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
  • B29C70/04—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
  • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
• • 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
  • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
  • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
  • B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B30—PRESSES
  • B30B—PRESSES IN GENERAL
  • B30B5/00—Presses characterised by the use of pressing means other than those mentioned in the preceding groups
  • B30B5/02—Presses characterised by the use of pressing means other than those mentioned in the preceding groups wherein the pressing means is in the form of a flexible element, e.g. diaphragm, urged by fluid pressure
• • 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
  • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
• • 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
  • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
  • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
• • 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
  • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
  • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
  • B32B37/1009—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure using vacuum and fluid pressure
• • 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
  • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
  • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
  • B32B37/1027—Pressing using at least one press band
• • 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
  • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
  • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
• • 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
  • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
  • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
  • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
  • B32B37/18—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
• • 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
  • B32B38/00—Ancillary operations in connection with laminating processes
  • B32B38/18—Handling of layers or the laminate
  • B32B38/1808—Handling of layers or the laminate characterised by the laying up of the layers
• • 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
  • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
  • B29K2101/12—Thermoplastic materials
• • 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
  • B29K2105/25—Solid
  • B29K2105/253—Preform
  • B29K2105/256—Sheets, plates, blanks or films
• • 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
  • B32B38/00—Ancillary operations in connection with laminating processes
  • B32B2038/0052—Other operations not otherwise provided for
  • B32B2038/0072—Orienting fibers
• • 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
  • B32B2305/00—Condition, form or state of the layers or laminate
  • B32B2305/07—Parts immersed or impregnated in a matrix
  • B32B2305/076—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
  • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
  • B32B2309/12—Pressure

