• 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:

    公开号:ES2784388T9
    申请号:ES16825340T
    申请日:2016-12-12
    公开日:2020-11-10
    发明作者:Carola Eyssell；Rüdiger Heinritz；Reiner Kelsch；Gerhard Mayrhofer；Christian Rouet；Johannes Riegler
    申请人:Voestalpine Stahl GmbH；Voestalpine Metal Forming GmbH；
    IPC主号:
    专利说明:

    [0001] Process for the manufacture of a semi-finished product or a construction part of metal and fiber composite material
    [0002] Technical field
    [0003] The invention relates to a process for the manufacture of a semi-finished product or a construction part according to claim 1, in which a metal support configured as a sheet or plate is coated with at least one prepreg product having a Duroplastic matrix that can be thermally cross-linked with endless fibers, the duroplastic matrix of the prepreg is pre-cross-linked by heating and the metal support coated with the pre-cross-linked prepreg is shaped to give a semi-finished product or a construction part by deep drawing or deep drawing with stretched. State of the art
    [0004] In order to be able to subject a metal support, specifically a sheet metal cut or sheet metal plate, reinforced with prepregs that have a duroplastic matrix with endless fibers, if possible without damage to a forming process, in particular deep drawing, it is known by the state of the art (document WO2013 / 153229A1) move the plastic deformations in the metal support towards the free areas of coating of the metal support. Accordingly, there are free areas of coating in the semi-finished product or construction part, which limits such semi-finished products or construction parts reinforced with FVK in terms of their lightweight construction potential and thus their application possibilities. In addition, this limitation of surface also limits the fiber length of the prepregs, which can lead to a reduction in stiffness and strength. In addition, in the case of semi-finished products or construction parts that have been deep drawn from sheet metal cuts with prepregs cured without pressure until obtaining the block strength, the tendency to delamination and / or a high porosity in the finally cross-linked fiber composite material - which interferes with the reproducibility of the process.
    [0005] Furthermore, a compression molding process is known from EP2647486A1, a forming process from US20130340928A1 and deep drawing from WO2015 / 052352A1.
    [0006] Description of the invention
    [0007] The invention has therefore been proposed with the aim of improving a process of the type described above in terms of its simplicity, possibilities of application and also its reproducibility. Furthermore, a low cycle time procedure will be possible.
    [0008] The invention solves the objective set due to the fact that during the previous crosslinking of the duroplastic matrix of the prepreg, its matrix is transferred to a state of viscosity that follows its minimum viscosity and even before reaching its gel point, the prepreg is formed. together with the metal bracket.
    [0009] If during the pre-crosslinking of the duroplastic matrix of the prepreg its matrix is transferred to a state of viscosity that follows its minimum viscosity and even before reaching its gel point the prepreg is formed together with the metal support, it can As a result, not only a plastic shape modification in the metal support in its fiber-reinforced areas is allowed, but also the reproducibility of the method can be clearly improved. The prepreg that is in this state can allow relative movements, specifically corresponding to the radius of shaping, between its endless fibers and the metal support. Consequently, even narrow bending radii can result in sheet metal cutting, without requiring fracture or delamination. The process according to the invention can therefore be used in a particularly varied way. Surprisingly, it was furthermore possible to achieve that the compaction of the matrix material with the fiber structure of the endless fibers can be considerably improved by the joint shaping. The comparatively short force load, in particular pressure load, during shaping can be used to reduce the porosity in the fiber composite material - whereby the laminate quality can be increased and the risk of delamination of the reinforcement can be further reduced with fibers in sheet metal cutting. According to the invention, therefore, by transferring the matrix to a state of viscosity that follows its minimum viscosity and shaping the prepreg together with the metal support even before reaching the gel point of the matrix the reproducibility of the procedure can be considerably improved. Furthermore, by forming the prepreg and the metal support together it is possible to facilitate a particularly rapid process development with a low cycle time. Furthermore, the process according to the invention does not require, in comparison with other known processes for the manufacture of semi-finished products or building parts of fiber composite material, any expensive installation techniques and / or complex handling - which means, in addition to a reduction in costs for the process according to the invention, also an improvement in its reproducibility.
