WO2015096831A1 - Procédé de production in situ d'éléments à structure sandwich renforcés par des fibres de renforcement - Google Patents

Procédé de production in situ d'éléments à structure sandwich renforcés par des fibres de renforcement Download PDF

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Publication number
WO2015096831A1
WO2015096831A1 PCT/DE2014/100458 DE2014100458W WO2015096831A1 WO 2015096831 A1 WO2015096831 A1 WO 2015096831A1 DE 2014100458 W DE2014100458 W DE 2014100458W WO 2015096831 A1 WO2015096831 A1 WO 2015096831A1
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WIPO (PCT)
Prior art keywords
systems
sandwich
reinforcing fibers
core
forming tool
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PCT/DE2014/100458
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German (de)
English (en)
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Rühl Puromer GmbH
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Publication of WO2015096831A1 publication Critical patent/WO2015096831A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
    • B29C70/026—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers and with one or more layers of pure plastics material, e.g. foam layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1228—Joining preformed parts by the expanding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter

Definitions

  • the material polyurethane (PUR) has been used for many years for the production of lightweight construction solutions in the form of fa ⁇ serverver prisonen components with sandwich structure.
  • the simplest form is to use the plant material PUR ⁇ in the form of rigid foams as core material of sand ⁇ more services network.
  • foam cores are provided in the form of semifinished products or molded foam cores that are prepared separately in a suitable foaming mold with fiber-reinforced top layers ⁇ . This can happen in the Kunststofflichsten under ⁇ ways, eg nier- in Handlami-, in Vakuuminfusions- in RTM (Resin Transfer Molding), in Fasersprüh- or pressing. Glass fiber, carbon fibers, natural fibers or other fiber types are used as fiber reinforcements.
  • As a matrix for the reinforced top layers turaver ⁇ also come very different resins such as epoxy (EP), unsaturated polyester (UP) and polyurethane resins are used.
  • SRIM Structuretural Reaction Injec- tion Molding
  • the Verstär ⁇ kung fibers mostly Wirr- or continuous fiber mats made of glass fiber reinforced ⁇ fibers, placed advertising tool for the upper and lower outer layer in a Formge-.
  • a Sp Drosse is placed, which alone ensures only that, the United ⁇ strengthening semifinished products before and positioned during the foaming process to the tool walls remain.
  • the reactive polyurethane foam mixture is added and pre-distributed as needed and then the tool is closed (open process) or closed to ⁇ next the mold and then injected via a Angusssystem the reaction mixture (closed process). Following the foaming and subsequent hardening of the PUR reaction mixture takes place in a closed molding tool ⁇ .
  • the layer construction described above may also take place directly in the tool, it being possible to dispense with the Transportme ⁇ medium. Subsequently, the tool is closed and the composite is pressed, whereby supernatants on fibers and core material can be separated directly in the tool. During the subsequent mold life, the PUR matrix hardens in the cover layers and forms an adequate bonding of the cover layers to the honeycomb webs of the core material by the usually slightly foaming adjustment of the reaction mixture.
  • the manufacturing process of the sandwich composite of this semi-finished fiber and the honeycomb core is characterized charak ⁇ terized in that the semi-finished fiber and the core material are brought together to ⁇ next to a semi-finished composite.
  • the reinforcing layers, this semi-finished composite are then sprayed evenly or demand-specific in ei ⁇ nem spray from both sides with a polyurethane system.
  • the sprayed semifinished packet is placed into a molding tool ⁇ .
  • the pressing, binding of the honeycomb material and curing of the fiber reinforced cover ⁇ then carried out in a pressing process similar to the above process variant layers to the finished sandwich component.
  • combinations of the above two variants of the method are also used in order, for example, to specifically reinforce certain regions , such as force introduction regions, with additional cut reinforcing fibers.
  • Even in the wetting of the reinforcing fibers in the spray process come in ⁇ between a variety of different variants are used.
  • This relates on the one hand the spraying process itself, coming from the pressure or air atomization over flat or round ⁇ jet nozzles to the use of the LFI technique used.
  • the spray application is carried out either via stationary spray mixing and robot gripper system and guided semi-finished packets or by robot-guided spray ⁇ mixing heads and separate handling devices for the half ⁇ generating packets. Also combinations of both variants are practiced.
  • Honeycomb cores are mainly used as core material and, due to their low cost, are usually made of paper.
  • foam cores in the form of cut semi-finished products or molded foam cores. Even such core solutions have already been tested.