Definitions

• the invention relates to a method for producing a (three-dimensional) component from a fiber composite material by forming a (two-dimensional) thermoplastic organic sheet.
• Organic sheet means in the context of the invention a plate-shaped (consolidated) semi-finished product, which consists of fibers which are embedded in a matrix of thermoplastic material.
• the fibers can be in the form of continuous fibers or long fibers, for example in the form of a fiber fabric or fiber fabric.
• the fibers may be, for example, carbon fibers, glass fibers or aramid fibers.
• Such organo sheets are used as fiber composites for the production of components (eg lightweight construction) for aerospace engineering (eg aircraft construction) and for vehicle technology (eg in the automotive industry).
• thermoplastic fiber matrix such organic sheets can be shaped similarly to metal sheets (warm), so that methods of sheet metal processing are used in practice in the processing of organic sheets or in the production of components from such sheets.
• DE 10 201 1 1 15 730 A1 describes a method for forming thermoplastic fiber semi-finished with oriented fibers to three-dimensionally shaped thermoplastic semi-finished products with defined degrees of orientation, which formed as an organic sheet semi-finished fiber plate heated by a heater to a temperature below a softening temperature of the thermoplastic is, wherein the semi-finished fiber plate is positioned on a mold module, which images the three-dimensional shape. Subsequently, a fluid is introduced into the mold
• DE 198 59 798 C1 describes the production of shaped bodies from fiber composite materials by the so-called prepreg method.
• thin layers of fibers embedded in partially cured resin are laminated until a preform of the molded article is formed.
• this preform is cured under mechanical pressure with simultaneous action of a vacuum to remove air bubbles from the preform by heating.
• This is typically done in an autoclave in which the preform rests on a negative mold and is covered by a flexible membrane. The flexible membrane is sealed against the negative mold.
• the so-called vacuum bag between the preform of the membrane nor a layer of fabric material is arranged, which serves to receive excess resin and to form a vacuum zone, the so-called vacuum bag.
• the area of the vacuum bag is connected to a vacuum source.
• DE 198 59 798 C1 describes a process for the production of shaped bodies from fiber composite materials, which is based on an RTM process.
• a fiber mat is applied and the fiber mat is covered with a flexible membrane.
• the membrane is circumferentially sealed against the negative mold around the fiber mat and the space thus sealed between the
• Negativfornn and the membrane is evacuated and on the back of the membrane facing away from the negative mold, a static pressure is applied. Then, in the space between the negative mold and the membrane, an amount of liquid resin having an injection pressure larger than the back pressure of the membrane is injected. The resin is heated by the heated negative mold under the influence of the overpressure on the back of the membrane and at least partially cured. The overpressure on the back of the membrane is then drained off and the molded body is removed from the mold with the fiber mat embedded in the at least partially cured resin.
• the negative mold can be heated continuously and the membrane can be cooled on its back.
• Composite body having a structure of uncompacted layers reinforcing fibers embedded in a matrix in a membrane press.
• the invention has for its object to provide a method for producing (lightweight) components made of fiber composites with high quality and high stability.
• the invention teaches a method for producing a component from a fiber composite material by forming a thermoplastic organic sheet in a membrane press,
• a mold is / is arranged, wherein at least one organo sheet is placed as a workpiece on or on the mold, wherein an elastically extensible membrane is biased stretched over the mold with the interposition of the organic sheet and wherein the organo sheet is formed to form the component in that an overpressure is applied to the membrane on the side facing the mold and to an overpressure on the side remote from the mold so that the organic sheet forms on the mold.
• the invention is based on the recognition that three-dimensional fiber composite components with high stability and high accuracy can be produced economically from organo sheets in a membrane press, such organo sheets as (two-dimensional) plate-shaped consolidated semi-finished available and outstanding in the membrane press using Pressure and heat can be transformed into three-dimensional structures that can be used, for example, in aircraft construction, vehicle construction or the like. It is - in contrast to conventional prepreg process - not worked with only partially cured mats, but with consolidated semi-finished products in the form of organo sheets, so that no injection of liquid resins or the like takes place in the press.
• an organo sheet is particularly preferably used as a prefabricated semifinished product, which consists of a plurality of organic sheet layers, which are folded together before being placed in the press and possibly joined together.
• a prefabricated semifinished product which consists of a plurality of organic sheet layers, which are folded together before being placed in the press and possibly joined together.
• very stable components can be produced, which can also have a certain thickness or wall thickness.
• perfect forming is possible because a (highly) elastically extensible membrane is clamped in the press,
• thermoplastics for example polyetheretherketone (PEEK) or polyphenylene sulphide (PPS), are particularly preferably used as the thermoplastic material.
• PEEK polyetheretherketone
• PPS polyphenylene sulphide
• PP polypropylene
• PA polyamide
• TPU polyurethane
• the respective organic sheet it is expedient to heat the respective organic sheet to a temperature above the glass transition temperature.
• the organo sheet it may be appropriate to the organo sheet to a temperature of more than 180 ° C, z. B. more than 200 ° C to heat.
• thermoplastic material it is expedient to heat the mold or at least its surface facing the organic sheet before and / or during the forming.
• the pressure medium with which the membrane is acted upon for example a compressed gas, is heated in order to optimize the heat input and to improve the hot working.
• a negative pressure is applied to the side of the membrane facing the mold, but the opposite side of the membrane is also subjected to an overpressure, with an overpressure of at least 10 bar, for example at least 20 bar, being particularly preferred.
• an overpressure of at least 10 bar, for example at least 20 bar, being particularly preferred.
• the membrane may also be attached to the press upper part elastically biased and then stretched over the mold in the course of closing the press.
• membranes made of rubber can be used.
• the invention recommends the use of a membrane made of a highly elastic and at the same time temperature-resistant material, for example silicone or silicone-based material.
• a membrane made of a highly elastic and at the same time temperature-resistant material for example silicone or silicone-based material.
• the membrane preferably has a thickness of at least 1 mm, more preferably at least 2 mm.