    [0010] In general it is mentioned that the metal support can be made of sheets with a material of iron, aluminum or magnesium, by a light metal or the like or by alloys of these. A metal carrier can be distinguished as a steel sheet with or without a protective layer, for example based on zinc. In general it is further mentioned that the duroplastic plastic matrix can have a combination with inorganic or organic reinforcing fibers, such as for example glass, basalt, carbon or aramid. Furthermore, it is conceivable to coat the metal support with several prepregs side by side as well as a stacking of prepregs (single or multi-layer) on the metal support. The fibers contained in the prepreg can be found as a pure unidirectional layer. This can create, with multi-layer prepregs, a unidirectional or multidirectional laminate on the metal support.
    [0011] Furthermore, it is generally noted that a duroplastic plastic matrix can also have combinations of modified duroplastic polymers, which preferably consist of phases that are not necessarily crosslinked with each other of epoxy and polyurethane phases. Known percent compositions are those of a PU-epoxy blend, eg, 5 to 25 parts of primary polyurethane phase in surrounding epoxy matrix. In general, it is further mentioned that the viscosity of the matrix is determined with a rheometer, specifically Anton Paar MCR 301 viscometer with oscillation (for example: plate-plate configuration, diameter 25 mm; space 1000 | jm; amplitude 0.5%; frequency angular 10 rad / s), evaluated according to ASTM D 447308/2016.
    [0012] In order to reduce the risk of undesired crushing of the prepreg of the heated duroplastic matrix above the minimum viscosity during shaping, it can be provided that before shaping the degree of crosslinking of the duroplastic matrix is adjusted to up to 4 to 15% (for example: by temperature and / or time).
    [0013] It can be particularly advantageous when the degree of crosslinking of the duroplastic matrix is adjusted to up to 20 to 45% during shaping (for example by temperature and / or time). As a result, the risk of undesired crushing of the duroplastic matrix during shaping can be further reduced in particular. Also, in the case of such a degree of crosslinking, pressure loading on the prepreg during shaping can provide optimal conditions for obtaining a high laminate quality of the prepreg. Furthermore, this can also be useful for the adhesive force between material partners.
    [0014] It can be particularly advantageous when the degree of crosslinking of the duroplastic matrix is adjusted to up to 25 to 40% during shaping (for example by temperature and / or time).
    [0015] If the duroplastic matrix is heated to 120 to 220 ° C during shaping, crosslinking can be accelerated - thus shaping can be carried out more quickly or the process cycle time can be reduced.
    [0016] It can be especially advantageous when the duroplastic matrix is heated to 150-180 ° C during shaping.
    [0017] Undesired cooling of the heated prepreg - and consequently a change in temperature disadvantageous for the process according to the invention - can be prevented when the forming mold is heated and the metal support is formed with the heated forming mold. In this way, the reproducibility of the method can be further increased. It is noted that for this purpose the temperature of the forming mold can be deviated from the temperature of the prepreg or of its matrix. It is also conceivable that the molds of the shaping mold have different temperatures, to heat the metal support in a targeted, zone-specific manner or to set a temperature gradient in the laminate. Cycle times for forming can be reduced when the prepreg is cured without pressure after forming together with the metal support - and as a result of this the forming mold can be detached especially quickly again.
    [0018] Since an intermediate layer is applied to the metal support before or during the coating of the metal support with the prepreg, through which the prepreg is attached to the metal support, the strength can be improved on the one hand. Adhesive, on the other hand, can also act in a compensatory way on thermal stresses. This intermediate layer had to be fully applied at least in that area of the metal support that is also coated with prepreg.
