• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    methods for producing a fiber preform and for producing a composite fiber component. the invention relates to a method for producing a fiber preform by depositing bundles of reinforcing fibers (20) on a surface (25), said method comprising the steps: - supplying at least one continuous segment in the form of a belt without - end (6) of reinforcing fibers incorporating a binder, wherein the continuous segment has a continuous segment width of at least 5 mm and a binder content ranging from 2 to 4% by weight; - spreading the continuous segment in a spreading unit (7) and transferring it in a transfer direction by means of a first transfer device (8) to a slitting device, thereby stabilizing the continuous segment in the direction transverse to the transfer direction, - cutting the continuous segment in the slitting device along the longitudinal extent of the continuous segment into at least two continuous sub-segments; and - transferring the continuous subsegments by means of a second transfer device (16) to a cutting unit, - cutting the continuous subsegments by means of the cutting unit (18) into bundles of reinforcing fibers, and - depositing the bundles of reinforcing fibers on a surface.
    公开号:BR112015008233B1
    申请号:R112015008233-5
    申请日:2013-10-11
    公开日:2021-07-20
    发明作者:Markus Schneider；Björn Lehmhaus
    申请人:Toho Tenax Europe Gmbh；
    IPC主号:
    专利说明:

    FIELD OF THE INVENTION
    [001] The present invention relates to a method for producing a fiber preform by depositing bundles of reinforcement fibers on a surface and/or bundles of reinforcement fibers deposited on the surface. The invention further concerns the production of a composite fiber component using a fiber preform produced in such a manner.
    [002] Components made of fiber composites are increasingly used, especially in the aerospace industries, yet also, for example, in the machine building industry or in the automotive industry. Fiber composites often offer the advantage of lighter weight and/or greater strength relative to metals. The volumetric percentage of the reinforcing fibers and especially also the orientation of the reinforcing fibers have a determining effect on the strength of the components, in particular in view of their stiffness and strength. However, heavy-duty materials and components of this type have yet to be cost-effectively produced in order to be economically attractive.
    [003] To produce composite components of this type, so-called fiber preforms are initially produced from reinforcing fibers in an intermediate step. These are semi-finished textile products in the form of two- or three-dimensional configurations made of reinforcing fibres, where the shape can practically already be the shape of the final component. For fiber preform embodiments of this type which consist substantially only of the reinforcing fibers and for which the percentage of matrix required for component production is still at least largely absent, a suitable matrix material is incorporated into the preform. of fiber in additional steps by means of infusion or injection, or also by applying a vacuum. Subsequently, the matrix material is cured as a rule at higher temperatures and pressures to form the finished component. Known methods for infusing or injecting matrix material are the liquid molding (LM) method or related methods such as resin transfer molding (RTM), vacuum assisted resin transfer molding (VARTM), infusion resin film (RFI), liquid resin infusion (LRI), or flexible resin infusion tooling (RIFT). The fiber material used to produce the fiber preforms may also already be pre-impregnated, for example, with small amounts of a plastic material, i.e. a binder material, in order to improve the fixation of the reinforcing fibers in the fiber preform. Pre-impregnated yarns of this type are described, for example, in WO 2005/095080.
    [004] Methods are also known in which composite components are produced from fiber preforms that already have a sufficient content of matrix material for the composite component. In such cases, these fiber preforms can be, for example, compacted directly into the component in a mold using higher pressure and/or higher temperature. Alternatively, it is possible to use a vacuum bag instead of a mold, into which vacuum bag the fiber preform is inserted and, after applying a vacuum and as a rule at higher temperature, it is compacted into the shape of the component. . Sufficient matrix material content for the component can, for example, be achieved where the fiber preform is produced from reinforcing fiber bundles which are produced from prepregs with the corresponding matrix content. Alternatively, during deposition, for example, of reinforcing fiber bundles to form the fiber preform, additional matrix material can be blasted, for example, during deposition.
    [005] To produce fiber preforms from reinforced fiber bundles, automated processes are often used in which fiber bundles are deposited by means of controlled deposition heads or also fiber deposition devices on or within corresponding molds, in which deposition can also take place by blasting the fiber bundles or in the molds. As a rule, a continuous strand of reinforcing fibers is hereby fed into the laying heads, which strand is then cut to the desired bundle length at the laying head or fiber laying device by means of suitable cutting devices. Deposition heads of this type with a device for cutting the continuous fiber segments to length are disclosed, for example, in WO 2011/045172 or US-A 3 011 257.
    [006] Fiber preforms can, for example, be produced in which short cut reinforcing fibers, together with a binder material, are blasted and dispersed in an air permeable sieve adapted to the shape of the desired fiber preform and said fibers are held in the sieve by applying a vacuum until, after cooling of the binding material, a sufficient stability of the preform is reached. Such a method is described, for example, in WO 98/22644. By means of the method of WO 98/22644, the reinforcing fibers are preferably arranged as short chopped fibers in a random isotropic arrangement and orientation. According to the examples of WO 98/22644, fiber volume fractions only in the range of up to approximately 15% by volume are achieved, and thus, because of the low fiber volume fractions, only a strength related to the relatively low thickness of the components.
    [007] To achieve larger volumetric fiber fractions in preforms or components produced therefrom, it is advantageous according to the embodiments of WO 2012/072405 to deposit the short chopped fibers in the form of reinforcing fiber bundles, in which the fiber bundles preferably have a length in the range of 10 to 50 mm. Furthermore, it is advantageous, in consideration of the highest possible fiber volumetric percentages and thus the highest obtainable mechanical characteristics, that the bundles have the fewest possible number of reinforcing fiber filaments, where a number from 1,000 to 3,000 filaments is particularly preferred. In this way, a virtually isotropic material is created with virtually isotropic mechanical characteristics in the directions of its extension. At the same time, because of the relatively small beam dimensions, this material does not have, or has only some regions with a higher proportion of resin and thus a reduced proportion of reinforcing fibre, which regions can lead to weak points in the component. It is relatively easy to see that the use of fiber bundles with low linear density, ie with low filament counts, leads to higher costs, in particular, also because of the use of relatively high priced source materials. On the other hand, although the use of fiber bundles of high linear density, ie fiber bundles with a high number of reinforcing fiber filaments, is certainly more cost-effective, high volumetric fiber fractions, as already explained, can only be accomplished with difficulty, if they can.
