WO2024074635A1 - Composant de structure renforcé par des fibres et recyclable et sa méthode de fourniture - Google Patents

Composant de structure renforcé par des fibres et recyclable et sa méthode de fourniture Download PDF

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Publication number
WO2024074635A1
WO2024074635A1 PCT/EP2023/077619 EP2023077619W WO2024074635A1 WO 2024074635 A1 WO2024074635 A1 WO 2024074635A1 EP 2023077619 W EP2023077619 W EP 2023077619W WO 2024074635 A1 WO2024074635 A1 WO 2024074635A1
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WO
WIPO (PCT)
Prior art keywords
continuous fiber
fiber bundle
structural component
matrix
section
Prior art date
Application number
PCT/EP2023/077619
Other languages
German (de)
English (en)
Inventor
Bosse ROTHE
Moritz Jonathan REINERS
Original Assignee
Holy Technologies Gmbh
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Filing date
Publication date
Application filed by Holy Technologies Gmbh filed Critical Holy Technologies Gmbh
Publication of WO2024074635A1 publication Critical patent/WO2024074635A1/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
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/02—Separating plastics from other materials
    • 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
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • 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
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • B29C70/205—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres the structure being shaped to form a three-dimensional configuration
    • 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
    • B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
    • B29C70/382—Automated fiber placement [AFP]
    • 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
    • B29C70/48—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 and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
    • 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
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/543—Fixing the position or configuration of fibrous reinforcements before or during 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
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/56—Tensioning reinforcements before or during shaping
    • 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
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • 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
    • B32B5/26—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 also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/02—Separating plastics from other materials
    • B29B2017/0213—Specific separating techniques
    • B29B2017/0293—Dissolving the materials in gases or liquids
    • 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
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • 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
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62K—CYCLES; CYCLE FRAMES; CYCLE STEERING DEVICES; RIDER-OPERATED TERMINAL CONTROLS SPECIALLY ADAPTED FOR CYCLES; CYCLE AXLE SUSPENSIONS; CYCLE SIDE-CARS, FORECARS, OR THE LIKE
    • B62K19/00—Cycle frames
    • B62K19/02—Cycle frames characterised by material or cross-section of frame members
    • B62K19/16—Cycle frames characterised by material or cross-section of frame members the material being wholly or mainly of plastics

