WO2016020430A1 - Dispositif et procédé servant à fabriquer un composant composite à base de fibres - Google Patents

Dispositif et procédé servant à fabriquer un composant composite à base de fibres Download PDF

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Publication number
WO2016020430A1
WO2016020430A1 PCT/EP2015/068042 EP2015068042W WO2016020430A1 WO 2016020430 A1 WO2016020430 A1 WO 2016020430A1 EP 2015068042 W EP2015068042 W EP 2015068042W WO 2016020430 A1 WO2016020430 A1 WO 2016020430A1
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WO
WIPO (PCT)
Prior art keywords
resin
mold
partial
forms
shapes
Prior art date
Application number
PCT/EP2015/068042
Other languages
German (de)
English (en)
Inventor
Gerd Falk
Harald Müller
Markus Blandl
Original Assignee
Ako Kunststoffe Alfred Kolb Gmbh
Innfa Gmbh
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ako Kunststoffe Alfred Kolb Gmbh, Innfa Gmbh filed Critical Ako Kunststoffe Alfred Kolb Gmbh
Publication of WO2016020430A1 publication Critical patent/WO2016020430A1/fr

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00Moulds or cores; Details thereof or accessories therefor
    • B29C33/38Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B29C33/40Plastics, e.g. foam or rubber
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/40Shaping or impregnating by compression not applied
    • B29C70/42Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46Shaping 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
    • B29C70/48Shaping 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 and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum

Definitions

  • the invention relates to a device for producing a fiber composite component and to a method for producing a fiber composite component with such a device.
  • the invention has for its object to provide an aforementioned device and an aforementioned method with which problems of the prior art can be achieved and in particular it is possible to produce fiber composite components very quickly in consistently high and accurate quality with the lowest possible machinery.
  • the device has at least a first part form and a second part form, which together form the shape for the fiber composite component. There may also be provided more sub-forms than only these two, but it is advantageous two.
  • the two partial shapes have inner sides, each with an inner contour, facing each other during production of the fiber composite component.
  • the inner contours form an interior of the mold consisting of the two partial shapes, wherein this interior is advantageously relatively flat or particularly advantageously has a relatively small thickness, which should not exceed 10 mm or more than 20 mm. This means that the fiber-composite component to be produced can be curved or can have another form deviating from the planar shape, but not too large Thickness, even if this should be given only in certain areas. For one thing, a lot of material is needed for that.
  • the inner sides of the part shapes are just facing each other.
  • the partial shapes are circumferentially around and largely closing or closed to each other. They are connected by means of connection, which will be discussed in more detail later.
  • a resin supply is provided which leads from the outside into the interior.
  • resin removal from the interior is also provided, which, on the one hand, naturally allows air and, on the other hand, excess resin to escape from the interior.
  • resin supply and resin removal are the only portions or parts that interrupt the otherwise closed state of the mold or of the two partial molds.
  • the partial shapes are made of plastic or are plastic components. It may be advantageous injection molded parts that can be made of thermoplastic material. It is particularly preferred disposable parts, which are intended only for single use and are then disposed of. If necessary, the plastic material can be recycled.
  • molds made of plastic for the production of fiber composite components has the advantage that these molds can be produced relatively inexpensively, in particular with an aforementioned injection molding process. This is procedurally well controlled and allows a cost-effective and rapid production of such forms or the corresponding part shapes.
  • An embodiment of the part shapes as disposable parts has the great advantage that the molds or part shapes then no longer need to be cleaned consuming after removing the finished fiber composite components.
  • the provision of bonding means on the part molds enables the dies no longer to remain in the press apparatus after curing of the part molds together to form the fiber composite member and curing to cure the resin for the fiber material until the resin is cured which takes a few minutes, typically 5min to 20min.
  • the mold with the fiber material and resin can be removed from it much earlier in the press, for example, even if the resin just begins to gel. After pressing in the resin-introduced press, all air should be removed from the fiber material and from the entire mold. Because the fiber material itself is usually quite soft or flexible, there are no major forces in not yet cured resin, which act on the mold or the part shapes and could cause deformation again.
  • the two partial shapes are formed substantially square in plan view of their essential surface.
  • they are approximately or completely rectangular, at least in this plan view. But they can also be round or oval or have a freeform.
  • a connecting line between the two partial shapes can lie substantially in one plane, under certain circumstances also lie completely in one plane.
  • the part shapes may have a circumferential wide edge, advantageously with a width of 1 cm to at least 2cm.
  • sealing means made of elastic material may also be provided here.
  • the inner contours for forming the outer contour of the fiber composite component are advantageously located a distance from the edges or edge regions of the partial shapes or extend at a distance therefrom. This makes it possible, for example, for these edge regions to lie in the same plane as the aforementioned connecting line between the partial shapes.
  • a distance of the inner contour to the edge regions may be a few centimeters, for example 1 cm to 5 cm.
  • the tool or the mold is tight or even vacuum-tight. This allows air pockets to be minimized when introducing resin.
  • this can also be done by pressing or pressing in an autoclave.
  • Sealant or a seal may be formed circumferentially. It can generally be inserted as a separate part in the part shapes, alternatively it can be molded on.
  • a circumferential seal need not be a seal in the classical sense, so with additional elastic or elastic material, but can alternatively be created by welding the two part shapes, which of course also seals obviously. Then there is a disposable concept, since the part forms must be destroyed to remove the finished component.
  • the inner sides of the part shapes are formed corresponding to each other.
  • a distance between these inner sides can be between 1 mm and 10 mm in the assembled state of the two partial shapes.
  • the distance is in At least 50% of the inner sides between 1 mm and 3mm, which then gives the thickness of the finished fiber composite component.
  • the ribs, reinforcements or the like. may extend from an outer edge to the opposite outer edge of the partial shape. Particularly advantageous they run only in one direction, but can also extend in both directions, for example at right angles to each other, over the outside of the part form.
  • both partial shapes can be provided with such ribs or reinforcements. It can also be provided that they extend on each part form only in one direction, but in the two partial shapes in total at right angles to each other.
  • reinforcements are provided only on the part form which has the predominant portion of outward bulges in the direction away from the other part form.
  • the strength of a part form can be sufficient for the other part form.
  • the partial shapes can for example consist of polyamide or POM as plastic, in particular PA6 or POM-C.
  • a good separation of the cured fiber composite component is given. It may also be provided a separating assisting release coating.
  • the partial molds may consist of PMMA, ie polymethyl methacrylate, for example PLEXIGLAS® GS from Evonik, or alternatively polycarbonate.
  • PMMA ie polymethyl methacrylate
  • PLEXIGLAS® GS from Evonik
  • polycarbonate ie polycarbonate
  • the material should be as good as possible UV-permeable, under certain circumstances also be clear.
  • it is possible to use a UV curing resin system because UV light can penetrate through the part molds to harden the resin. So can be dispensed with a costly heating.
  • the partial molds are made of microwave-active material for heating by irradiation with microwaves from the outside.
  • electrically conductive additives can be added to the material or the plastic of the partial forms, in particular carbon black or carbon-based additives.
  • heat distribution inserts are better thermally conductive than the other base material of the part shapes.
  • the finished closed mold with the impregnated fiber material can then be driven through a treatment section with microwave irradiation, for example as a kind of hardening tunnel with a plurality of microwave generators.
  • a treatment section with microwave irradiation for example as a kind of hardening tunnel with a plurality of microwave generators.
  • At least one channel can be provided for a resin feed into the assembled partial forms, whereby a partial channel can be formed for the channel in both partial forms.
  • the direction of the channel is approximately in the area of the interior, so that resin to be introduced is introduced with a direction corresponding to a substantial extent or the essential dimensions of the fiber composite component.