    [0019] The layer thickness of the intermediate layer can be preferably 50 µm to 1000 µm, with layer thicknesses of 80 µm to 700 µm being preferred. Thicker layers, preferably layer thicknesses of 500 jm to 1000 jm, can be characterized in that they also offer protection against corrosion (barrier layer). In the case of applications with high stiffness requirements, thin films are preferred (preferably <150 jm). In addition, the processing time, ie the reaction time, is relevant - which is to be observed especially at shorter cycle times. In this connection, it has been shown that interlayers based on polyethylene, polypropylene and / or with a polyamide core or else interlayers based on co-polyamide can be particularly very suitable. These can be for example systems from Nolax, specifically products Cox 391, Cox 422, Cox 435, systems from Evonik, specifically Vestamelt X1333-P1 or systems from Hexcel, specifically the products TGA25.01A or DLS 1857.
    [0020] To guarantee a high quality of the laminate, it can be provided that the matrix of the prepreg is loaded with a pressing force during shaping. Such a pressure load can be generated, for example, when the metal support coated with prepreg and configured as sheet metal is formed by deep drawing or drawing drawing. The metal support can be generated, for example, by transverse cleavage of a metal strip, it can also be configured as a flat sheet or plate.
    [0021] Crease formation or fiber drawing in the prepreg can be prevented when the prepreg during shaping is pressed into the metal support in areas and is thereby fixed there on the metal support. Through this local fixing of limited areas of the metal support coated with prepreg, which can be achieved, for example, with the aid of a matrix insert, the prepreg can, for example, be allowed endless mobility in a manner corresponding to the respective orientation of its fibers. in other directions. For this it is also conceivable that the shaping mold has a plurality of such fasteners. Such a fastener can also be created by reducing local mold space for example between dies and punch.
    [0022] The risk of creasing or fiber drawing can be further reduced when the prepreg during shaping is in shaping gear with successively acting segments or groups of segments of a die and / or a punch of a shaping mold. In this way, a reinforced action of the forming mold on the prepreg can be achieved - so that the prepreg can better follow the plastic shape changes of the metal support. If the mesh area is widened in the course of the segment or group segment forming process towards an edge of the metal support, possible folds in the prepreg or air inclusions contained therein can be finely pressed in the direction of the prepreg. from the edge of the metal bracket. With the aid of the shaping mold, for example, subsequent smoothing of the prepreg can be dispensed with. To facilitate deep drawing or also drawing drawing, it can be provided that the metal support is coated in areas with at least one prepreg. This can further increase the reproducibility of the procedure.
    [0023] The above mentioned advantages can be adjusted in particular when 20 to 40% of one of the flat sides of the metal support has been coated with prepreg.
    [0024] In particular, the method according to the invention may be suitable for the manufacture of a structural component of a vehicle. In general it is mentioned that a structural building part can be a building part of a supporting structure of a vehicle, in particular of an automobile, a road vehicle, a transport vehicle, a rail vehicle, a aircraft or spaceship. A structural building part can be configured for example as a side skirt, as an A-post, as a B-post, as a C-post, as a cross member or as a spar.
    [0025] Brief description of the drawing
    [0026] The figures show in more detail by way of example the method according to the invention for the manufacture of a semi-finished product or construction part. Show
    [0027] figure 1 a development of the process according to the invention, in which a deep drawing mold is used for shaping a metal support joined with a prepreg product, figure 2 a separate and enlarged section view on a product semi-finished manufactured according to the procedure according to figure 1 and
    [0028] FIG. 3 shows a time-dependent representation with respect to the viscosity and degree of crosslinking of the matrix of the prepreg used in the process according to FIGS. 1 and 2.
    [0029] Mode for carrying out the invention
    [0030] According to the development shown according to FIG. 1 of the method 1 according to the invention for the manufacture of a construction part 2, for example a structural construction part 2.1 of a vehicle, a support is generated in a first step of metal 3 made as a sheet metal cut 30, with specifically a plate 30, of a metal strip 4 of a coil 5 by means of transverse cleavage. The metal support 3 is pre-cleaned possibly still on one flat side 3.1, of the two flat sides 3.1, 3.2, which is to be coated with prepreg 6, and / or is pre-treated chemically, which however it has not been represented in more detail. Subsequently, the metal support 3 is coated with the aid of a robot 7 with several prepregs 6. The metal support 3 can optionally be preheated for this.