Definitions

  • the invention relates to a fiber-reinforced and recyclable structural component and a method for providing a fiber-reinforced and recyclable structural component.
  • a use of a corresponding structural component for providing a recyclable component for a bicycle is specified.
  • the invention can advantageously be used to produce fiber-plastic composites more sustainably and, in particular, to recycle them better.
  • a fiber-plastic composite (FRP for short; also fiber-reinforced plastic or fiber-reinforced plastic, FRP for short) is a material that contains reinforcing fibers and a plastic matrix. The matrix surrounds the fibers, which are bonded to the matrix by adhesive interactions. Due to the use of fiber materials, fiber-plastic composites generally have a direction-dependent elastic behavior. Without a matrix material, the high specific strengths and stiffnesses of the reinforcing fibers are usually not usable. A new construction material is only created by the appropriate combination of fiber and matrix material. A combination suitable for many areas of application is resin-bonded fiber composite materials.
  • the best-known fiber composite plastics are glass fiber reinforced plastic (GFRP for short) and carbon fiber reinforced plastic (CFRP for short). Fiber-plastic composites generally have high specific stiffnesses and strengths. This makes them suitable materials in lightweight construction applications. Fiber-plastic composites are mainly used to produce flat structures.
  • a disadvantage of most known fiber-plastic composites is that they cannot be recycled, and in particular not easily. Many fiber-plastic composites cannot be recycled at all and can only be disposed of after use.
  • the recycling methods known to date mostly rely on shredding fiber-plastic composites or components made from them, such as mechanical shredding, in order to then thermally recycle the resulting fiber-plastic composite residues.
  • the matrix is pyrolyzed and the shredded fibers can be consolidated into a random fiber mat in an additional process step.
  • the main disadvantage of this process is that the recycled material experiences a significant loss of mechanical properties and thus cannot be used again for the original or a similar application.
  • This downcycling means that only newly produced fibers can be used, particularly for structural, highly stressed components.
  • the fibers are always significantly shorter than the fibers originally used to manufacture the recycled component. Due to the high resource intensity that the new production of the raw material entails, reuse of the fibers and the matrix should be sought.
  • the object of the present invention is to at least partially solve the problems described with reference to the prior art.
  • a structural component and a method for its production are to be specified which contribute to increasing the sustainability and/or recyclability of fiber-reinforced components.
  • the waste during the production of fiber-reinforced components is to be minimized.
  • a further aim can be to increase the production speed in the production of recyclable fiber-reinforced components.
  • an object can be seen in increasing the mechanical performance of fiber-reinforced components.
  • a fibre-reinforced and recyclable structural component contributes to this, comprising:
  • the resin system comprises at least one polymer material for the matrix, wherein the resin system is designed such that it allows depolymerization of the polymer material after curing of the resin system, in particular in order to be able to remove the continuous fiber bundle from the structural component again.
  • the fiber system can be formed in the manner of a textile semi-finished product provided for reinforcing the component.
  • the fiber system can comprise a continuous fiber bundle or several continuous fiber bundles.
  • the fiber bundles can be formed in particular in the form of rovings.
  • the rovings can be formed, for example, from a large number of individual fibers or monofilaments or threads that have been created by twisting individual fibers or fiber bundles.
  • the fibers can be, for example, glass fibers, carbon fibers, polymer fibers or natural fibers.
  • the fibers are preferably carbon fibers.
  • the continuous fiber bundle can therefore preferably be a continuous carbon fiber bundle.
  • the fiber-reinforced components are, for example, carbon fiber-reinforced components.
  • other fiber types such as flax or aramid fibers, can also be considered.
  • the textile semi-finished products used to reinforce the materials are in particular fiber bundles in the form of rovings made of continuous fiber strands that are not cut off within the component.
  • this process can be used to produce fiber-reinforced components that have a component size of at least 5x5x10 cm [centimeters] and a thickness of at least 2 fiber layers. This results in a minimum total fiber length per component of 8 m [meters] with an exemplary fiber spacing of 2.5 mm [millimeters].
  • continuous fiber or “continuous fiber bundle” is not to be understood as meaning that the fibers have an infinite length or are actually endless. Rather, there is always a certain limitation to the length of the fiber due to the size of the component, such as in the example given above a total fiber length of 8 m [meters] in a component of 5x5x10 cm [centimeters].
