DE102008057462A1 - Fiber composite-spring for use in vehicle construction, has end-, winding- and deflecting sections alternatively arranged on top of each other, formed geometrically different from each other and provided with meander-shaped folded layers - Google Patents

Abstract

The invention relates to a spring made of a fiber composite material having two end portions and arranged therebetween Windungsabschnitte. In this case, this spring (1) is characterized in that the end sections (2, 6) and the turn sections (4, 5) are connected in one piece via deflection sections (3), all sections (2, 3, 4, 5, 6) consist of alternately superimposed, geometrically different shaped and meandering folded layers of a fiber composite material. Preference is given to using prepreg layers (14, 15) which run sinusoidally or cosinusoidally along their longitudinal extension and are alternately superimposed. Furthermore, the invention relates to a method and an apparatus for producing such a spring.

Description

The The invention relates to a spring made of a fiber composite, the two end portions and interposed Windungsabschnitte and a method and an apparatus for producing the same the same.

feathers are well known as structural elements of mechanical engineering. For example, there are leaf springs, disc springs, coil springs or coil springs, in relation to their assigned task in different geometries, dimensions and properties, for example as a tension spring, as a compression spring or as a torsion spring, be used. Such springs are usually made of one Made of spring steel, which of the spring depending on the design and dimension gives different spring force. Although such Steel springs have a number of advantages, so these are for some applications less well suited. Especially with comparatively large springs makes up their weight disadvantageous noticeable. So is the need in modern vehicle construction originated for feathers, which are the same or better Have properties as steel springs, yet are lightweight.

Against this background is from the DE 30 00 520 A1 a carbon fiber reinforced, helically wound spring and a process for their preparation has become known. This fiber composite coil spring is made of braided carbon fibers and an amount of a resin serving as a piling material for the braided fibers, wherein the carbon fibers are braided at an angle of about plus or minus 30 ° to plus or minus 60 ° to the strand axis.

Around to produce such a carbon fiber reinforced coil spring is according to known from this document Method provided that one of carbon fiber strand, in the fibers at an angle of something plus or minus 30 ° to plus or minus 60 ° braided to the strand axis, with one as essentially closed, coherent Impregnating resin which does not solidify, the so-so-absorbed strand of wire wound into a groove, which is helical along the surface of a cylindrical mandrel extends, and thereby reinforced with carbon fibers Coil spring composite gives the helical shape, then the serving as the embedding material of the coil spring resin for Freezing brings, and finally the solid spring from the thorn decreases.

This Manufacturing process is judged to be less practical, since in particular the molding of the solidified spring from the mandrel is difficult. In addition, can be with the known manufacturing process do not realize a continuous manufacturing process, whereby the Manufacturing costs in such a manufacturing process comparatively are high.

In front In this background, the invention is based on the object Method and device for producing a spring from a To propose fiber composite material with which springs from a Fiber composite material continuously and cost-effectively can be produced. In addition, such a spring in terms of their Structure to be described.

The Solution of these tasks is in the independent Claims 1, 15 and 24 described while advantageous Embodiments and developments in the respectively associated Subclaims are defined.

Of the Invention is based on the finding that a spring a fiber composite material by a meandering Folding or forming a continuous manufacturing device supplied strand of prepreg material can be produced, the prepreg material is known to be made of synthetic fibers which is embedded in a non-solidified resin matrix are. A knowledge based on this is that the individual, caused by the described folding of the prepreg material Winding sections of such a spring in each case sequentially curing successively have to go through before the next turn section Wrinkles are made and cured. A central Drill hole or opening in the finished spring according to another knowledge by a Laying several prepreg layers vertically one above the other generate alternately a sine or cosine curve consequences.

According to the Features of claim 1 has an inventive Spring made of a fiber composite material therefore two end sections and in between arranged Windungsabschnitte, wherein the end portions and the Windungsabschnitte integrally via deflecting sections connected to each other, and at the all mentioned sections off alternately superimposed, geometrically different shaped and meandering folded layers of a Consist of fiber composite material.

Roughly speaking, such a spring has approximately the same shape as a rectangular piece of paper folded meander-shaped along its longitudinal extension, the folded sections all being penetrated by a central hole. Nevertheless, it has all the essential properties of a spring, in particular a compression or tension spring on.

