layer 27.

In the next step, the elastomer layer 16 or 26 is applied to the outer layer 18 (in the first exemplary embodiment according to FIG. 1) or to the additional synthetic resin layer 27 (in the second exemplary embodiment according to FIG. 2). This is preferably applied as a raw, uncrosslinked elastomer or TPE film.

In the next step, the first layer 12 or 22, which acts as a reinforcement, is applied with the fiber reinforcement 14 or 24 to the elastomer layer 16 or 26. In the last step, all layers 12, 16 and 18 or 22, 26, 27 and 28 are cured or cured together by a common heat treatment or another energy input. The curing temperature is preferably between 80 and 200 ° C.

A preferred use of a composite component 10 or 20 according to the invention is, for example, a planar vehicle component in the outer region of the body or else an interior trim part of a vehicle. However, it is also a variety of other uses, such as consumer goods, sports equipment or high-quality consumer goods possible.

LIST OF REFERENCE NUMBERS

composite component

Plastic carrier layer (first layer)

fiber material

Elastomer layer (second layer)

Outer layer (third layer)

composite component

Plastic carrier layer (first layer)

fiber material

Elastomer layer (second layer)

(further) plastic layer

tissue

Outer layer (third layer)

Claims

claims

A composite component (10; 20) comprising at least two layers (12, 14, 16, 18;

22, 24, 26, 27, 271, 28), wherein a first layer (12, 22) consists at least partially of a plastic (FRP, CRP, GRP) reinforced by fibers (14, 24) and wherein a second layer (16 26) consists at least partially of an elastomer,

characterized in that the first layer (12; 22), the second layer (16; 26) and a third one of a gelcoat or a

Synthetic resin paint existing layer (18, 28) are joined together by a common cross-linking or curing as a composite component (10). 2. Composite component according to claim 1, characterized in that between the second layer (16; 26) and the third layer (18; 28) a further, in particular by means of a fabric (271) reinforced plastic layer (27) is arranged. 3. Composite component according to one of the preceding claims, characterized in that the first layer (12; 22) is formed from a synthetic resin, such as polyester resin, phenol-formaldehyde resin, cyanate ester resin, epoxy resin or acrylate resin of the preceding claims, characterized in that the fibers (14; 24) of carbon fibers, glass fibers, nylon, polyester, viscose, aramid fibers, metal fibers or fibers of natural, renewable raw materials in loose form, in the form of a fabric, a Geleges or a Pulp are formed.

5. Composite component according to one of the preceding claims, characterized in that the second layer (16; 26) of ethylene-propylene rubber (EPM), ethylene-propylene-diene rubber (EPDM), ethylene Acrylic rubber (EAM), fluorocarbon rubber (FKM), acrylate rubber (ACM), acrylonitrile butadiene rubber (NBR), optionally blended with polyvinyl chloride (PVC), hydrogenated nitrile rubber (HNBR), carboxylate nitrile Rubber (XNBR), Hydrogenated Carboxylate Nitrile Rubber (XHNBR), Natural Rubber (NR), Ethyl Vinyl Acetate (EVA),

Chlorosulfonyl Polyethylene Rubber (CSM), Chlorinated Polyethylene (CM), Butyl or Halobutyl Rubber, Silicone Rubber (VMQ, MVQ), Fluorosilicone Rubber (FVMQ, MFQ), Chlorohydrin Rubber (CO), Epichlorohydrin Rubber (ECO), polychloroprene rubber (CR), one-component polyurethane (PU) or a combination or a

Mixture of the aforementioned substances.

6. Composite component according to one of claims 1 to 4, characterized in that the second layer (16) consists of a thermoplastic elastomer (TPE).

7. Composite component according to one of claims 2 to 6, characterized in that the further plastic layer (27) is formed by a resin-impregnated fabric (271).

8. Composite component according to claim 7, characterized in that the fabric (271) is formed by carbon fibers.

9. A method for producing a composite component (10, 20) from at least three layers (12, 14, 16, 18, 22, 24, 26, 27, 271, 28), wherein a first

Layer (12; 22) consists at least in part of a plastic reinforced with fibers (14; 24), wherein a second layer (16; 26) consists at least partly of an elastomer, and wherein a third layer (18; 28) of a gelcoat or a synthetic resin varnish, characterized by the following process steps:

a) feeding the third layer (18; 28) into a mold which is preferably provided with a release agent, b) feeding the second layer (16; 26) into the mold subsequent to the third layer (18; 28);

c) feeding the first layer of plastic reinforced with fibers (14) into the mold subsequent to the second layer (16; 26);

d) joining the first layer (12; 22), the second layer (16; 26) and the third layer (18; 28) by co-curing with energization.

10. The method according to claim 9, characterized in that

e) between the method step a) and b) on the third layer (18; 28) first a further layer (27) with a reinforcing fabric (271) is applied.