  • an aforementioned sub-channel in both sub-shape s the same size or the same design.
  • a partial channel in each partial shape is semicircular, so that the overall result is a round channel for the resin supply.
  • Another channel may be provided for resin removal from the mold. It can basically be designed similar to the channel for the resin supply, under certain circumstances it can be shorter.
  • the channel for the resin supply may be provided to go in at least 50% of a lengthwise extent of the partial molds in one direction.
  • the channel for the resin supply opens into an area adjacent to the actual interior to form the fiber composite component from the outside and extends over the substantial length of the mold and then leads in an arc to an end portion of the interior. At the other or opposite end region of the interior then leads out the channel for the resin removal.
  • an external mixer cartridge can advantageously be used because of the small dimensions, which is then docked to the tool via a connecting piece.
  • helical mixer contours can be incorporated, attached or molded into open sub-channels on the sub-shapes, which then together in the assembled state together form the closed channel for the resin feed.
  • These helical mixer contours each act together on the two part molds to form a helically twisted channel for the resin function.
  • This helically twisted channel causes a mixing function for mixing a Center Seari- gen resin when separately introducing the individual components in the mold.
  • the injection molding of such mixer contours saves the step of retrofitting a mixer contour.
  • the further advantage is that multicomponent or two-component resins do not have to be mixed before injection, but this happens automatically during injection. By moving the mixing function into the mold, which is then removed with the fiber composite component to be produced, the step of cleaning the external mixer contours or on the device for introducing the components, for example an RTM machine, is eliminated.
  • a mixer contour can be removed from a partial mold after use of the partial mold, if the partial mold or the entire mold is to be reused.
  • the mixer contour can then be disposed of, because it is difficult to clean, while the part shapes including channels are easy to clean.
  • mixer contours may be disposed in channel inserts which are inserted into the channels of the molds and which may extend to the interior or contours of the resin so that only they actually come into contact with the resin.
  • a partial mold may have at least one reservoir to house resin and / or hardener or an additive for the resin to infiltrate the fiber material.
  • this infiltration material together with the fiber material can be accommodated quasi finished in the form, for example, still enclosed in a dense plastic bag or the like, which can be inserted into the pantry.
  • a storage space advantageously has a supply channel closed to the interior by a detachable or removable closure. Then this so to speak finished stocked and at least partially closed form can be stored or delivered and only at a later date, for example, hours, days or weeks later, by introducing the resin together with additive or hardener in the fiber material continue to be used to produce the finished fiber composite -Bauteils.
  • a part of the form of at least one receiving space for receiving excess resin after infiltration of the fiber material with resin wherein the receiving space is separate from the interior.
  • the receiving space is connected to a receiving channel with the interior and collects excess resin after infiltration. So there is no need to provide external collection, which makes infiltration much easier and cleaner.
  • the collected resin remains in the molds and is easily disposed of with them.
  • the two sub-forms can be made in one piece contiguous and be collapsible for assembly after insertion of the fiber material.
  • the two partial shapes are preferably connected to at least one connecting region or connecting web, which remain connected during folding or assembly and can thus effect at least one type of prefixing on one side. This also facilitates the attachment or connection of the connecting means, which hold the part molds finally in the intended closed end position for curing the resin.
  • the aforementioned connectable or closable connection means for connecting the part shapes to one another are preferably provided at least in corner regions and / or in edge regions of the part shapes. Depending on the size and necessary holding force, they can also be provided along the sides.
  • the connecting means are formed automatically holding or for a self-producible connection. Furthermore, it can be provided that they can be solved only with destruction, which is less an intrinsic purpose, but makes it possible just in the aforementioned disposable parts for the part shapes to make the connection means very simple and very effective, but that for their solubility for removal the finished fiber composite components no effort and no disadvantages must be accepted.
  • the connecting means may be, for example, simple clamping hooks or latching hooks in the aforementioned corner regions and / or edge regions of the partial molds, so that these connecting means are formed directly on the partial molds. Especially for them can be provided that once they have firmly connected the two sub-forms, they must be destroyed in order to solve them again.
  • the connecting means may be provided separately, for example as screws, clamping bolts, locking bolts or rivets. At least screws can be detachable.
  • the connecting means in particular snap-in hooks or latching bolts, may be designed on the part molds such that they automatically connect or hold together when the part molds are assembled. This can even take place in two or more stages, so that they do not compress the partial shapes in a first stage quite firmly, but prevent slipping of the inserted fiber material. In a second stage, they are then firmly or maximally compressed. Due to the automatic connection, no manual or additional work step is necessary, which would be difficult to carry out, for example, in a pressing device. Thus, the part shapes can only be compressed in the final position in the pressing device.
  • ARTM method is applicable, in which also a dense or vacuum-tight tool is used with the two sub-forms, which, however, unlike the RTM method, not completely closed to final component dimension.
  • There remains a small air gap advantageously between 0.5 mm and 5 mm, in which the resin is injected at a relatively low pressure.
  • the resin can run over the fiber material and thereby achieve a partial impregnation.
  • the two partial shapes are closed completely or to their final dimensions and the resin is pressed through the fiber material.
  • an important advantage over the standard RTM is that the resin only has to penetrate a relatively short distance in the thickness direction of the component. This produces the necessary or relatively high mold cavity pressure, which at the same time fully impregnates and compacts the preform. Overall, better component quality and a significantly shorter cycle time can be achieved with lower press forces.
  • An advantage of the invention may be that the pressing device may be a horizontal pressing device.
  • the resin is advantageously already introduced into the mold and thus into the fiber material.
  • the horizontal direction which simplifies and speeds up the pressing process.
  • one or more layers of a sheet of fibrous material are placed between two partial shapes of a mold.
  • they are placed particularly advantageously on a substantially planar placed part form, in the aforementioned inner contour, possibly also in each part form of fiber material.
  • the part shapes are brought together, compressed and firmly connected to each other by means of the described connection means. Resin is pressed into the mold or between the part molds via the channels for resin feed and resin removal. When removing resin, both air and excess resin can escape.
  • the part molds with the impregnated fiber material are interposed therebetween in an aforementioned pressing device. In it, the part shapes are compressed even more, especially in their final position to each other to form the fiber composite component in the desired shape. It can leak again excess resin.