According to one Further development of the invention is the fiber composite material of prepreg layers formed, which along its longitudinal extent sinusoidal or cosinus-shaped and alternately on top of each other are laid. Preferably, it is provided that several layers of sinusoidal or cosine-shaped prepreg layers vertically so superimposed, and that the respective Prepreg layers alternately the course of the same sinusoid or follow the course of the same cosine curve.

One thus formed strand of a not yet set Fiber composite material, viewed in a plan view along its longitudinal extension two prepreg main strands in each case the course of a sine curve or a cosine curve consequences. The two prepreg main strands change each from right to left and vice versa, these being in the overlay points alternately lying up or down. This will be more detailed in connection with an exemplary embodiment.

at This spring is preferably provided that there, where layers of the fiber composite material, the respective deflection sections the spring are formed.

Provided The technical constraints may require it, according to a Further development of a spring according to the invention is provided be that their end portions and turn sections as a sheet with largely flat surfaces and the deflection sections are formed curved. Through such a curved, and therefore not sharp folded training of Umlenkabschnitte Advantageously, stress peaks in the material of the finished Spring avoided.

Around straight and horizontally aligned bearings form the spring is preferably provided that the end portions the spring along a transverse axis Ly perpendicular to the longitudinal axis Lx of the spring are arranged aligned.

deviant Of these, the winding sections have a pitch angle in the direction the longitudinal extent of the spring, so that these turns sections according to the convolution at an angle α with respect arranged to the end sections, the larger is 0 ° and less than 45 °.

As already briefly indicated has a manufactured according to the invention Spring on two end portions, which cured in chronological succession are. Another feature of such produced according to the invention Spring is that the end portions and the winding sections over seen the longitudinal extent of the spring in each case in succession are cured. In further development of this feature can be provided that at least one end portion and a precise Hardened at this end portion associated deflecting simultaneously are. In addition, a structural feature of a fiber composite spring made according to the present invention may be consist in that the winding sections each with an associated Deflection section are cured simultaneously.

deviant this can be considered in a worse than because be prepared discontinuously manufactured spring that at this spring both the end portions and the deflection and winding sections cured at the same time. This simultaneous curing For example, after depositing a portion of the fiber composite strand of material on a folded surface of a mold and subsequent pressing the fiber composite material strand under heat respectively.

When less advantageous is the spring just described as well as the associated manufacturing method therefore judged because in this discontinuous manufacturing process, the fibers of the fiber composite material strand can not be cured under a tensile load. As a result, the fibers of the fiber composite material strand of the Spring arranged too little directed, so not optimal properties be expected of such a spring.

Therefore is at one produced by a preferred manufacturing process Fiber composite spring provided that their associated Sections, namely each end portion and deflection section as well as winding section and deflection section, under a tensile load the fibers of the fiber composite material are cured. This tensile load is to maintain the sine or cosine curve the prepreg layers are not very high, but it is enough, so the fibers of the spring are oriented substantially parallel to one another, which also gives an optimal ratio of fiber content to Resin content is generated in the finished spring. This is among other things because the synthetic resin is aligned parallel to each other Distribute fibers between the fibers particularly well as well as excess Synthetic resin can drain easily.

In order for a fiber composite spring produced according to the invention to have desired mechanical properties, it can be provided that the material thickness of the deflection sections is greater than the material thickness of the end portions and the turn portions is.

Yet more important is the adjustment of the fiber volume fraction in the respective Spring cross sections, ie in the end sections, the Windungsabschnitten and the deflecting portions of the spring, whereby the present there Spring properties are determined. The fiber volume fraction is included the percentage of fibers in each component cross-section of the fiber composite material. If, for example, the Proportion of the synthetic resin in such a component cross-section 34%, so the fiber volume fraction at this point is 66%. The higher the fiber volume fraction in a particular spring section is, the stiffer the fiber composite spring is at this point. on the other hand this spring section is set the softer, the lower the proportion of fibers in the considered component cross-section is.