    [008] There is therefore a need for an automatable method for producing a fiber preform, whereby a cost-effective production of fiber preforms is possible while still achieving high volumetric fiber preforms in the preforms. -fiber forms or composite components produced from them.
    [009] It is, therefore, the aim of the present invention to provide such a method to produce a fiber preform.
    [0010] The object according to the invention is achieved by a method for producing a fiber preform by deposition of reinforcement fiber bundles on a surface and/or in reinforcement fiber bundles deposited on the surface, wherein the method comprises the steps of: - supplying at least one continuous segment in tape form of reinforcing fibers provided with a binder from a supply device in a deposition head, wherein at least one continuous segment has a width of pile minus 5 mm and a concentration of binder in the range of 2 to 70% by weight with respect to the weight of the continuous segment in tape form, - spread at least one continuous segment in tape form in a spreading unit arranged in the deposition head and transferring at least one continuous segment in the transfer direction by means of a first transfer device arranged in the deposition head to a longitudinal splitting device arranged in the deposition head, - est. hereby smoothing at least one continuous segment in the direction transverse to the transfer direction, - cutting at least one continuous segment in the longitudinal dividing device along its longitudinal extent into two or more continuous sub-segments by means of at least one dividing element, - transfer the continuous sub-segments in the transfer direction by means of a second transfer device arranged in the deposition head to a cut-to-length unit arranged in the deposition head, - cut the continuous sub-segments by means of the cut-to-length unit in bundles of reinforcement fibers of defined length, and - depositing the reinforcement fiber bundles on a surface and/or in surface-deposited reinforcement fiber bundles and fixing the reinforcement fiber bundles on the surface and/or in fiber bundles of reinforcement deposited on the surface to form the fiber preform, in which a relative movement between the deposition head and the surface is adjusted to provide properly loaded deposition of the reinforcing fiber bundles on the surface.
    [0011] By means of the method according to the invention, a cost-efficient production of fiber preforms from reinforced fiber bundles is possible, i.e. from fiber bundles made from reinforced fibers , with low numbers of fiber reinforcement filaments, yet obtaining high volumetric percentages of fibers in the fiber preform or fiber composite component produced therefrom. Hereby, continuous segments in tape form, for example, in the form of cost-effective linear high density fiber reinforcement strands, can be used as the source material. Linear high density reinforcing fiber strands of this type may initially be divided by means of the longitudinal splitting device into several continuous sub-segments along the length of the reinforcing strands filaments forming the strands, wherein the individual continuous sub-segments then have a reduced number of filaments when compared to the original yarn.
    [0012] Fibers of carbon, glass or aramid, or mixtures of these fibers with each other or with thermoplastic fibers are preferably used for the reinforcement fibers in the method according to the invention, which fibers form at least one continuous segment in the form of a ribbon. Carbon fibers are particularly preferred.
    [0013] In a preferred embodiment, at least one tape-like continuous segment of reinforcing fibers provided with a binder is a filament yarn with a filament count of at least 12,000 filaments, which yarn has been spread in a ribbon-like fashion . Filament yarns of this type with a filament count in the range of 24,000 to 50,000 are particularly preferred. In the case where the tape-like continuous segment of reinforcing fibers provided with a binder is a filament yarn, then the concentration of the binder in a preferred embodiment is in the range of 2 to 14% by weight, and in a particularly embodiment It is preferred in the range of 3 to 7% by weight with respect to the total weight of the filament yarn provided with the binder.
    [0014] The binder can be a fiber preparation, as is commonly applied to filament yarn filaments to achieve better processability and good fiber cohesion, that is, at least partial connection of the fibers to each other. Preparations of this type are commonly based on epoxy resins. For the method according to the invention, however, a higher content is required, unlike the commonly used concentrations of the preparation, the content of which is, as explained, preferably in the range of 2 to 14% by weight and particularly preferably in the range of 3 at 7% by weight with respect to the total weight of the filament yarn provided with a binder.
    [0015] As binders, uncured or partially cured thermoplastic or duroplastic polymers, or also polymer compositions of these polymers can be used for this. Suitable thermoplastic polymers are, for example, polyethyleneimine, polyetherketone, polyetheretherketone, poly(phenylene sulfide), polysulfone, polyethersulfone, polyetherethersulfone, aromatic polyhydroxyethers, thermoplastic polyurethane resins, or mixtures of such polymers. As uncured or partially cured duroplastic polymers, for example, epoxides, isocyanates, phenol resins, or unsaturated polyesters can be used. It is hereby advantageous that the tape-like continuous segment of reinforcing fibers provided with a binder is a filament yarn which is not tacky at the processing temperature in the area of the deposition head, i.e., as a rule, at the temperature environment, and may, for example, be unwound from a spool.
    [0016] At higher temperatures, the binder or the reinforcing fibers provided with the binder, however, must be sticky and lead to good adhesion to the fiber bundles produced from them. Reinforcing fiber strands or continuous segments of reinforcing fibers of this type are described, for example, in WO 2005/095080, the disclosure of which is explicitly referred to in this point. The filament yarn therein has been infiltrated with a binder composed of a plurality of different epoxy resins, wherein these epoxy resins differ from each other in a defined manner with respect to their characteristics such as epoxy value and molecular weight, as well as with respect to their concentrations.