  • an extraction of resin may be provided, as is known per se.
  • a heating of the resin can be effected, for example by a heated pressing device.
  • heating of the resin may take place only after removal of the compressed partial molds from the pressing device for curing.
  • the mold remains in the pressing device until the resin begins to gel or is no longer very fluid. From then on, a risk of deformation for the mold or the partial molds is relatively low.
  • the mold can be removed again very quickly for a subsequent curing.
  • this mold can either already be introduced into the pressing device. In this case, even a certain pressing force can be exercised, which in particular amounts to 50% of the total pressing force.
  • the resin may be pressed into the mold before it is in the press apparatus. Then, in the pressing device, the final compression is effected by pushing out resin. Either simultaneously with it or after removal from the pressing device, the resin is heated to cure as described above, for example by one of the aforementioned methods.
  • the next prepared mold can be inserted into the press.
  • a curing of the resin in the pressing device is not necessary, which significantly speeds up the entire process.
  • the finished fiber composite component can be removed from the two partial molds.
  • the finished fiber composite component can then be further processed as usual.
  • FIG. 2 shows the partial form of Fig. 1 in a modified view
  • Fig. 3 is a schematic representation of the insertion of fiber material between two
  • FIG. 4 shows a section through a composite mold after assembly according to FIG. 3, FIG.
  • Fig. 5 shows the handling of a composite mold on a base with a robot arm
  • a partial mold 1 1 a is shown in an oblique view. It consists, as stated above, advantageously made of plastic or is produced by plastic injection molding, particularly advantageous from a thermoplastic such as POM or PA6. Alternatively, it may be an aforementioned UV-transparent plastic.
  • the part mold 1 1 a has an inner side 13 a, which has the subsequent assembly to a corresponding part form 1 1 b according to FIG. 3.
  • the inner side 13a has an inner contour 15a, shown very simply here with a recess, but basically in any form.
  • the inner contour 15a here is substantially rectangular, but of course may also have other outline shapes, depending on the fiber component to be manufactured as well as depending on the nature of the introduction of the fiber material for it.
  • an edge strip 16a is provided on the inner side 13a, which has a certain width.
  • This edge strip 16a is flat here, so that the corresponding part shape 1 1 b is just as well for a good, simple and safe investment of the two sub-forms 1 1 a and 1 1 b to each other.
  • the partial mold 1 1 a has an initially explained resin supply 17a and a resin removal 19a. Both are relatively large or have a large diameter. In the case of the resin feed 17a, the channel forming it with an essentially constant cross section extends almost over the entire length of the part mold 11a, in order then to introduce the inner contour 15a from behind. In the large volume, as previously explained, also resin together with hardener are deposited, for example, each in separate plastic bags odgl .. The resin removal 19a is only relatively short and leads directly from the inner contour 15a to the outside. Also, their diameter is very large, which has the consequence that this volume can also be used as a kind of storage volume or depot volume as previously explained. Here, excess resin sucked from the fiber material can be left as it were and then removed.
  • the edge strip 16a also has a circumferential circular seal 21 a, which may have any cross-section per se. This is provided in all cases in the flat areas of the edge strip 16a to be applied sealingly against the corresponding edge strip 16b of the other part form 1 1 b. It can, as shown here, also pull through resin supply 17a and resin removal 19a, but this need not be. In the other part form 1 1 b no seal needs to be provided.
  • holes 22a are provided. These serve as connecting means in the form of screws or bolts. Alternatively, it could also, as explained above, connecting means such as screws, locking clips, dowels or the like. be provided.
  • the part mold 1 1 a of FIG. 1 is shown in a slightly more tilted position.
  • three ribs 23 a are provided on the outside thereof, as they can be seen even better from the Fig. 3 on the outside of the other part mold 1 1 b.
  • These ribs 23a and 23b serve to stiffen the part shapes 1 1 a and 1 1 b, to which they can stand quite far. Due to the shape of the inner contour 15a shown here in the longitudinal direction of the partial mold 11a and the resin feed 17a, a certain stiffening of the partial mold 11a into the one axis takes place.
  • the perpendicularly extending ribs 23a cause reinforcement in the other direction for a generally rigid component.
  • a mixer 25 is introduced in a spiral formation and in the resin supply 17 of the lower part mold 1 1 a is inserted.
  • This mixer should not survive outside on the part mold 1 1 a or the finished mold 12.
  • the mixer 25 may be provided in a corresponding form on the part molds 1 1 in the respective resin supply 17 itself or be made there in one piece, in particular be molded. This is known in principle to the person skilled in the art and is not particularly great difficulty.
  • the provision of the mixer contour or a mixer generally in the finished composite mold 12 has the great advantage that then the two-component matrix material or resin can be supplied separately and need not be premixed. Thus, there is a workload or cleaning effort is greatly reduced.
  • the mixer 25 as a disposable part can then be disposed of.
  • the lower part mold 1 1 a is supported here with bolts or other fasteners on a base 24. In particular, it is also held distortion-free.
  • a substantially rectangular trained scrim made of fiber material 27 is introduced. It has approximately the size of the inner contour 15a, is therefore rectangular and extends at the front and at the rear end to the resin supply 17a and the resin discharge 19a.
  • the upper part mold 1 1 b is introduced and fittingly attached to the lower part mold 1 1 a.
  • four screws 26 are passed as connecting means through the respective holes 22a and 22b and there is a prefixing of the two part molds 1 1 a and 1 1 b together, preferably with something Distance, so that no pressing pressure is exerted.
  • a robot arm 29 grips the mold 12, optionally with base 24, in particular on the base 24, and further transports.
  • a pressing device 31 with two pressing jaws 32.
  • the pressing device 31 is a horizontal press, whereby it must be less expensive. In the press only the mold 12 without base 24 is introduced.
  • the prepared mold 12 is impregnated therein with the fiber material 27 and the corresponding fiber component produced.
  • resin or another matrix material is introduced via the resin feed 17, possibly with a mixing by the mixer 25.
  • the resin is sucked off.
  • a corresponding device preferably a corresponding RTM machine, connected. This can be done between the steps of Fig. 5 and 6, so if the mold 12 is still attached to the base 24 to prevent warping. Since this impregnation can be done according to the prior art, it need not be further illustrated.
  • the mold 12 can be removed, which can be done very quickly, for example, after just 1 min. In this short time, the resin can already begin to harden or gel first, which already reduces the deformability. But this need not be, advantageously the shape can be taken much earlier. This significantly reduces the residence time in the pressing device 31 and increases its throughput enormously.
  • the mold 12 can be supplied to a heating, for example, according to the aforementioned DE 102012105145 A1 by an oil bath, or in a previously explained microwave system. For this purpose, the plastic material of the mold 12, the aforementioned additives, which cause heating by irradiation with microwaves.
  • the finished fiber composite component can be removed from the mold 12.
  • the part forms 1 1 a and 1 1 b separated, possibly with destruction of the connecting means,