  • continuous fiber or “continuous fiber bundle” is to be understood as meaning that understand that the fiber bundles in the component are arranged and designed in such a way that the component has the longest possible fiber lengths, which can later be recovered non-destructively (without affecting the fiber) in a recycling process.
  • the continuous fiber bundle has a first section and a second section, wherein the first section and the second section are connected via the deflection or (in the case of several deflections) via one of the deflections.
  • the first section and the second section can in particular be arranged straight.
  • the first section and the second section can be aligned at an angle or parallel to one another. It is preferred if the first section and the second section are aligned substantially parallel to one another.
  • the first section and the second section can be arranged specifically along load paths that run at an angle to one another, wherein the first section and the second section can be aligned at an angle to one another.
  • the continuous fiber bundle has a change in direction of the continuous fiber bundle in the area of the one or more deflections.
  • the continuous fiber bundle can have a deflection angle in the area of the deflection.
  • the deflection angle of at least one of the deflections can preferably be greater than 90° (particularly preferably greater than 135°) and/or less than 270° (particularly preferably less than 225°).
  • the matrix is formed as a solid material between the first section and the second section.
  • the matrix has no cavity in the area between the first section and the second section. This further improves stability. With this design, since there is no cavity between the first and second sections, no goods to be stored can be introduced into a cavity at this point.
  • components can also have a different geometric nature.
  • components can also have flat or hollow cross-sections as well as bionic structures or bionic supporting structures.
  • Continuous fiber bundles can be arranged in the component in such a way that the fiber directions in the continuous fiber bundles are adapted to the respective shape of the component.
  • components can have integrated interfaces to other components.
  • so-called inserts can be integrated into the components, which enable connection to other components.
  • Such insert components can, for example, be metal components that are integrated into the matrix of the component and which, for example,
  • Continuous fiber bundles are preferably arranged in the component in such a way that the transfer of forces from the insert components to the continuous fiber bundles is promoted.
  • insert components can be arranged between individual strands of continuous fiber bundles.
  • the invention focuses exclusively on resin systems that allow depolymerization after the component has hardened in order to be able to completely separate the fibers from the matrix in the recycling process.
  • Depolymerization can be achieved, for example, by thermally or chemically splitting or dissolving the polymer material into shorter polymers or monomers. This makes the polymer material liquid or at least plastically deformable to such an extent that the continuous fibers of the continuous fiber bundles can be removed from the polymer material without destroying the fibers.
  • One or more of the following systems can be used as a resin system or matrix system:
  • thermosets such as epoxy resins
  • vitrimers which have particular advantages as a resin system or matrix system for the component described here.
  • Vitrimers are a class of plastics derived from classic thermosets and have strong similarities to them. They are made up of covalent networks that can change their topology through thermally activated bond exchange reactions. Vitrimers are strong glass formers. At high temperatures they flow and behave like a viscoelastic fluid. At low temperatures the exchange reactions are immeasurably slow (“frozen”) and the vitrimers behave like classic thermosets. Due to the fact that vitrimers behave like liquids at high temperatures, they are particularly suitable for the components described here. Continuous fibers or continuous fiber bundles can be recycled particularly well from a matrix material.
  • Matrix materials which, for example, change from a solid phase to a liquid or highly viscous phase at a limit temperature above 80°C are preferred.
  • a matrix material is particularly preferred which only undergoes a transition to the liquid or highly viscous phase after a certain period of time in which the limit temperature acts on the matrix material (“exposure time”). It is also advantageous if additional properties and/or influences must be added in order to cause the matrix to dissolve. These are particularly preferred influences which do not act on the component under normal conditions of use of the component in order to avoid undesirable dissolution of the matrix. This can include, for example, the effect of a mild acid in combination with the introduction of heat, for example acetic acid.
  • matrix materials are, for example, vitrimer resins. Such materials are an intermediate stage between thermosets and thermoplastics and can be dissolved, for example, under the influence of diethylenetriamine or propylamine at 60 °C to 100 °C.
  • the patented process enables fiber-reinforced components to be manufactured without creating fiber waste when cutting and trimming the component, or when inserting openings in the semi-finished fiber product or hardened component.