    [0017] In a preferred embodiment of the method according to the invention, at least one continuous segment is a pre-impregnated filament yarn and the binder consists of a first and a second resin composition, wherein the filament yarn filaments are impregnated with a first resin composition and are at least partially connected by means of the first resin composition, wherein the first resin composition contains at least two bisphenol A resins epichlorohydrin H1 and H2 in an H1:H2 weight ratio of 1.1 to 1.4, where H1 has an epoxy value of 1,850 to 2,400 mmol/kg, an MN average molecular weight of 800 to 1,000 g/mol, and is solid at room temperature, and H2 has a value of epoxy of 5,000 to 5600 mmol/kg, an MN average molecular weight of < 700 g/mol, and is liquid at room temperature, and additionally contains an aromatic polyhydroxyether P1, which has an acid value of 40 to 55 mg KOH/ ge an MN average molecular weight of 4000 to 5,000 g/mol, and wherein the pre-i filament yarn impregnated has a second resin composition on its outer side in the form of particles or drops that adhere to the filaments, wherein the second resin composition is solid at room temperature, has a melting temperature in the range of 80 to 150°C, and is present on the outer side of the yarn in a concentration of 0.5 to 10% by weight relative to the total weight of the pre-impregnated filament yarn, and wherein at least 50% of the surface area on the outer side of the yarn is free from second resin composition and the interior of the wire is free from the second resin composition. Filament yarns of this type pre-impregnated with a binder are described in patent application WO 2013/017434, to which reference is made explicitly concerning the disclosure in this regard.
    [0018] In a further preferred embodiment, at least one continuous segment may be a prepreg made of reinforcing fibers unidirectionally arranged in the direction of extension of the prepreg and thus in the direction of transfer of the prepreg. In the context of the present invention, it is understood that a prepreg is a semi-finished product of reinforcing fibers impregnated with a polymer matrix system. This can thus be a prepreg fiber, i.e. an individual yarn that is impregnated with a matrix system. However, it can also be a semi-finished product in sheet form which consists of unidirectionally oriented reinforcing fibers arranged adjacent and parallel to each other, which reinforcing fibers are impregnated with a matrix system. In the case where a prepreg is used, then the matrix system is the binder.
    [0019] As the matrix or binder system, thermoplastic polymers, uncured or partially cured duroplastic polymers, or polymer compositions are similarly used in these cases where the polymers previously listed may be used. In the case where at least one continuous segment of reinforcing fibers provided with a binder is a prepreg, then it is preferred that the binder, i.e. the matrix system, be present in a concentration in the range of 15 to 70% by weight with respect to the weight of the prepreg, and in the case where the reinforcing fibers are carbon fibres, particularly preferably in the range of 20 to 60% by weight.
    [0020] At least one continuous tape-shaped segment of reinforcing fibers provided with a binder may be unwound from a spool or, in case a prepreg is used, from a roll as a supply device, and fed into the head of deposition. Preferably, the supply device, i.e. the spool or roller, is rigidly connected to the deposition head, so that, during movements of the deposition head, the supply device is loaded with it. By this, a stable movement of the at least one continuous segment is achieved.
    [0021] To improve secure positioning of at least one continuous segment in tape form, increase its width, and achieve a good result of the slitting device, at least one continuous segment is fed by means of an arranged spreading unit at the deposition head, which spreading unit is arranged, when viewed through the deposition head, in front of the first transfer device in the transfer direction of the at least one continuous tape-shaped segment. A single rod or an arrangement of a plurality of fixed and/or rotationally mounted rods is suitable as the spreading unit, by means of which rods the tension of the continuous filament can be increased. The surface of the rods should advantageously be constituted in such a way that the abrasion of the continuous threads fed onto the rods is kept low. Known surfaces and materials can be used for this purpose. The rods are preferably arranged so that at least one continuous tape-like segment is fed with a winding angle in the range greater than 20° around the rods.
    [0022] Preferably, at least one continuous segment of reinforcing fibers provided with a binder has a width of at least 6 mm. It is similarly preferred that at least one continuous segment has a width to thickness ratio of at least 20.
    [0023] After the spreading unit, at least one continuous segment passes through the first transfer device, whereby a defined transfer rate is set for at least one continuous segment and through which at least one continuous segment is fed in the longitudinal division device.
    [0024] At least one continuous segment is stabilized by means of devices suitable for lateral conduction of at least one continuous segment of reinforcement fibers in the direction transverse to the transfer direction, so that said continuous segment is fed directly and without lateral deviations through the individual transfer and split devices. Hereby, a sharp cut with sharp cutting edges can be achieved in the longitudinal splitting device, in that the cutting can take place at least substantially parallel to the filaments of at least one continuous segment. For this purpose, rods, rollers, rollers, or other guiding devices, as well as possibly transfer devices, are aligned at right angles to the transfer direction of at least one continuous tape-like segment, as well as parallel to each other . Furthermore, rods, rollers, rollers, and other guide elements, by means of which at least one continuous segment in tape form is guided, can be convex at the respective points of contact with the continuous segment. The contour of the guide elements in the region of the convexity preferably has a radius in the range of 50 to 600 mm.
    [0025] It is advantageous for the longitudinal and transverse cutting process (cut to length process) that at least one continuous segment of reinforcing fibers is fed under tension through the deposition device and, in particular, that a tension is generated in at least one continuous segment of reinforcing fibers between the first and second transfer devices. Hereby, a secure performance and a good spreading are achieved for at least one continuous segment of reinforcing fibers, as well as a stable movement of at least one continuous segment of reinforcing fibers, which in particular promotes a good result of cut on the longitudinal splitting device. This, for example, can be achieved in that the speeds of the first and second transfer devices are set such that the speed of the second transfer device is greater than the speed of the first transfer device. At least one continuous segment is preferably fed into the longitudinal splitting device at a continuous filament tension in the range of 40 to 300 cN per mm continuous segment width.