    [0031] For cutting the prepreg 6, for example, a robot 8 is provided with cutting devices not shown in more detail, for example with an ultrasound-induced cut, which separates it from a fabric / cloth / braid / knitted / knitted fabric. etc. 10 (FVK) previously impregnated with plastic matrix, rolled in a roll 9. The fabric / cloth / braiding / knitting / knitting etc. 10 of endless fibers is already impregnated in the exemplary embodiment with a duroplastic matrix, which can be thermally crosslinked.
    [0032] However, it is conceivable also in general - however not shown - that the metal support 3 is coated with prepregs 6 previously conditioned, for example in an automated way, as represented in FIG. 1, and / or manually . These prepregs 6 can be pre-conditioned - for example stacked in a stack - already in their dimensions, in density, in the number of layers and / or with an intermediate layer etc.
    [0033] After this coating, the metal support 3 coated with this is irradiated with the aid of a heat source 11 - and as a result the crosslinking of the matrix is adjusted in a targeted manner. This crosslinking of the matrix is carried out without pressure and is carried out using a fabric / cloth / braid / knitwear / knitting etc. 10 pre-impregnated by heating from 80 ° C to 200 ° C, preferably from 100 ° C to 180 ° C, with a heating rate of 1 to 40 ° C / min, preferably 5 to 25 ° C / min - for thereby adjust a degree of crosslinking a before shaping of 4 to 15%. Instead of the heat source 11 represented as an IR or NIR radiator, for example, a continuous-flow furnace is also conceivable, which, however, is not represented in more detail in the exemplary embodiment.
    [0034] Next, the coated metal support 3 is placed in a shaping mold 12 and formed.
    [0035] According to the invention, this shaping is carried out according to the preliminary crosslinking of the duroplastic matrix of the prepreg 6, as can be deduced from FIG. 3. For this, this matrix is transferred to a state of viscosity r which follows its minimum viscosity r | Min and even before reaching its gel point Pc is formed together with the metal support 3 with the aid of the shaping mold 12. The shaping mold 12 is transferred from an open position to a closed position for this purpose. The advantageous joint shaping of the duroplastic matrix with the metal support 3 is possible according to the invention, since the prepreg 6 used in the state described according to the invention can follow the plastic shape modifications by shaping. The endless fibers of the prepreg 6 have moved relatively in the prepreg 6 particularly even compared to the metal support 3. The matrix of the prepreg 6 is in a state of viscosity n which follows its minimum viscosity r min , so that there is no endless fiber breakage or delamination of the fiber reinforcement in the metal support 3 during shaping - as this can be distinguished in more detail in figure 2. According to the invention it is In this way, a common shaping with bending radii 13 is possible in the metal support 3 in its areas free of prepreg 6 as well as in its areas 14 coated with prepreg 6.
    [0036] As can be distinguished in figure 1, therefore, the metal support 3 is coated only in areas with the prepreg 6, and in fact on a flat side 3.1 in from 20% to 40%, which clearly facilitates the shaping joint. The area 14 of the flat side 3.1 coated with prepreg 6 is therefore, in terms of area, smaller than the entire area of the flat side 3.1.
    [0037] The representation according to FIG. 3 refers to the following fiber composite material:
    [0038] Metal bracket: sheet steel: sheet thickness 0.81 mm
    [0039] Laminate: unidirectional, four layers of prepreg
    [0040] Prepreg: endless fibers with a fiber content of 57% in the matrix, thickness: 0.22 mm Matrix: duroplastic base (SGL type E201: modified epoxy resin system)
    [0041] r min = 0.9 Pa * s
    [0042] Pc = 45%
    [0043] Intermediate layer: 100 | jm of polypropylene
    [0044] The degree of crosslinking a of the matrix was determined by means of differential scanning calorimetry (DSC) measured according to ISO 11357-5: 2013.