So For example, it may be provided that the fiber volume fraction is greater in the Umlenkabschnitten than in the End sections and in the winding sections, so that in the dynamic Particularly stressed deflecting portions of the spring increased Stiffness is realized.

at another interpretation may be provided that the fiber volume fraction is smaller in the Umlenkabschnitten than in the end sections and in the Windungsabschnitten, so that in the deflection sections of the Spring lower component stiffness is present.

at a further design can be provided that the fiber volume fraction is the same in the Umlenkabschnitten as in the end sections and in the Windungsabschnitten, so that everywhere in the fiber composite spring the same component stiffness is present.

After all can the deflecting sections, the end sections and the Winding sections of the spring, each with different fiber volume fractions be educated.

The each adjustment of the fiber volume fraction can be by a more or less strong pressing out yet set resin from the sections of fiber composite web to reach.

One Another feature of a manufactured according to the invention Spring is that the circumferential contour of the spring at each end section and winding section in the region of the deflection straight and in the intermediate regions of the end and turn sections is formed circular arc. The straightforwardness of Turning sections is by a straight folding or folding of the fiber composite material strand generated while the circular arc-shaped geometry of the other peripheral sections through the sinusoidal or cosinusoidal course of the prepreg layers was generated.

Further there is a further advantageous feature of an inventively designed Spring in that this due to the selected sine or Cosine gradient and the selected width of the prepreg layers transverse to their longitudinal extent after their hardening has a central bore or recess, which all end portions and Winding sections of the spring penetrates.

When Base materials for the prepreg layers come from fibers Glass, carbon or, for example aramid in question. To produce The resin matrix of the prepreg sheets is preferably thermoset Resins used mixed with hardeners and accelerators are.

Further the invention provides a method for producing a novel Fiber composite spring before, which is the following process step having:

S1: Feeding at least two prepreg webs to a transport device.

S2: Alternate deposition of at least two prepreg webs on the Transport device such that a prepreg sheet of a sinusoidal curve and the other prepreg path follows a cosine curve, which is a common, form uncured fiber composite web.

S3: Feeding the uncured fiber composite web to a heater and retracting the fiber composite web in a gap between two heat rollers, in the conveying direction seen behind the heater are arranged.

S4: Redirecting the fiber composite web around one of the two heating rollers less than 181 °.

S5: Stop the transport of the fiber composite web.

S6: Actuation of the heater and the heating of the from the fiber composite web partially wrapped heat roller.

S7: Curing an end portion or a winding portion under the heater and simultaneous curing a deflecting section on the heating roller.

S8: further transport of the hardened En dabschnitts or the cured Windungsabschnitts through the gap of the two heating rollers and simultaneous further transport of the hardened deflection section by lifting the deflection of the heating roller.

S9: Feeding and diverting a not yet cured Section of the fiber composite web around the opposite Heating roller less than 181 °.

S10: Go to step S5 to step S9 until the desired one Length of the spring is reached.

S11: Separating the spring when reaching a certain length.

S12: Remove the spring and continue with step S6.

With This manufacturing method can be inventively formed Springs made of a fiber composite material in a continuous Produce production process very cost-effectively. The curing the fiber composite sheet under the heater and on the heating rollers is preferably to achieve short cycle times only until these sections of spring are sufficiently stiff to to maintain their existing geometric shape. The in these Residual heat containing spring sections is used in the following Procedure for complete curing of the same.

According to one Further development of this manufacturing process is provided that under the heater a planner or only slightly curved Section of the fiber composite web to an end portion or is hardened to a winding section. Although this Production feature is preferred, so it is not excluded harden the end and turn sections more or less curved, provided the desired geometry of the spring to be produced this requires.

Around at the beginning of the production of inventive Springs to have a spring section in the present, with the future Spring held under tension and with a not yet cured Section is easily wrapped around the respective heating roller is provided according to a further embodiment, that at the beginning of the manufacturing process exclusively under the heater and before the heating rollers a planner or only slightly curved portion of the fiber composite web is cured to an end portion.

Furthermore is provided that the deflection and a pressing of not yet cured fiber composite web on the respectively associated heating roller with the help of at least one pressure and deflection roller he follows. By this method step is achieved that the Fiber composite web smooth and full surface on the respective heating roller rests and under the influence of a tensile stress under the heater and harden on the heating roller can.