    [0026] The first and/or second transfer device passing through at least one continuous segment consists of an advantageous mode of one or more drive rollers or rollers, by means of which at least one continuous segment is conveyed. The rollers or rollers can be arranged relative to one another in such a way that, in application, at least one continuous segment of reinforcing fibers can be looped around the roller or roller. In a further preferred embodiment, the first and/or second transfer device comprises a driven pair of rollers, the speed of which can be controlled, with an adjustable clearance between the rollers of the pair of rollers, through which clearance at least one continuous segment of Reinforcement fibers are transferred as a result of the pressure exerted by the pair of rollers.
    [0027] Furthermore, in an equally preferred embodiment, the first and/or second transfer device may comprise a blowing device, by means of which at least one continuous tape-shaped segment of reinforcing fibers is transferred. For this purpose, the blowing device is coupled to an air supply that can be regulated.
    [0028] At least one continuous segment is cut along its longitudinal extent into continuous subsegments by means of the longitudinal splitting device. The continuous subsegments thus obtained preferably have a width in the range from 0.5 to 5 mm and in particular preferably in the range from 0.5 to 3 mm. Using fiber bundles produced from continuous subsegments of this type, high fiber volumetric percentages can be achieved in the fiber preform or in the composite fiber component produced therefrom.
    [0029] The longitudinal splitting device comprises at least one splitting element for splitting at least one continuous segment of reinforcing fibers along its longitudinal extent. At least one dividing element of the longitudinal dividing device may be at least a laser beam arrangement, air jet arrangement, or water jet arrangement, or a mechanical dividing element, for example in the form of at least one fixed element. for example a fixed blade, or also in the form of at least one rotating dividing disk, which is preferably driven. The drive can be regulated and designed in such a way that a speed difference can be adjusted between the circumferential speed of the at least one splitter disk and the transfer speed of at least one continuous segment of reinforcing fibers passing through the splitting device longitudinal. The rotational direction of the at least one rotating divider disc can be the transfer direction of the at least one continuous segment in tape form or also opposite to it. In the method according to the invention, it has been observed that it is advantageous that the circumferential speed of at least one dividing disc is 2 to 15% greater than the transfer speed of at least one continuous segment passing through the longitudinal dividing device. A circumferential speed of at least one divider disk that is 4 to 10% greater than the transfer speed of at least one continuous segment is particularly advantageous.
    [0030] In a preferred embodiment, in which case at least one divider element is a mechanical divider element, at least one continuous segment and at least one divider element are pressed together using a force defined by means of a clamping device controlled by force. The rotating divider disk can, for example, be connected to a force-controlled clamping device, whereby the rotating divider disk is pressed with a defined force against at least one continuous segment of reinforcing fibers to be divided along the its longitudinal extension. Preferably, at least one continuous segment is pressed against at least one mechanical divider element by the clamping device. When used in the case where at least one continuous segment of reinforcing fibers has a twist, for example a yarn twist, in the case where the continuous segment is a yarn, a division of the continuous segment in the region of the twist transverse to the direction of the fiber can be avoided by means of a clamping device of this type. An existing partial splitting of the continuous segment transverse to the fiber direction can lead to breakage of the continuous segment and, as a result, to an interruption of the cutting process and thus of the deposition process.
    [0031] In an advantageous embodiment of the method, at least one continuous segment of reinforcing fibers provided with a binder can be cut into more than two continuous subsegments in the longitudinal direction. In this way, the number of filaments in the individual continuous subsegments can be reduced to such a point that fiber bundles of sufficiently small width are obtained. The use of fiber bundles of this type with smaller width in turn allows the realization of higher volumetric percentages of fibers in the fiber preform produced from them or in the resulting composite components. The number of dividing elements of the longitudinal dividing device is then determined by the number of continuous sub-segments that must be obtained.
    [0032] It is also a preferred embodiment if at least one continuous segment is cut into continuous subsegments of different widths. At least one dividing element can thus be arranged with respect to the devices for laterally guiding at least one continuous segment in the form of ribbon of reinforcing fibers in such a way that at least one continuous segment is divided centrally or off-center into continuous sub-segments. Similarly, in the case of a continuous segment of individual reinforcement fibers, which is to be divided into three or more continuous sub-segments, the multiple dividing elements can be arranged relative to each other and/or relative to the side guide devices in such a way that results in continuous subsegments of different widths.
    [0033] In a preferred embodiment of the method according to the invention, multiple continuous tape-shaped segments of reinforcing fibers provided with a binder are available and guided to the deposition head or to devices arranged on them such as, between others, the longitudinal division device and the cut-to-length unit. The continuous segments can hereby be identical or different, for example all multiple continuous segments can be continuous segments of carbon fibers. However, for example, continuous segments of carbon fibers can also be combined with continuous segments of glass fibers.
    [0034] In the case of guiding multiple continuous segments of reinforcing fibers provided with a binder to the deposition head, multiple supply devices are then present, for example, in the form of a basket and a corresponding number of devices for laterally guiding the individual continuous segments. By this, multiple continuous segments can be fed in such a way that they are arranged next to each other, whereby the individual continuous segments can be at a distance from each other, or can also be in contact with each other. The longitudinal splitting device then comprises multiple dividing elements, the number of which is determined by the number of continuous sub-segments that are to be produced from the multiple continuous segments of adjacent arranged reinforcing fibers, for example, the longitudinal splitting device has four dividing elements when two continuous segments of ribbon-shaped yarn arranged adjacent to each other must each be cut into three continuous subsegments.
    [0035] In a further preferred embodiment, in the case of supplying multiple continuous segments in tape form of reinforcing fibers provided with a binder, i.e. multiple continuous segments of reinforcing fibers, these continuous segments can be fed by means of suitable guiding devices by means of the first transfer device to the longitudinal splitting device in such a way that said continuous segments are arranged superimposed, i.e. they lie one above the other. In this case, the continuous tape-shaped segments can be cut together by the same dividing element in the longitudinal direction. For example, the longitudinal splitting device then has two splitting elements for the case where two continuous segments of ribbon-shaped wire are each to be cut into three continuous subsegments.