  • no further processing takes place in the described component that could cause fibers of the continuous fiber bundles arranged in the component to be severed.
  • no material-removing processing steps are carried out that affect areas of the component in which the continuous fiber bundles are located.
  • inserts can be incorporated into the fiber semi-finished product in a way that is appropriate for the fibers, and thus a subsequent breakthrough through mechanical processing is no longer necessary.
  • their effect on the recovery of the fibers from the continuous fiber bundles is particularly preferably taken into account.
  • inserts and continuous fiber bundles are preferably aligned with one another in the component in such a way that, on the one hand, force can be transmitted from the inserts to the continuous fiber bundles and vice versa as desired, and, on the other hand, the inserts do not hinder the removal of continuous fibers.
  • inserts and continuous fiber bundles are, for example, incorporated into the matrix material in such a way that inserts can be removed after the matrix has dissolved without disturbing the position of the fibers, so that the continuous fibers can be removed after the inserts have been removed.
  • continuous fibers and inserts are, for example, introduced into the matrix material in such a way that, after the matrix has been dissolved, continuous fiber bundles can be removed without the continuous fibers colliding with the inserts or being blocked by the inserts.
  • the invention can advantageously contribute to increasing the production speed in the manufacture of recyclable fiber-reinforced components.
  • a manufacturing method designed for automated production that minimizes manual intervention and eliminates essential process steps such as cutting the fibers, trimming the semi-finished product and the finished component can achieve significant savings in process time.
  • the use of the continuous fiber bundles described here can therefore be used in an optimized overall process. Savings in process time can partially compensate for additional costs that arise from the use of continuous fiber bundles.
  • a further aspect of the invention is the realization of fiber orientations and courses that are specifically adapted to the component and non-linear fiber arrangements through the manufacturing process with uncut fibers.
  • the free manipulation of the fibers enables optimized, fiber-appropriate load introduction and distribution. This can advantageously contribute to increasing the mechanical performance of fiber-reinforced components.
  • the polymer material is such that after curing of the resin system it can be thermally and/or chemically dissolved into at least one monomer or shorter polymers.
  • the continuous fiber bundle has a length of at least 5 m, preferably a length in the range of 5 m to 10,000 m.
  • the continuous fiber bundle runs with one or more deflections and/or with one or more turns in the structural component.
  • a method for providing a fiber-reinforced and recyclable structural component comprising at least the following steps: a) providing a continuous fiber bundle, b) arranging and/or aligning the continuous fiber bundle, c) Surrounding the arranged and/or aligned continuous fiber bundle with a polymer material to form a matrix for holding the continuous fiber bundle, wherein the polymer material is provided in such a way that it can be thermally and/or chemically broken down into shorter polymers or monomers and thus completely separated from the fiber bundle.
  • steps a), b) and c) can be carried out, for example, at least once and/or repeatedly in the order given. Furthermore, steps a), b) and c), in particular steps a) and b), can be carried out at least partially in parallel or simultaneously.
  • the method is carried out to produce a structural component described here.
  • the method can be carried out to produce a structural component described here.
  • the method further comprises the following steps: d) thermal and/or chemical dissolution of the matrix, e) removal and/or collection of the continuous fiber bundle.
  • a use of a structural component described here for providing a recyclable component for a bicycle is specified.
  • Fig. 1 an example of a structure of a structural component described here.
  • Fig. 2 an exemplary sequence of a method described here.
  • Fig. 3 an example of an embodiment of an aspect of the method.
  • Fig. 4 an example of another embodiment of an aspect of the method.
  • Fig. 5 an example of an embodiment of another aspect of the
  • Fig. 6 an example of an embodiment of another aspect of the
  • Fig. 1 shows schematically an example of a structure of a fiber-reinforced and recyclable structural component 1 described here.
  • the structural component 1 has a resin system that forms a matrix 2, as well as a fiber system 3 with a continuous fiber bundle 4 held in the matrix 2.
  • the arrangement and/or orientation of the continuous fiber bundle 4 helps to define at least part of the shape 5 of the structural component 1.
  • the resin system comprises at least one polymer material 6 for the matrix 2.
  • the resin system is designed in such a way that it allows depolymerization of the polymer material 6 after the resin system has hardened. This advantageously contributes to the continuous fiber bundle 4 being able to be removed from the structural component 1 and, if necessary, reused or recycled.
  • the polymer material 6 can be designed in such a way that after curing of the resin system, shorter polymers or monomers dissolve thermally and/or chemically and can thus be completely separated from the fiber bundle.