Around to generate a circumferential geometry of the spring to be produced, which is largely that of a conventional coil spring made of a spring steel corresponds and to a desired fiber volume fraction to adjust in certain cross sections of the spring is according to a further embodiment provided that the leadership and Shaping the uncured fiber composite web before the heater and / or on the heating rollers so, that the spring has a circumferential geometry with at the deflection sections straight course and between these deflecting a circular segment-shaped History has. The sinusoidal or cosinusoidal course The prepreg layers offers the best conditions for this.

In In this context, it is therefore considered advantageous if the manufacturing process is operated so that the leadership and shaping as well as the adjustment of the fiber volume fraction of the still uncured fiber composite web in front of the heater and / or on the heating rollers so that the material thickness of the deflection sections is greater than the material thickness of the end sections as well as the winding sections.

In Further development of this last-mentioned method step is preferred provided that the not yet cured fiber composite web before the heater and / or on the heating rollers in such a way compressed transversely to its longitudinal extent is that the material thickness of the deflection sections larger is the material thickness of the end portions as well as the turns portions.

The Spring is used to adjust the concrete spring characteristics of Sections of the spring are made so that the fiber volume fraction the respective deflection sections, end sections and turn sections smaller, equal to or greater than the fiber volume fraction the respectively adjacent deflection sections, end sections and turn sections. The adjustment of the respective fiber volume fraction is preferred by a sectionwise pressing out of not yet set off Resin from the supplied fiber composite web reached.

To set and fix the pitch angle α of the winding sections of the spring can be provided according to a further method step that the pitch angle α of Windungsab cuts by pivoting the heating rollers to a certain Verschwenkweg above or below the plane in which the fiber composite material web is below the heater.

• – eine Zuführzone zum Zuführen von wenigstens zwei Prepreg-Bahnen zu einer Transportvorrichtung,
• – ein Ablege- und/oder Formwerkwerkzeug zum Ablegen und Formen der wenigstens zwei Prepreg-Bahnen auf der Transportvorrichtung, mit dem die Prepreg-Bahnen wechselweise dem Verlauf einer Sinus-Kurve oder dem Verlauf einer Kosinus-Kurve folgend zur Bildung einer gemeinsamen, nicht ausgehärteten Faserverbundwerkstoff-Bahn vertikal übereinander abgelegt werden,
• – eine in Transportrichtung folgende und im Wesentlichen geradflächige Heizzone mit einem Heizgerät zum Formen und Aushärten von geradflächigen Endabschnitten und Windungsabschnitten der Feder,
• – eine in Transportrichtung nach der Heizzone folgende Umlenkzone zum Formen und Aushärten von gekrümmten Umlenkabschnitten der Feder,
• – zwei in der Heizzone gegenüberliegend angeordnete Heizwalzen, die einen Spalt zur Aufnahme der Faserverbundwerkstoff-Bahn zwischen sich bilden,
• – ein Anpress- und Umlenkmittel zum wechselseitigen Auflegen und Anpressen von noch nicht ausgehärteten Abschnitten der Faserverbundwerkstoff-Bahn an eine der beiden Heizwalzen,
• – und eine Trennvorrichtung zum Abtrennen von Federn vorbestimmter Länge von dem kontinuierlich hergestellten Verlauf der Feder.

In order to carry out the described manufacturing process, an apparatus for producing a spring made of a fiber composite material is necessary, which will be briefly described below. This device is characterized by the following device components:

• A feed zone for feeding at least two prepreg webs to a transport device,
• A laying and / or forming tool for depositing and forming the at least two prepreg webs on the transport device, with which the prepreg webs alternately following the course of a sinusoidal curve or the course of a cosine curve to form a common uncured Fiber composite web are placed vertically on top of each other,
• A heating zone following in the direction of transport and essentially flat, with a heating device for shaping and hardening straight-sided end sections and turn sections of the spring,
• A deflection zone following the heating zone in the direction of transport for shaping and curing curved deflecting sections of the spring,
• Two heating rolls arranged opposite one another in the heating zone, which form a gap between them for receiving the fiber-composite web,
• A pressing and deflecting means for mutual laying on and pressing of not yet cured sections of the fiber composite web to one of the two heating rollers,
• - And a separator for separating springs of predetermined length from the continuously produced course of the spring.