    [0036] After cutting at least one continuous segment of reinforcing fibers into continuous subsegments, these continuous subsegments are fed into the cut-to-length unit by means of the second transfer device. By means of the cut-to-length unit, the continuous sub-segments obtained in the longitudinal splitting device are then cut transversely to their direction of extension into fiber bundles of defined length, i.e., of a predetermined length, where the length of the bundles of resulting fibers depends on the frequency with which the cut is performed transverse to the direction of extension of the continuous subsegments as a function of the transfer speed, i.e. the frequency of the transverse cut. In a preferred embodiment, the cut-to-length unit is coupled to the transfer devices in such a way that, by changing the transfer rate, the frequency of the cross-cut is changed so that the length of the resulting reinforcing fiber bundles remains the same. . In a further preferred embodiment, the cross-cut frequency can be adjusted independently of the transfer speed so that when the transfer speed remains the same, different lengths of bundles of reinforcing fibers can be produced. Of course, a combination of the adjustment possibilities is also encompassed by the invention, for which combination, on the one hand, the protractor speed serves as the actuating variable for the cross-cut frequency, but the cross-cut frequency can be varied to one established transfer speed. Hereby, the length of the fiber bundles can be varied during carrying out the method according to the invention and, for example, adjusted in the contour properties of the fiber preform to be produced. Therefore, in a preferred embodiment, the cross-section frequency is changed over time to vary the length of the fiber bundles. The continuous subsegments are preferably cut by means of the cut-to-length unit such that the resulting fiber bundles have a length in the range of 10 to 100 mm. A fiber bundle length in the range of 10 to 75 mm is particularly preferred.
    [0037] With respect to the cut-to-length unit, known assemblies and methods for cutting reinforcement fibers transverse to their direction of extension can be used. Sets of this type include, for example, sets for cutting fibers with water jet or air jet, for cutting fibers by means of laser beams, sets, for example, with pneumatically driven guillotine blades transverse to the transfer direction, transverse shears rotary with cutting roller and counter-roll, or also rotary cutting blades, its rotational axis extending in the transfer direction of the continuous sub-segments, or at an angle with it of up to 60°, preferably up to 20°. These cited rotational cutting blades are disclosed, for example, in DE 20 2010 017 556 U1 or EP-A-2 351 880. In a preferred embodiment, the continuous subsegments are cut to length into fiber bundles by means of transverse scissors rotary, in which the blades are pressed against at least one continuous segment of reinforcing fibers to be cut without exerting substantial back pressure on the other side of the continuous segment. This method leads, in the case of brittle reinforcement fibers such as carbon fibers or glass fibers, to a brittle fracture at the point of load and thus to a cut to the sharp length of the continuous segment of reinforcement fibers. Assemblies of this type are described, for example, in EP-A-1 144 738, EP-A-1 394 295, EP-A-1 723 272, or WO 02/055770, to which reference is explicitly made concerning the disclosure to this respect.
    [0038] In a preferred embodiment, the obtained fiber bundles are transported out of the cutting device to length by means of an appropriate device. This can take place, for example, by means of a short transfer belt. The fiber bundles are in particular preferably transported out of the cutting unit to length by means of the nozzle channel of a nozzle head pressurized with compressed air. A Venturi nozzle is preferably arranged in the nozzle channel of the nozzle head to introduce compressed air into the nozzle channel. Hereby, the fiber bundles to produce the fiber preform can be deposited at high speed, i.e. blasted, onto the surface and/or onto reinforcement fiber bundles deposited on the surface.
    [0039] The nozzle head for transporting the fiber bundles out may have device for introducing matrix material into the nozzle channel. In an advantageous embodiment of the method, particulate matrix material can be introduced via this device into the nozzle channel, which particulate matrix material can be applied, together with the fiber bundles cut to length, through the nozzle head, and deposited or blasted onto the surface and/or the fiber bundles deposited on the surface. The device for introducing matrix material can be, for example, a Venturi nozzle, which projects into the nozzle channel and by means of which matrix particles are introduced into the nozzle channel. However, it can also be a spray nozzle arranged in the nozzle channel, whereby the nozzle of liquid spray matrix material is blasted. The feeding of matrix material can be advantageous in order to realize, during deposition of the fiber bundles produced by means of the deposition device on a surface, a better adhesion to each other because of the matrix material and thus a better adhesion of the bundles of fibers between each other and on the surface. At the same time, matrix material may already have been supplied, for example, in the quantity necessary for the production of a composite component during the production of the fiber preform.
    [0040] With respect to the implementation of the method according to the invention, it may be advantageous, in view of a better adhesion to each other, and thus a better fixation of the fiber bundles to each other and to the surface, than the fiber bundles and the matrix material in the form of particle or droplet possibly supplied is heated after the unit cutting to length and before deposition or during deposition on the surface and/or on the fiber bundles deposited on the surface. Hereby, the binder with which the fiber bundles are provided and/or the matrix material can be activated, i.e., transformed into an adhesive state, for example, in which the fiber bundles are heated to a temperature above the melting point of the binder. Heating can, for example, be done by blowing hot air or heated ambient air, laser radiation, or infrared radiation. After the fiber bundles come into contact with the surface of the fiber preform to be produced, and after cooling, the fiber bundles are fixed by means of the then resolidified binder.
    [0041] According to a further preferred embodiment of the method, matrix material formed of particle or droplet can also be blasted, separately from the fiber bundles yet simultaneously with the fiber bundles, on the surface and/or in the fiber bundles deposited on the surface. This can occur, for example, by direct spraying of particles or droplets of this type onto the surface using a heat source such as a flame or a microwave or infrared field. A thermal spray method is preferred here, as described in WO 98/22644 or US 2009/0014119 A1 .