  • the foam cores having to have a sufficiently high Druckfestig ⁇ ness to bar may occur in the pressing process in which pressures of from 10 to 20, not to collapse and to thereby depict an adequate surface quality.
  • the method used here ver ⁇ are primarily suitable for the production of smaller series. If such methods as, for example, the RTM method are trimmed to larger numbers or shorter Taktzei ⁇ th, so rise due to the necessary process for short and thus the injection times, the inner ⁇ molding pressures. As a result, the foam cores used for this purpose must have higher compressive strengths, which either requires the use of higher density foams and thus at the expense of component weight or requires the use mecanicwerti ⁇ ger and thus more expensive foam types.
  • Sandwichher ⁇ position always the separate manufacture and handling of the foam core either (in the form of semi-finished products Her ⁇ position of foam blocks, trimming, transport and logistics tik) or in the form of a separate foam molding process with tool, machine, etc. This has a negative effect on the construction ⁇ part costs.
  • hard PU foam types are always necessary to achieve the required mechanical property level in order to achieve the full performance potential of the composite in the fiber-reinforced cover layers.
  • special additional properties such as a good thermal or acoustic insulation effect are required, which are significantly influenced by the component core , s can be in this process not or only inadequate pose, since only a foam system is used This limits the scope of this method.
  • the polyurethane honeycomb sandwich technology (c)) is driving ⁇ a Ver, which is ⁇ is already in mass production for many years. Cycle times of 2 minutes with cure times of 45 up to 90 seconds are state of the art today. With tools with double cavities, cycle times of 1 minute can be achieved.
  • Kernmate ⁇ rial is limited from a commercial point of view essentially on honeycombs made of paper.
  • Wa ⁇ benmaterialien can be used.
  • this is usually at the expense of component costs, since alternative honeycombs are sometimes significantly more expensive.
  • properties that can be realized by the honeycomb generally poor.
  • the thermal and acoustic isolation possibility is very limited by the comparatively large honeycomb cavities, which also extend from cover layer to cover layer.
  • the paper honeycomb also has the disadvantage that it absorbs moisture and can therefore fail as a core material in the component. This allows the use of this honeycomb ⁇ type in applications involving exposure to moisture, such as in the car is only possible ⁇ mobile outdoor use. While there is (paten ⁇ oriented) solutions to impregnate the paper honeycomb and moist resistant equip. However, this is at the expense of the nuclear material costs. The use of polymer foams and thus also PUR foams can indeed solve these problems. Process Due to the comparatively high Forminnendrü ⁇ bridge, however, this approach is limited, as are necessary to accommodate the high pressing forces either foams higher you ⁇ te or higher quality more expensive foam cores.
  • the polymer backbone for such structural ⁇ turCume limited to hard materials is to accommodate the compressive forces.
  • this form of sandwich production as above requires the separate production of the foam cores and the final sandwich ⁇ component.
  • the object of the vorlie ⁇ constricting invention to provide a novel process for the Preparation of Reinforcing fibers reinforced sandwich components to create, which allows a high degree of flexibility in relation to the ver ⁇ used polyurethane systems with faster component ⁇ manufacturing.
  • the process should take place in a shaping tool ⁇ imaging simultaneously and in situ.
  • the method of the invention solves the above-be ⁇ signed disadvantages of the prior art in the way that come for the production of the fiber reinforced sandwich construction ⁇ share at least two different polyurethane systems for a ⁇ rate and shaping the final sandwich component in situ, that is wet done in wet in a manufacturing process.
  • PUR systems or related material systems such as polyurea systems or polyisocyanurate systems (PIR) - hereinafter referred to as PUR systems - ensures that the material used for forming the core layer PUR foam system - hereinafter referred to as Kern harshSystem - so elected ⁇ the can as required by the component specifications.
  • the core layer system can for example be chosen as a foam of very low density, so that a sandwich component with as ge ⁇ low weight is created.
  • the core layer system can be selected such that special component properties are generated , such as eg a good thermal insulation effect and / or good acoustic component properties.
  • Minim ⁇ least two polyurethane systems has the advantage that the required to form the component contour tool internal pressure is not produced by a pressing process, which requires a sufficient pressure stability of the core material, but by the in-situ process from the inside out through the AufMumpro - Zess is generated during the molding.
  • This has on the one hand the advantage that depending on the component lower closing forces for the tumbler of the tool are required which reduces the investment costs in ⁇ .