The Pressing and deflection means can by one or more rollers or Mandrels or rods to be formed. In addition, according to a Variation be provided that under the heater curved End and turn sections can be produced. Because the diameter the heating rollers the deflection radius of the deflection of the fiber composite spring determined, these are preferably designed interchangeable to to produce so different spring batches.

Furthermore It is judged to be very advantageous when in this manufacturing device a tensioning device is provided, in cooperation with the feed force of the two driven heating rollers a tensile force on the fiber composite web during its curing can be generated.

Further is preferably provided in this manufacturing device that in Area of the feed zone and / or immediately before the two Heating rollers and / or on the two heating rollers laying and / or mold tools to the not yet cured fiber composite web can be applied, with which the circumferential geometry and / or the Form fiber volume fraction of sections of the spring to be produced leaves.

For this can the surfaces of the two heating rollers themselves as molding tools for shaping and / or adjusting the fiber volume fraction the not yet cured fiber composite web be formed, so that different circumferential geometries and cause spring properties reproducible.

So may be the surfaces of the two heating rollers and / or the said laying and / or mold tools in the region of the feed zone be formed such that with them the fiber composite web in the area of the later deflection sections transversely to their Longitudinal extent reducible in their width and in their Material thickness is increased, or that the Fiber volume fraction in the deflecting sections compared to the adjacent Windungsabschnitten is increased.

After all the manufacturing device preferably has a pivoting device on, with the heating rollers above and below that level are pivotable, in which the fiber composite web under the Heater is or which by the conveyor belt Transport device is clamped. By such pivoting the heating rollers can adjust the pitch angle α, below which the winding sections transverse to the longitudinal extent the spring are employed.

following be a fiber composite spring produced according to the invention, a manufacturing apparatus therefor as well as for the production the spring necessary process steps on embodiments explained with the help of a drawing. In this shows

1 a schematic side view of an inventively designed and manufactured fiber composite spring,

2 the spring of 1 in a perspective view A on a front side of the same,

3 a schematic representation of a manufacturing apparatus for producing the spring according to 1 and 2 .

3a a schematic plan view of two superimposed prepreg layers, which follow the course of a sine or cosine curve, and

4 to 11 schematic representations of further production steps for producing a spring according to the invention.

The 1 and 2 show schematically in a side view and in a frontal plan view A a tension or compression spring 1 which is made of a fiber composite material. The feather 1 extends along a longitudinal axis Lx and two perpendicular thereto aligned transverse axes Ly and Lz, wherein the transverse axis Lz in 1 is perpendicular to the paper plane of the drawing. The feather 1 points in the side view according to 1 Although the shape of a coil spring, but it has no continuous from one axial end to the other axial end, a helix following course. The feather 1 Instead, it has approximately the same geometry as a rectangular paper sheet folded regularly along its longitudinal extent.

Accordingly, the spring has 1 at the respective axial ends via an upper end portion 2 and a lower end portion 6 in the illustrated embodiment substantially with non-curved surfaces 12 . 12 ' are formed and aligned parallel to a plane spanned by the transverse axes Ly and Lz plane. Starting from the lower end section 6 follows a deflected in the direction of the longitudinal axis Lx deflection 3 , which at its other end with a meandering section 4 is integrally connected. This is also followed in one piece by another deflection section bent in the opposite direction to the first deflection section 3 which in the following with a second winding section 5 is integrally connected. This is how the spring settles 1 to its upper end portion 2 from a regular sequence of deflecting sections 3 and winding sections 4 . 5 together.

In the area of the deflection sections 3 To set a desired fiber volume fraction, the mechanical properties of the spring 1 affects the spring 1 on its outer circumference in the area 3c the end sections 2 . 6 and the winding sections 4 . 5 be shaped such that the deflection sections 3 essentially rectilinear (see view B) and in the intervening areas 3a . 3b are formed substantially circular segment-shaped.

If the fiber volume fraction compared to the adjacent end sections 2 . 6 and winding sections 4 . 5 should remain the same, so leads the superposition of prepreg layers 14 . 15 in their crossing points in the deflection sections 3 to a radially greater thickness D2 compared to the thickness D1 of the turn portions 4 . 5 ,

If the fiber volume fraction in the region of the deflection sections 3 is to be increased, this is in the range of the deflection 3 achieved by squeezing out not yet set resin and thereby simultaneously the thickness D2 of the deflection section, for example, the same or approximately the same as that of the adjacent spring sections held.