  • the continuous fiber bundle 4 can have a length of at least 5 m.
  • the continuous fiber bundle 4 can have a length in the range of 5 m to 10,000 m.
  • the continuous fiber bundle 4 can run with one or more deflections 7 and/or with one or more turns in the structural component 1 or can be arranged and/or aligned accordingly.
  • the continuous fiber bundle 4 has first sections 19 and second sections 20, which are each connected via a deflection 7, 7'.
  • the deflections 7, 7' can be obtained by arranging and/or aligning the continuous fiber bundle 4 with one or more deflections 7, 7' of the continuous fiber bundle.
  • the deflections 7, 7' can be formed with the deflection rollers 14 described below.
  • the first section 19 and the second section 20 are arranged straight.
  • the first and second sections 19, 20 connected via the deflection 7 are aligned parallel to one another.
  • the continuous fiber bundle 4 has a change in direction of the continuous fiber bundle 4 in the area of the deflection 7, 7'.
  • the continuous fiber bundle 4 has a deflection angle in the area of the deflection 7, 7'.
  • the deflection angle of the deflection 7 is 180° in the embodiment shown.
  • the continuous fiber bundle comprises a further deflection 7', wherein the deflection angle of the deflection 7' is less than 180°.
  • the matrix 2 is formed as a solid material.
  • the matrix 2 has no cavity in the area between the first section 19 and the second section 20.
  • the structural component has a U-shaped form 5.
  • the fiber system 3 in the polymer component is formed by a continuous fiber bundle 4, which is continuous and embedded in a polymer material as a matrix. Sections of the same continuous fiber bundle 5 extend through both legs of the U-shape 5.
  • the continuous fiber bundle 5 has individual strands, each of which is connected to one another by deflections 7. In order to be able to extend into the two legs of the U-shape, the continuous fiber bundle 5 is folded out at a central position. This arrangement allows the continuous fiber bundle to be efficiently set up so that it is adapted to the U-shape.
  • Fig. 2 shows an example of a process described here. The process steps a), b), c) and possibly also d) and e) can be seen, which are carried out one after the other.
  • the method serves to provide a fiber-reinforced and recyclable structural component 1.
  • the sequence of steps a), b) and c) shown in blocks 110, 120 and 130 is exemplary and can be used, for example, in a regular sequence of the method.
  • a continuous fiber bundle 4 is provided.
  • the continuous fiber bundle 4 is arranged and/or aligned.
  • the arranged and/or aligned continuous fiber bundle 4 is surrounded with a polymer material 6 to form a matrix 2 for holding the continuous fiber bundle 4, wherein the polymer material 6 is provided in such a way that it can be thermally and/or chemically dissolved into at least one monomer and/or shorter polymers.
  • the method can be carried out, for example, to produce the structural component 1 shown in Fig. 1.
  • the matrix 2 can be thermally and/or chemically dissolved.
  • the continuous fiber bundle 4 can be removed and/or picked up.
  • Fig. 3 shows schematically an example of an embodiment of an aspect of the method.
  • Fig. 3 shows a machine 10 for forming the fiber system 3.
  • the view of the machine 10 is from above in Fig. 3a and from the side in Fig. 3b.
  • the fiber system 3 is clamped by a frame 11 with two frame segments 13.
  • the frame segments 13 are moved apart in a clamping direction 18.
  • the deflection rollers 14 which are held on the frame segments 13, several deflection areas 7 are formed in the arrangement and orientation of the continuous fiber bundle 4.
  • several partial areas 9, 9' and 9" of the continuous fiber bundle 4 can be arranged one above the other.
  • ⁇ layers 8 with a continuous fiber bundle 4 or a partial area 9 of the continuous fiber bundle 4 can be arranged one above the other.
  • the continuous fiber bundles 4 or partial areas 9 of the continuous fiber bundle 4 can be aligned differently to one another in layers 8 lying one above the other.
  • the subregions 9, 9’ and 9” can form three exemplary layers 8.
  • Fig. 4 shows schematically an example of a further embodiment of an aspect of the method.
  • a machine 10 for forming a fiber system 3 is shown, with which several layers 8 of a roving can be formed, in which the fibers are each aligned differently (here at a 90° angle to each other) and which nevertheless form a continuous fiber bundle 4.
  • the fibers are each aligned differently (here at a 90° angle to each other) and which nevertheless form a continuous fiber bundle 4.
  • a continuous continuous fiber bundle 4 runs on the deflection rollers 14 of all four frame segments 13, the partial areas 9 of which are each extended by tensioning in the tensioning direction 18, so that the continuous fiber bundle 4 is produced from a fiber feed roller.
  • Fig. 5 shows schematically an example of an embodiment of a further aspect of the method.
  • Fig. 5 shows a schematic example of an embodiment of a further aspect of the method.
  • Fig. 6 shows the closed mold with lower part 15 and upper part 16.
  • resin inlets 17 are shown through which the polymer material 6 can be introduced.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Textile Engineering (AREA)
  • Robotics (AREA)
  • Environmental & Geological Engineering (AREA)
  • Reinforced Plastic Materials (AREA)