  • this has the advantage that the Kernma ⁇ TERIAL terms of pressure stability and other core Mate ⁇ rialeigenschaften need not be designed to the pressing process, since the core material is ent ⁇ only during molding and can be so far designed exactly as it component specifications, require.
  • the in-situ production of the foam core also has the advantage that the foaming process in the core region ensures good bonding of the fiber-reinforced cover layers to the core. Special measures such as punching a foam core or the production of grooves in the foam core omitted here.
  • the good connection due to a fact that the foam system of the core material, at least partially penetrate into the reinforcing layers Ver ⁇ with and there may anchoring.
  • a chemical bond between the core material and the PUR matrix in the cover layers occurs in parallel, since the two chemical polymer formation reactions in the insitu process occur at least in phases at the same time.
  • At least one further PUR system for producing the fiber composite matrix in the schwver ⁇ reinforced cover layers - hereinafter be ⁇ is characterized as a matrix system - this can be chosen so that optimum Mat ⁇ rixeigenschaften arise.
  • This can be eg Community level hard compact or microcellular polyurethane systems with high mechanical self ⁇ which give the final sandwich component high stiffness and strength combined with low weight.
  • the matrix can also consist of tough-elastic PUR systems in order to give the component a high impact strength and a good impact behavior. This may include the selection of certain foam systems for the core area to support po ⁇ sitive.
  • polyurethane foam systems as matrix systems for fiber-reinforced cover layers ⁇ ⁇ used to to produce certain properties such as better Faser easilytränkung at comparatively thick encryption Strengthening layers, the generation of special shenei ⁇ properties or further weight reduction of the final component.
  • the invention has the advantage that on the one hand as described above, a good connection of core and fiber-reinforced cover ⁇ layers can be generated by the in-situ process.
  • the in-situ process has the advantage that the separate production of a core material and, if appropriate, the pretreatment prior to the production of the sandwich component and the corresponding handling, cutting and logistics are eliminated. This has a positive effect on the production costs.
  • the in-situ process also has the advantage that the necessary for shaping cavity pressure from the inside out and thus the core material and the outer layer ⁇ matrix need not be matched to a pressing process. This gives more freedom in the selection of PUR systems.
  • Step Example ⁇ len The invention will be further illustrated by Step Example ⁇ len.
  • the inventive method is characterized in its main ⁇ coatings essentially characterized in that this molding process for the production of turaverstärk ⁇ th sandwich components made of polyurethane (PUR) on the one hand for the core area and the fiber-reinforced cover layers provides at least two different polyurethane systems.
  • the method is characterized in that the production of the foam core and the impregnation, impregnation and Aushär ⁇ tion of the fiber-reinforced cover layers in-situ takes place in a production process. This also exploits that the formation and curing of the matrix in the surface layers and the Bil ⁇ extension of the foam core of the component is effected at least in phases simultaneously in the closed molding tool.
  • the process steps of the invention are the following.
  • the reinforcing fibers which may consist of glass fibers, carbon fibers, natural fibers, other types of fibers such as aramid fibers or combinations of different types of fibers, with one or more PUR systems for generating the matrix of the outer layers - in Wei ⁇ nic called PUR matrix system - the final sandwich ⁇ component in a first process step wetted, wherein a spray, squeegee or cutting fiber method is used.
  • the one or PUR-matrix system (s) will be discharged by means of ei ⁇ ⁇ nes spraying or knife coating process directly onto the at ⁇ the tool halves of the forming tool. Subsequently, the reinforcing fibers are placed in the form of semi-finished products directly on the surfaces of the forming tool, wherein the upper reinforcing layer can be placed on the lower tool ⁇ half after the entry of PUR core layer system. b) First, the reinforcing fibers in the form of semi-finished products are placed directly in the forming tool . Subsequently, the PUR matrix system (s) are applied to the reinforcing fibers by means of a spray or doctor blade method. The upper
  • Reinforcement layer can be placed directly on the Oberflä ⁇ surface of the upper forming tool who ⁇ or after the entry of PUR Kern MrsSystems placed on the lower mold half and wetted afterwards.
  • the or the PUR matrix system (s) are applied by means of ei ⁇ nes spraying or doctor blade method outside the mold ⁇ tion tool on the on the reinforcing fiber semi-finished and / or both sides.
  • the upper wetted reinforcement layer can be placed directly on the surface of the upper forming tool or after the entry of the PUR-