    [0045] Instead of the steel sheet, a sheet made of an aluminum alloy, for example of the 6xxx series, is also conceivable.
    [0046] According to FIG. 1, for example, a deep-drawing mold 15 is represented as a shaping mold 12, for thereby shaping or deep-drawing the coated metal support 3. However, it may be quite conceivable that the metal support 3 with a shaping mold not shown is subjected to a combined drawing and deep drawing.
    [0047] To reduce the risk of a crushing of the duroplastic matrix of the prepreg 6 during shaping, this matrix is previously crosslinked as mentioned by 4 to 15%, before the shaping mold 12 exerts forces on the prepreg. 6 - what is produced as represented in the Figure 1 when the shaping mold 12 is transferred from its open position to its closed position. In general, it is mentioned that for the measurement of crosslinking by means of differential scanning calorimetry (DSC) the isothermal procedure according to ISO 11357-5: 2013 may be especially suitable.
    [0049] In the heated shaping mold 12, the degree of crosslinking a of the matrix is adjusted starting from 4 to 15% before shaping up to 20 to 45%, preferably up to 25 to 40%, during shaping, the limits of which are 20 at 45% were plotted by dots in FIG. 3. Such an adjustment can be made for example by temperature and / or time. After this, the construction part 2 is removed from the shaping mold 12. Preferably, the construction part 2 is removed from the shaping mold 12 during or after obtaining the gel point of the respective matrix. This allows, with the same laminate quality in the prepreg 6, a very shortened cycle time compared to known processes and guarantees the sufficient stability of the matrix system with the fibers itself.
    [0051] With a shaping mold 12 that is heated, that is to say tempered in a targeted manner, it can also be ensured that during shaping the duroplastic matrix is kept at a temperature of 120 to 220 ° C, so that the construction part 2 can be removed earlier from the mold of faster shaping by crosslinking and thus be able to shorten the procedure. A temperature from 150 to 180 ° C could be distinguished repeatedly. For heating the shaping mold 12 or the deep drawing mold 15, the latter has an electrical heater 16, which heats the die 17 and the punch 18 of the shaping mold 12. A heating for the holder 19 is not shown, which however it is equally conceivable. For example, by means of differently tempered zones, a temperature gradient can be set in the matrix or in the prepreg 6, in order to be able to precisely set physical and chemical parameters - such as, for example, adhesive strength, viscosity state n etc.
    [0053] After shaping, the building part 2 is removed from the shaping mold 12 and the matrix of the prepreg 6 is subsequently cured without pressure outside the shaping mold 12 - that is to say with another heat source 20 which can be distinguished according to FIG. 1. For this, among other things, a continuous-pass furnace, not shown, is again conceivable. This further curing is preferably carried out by means of the heat source 20 at a temperature of 100 to 200 degrees Celsius (° C), thereby reducing, for example, inherent stresses by subsequent cooling to room temperature. Repeatedly, a temperature of 120 to 150 ° C was able.
    [0055] The metal support 3 to be coated also has, among other things, a protective coating 21, for example a layer of zinc or zinc alloy - as can be distinguished from FIG. 2. On this protective coating 21 or on On the flat side of the metal support 3, an intermediate layer 22 is applied in the area completely coated with prepreg 6. This intermediate layer 22 is generated by applying a polyamide-based adhering agent to the metal support 3. Through this intermediate layer 22 can bond the prepreg 6 to the metal support 3 in an extremely fixed manner and with low tension.
    [0057] During shaping, the prepreg 6 is kept pressed into the metal support 3 by zones and thus fixed there on the metal support 3 - as indicated in figure 2. The segment 23 of the die 17 presses the prepreg 6 on the metal support 3, which is stabilized by a dolly 24 represented, for example, of the dies 17 in this area. The formation of folds or the drawing of the fibers in the prepreg is avoided in this way.