By the manufacturing method according to the invention and in particular by the alternating intersecting sinusoidal or cosinusoidal prepreg layers 14 . 15 is achieved that automatically has a central recess in the finished spring 1 is formed, as is known for example from conventional coil springs.

2 shows in an end view of the spring 1 in that these consist of several prepreg layers 14 . 15 or two prepreg main strands each having a plurality of prepreg layers, which in the region of the deflection sections 3 alternately superimposed. To illustrate this further, which is a prepreg layer 14 with a dotted face and the other prepreg layer 15 shown with a non-dotted face. The two dashed lines mark the course of a prepreg layer which is covered by the other Pepreg layer.

In 3 is a production plant for producing a spring according to the invention 1 made of fiber composite material shown schematically. As the right half of the drawing illustrates, there are two prepreg rolls 16 and 17 Prepreg sheets 14 respectively. 15 unrolled. Between two prepreg layers on the prepreg rollers 16 . 17 present release agent 26 . 27 (such as paper) is also used by the rollers 16 and 17 removed and rolled up separately. The two prepreg webs 14 and 15 are then followed by a tensioner 25 acted upon and then merged so that the one prepreg web 14 one sinusoidal and the other prepreg web 15 has a cosinusoidal course. Therefore, both prepreg sheets overlap 14 . 15 in superposition points of the fiber composite web thus formed 8th , which in the later production process the deflection sections 3 the feather 1 form (see also 3a ). About the tension pulley 25 At least one weight force Fg and an axial tensile force Fx act on the fiber composite web 8th , whereby the fibers of the fiber composite web 8th keep aligned parallel to each other without causing the just described and in 3a illustrated geometry of the fiber composite web 8th is impaired.

The fiber composite web 8th is in the middle section of the 3 from a transport device 19 towards a heater 10 and two in the transport direction behind the heater 10 arranged, transported against opposite heating rollers W1 and W2. The transport device 19 consists of a heat-resistant conveyor belt 20 which on rollers 22 guided and of these in the transport direction 21 is driven. Between the fiber composite web 8th and the conveyor belt 20 can, as in the embodiment shown, a separation and isolation track 18 be arranged, which of a roll 23 unwound and after leaving the conveyor belt 20 on the same or a different role 24 is wound up.

The transport device 19 has a feed zone Z and in the transport direction 21 adjoining heating zone H1. In the feed zone Z is a depositing and / or forming tool 28 arranged on the conveyor belt 20 or on the fiber composite web 8th is arranged lowerable. With this depositing and / or forming tool 28 can be made from the two prepreg sheets 14 and 15 existing fiber composite web 8th be shaped so that a desired geometry of the fiber composite spring to be produced 1 can be generated or maintained under the effective tensile force Fx. Forming the fiber composite web 8th For example, by an at least partially constricting this web 8th take place, resulting in certain sections material accumulations or material reductions in the fiber composite web 8th result or remain preserved. Such or another or further depositing and / or forming tool 28 can also be arranged in the region of the two heating rollers W1, W2 and lowered to this purpose for the purpose of shaping (not shown) to fulfill the same purpose.

In the heating zone H1, as already mentioned, the heater 10 arranged, which, for example, electrically or in other ways dotted drawn thermal radiation on the fiber composite material web 8th can radiate. As an alternative to the illustrated device, the heater 10 also below the conveyor belt 20 be arranged, and from below on the fiber composite web 8th for at least partially curing the same effect. Regardless of the arrangement of the heater 10 This serves to make sure that in the area of this heater 10 located portion of the fiber composite web 8th if it is cured so that it is a mechanically rigid, so at least by the influence of gravity does not permanently deformable structure.

The free end 13 the fiber composite web 8th is through the gap formed by the two heating rollers W1 and W2 9 guided and protrudes through this far from the heater 10 therethrough. The two heating rollers W1 and W2 are applied to the fiber composite web with a contact force Fp 8th Pressed, which is set so that on the one hand a desired geometric shape of the future spring 1 can be generated and on the other hand, if necessary, excess resin from the fiber composite web 8th can be pressed out ( 4 ).