  • KernstoffSystems be placed on the lower mold half. d) There are combinations of the described under a) to c) process variants for wetting the
  • the reinforcing fiber half each one or both sides with the or the PUR matrix system (s) can be wetted.
  • the PUR-matrix system (s) will be ⁇ discharged together with the mixing and spray member cut Verstärkungsfa ⁇ fibers (for example, LFI, Interwet- or CSM process) di rectly ⁇ on the mold surfaces of the tool and distributed.
  • f) There is a combination of the process variants described under a) to d) with the process variants described under e), in order to realize, for example, local additional reinforcements.
  • the entry of the PUR foam system for forming the core layer will - in the long ⁇ ren called PUR core layer system - the sandwich construction ⁇ partly and connection of the core layer to the outer layers instead.
  • the entry can be carried out in the open form (open procedure) and either selectively added, coarse pre-distributed over a handling system or by means of a spraying or doctor blade method distributed over a large area ⁇ the.
  • process step 1 which are the use of reinforcing fiber semifinished be ⁇ serve (a) to d)) is carried out first inserting the unwetted (a), directly wetted in the tool (b)), wetted out ⁇ half of the tool (c)) or by a combination of these process variants wetted lower reinforcing layer in the lower half of the forming tool.
  • the PUR core layer system will be above ⁇ enrolled applied.
  • the wetted reinforcing fibers are applied directly to the Formoberflä ⁇ chen and the entry of PUR KernhusSystems was either after entry of the lower reinforcing layer and before order the upper reinforcing layer or entry of the upper and lower reinforcing layer.
  • the tool is closed and the formation of the sandwich component can take place.
  • the open process of the entry of the PU core layer system can follow it ⁇ also via one or more fonts to ⁇ into the closed mold (closed process).
  • the wetted reinforcing layers are already in the forming tool, the tool is closed and only after the PUR core layer system is ⁇ carried.
  • the foaming of the polyurethane core layer system then takes place in the ge ⁇ closed forming tool.
  • the foamed core ⁇ layer forms and the reinforcing layers are pressed in the Randbe ⁇ rich of the component.
  • THE PUR core layer system can penetrate with the reinforcing layers in order to realize a besse ⁇ re connection of the outer layers to the core.
  • the height of the internal mold pressure, the sufficiently good shape of the Sandwich component is required, can be influenced by the composition ⁇ tion of the PUR Kern AnlagenSystem.
  • the impregnation of the reinforcement layers in the cover layer regions also takes place.
  • the foaming process in Kernbe ⁇ rich in the impregnation in the cover layers and the polymer forming reaction of the various polyurethane systems takes place, that is the PU systems cure into a polymer. Since ⁇ at it can also lead to chemical reactions between the core layer and cover layer ⁇ matrix, the connection of the core to the surface layers by chemical bonds verbes ⁇ sert.
  • the construction can be laminated for example ⁇ parts directly in the mold to achieve specific surface properties. This can be done for example by inserting films, decors, fleeces or carpets before entry of the fibers and foam systems.
  • special surface properties such as a simpler paintability can be additional polyurethane layers or applied in-mold Coeting layers prior to entry of the fibers and Fa ⁇ foam systems on one or both horroberflä ⁇ chen.
  • PU systems with the lowest possible reaction exothermicity. This is particularly relevant when using foli ⁇ en, decors or carpet laminates, the are temperature sensitive and, for example, only withstand temperatures below 100 ° C during molding.
  • FIG. 1 shows a possible process structure of he ⁇ inventive method with sandwich component and Fig. 2, the set ⁇ divided into a plurality of process steps in the method of forming tool ⁇ convincing.
  • FIG. 1 shows, on the one hand, the daily containers 1 and 2 for receiving the basic chemical substances, which are fed to a mixer 3, which prepares the chemical reaction by the mixing process.
  • the reactive Mi ⁇ research is applied by means of a spray head on the shaping tool or directly to the semifinished fiber product from the mixing container.
  • the forming tool 5 in this case includes the sandwich component on top and bottom.
  • the core foam 6 is shown as the thickest layer.
  • the fiber-reinforced cover layers which result from the depending ⁇ ips fiber reinforcements 8 and the matrix systems 7 are found together ⁇ menage.
  • the process flow shown schematically in FIG. 2 comprises the following steps.
  • the matrix system 7 is sprayed onto the tool 5 as the first method step a). In the present case, only the underside of the tool 5 is sprayed with a matrix system 7.
  • a fiber mat 8 is now placed on the tool underside 5 sprayed with the matrix system 7.
  • the core layer system is metered onto the previously introduced 2 layers.
  • a new fiber mat 8 is applied to this core layer system to produce a top-side fiber-reinforced cover layer.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