    [0042] Depending on the binder with which at least one continuous segment of reinforcing fibers is provided, the matrix materials possibly supplied, and the temperatures prevailing during the deposition of the fiber bundles, a cooling step subsequent to the deposition of the fiber bundles. fiber is advantageous for stabilizing the fiber preform.
    [0043] According to the method of the invention, the reinforcement fiber bundles are deposited on a surface and/or in reinforcement fiber bundles deposited on the surface and are fixed on the surface and/or in reinforcement fiber bundles deposited on the surface to form the fiber preform. The surface, i.e. the deposition area, preferably already has a contour which is adapted to the contour of the fiber preform to be produced or the composite fiber component to be produced therefrom.
    [0044] The surface or the deposition area may be a sieve with holes, on which sieve the fiber bundles are deposited, possibly with the simultaneous addition of matrix material, or on which sieve they are blasted. In the case where such a sieve is used, a fixation of the fiber bundles can at least be supported whereby a vacuum is applied on the side of the sieve which faces away from the side of the sieve on which the fiber bundles are deposited. In this way, air is sucked through the sieve, whereby fixation of the fiber bundles can be achieved. The surface can also be provided with a pre-applied binder or matrix material and adhesive during deposition, so that an adhesion to the fiber bundles is ensured. Adhesion can also be carried out by said matrix material using a simultaneous addition of matrix material together with the fiber bundles.
    [0045] It is advantageous for the production of composite fiber component with high fiber volumetric percentages that a compaction step follows the step of deposition of the reinforcement fiber bundles in the method according to the invention, in which compaction step the bundles of deposited reinforcement fibers are compacted to achieve a higher fiber volumetric percentage. This compaction step can be carried out in such a way that the preform obtained after deposition of the fiber bundles is fixedly exposed in a mold at a higher pressure, for example, in a press, preferably at a higher temperature. Similarly, the preform obtained after deposition of the fiber bundles can be packed in a vacuum bag and compaction can be carried out by applying vacuum and the higher temperature.
    [0046] In a preferred embodiment of the method for producing a fiber preform, the deposition head is connected with a controllable positioning unit, by means of which the deposition head is moved relative to the surface. In one configuration, the deposition head can be connected by means of an articulated arm robot located on a base of the machine, and can be positioned on at least two axes relative to the surface by means of the articulated arm and a robotic joint supported by the arm. articulated. In a further embodiment, the deposition head can be fixed by means of a hinged head on a gantry frame and can be positioned on at least two axes with respect to the surface. The deposition head can preferably be positioned on at least 6 and in particular preferably on at least 9 axes.
    [0047] In a further embodiment, the surface on which the fiber bundles are deposited is fixed and the relative movement between the deposition head and surface is made by a movement or positioning of the deposition head. Alternatively, the surface on which the fiber bundles are deposited can be moved, for example, by means of an articulated arm robot, and the deposition head can be fixed. Of course, mixed shapes of the present method are also included, in which, for example, the surface is moved, for example, in 6 axes by means of an articulated-arm robot and the deposition head can be similarly positioned, for example, in 3 axes.
    [0048] Composite components can be produced from fiber preforms produced by the method according to the invention, whose components are characterized by a high volumetric percentage of fiber and thus by high specific mechanical characteristics, such as high strength . The invention, therefore, also concerns a method for producing a fiber composite component using a fiber preform which has been produced according to the method of the invention to produce a fiber preform, comprising the steps of: - introducing the fiber preform produced according to the method of the invention into a shaping device, - exposing the fiber preform to pressure and/or vacuum and/or higher temperature to form the composite fiber component, - cooling of the fiber composite component, - removal of the fiber composite component from the shaping device.
    [0049] Depending on the amount of matrix material present in the fiber preform used, as well as the type of matrix material, different modalities of the method for producing the composite component arise. Thus, a composite component can be produced using the previously listed method steps by direct compaction, without the need to supply additional matrix material, if, according to the method of the invention, the fiber preform used was produced using a prepreg for at least one continuous segment of reinforcing fibers provided with a binder, and the prepreg had a matrix or binder content above approximately 25% by weight. Similarly, the production of the composite component, for example, by direct compaction, is possible, if the production of the fiber preform would certainly take place from the continuous segment in the form of ribbons of reinforcing fibers provided with a binder, for which reinforcing fibers the binder concentration was relatively low and not sufficient to produce a component with a continuous matrix phase, but additional matrix material was supplied before the deposition of the fiber bundles or during the deposition of the fiber bundles.
    [0050] The time for compaction under pressure and/or vacuum and the highest temperature depends in particular on the type of matrix material. If the matrix material is a thermoplastic polymer or a mixture of thermoplastic polymers, then times for compaction can be kept relatively short. For binders and/or matrix materials based on uncured or partially cured duroplastic polymers, the time required for compaction depends on the times that are required for curing the matrix.
    [0051] In the case where a fiber preform is used in the method to produce a composite component, in which fiber preform the fiber bundles have only a relatively low binder content, for example, in the range of 2 at 14% by weight with respect to the reinforcing yarn provided with a binder, and the binder is based, for example, on uncured or partially cured duroplastic polymers or resins, then the matrix material still exhibited for the production of the composite component can further be introduced into the shaping device according to the methods for infusion or injection of matrix material mentioned at the beginning, before a compaction into a component takes place under pressure and/or vacuum and at the highest temperature.
    [0052] To implement the method according to the invention, a deposition device is well suited, as will be explained by means of the following schematic representation in figure 1.
    [0053] The deposition device will subsequently be explained below by means of the schematic representations in the figures. The content of the figures is as follows:
    [0054] Figure 1: side view of a deposition device segment with deposition head.
    [0055] Figure 2: isometric representation of the deposition device segment of Figure 1.
    [0056] Figure 3: Deposition device with articulated arm robot.