Abstract

L'invention concerne un composant de structure (1) renforcé par des fibres et recyclable, comprenant : - un système de résine qui forme une matrice (2) ,- un système de fibres (3) avec un faisceau de fibres continues (4) maintenu dans la matrice (2), l'agencement et/ou l'orientation du faisceau de fibres continues (4) définissant au moins une partie de la forme du composant de structure (1), le système de résine comprenant au moins un matériau polymère (6) pour la matrice (2), le système de résine étant configuré de telle sorte qu'il permet une dépolymérisation du matériau polymère (6) après durcissement du système de résine, en particulier de telle sorte que le faisceau de fibres continues (4) peut être à nouveau retiré du composant de structure (1).
PCT/EP2023/077619 2022-10-07 2023-10-05 Composant de structure renforcé par des fibres et recyclable et sa méthode de fourniture WO2024074635A1 (fr)

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DE102022125975.7 2022-10-07
DE102022125975.7A DE102022125975A1 (de) 2022-10-07 2022-10-07 Faserverstärktes und recycelbares Strukturbauteil sowie Verfahren zu dessen Bereitstellung

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Citations (4)

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US4460531A (en) * 1982-05-10 1984-07-17 The Boeing Company Composite fiber reinforced propeller
WO2001064570A1 (fr) * 2000-02-29 2001-09-07 Corbin Pacific, Inc. Elements structuraux composites
EP2246180A2 (fr) * 2009-04-28 2010-11-03 Bayerische Motoren Werke Structure de renforcement en matériau fibreux pour composants en plastique
DE102018105280A1 (de) * 2017-03-10 2018-09-13 Grob Aircraft Se Verfahren für die Herstellung eines faserverstärkten Bauteils

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AT227369B (de) 1959-07-02 1963-05-10 American Viscose Corp Verfahren zur Herstellung von geformten Gegenständen aus regenerierter Cellulose
PT2643485E (pt) 2010-11-25 2014-11-13 Studiengesellschaft Kohle Mbh Método para a despolimerização catalisada com ácido de celulose
DE102011122560B4 (de) 2011-12-29 2022-09-08 Technikum Laubholz GmbH (TLH) Textilverstärkter Formkörper, ein Verfahren zu dessen Herstellung sowie seine Verwendung
JP7342810B2 (ja) 2020-07-09 2023-09-12 トヨタ自動車株式会社 炭素繊維をリサイクルする方法

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US4460531A (en) * 1982-05-10 1984-07-17 The Boeing Company Composite fiber reinforced propeller
WO2001064570A1 (fr) * 2000-02-29 2001-09-07 Corbin Pacific, Inc. Elements structuraux composites
EP2246180A2 (fr) * 2009-04-28 2010-11-03 Bayerische Motoren Werke Structure de renforcement en matériau fibreux pour composants en plastique
DE102018105280A1 (de) * 2017-03-10 2018-09-13 Grob Aircraft Se Verfahren für die Herstellung eines faserverstärkten Bauteils

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LIU TUAN ET AL: "Progress in Chemical Recycling of Carbon Fiber Reinforced Epoxy Composites", MACROMOLECULAR RAPID COMMUNICATIONS, vol. 43, no. 23, 15 September 2022 (2022-09-15), DE, XP093113572, ISSN: 1022-1336, Retrieved from the Internet <URL:https://onlinelibrary.wiley.com/doi/full-xml/10.1002/marc.202200538> [retrieved on 20231220], DOI: 10.1002/marc.202200538 *

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