In a deflection zone U, which includes the location of the two heating rollers W1, W2, two pressing and deflection rollers W3 and W4 are arranged, which work alternately and with their help each a non-hardened section 11 the fiber composite web 8th on the respective heating roller W1 or W2 to form the deflection section 3 can be stored and pressed.

The two heating rollers W1 and W2 can be operated continuously heating, while the heater 10 heat only on the fiber composite web during certain periods of time 8th emits. By this construction, it is possible that in the heating zone H1 in the range of the heater 10 an end section 2 . 6 or a winding section 4 . 5 the future spring 1 is cured, while located in the feed zone Z and in the deflection zone U sections 11 the fiber composite web 8th initially not remain cured.

If the under the heater 10 lying portion of the fiber composite web 8th Hardened, this fiber composite web becomes 8th so far in the direction 21 through the gap 9 the two heating rollers W1, W2 transported, that of the previously located in the feed zone Z and not yet cured section of the fiber composite web 8th is arranged in the deflection section U. Here is this not yet cured section of the web 8th pressed by one of the two pressure and deflection rollers W3 or W4 on the surface of one of the two heating rollers W1 or W2 and this track section 11 then cured on this heat roller W1 or W2. At the same time or after the heater can also 10 be active, so that too in the range of this heater 10 located portion of the fiber composite web 8th is cured.

By alternately applying the not yet cured portion of the fiber composite web 8th on the heating roller W1 or W2, a folding of the fiber composite web takes place 8th resulting in a continuous product strand from which springs 1 . 1' can be cut off predetermined length.

In the 1 shown slope α of the winding sections 4 . 5 the feather 1 can be according to the manufacturing device 3 through a change set wise pivoting of the two heating rollers W1 and W2, which are arranged about a Schenkweg V (α) above or below that plane pivotally, in which the fiber composite material web 8th under the heater 10 lies or which by the conveyor belt 20 the transport device 19 is stretched.

The 3 to 12 show the production of a spring according to the invention 1 in the manufacturing device according to 3 with the manufacturing steps S1 to S12 in detail. In 3 the production steps S1 to S3 are shown as already explained.

At the beginning of the manufacturing process, two prepreg webs 14 . 15 of prepreg rolls 16 . 17 unrolled and under tensile load by the tension role 25 to a arranged in a feed Z transport device 19 guided. Then the two prepreg webs 14 . 15 on the conveyor belt 20 the transport device 19 stored according to the course of a sinusoidal curve or the course of a cosine curve, wherein this in the range of future deflection sections 3 the finished spring 1 alternately superimposed and a not yet cured fiber composite web 8th form.

Subsequently, the fiber composite web 8th from the transport device 19 to the heater 10 transported and then with its free end 13 through the gap 9 the two heating rollers W1 and W2 plugged. When starting production, only the heater 10 activated, leaving a first, straight section of the fiber composite web 8th is cured.

The adjustment of the fiber volume fraction of sections of the spring 1 can be done in all production phases, which are before the curing of the resin.

4 shows the next production step S4, in which the already cured portion of the fiber composite web 8th together with an uncured section 11 are deflected by the heat roller W2 with the help of the pressure and deflection roller W4. Under the non-active heater 10 is also a not yet cured portion of the fiber composite web 8th arranged.

In 5 are then the following steps S5, S6 and S7 shown, in which the transport of the fiber composite web 8th stopped and the heating roller W2 and the heater 10 heat. Thereby, the portion wound around the heat roller W2 and that under the heater become 10 arranged section of the railway 8th hardened. In 5 is also hinted that the initially free end 13 the fiber composite web 8th cut off early.

As 6 is removed, after curing of the wound around the heating roller W2 section and the curing of the under the heater 10 arranged portion of the fiber composite web 8th the transport device 19 activated again, so that according to production step S8 of a cured web section 3 lifts from the heating roller W2 and the other cured track section 4 through the gap 9 the two heating rollers W1, W2 is pushed through. 6 also illustrates that the straight and already cured track sections the lower end section 6 and the first turn section 4 the future spring 1 according to 1 form during the hardened on the heating roller W2 section the deflection section 3 forms.

In 7 the production step S9 is shown, in which again a not yet cured section of the fiber composite web 8th through the gap 9 the two heating rollers W1 and W2 transported through and then stored and pressed with the help of the pressure and deflection roller W3 on the heating roller W1. The heater 10 is switched off.