L'invention concerne un procédé de production in situ d'éléments à structure sandwich renforcés par des fibres de renforcement (8) selon un procédé de moulage reposant sur l'utilisation de différents systèmes de polyuréthane modifiés par des charges ou non et constitués d'au moins un réactif, ou de systèmes de matières synthétiques réactifs analogues tels que des systèmes à base de polyurée ou de polyisocyanurate. Pour former une couche supérieure renforcée par des fibres, les fibres de renforcement (8) sont mouillées avec un système de matrice (7) compact ou apte au moussage ou sont déjà incluses dans ce système de matrice (7) sous la forme de fibres courtes, et un noyau de mousse est produit à partir d'au moins un autre système de matières synthétiques réactif (6) apte au moussage. Pour obtenir un composant à structure sandwich renforcé par des fibres, le moulage et le durcissement des systèmes (6, 7) s'effectuent simultanément in situ dans un moule (5) et en un seul processus de fabrication.
PCT/DE2014/100458 2013-12-23 2014-12-18 Procédé de production in situ d'éléments à structure sandwich renforcés par des fibres de renforcement WO2015096831A1 (fr)

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DE102013114770.4A DE102013114770A1 (de) 2013-12-23 2013-12-23 Verfahren zur in situ Herstellung von mit Verstärkungsfasern verstärkten Sandwichbauteilen
DE102013114770.4 2013-12-23

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WO2015096831A1 true WO2015096831A1 (fr) 2015-07-02

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DE102015120270A1 (de) * 2015-11-23 2017-05-24 Airbus Operations Gmbh Herstellungsverfahren für ein Bauteil mit einer porösen Faser-Matrixstruktur
DE202017007619U1 (de) 2016-01-25 2023-09-01 Erwin Härtwich Fahrzeug in Form eines Wohnmobils oder Wohnwagens
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DE102018130816A1 (de) * 2018-12-04 2020-06-04 Kögel Trailer GmbH Isolierpaneel, Komponente eines Fahrzeugaufbaus, Fahrzeugaufbau, Fahrzeug und Herstellungsverfahren
DE102019128881A1 (de) * 2019-10-25 2021-04-29 Windmöller Gmbh Dimensionsstabiler Bodenbelag und Verfahren zu seiner Herstellung
DE102020111058A1 (de) 2020-04-23 2021-10-28 Bayerische Motoren Werke Aktiengesellschaft Faserverbund-Sandwich mit expandierendem Strukturschaum
DE102020113378A1 (de) 2020-05-18 2021-11-18 Audi Aktiengesellschaft Verfahren zur Herstellung eines Sandwichbauteils, insbesondere eines Unterbodenbauteils eines Kraftfahrzeugs

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