    [0057] Figure 1 shows a schematic representation of a segment of a deposition device, in which the deposition head 1 is connected to a controllable positioning unit 3 by means of a joint 2. Two supply devices 4 for the spools 5 as a means for providing the continuous tape-like segments 6 of reinforcing fibers provided with a binder are connected in this case to the deposition head 1, which supply devices are preferably driven by means of control motors. Connection between the deposition head 1 and the supply devices can take place using suitable clamps (not shown here).
    [0058] Of the spools 5 located in the supply devices, continuous tape-like segments 6 of reinforcing fibers provided with a binder are unrolled and guided around a spreader roller 7, which is preferably convexly projected. By means of the spreader roller 7, the continuous segments 6 are spread out and, if necessary, separated. Because of the convex design of the spreader roller 7, a side guide of the continuous segment 6 can be simultaneously realized.
    [0059] Of the spreader roller 7, continuous segments 6 are fed into a first transfer device 8, which comprises a pair of rollers driven on the deposition device in figure 1. For this purpose, the lower roller 9 is pressed by means of a tensioning device 10 against the upper roller 11, provided with a rubber coating so that the transfer of the continuous segments 6 can take place without slipping.
    [0060] After passing through the first transfer device 8, the continuous segments 6 are fed into the longitudinal splitting device 12, in which the continuous segments 6 are cut along their direction of extension into continuous sub-segments 13. An arrangement of a plurality of rotating divider disks 14 serve this purpose, against which the continuous segments 6 to be divided are pressed with a defined force by means of two clamping rollers with controlled force 15. The continuous subsegments 13 obtained in the longitudinal division device 12 are fed into the second transfer device 16, likewise implemented as a pair of driven rollers. By setting a speed difference between the second transfer device 16 and the first transfer device 8, in which the transfer speed of the second transfer device 16 is set slightly higher than that of the first transfer device 8, a defined voltage it can be applied on continuous segments 6 and continuous subsegments 13, whereby a better cutting result is obtained in the longitudinal division device 12.
    [0061] The lower roller 17 of the second transfer device 16 simultaneously serves as a counterroll for the cut-to-length unit 18, implemented as a rotating transverse scissors in the present example, comprising the cutter roller 19 and counterroll 17. In the cutting unit cut to length 18, the continuous subsegments 13 are cut into reinforcing fiber bundles or fiber bundles 20 of a defined length. The fiber bundles cut to length 20 are removed from the cut-to-length unit by the nozzle head 21 and blasted through the nozzle channel of the nozzle head 21 pressurized with compressed air at high speed on a surface to produce a pre. - fiber form.
    [0062] Figure 2 shows for clarification of the spatial arrangement, in particular of the deposition head elements, a perspective representation of the segment of a deposition device represented in Figure 1, in which the same reference numbers in the figures are related to the same elements on the device.
    [0063] Figure 3 shows an embodiment of the device that can be used in the method according to the invention, with an articulated arm robot 23 located on a base of the machine 22, at whose end of the arm the deposition head 1 is mounted by means of a joint 24, and by means of which the deposition head can be moved in a plurality of axes with respect to the surface 25 of a molded body used to produce a fiber preform.
    [0064] Hereby, the fiber bundles 20, obtained by means of the longitudinal splitting device 12 and the cutting-to-length unit 18 in the deposition head 1, and applied by means of the nozzle head 21, can be blasted into tracks defined on the surface 25 according to the requirements of the structure of the fiber preform to be produced or the composite component to be produced therefrom.
    权利要求:
    Claims (18)
    [0001]
    1. Method for producing a fiber preform by depositing bundles of reinforcement fibers on a surface and/or bundles of reinforcement fibers (20) deposited on the surface (25), characterized in that it comprises the steps of: - supplying at least one continuous tape-like segment (6) of reinforcing fibers provided with a binder from a supply device (4) in a deposition head (1), wherein at least one continuous segment (6 ) has a width of at least 5 mm and a binder concentration in the range of 2 to 70% by weight relative to the weight of the continuous segment in the form of a ribbon (6), - spread at least one continuous segment in the form of a ribbon ( 6) in a spreading unit (7) arranged in the deposition head (1) and transfer at least one continuous segment (6) in the transfer direction by means of a first transfer device (8) arranged in the deposition head (1 ) for a longitudinal splitting device (12) arranged in the d head. eposition (1), - hereby stabilize at least one continuous segment (6) in the direction transverse to the transfer direction, - cut at least one continuous segment (6) in the longitudinal dividing device (12) along its longitudinal extension in two or more continuous subsegments (13) by means of at least one dividing element, - transferring the continuous subsegments (13) in the transfer direction by means of a second transfer device (16) arranged in the deposition head (1) to a cut-to-length unit (18) arranged in the deposition head (1), - cutting the continuous sub-segments (13) by means of the cut-to-length unit (18) into bundles of reinforcing fibers (20) of defined length, and - depositing the bundles of reinforcing fibers (20) on a surface (25) and/or bundles of reinforcing fibers deposited on the surface and fixing the bundles of reinforcing fibers (20) on the surface (25) and/or on reinforced fiber bundles deposited on the surface. to form the fiber preform, wherein a relative movement between the deposition head (1) and the surface (25) is adjusted to provide properly loaded deposition of the reinforcing fiber bundles (20) on the surface (25 ).
    [0002]
    2. Method for producing a fiber preform according to claim 1, characterized in that at least one continuous segment (6) is a filament yarn with a filament count of at least 12,000 filaments.