    [0059] The prepreg 6 is also encountered during the shaping gear shaping with segments 25, 26 acting successively from the die 17 of the shaping mold 12. This can be distinguished in Figure 2 in that a segment 26 of the die 17 differs of the segment 25 is not yet in full contact with the prepreg 6. Furthermore, it can be distinguished in the succession of the segments 25, 26 that the engagement area 27 widens in the course of the segment forming process towards the edge 28 of the metal support 3. Hereby, through the segmented shaping mold 12 a type of smoothing of the prepreg during shaping can be allowed, which reproducibly excludes the formation of folds and air inclusions in the prepreg.
    权利要求:
    Claims (15)
    [1]
    1. Procedure for the manufacture of a semi-finished product or a construction part (2), in which a metal support (3) configured as a sheet or plate (30) is coated with at least one prepreg (6) that has a duroplastic matrix, which can be thermally crosslinked with endless fibers,
    the duroplastic matrix of the prepreg (6) is pre-crosslinked by heating and the metal support (3) coated with the prepreg (6) previously crosslinked is shaped to give a semi-finished product or a construction part (2) by deep drawing or drawing drawing, in which during the previous crosslinking of the duroplastic matrix of the prepreg product (6) its matrix is transferred to a state of viscosity (r) that follows its minimum viscosity (r | min ) and still Before reaching its gel point (Pc), the prepreg (6) is formed together with the metal support (3).
    [2]
    Method according to claim 1, characterized in that the degree of crosslinking ( a) of the duroplastic matrix is adjusted to up to 4 to 15% before shaping.
    [3]
    Method according to claim 1 or 2, characterized in that during shaping the degree of crosslinking (a) of the duroplastic matrix is adjusted up to 20 to 45%.
    [4]
    Method according to claim 3, characterized in that the degree of crosslinking (a) of the duroplastic matrix is adjusted to 25 to 40% during shaping.
    [5]
    Method according to one of Claims 1 to 4, characterized in that the duroplastic matrix is heated to 120 to 220 ° C during shaping.
    [6]
    6. Process according to claim 5, characterized in that the duroplastic matrix is heated to 150 to 180 ° C during shaping.
    [7]
    Method according to one of Claims 1 to 6, characterized in that the forming mold (12) is heated and the metal support (3) is formed with the heated forming mold (12).
    [8]
    Process according to one of Claims 1 to 7, characterized in that the prepreg (6) is cured without pressure after forming together with the metal support (3).
    [9]
    Method according to one of Claims 1 to 8, characterized in that before or during coating of the metal support (3) with the prepreg (6), an intermediate layer (22) is applied to the metal support (3) , through which the prepreg (6) is attached to the metal support (3).
    [10]
    Method according to claims 1 to 9, characterized in that the prepreg (6) is pressed into the metal support (3) in areas during shaping and is thereby fixed there on the metal support (3).
    [11]
    Method according to claim 10, characterized in that the prepreg (6) during shaping is in shaping gear with successively acting segments (23, 25, 26) or groups of segments (24, 25, 26) of a die (17) and / or a punch (18) of the shaping mold (12).
    [12]
    Method according to claim 11, characterized in that the engagement area (27) widens towards an edge of the metal support (3) during the segment or group segment forming process.
    [13]
    Method according to one of Claims 1 to 12, characterized in that the metal support (3) is area-coated with at least one prepreg (6).
    [14]
    Method according to claim 13, characterized in that 20 to 40% of one of the flat sides (3.1, 3.2) of the metal support (3) is coated with prepreg (6).
    [15]
    Method according to one of Claims 1 to 14 for the production of a structural component (2.1) of a vehicle.
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    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    EP15199680.8A|EP3178638A1|2015-12-11|2015-12-11|Method for producing a semi-finished part or component from metal and composite|
    PCT/EP2016/080705|WO2017098060A1|2015-12-11|2016-12-12|Method for manufacturing a semifinished product or a part made of metal and fiber composite|
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