• a prefabricated semifinished product made of a plurality of organic sheet layers or a multiplicity of organic sheet layers is particularly preferably used as organic sheet, which are combined before being placed in the press and possibly joined together. It is within the scope of the invention to combine the organic sheet layers individually and to press together. Preferably, however, the organic sheet layers are previously bonded to each other (in a desired arrangement), for example by welding and / or gluing, in which case an intimate connection subsequently takes place in the course of forming in the membrane press. Alternatively, it is within the scope of the invention to connect the individual organic sheet layers in a pre-press to a uniform organic sheet.
• a multiplicity of layers can be used, for example at least five layers, preferably at least ten layers.
• more than twenty layers can also be joined together to form an organic sheet.
• an oblique edge geometry can be produced by the deformation, and vice versa, a straight edge geometry can be achieved by an oblique arrangement of the individual layers in the edge region.
• a straight edge geometry can be achieved by an oblique arrangement of the individual layers in the edge region.
• the invention also relates to a press for producing a component from a fiber composite material according to a method of the type described.
• a press is constructed as a membrane press, which has a press lower part, on / on which a mold is arranged and which presses a press
• Upper part has, which has a sealable against the press base pressure case.
• a membrane is provided, which can be tensioned over the form.
• the press has at least one pressing cylinder which acts on the press upper part and / or the lower press part.
• the press has a vacuum pump with which on the one side of the membrane, for example the underside, a negative pressure can be generated and an overpressure pump with which on the other side of the membrane, an overpressure can be generated.
• the press can be designed so that the mold or the press base are heated and thus equipped like a heater.
• the press is designed so that the pressure medium, with which the membrane is acted upon, can be heated, for example by a heating device in the region of the feed for the pressure medium is arranged.
• the membrane is attached to the press base and clamped over the mold.
• the membrane is attached to the press upper part, for example to the pressure box, elastically biased.
• FIG. 1 shows a membrane press according to the invention in a simplified form
• FIG. 2 shows the object according to FIG. 1 in another functional position
• FIG. 3 shows a modified embodiment of the press according to FIG. 1
• FIG. 4 shows the press according to FIG. 3 in another functional position
• FIG. 5 shows a forming process of a multi-layered organic sheet
• a membrane press 1 for the production of a component made of a fiber composite material is shown.
• a component made of a fiber composite material by forming a thermoplastic organic sheet 2 is produced.
• the membrane press 1 has a press lower part 3, which is designed as a press table, on which a mold 4 is arranged as a negative mold of the component to be produced.
• the press 1 a press upper part 5, which has a sealable against the press base 3 hood-like pressure box 6.
• the lower, on the press table settable circumferential end face 7 of the pressure box 6 is provided with a circumferential seal 8.
• the press upper part 5 acts a pressing cylinder 9, wherein in the exemplary embodiment, the piston 10 of the pressing cylinder 9 is connected to the pressure box 6, so that the pressure box 6 with the cylinder 9 and its piston 10 is pressed against the press base 3.
• the membrane press 1 is equipped with an elastically extensible membrane 1 1, which is clamped on the mold 4.
• a vacuum pump 12 is provided, which is connected in the embodiment of the press base 3.
• a pressure pump 13 is provided in the
• this organic sheet is placed on the mold 4 and the membrane 1 1 is stretched and biased with the interposition of the orange plate 2 on the mold 4.
• the organo sheet is formed to form the component by the membrane 1 1 is acted upon on the side facing the mold 4 via the vacuum pump 12 with a negative pressure and on the side facing away from the mold 4 with the pressure pump 13 is acted upon by an overpressure, so that the organo sheet 2 forms the shape 4 to form the component.
• the organic sheet 2 is heated prior to insertion into the press 1.
• the mold 4 or at least its surface facing the organic sheet 2 is heated before and / or during the forming process.
• a heater 14 is indicated in the figures. The heaters for heating the organic sheet and heating the mold are not shown.
• Fig. 1 shows a first embodiment of such a membrane press, in which the membrane 1 1 attached to the press base 3 and stretched over the mold 4.
• Fig. 1 shows the press, after the organic sheet 2 is placed on the mold 4 and the membrane 1 1 was stretched over the mold 4 with the interposition of the organic sheet 2.
• the press upper part 5 was lowered after inserting the organo sheet 2 and after tensioning the membrane 1 1 on the press base 3 and
• the negative pressure can be generated with the vacuum pump 12 before and / or after lowering the press upper part. After the press upper part 5 has been lowered and sealed against the press lower part 3, the interior of the pressure box 6 is subjected to the overpressure. It can be provided that the pressing pressure generated by the cylinder 9, with which the membrane press is kept in self-building up internal pressure, successively increased with the structure of the internal pressure and thus adjusted. 2 shows the press after completion of the overpressure and the vacuum with reshaped organo sheet 2.
• FIG. 3 and 4 show a modified embodiment of such a membrane press, in which the membrane is not attached to the press base 3, but on the press upper part 5, namely on the pressure box 6 and is resiliently biased (Fig. 3).
• the pressure case 6 is lowered while the membrane with the interposition of the organic sheet 2 over the form stretched (Fig. 4).
• the press has been closed, on the one hand the negative pressure and on the other hand the overpressure are built up and thus the organo sheet 2 is reshaped and the component is produced.
• the organic sheet 2 may consist of a plurality of individual organic sheet layers 2a, which are combined to form the organo sheet 2 and formed in the press.
• the layers 2a can be matched in their geometry to one another such that the individual layers 2a shift in the course of forming with changing the edge geometry of the component against each other. This option is shown in FIGS. 5 and 6. According to FIG. 5, the individual layers 2a are combined to form an organic sheet 2 with straight edges. In the course of forming it comes to a
• FIG. 6 shows an embodiment in which the individual layers 2 a of the organic sheet 2 are not flush over one another, but form oblique edges, so that in the course of forming a component with straight edges without bevels arises.

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

Priority Applications (7)

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Publications (1)

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Family Applications (1)

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Families Citing this family (13)

Citations (10)

Family Cites Families (11)

• 2015
  • 2015-10-20 DE DE102015117857.5A patent/DE102015117857A1/de not_active Withdrawn
• 2016
  • 2016-10-18 WO PCT/EP2016/074988 patent/WO2017067934A1/de not_active Ceased
  • 2016-10-18 US US15/763,171 patent/US20180281319A1/en not_active Abandoned
  • 2016-10-18 ES ES16782256T patent/ES3012789T3/es active Active
  • 2016-10-18 EP EP16782256.8A patent/EP3365158B1/de active Active
  • 2016-10-18 CN CN201680061105.5A patent/CN108349174B/zh active Active
  • 2016-10-18 JP JP2018520142A patent/JP6689377B2/ja active Active
  • 2016-10-18 BR BR112018007957-0A patent/BR112018007957B1/pt active IP Right Grant

Patent Citations (10)

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