    [0003]
    3. Method for producing a fiber preform according to claim 1 or 2, characterized in that at least one continuous segment (6) is a pre-impregnated filament yarn and the binder consists of a first and a second resin composition, wherein the filaments of the filament yarn are impregnated with the first resin composition and are at least partially connected by means of the first resin composition, wherein the first resin composition contains at least two bisphenol resins Epichlorohydrin H1 and H2 in an H1:H2 weight ratio of 1.1 to 1.4, where H1 has an epoxy value of 1,850 to 2,400 mmol/kg, an MN average molecular weight of 800 to 1,000 g/mol , and is solid at room temperature, and H2 has an epoxy value of 5,000 to 5,600 mmol/kg, an average molecular weight MN of <700 g/mol, and is liquid at room temperature, and additionally contains an aromatic polyhydroxyether P1, which has an acid value of 40 to 55 mg KOH/g and an MN average molecular weight of 4,000 at 5,000 g/mol, and wherein the pre-impregnated filament yarn has a second resin composition on its outer side in the form of particles or drops adhering to the filaments, wherein the second resin composition is solid at room temperature, it has a melting temperature in the range of 80 to 150°C and is present on the outer side of the yarn in a concentration of 0.5 to 10% by weight with respect to the total weight of the pre-impregnated filament yarn, and in which at minus 50% of the surface area of the outer side of the yarn is free of the second resin composition and the inner yarn is free of the second resin composition.
    [0004]
    4. Method for producing a fiber preform according to claim 2 or 3, characterized in that the binder is present in a concentration in the range of 2 to 14% by weight in relation to the total weight of the yarn. filament provided with the binder.
    [0005]
    5. Method for producing a fiber preform according to claim 1, characterized in that at least one continuous segment (6) is a prepreg with reinforcement fibers arranged unidirectionally in the direction of extension of the continuous segment (6 ).
    [0006]
    6. Method for producing a fiber preform, according to claim 5, characterized in that the binder is in a concentration in the range of 15 to 70% by weight in relation to the mass per unit area of the prepreg.
    [0007]
    7. Method for producing a fiber preform according to any one of claims 1 to 6, characterized in that at least one continuous segment (6) is cut in the longitudinal direction into more than two continuous subsegments (13) .
    [0008]
    8. Method for producing a fiber preform according to any one of claims 1 to 7, characterized in that at least one continuous segment (6) has a width to thickness ratio of at least 20.
    [0009]
    9. Method for producing a fiber preform according to any one of claims 1 to 8, characterized in that the width of the continuous subsegments (13) is in the range of 0.5 to 5 mm.
    [0010]
    10. Method for producing a fiber preform according to any one of claims 1 to 9, characterized in that the fiber bundles (20) cut by means of the cut-to-length unit (18) have a length in the range from 10 to 100 mm.
    [0011]
    11. Method for producing a fiber preform according to any one of claims 1 to 10, characterized in that multiple continuous segments (6) of reinforcing fibers provided with a binder are fed into the deposition head (1) , wherein the multiple continuous segments (6) can be the same or different.
    [0012]
    12. Method for producing a fiber preform according to any one of claims 1 to 11, characterized in that the deposition head (1) is connected to a controllable positioning unit (3), whereby the deposition head (1) is moved with respect to the surface (25).
    [0013]
    13. Method for producing a fiber preform according to any one of claims 1 to 12, characterized in that the fiber bundles (20) are heated after the cut-to-length unit (18) and before deposition on the surface (25) and/or on the fiber bundles deposited on the surface.
    [0014]
    14. Method for producing a fiber preform according to any one of claims 1 to 13, characterized in that the fiber bundles are transported out of the cut-to-length unit (18) by means of the nozzle channel of a nozzle head (21) pressurized with compressed air.
    [0015]
    15. Method for producing a fiber preform according to any one of claims 1 to 14, characterized in that particulate or droplet-shaped matrix material is blasted together with fiber bundles (20) on the surface ( 25) and/or the fiber bundles deposited on the surface.
    [0016]
    16. Method for producing a fiber preform according to claim 15, characterized in that particulate matrix material is introduced into the nozzle channel, which material is blasted together with fiber bundles (20) on the surface (25) and/or the fiber bundles deposited on the surface.
    [0017]
    17. Method for producing a fiber preform according to any one of claims 1 to 16, characterized in that a compaction step follows the step of depositing the reinforcing fiber bundles (20), in which step of compaction the deposited reinforcement fiber bundles (20) are compacted to reach a higher fiber volumetric percentage.
    [0018]
    18. Method for producing a fiber composite component using a fiber preform produced according to any one of claims 1 to 17, characterized in that it comprises the steps of: - introducing the fiber preform into a device shaping, - exposing the fiber preform to pressure or vacuum and/or higher temperature to form the fiber composite component, - cooling the fiber composite component, - removing the fiber composite component from the shaping device.
    类似技术:
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    同族专利:
    公开号 | 公开日
    WO2014067763A1|2014-05-08|
    PL2727693T3|2015-05-29|
    AR093349A1|2015-06-03|
    US10059042B2|2018-08-28|
    JP2015534914A|2015-12-07|
    EP2727693B1|2015-01-14|
    CA2888951C|2020-10-27|
    RU2632298C2|2017-10-03|
    KR20150081277A|2015-07-13|
    AU2013339697B2|2017-07-06|
    KR102091993B1|2020-03-23|
    JP6195933B2|2017-09-13|
    CN104768725B|2016-11-23|
    CA2888951A1|2014-05-08|
    AU2013339697A1|2015-04-23|
    EP2727693A1|2014-05-07|
    US20150273736A1|2015-10-01|
    TWI597155B|2017-09-01|
    RU2015116163A|2016-12-27|
    BR112015008233A2|2017-07-04|
    ES2531582T3|2015-03-17|
    CN104768725A|2015-07-08|
    TW201429694A|2014-08-01|
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    法律状态:
    2018-03-06| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2018-03-13| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
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    优先权:
    申请号 | 申请日 | 专利标题
    EP12191274.5A|EP2727693B1|2012-11-05|2012-11-05|Method for manufacturing fibre preforms|
    EP12191274.5|2012-11-05|
    PCT/EP2013/071259|WO2014067763A1|2012-11-05|2013-10-11|Method for producing fibre preforms|
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