Abstract

L'invention vise à fabriquer un composant composite à base de fibres. Un premier moule partiel (23a) et un deuxième moule partiel (23b) comportent en tant que moule respectivement des faces intérieures pointant les unes vers les autres pourvues respectivement d'un contour intérieur servant à former un espace intérieur du moule conformément au contour extérieur souhaité du composant composite à base de fibres fini. Dans l'état assemblé, les moules partiels reposent les uns contre les autres tout autour en périphérie en ayant une action de fermeture, et sont reliés les uns aux autres de manière solidaire par des moyens de liaison. Ils comportent une arrivée de résine de l'extérieur dans l'espace intérieur et une sortie de résine hors de l'espace intérieur. Les moules partiels sont constitués de matière plastique et sont des composants en matière plastique, ce qui permet de les fabriquer en toute simplicité en tant que pièces coulées par injection.
PCT/EP2015/068042 2014-08-08 2015-08-05 Dispositif et procédé servant à fabriquer un composant composite à base de fibres WO2016020430A1 (fr)

Applications Claiming Priority (2)

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DE102014215792.7A DE102014215792A1 (de) 2014-08-08 2014-08-08 Vorrichtung und Verfahren zur Herstellung eines Faserverbund-Bauteils
DE102014215792.7 2014-08-08

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Publication Number Publication Date
WO2016020430A1 true WO2016020430A1 (fr) 2016-02-11

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DE102022105064A1 (de) 2022-03-03 2023-09-07 Deutsches Zentrum für Luft- und Raumfahrt e.V. Verfahren zur Herstellung eines Faserverbundbauteils aus einem Faserverbundwerkstoff

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