8th shows how again according to the production steps S5 to S7 on the heating roller W1 and under the heater 10 arranged and not yet cured sections of the fiber composite web 8th be cured by the action of heat energy (dotted lines). Above the heating roller W1 are already produced and therefore already cured sections of the future spring 1 recognizable.

In 9 and 10 the production steps S8 and S9 are shown, in which in step S8 the cured on the heating roller W1 section of the fiber composite web 8th by further transporting them through the gap 9 of the two heating rollers W1, W2 has lifted from the heating roller W1 and under the heater 10 cured section through this gap 9 was passed through. In step S9, another supplied and not yet cured portion of the fiber composite web 8th by means of the pressure and deflection roller W4 placed on the heating roller W2 and pressed. The heater 10 is switched off and both heating rollers W1, W2 can also be switched off.

In 11 is shown in an overview representation, as the production steps S6 and S7 are currently running, while already a larger number of end sections 2 . 6 , Deflection sections 3 and winding sections 4 . 5 is made. Because the Number of these sections 2 . 3 . 4 . 5 . 6 for the production of a spring 1 With the length L is already large enough, in a production step S11 is a separator 29 activated, which is the spring 1 from the course of the next, still in the making spring 1' separates. The finished spring 1 is removed in a production step S12 and the manufacturing device according to 3 continuously operated.

1

feather

1'

feather during their production

2

Oberer End portion of the spring

3

deflection section

3a

peripheral portion the feather

3b

peripheral portion the feather

3c

peripheral portion the feather

4

turn section

5

turn section

6

lower End portion of the spring

7

axial bore in the spring

8th

Fiber composite material-Bahn

9

gap between the two heating rollers

10

heater

11

Unhardened section of the track 8th

12

Surface of the end section 2

12 '

Surface of the end section 6

13

Free End of the fiber composite web

14

Prepreg sheet Prepreg layer

15

Prepreg sheet Prepreg layer

16

Prepreg role

17

Prepreg role

18

separating and insulating agent web

19

transport device

20

conveyor belt

21

transport direction

22

role the transport device

23

separating and insulation agent role

24

separating and insulation agent role

25

idler

26

release agent

27

release agent

28

Depositing tool mold

29

separating device

30

drill

31

movement direction of the drill

A

front the feather

B

sideview the feather

fg

Weight of the tension pulley 25

fp

pressing force the heating rollers W1, W2

Fx

Tensile force on the fiber composite web 8th

H1

heating zone under the heater

L

length the feather

Lx

longitudinal axis the feather

Ly

transverse axis the feather

U

deflection

S1-S12

steps

V (a)

pivoting the heating rollers W1, W2

W1

heating roller

W2

heating roller

W3

contact pressure and guide roller, contact and deflection

W4

contact pressure and guide roller, contact and deflection

Z

feed zone

α

Gradient of a meandering section 4 . 5

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - DE 3000520 A1 [0003]

Claims (35)

Feather ( 1 ) of a fiber composite material having two end sections and winding sections arranged between them, characterized in that the end sections ( 2 . 6 ) and the winding sections ( 4 . 5 ) via deflection sections ( 3 ) are integrally connected, all sections ( 2 . 3 . 4 . 5 . 6 ) consist of alternately superimposed, geometrically different shaped and meandering folded layers of a fiber composite material. Spring according to claim 1, characterized in that prepreg layers ( 14 . 15 ) are used, which along its longitudinal extent sinusoidal or cosinus-shaped and are alternately superimposed. Spring according to claim 2, characterized in that a plurality of layers of sinusoidal or cosine-shaped prepreg layers ( 14 . 15 ) are stacked vertically in such a way, and that the respective prepreg layers ( 14 . 15 ) alternately follow the course of the same sine curve or the course of the same cosine curve. Spring according to one of claims 1 to 3, characterized in that through those regions of the spring ( 1 ), in which the layers ( 14 . 15 ) of the fiber composite material, the respective deflection sections ( 3 ) the feather ( 1 ) are formed. Spring according to one of claims 1 to 4, characterized in that the end sections ( 2 . 6 ) and the winding sections ( 4 . 5 ) as a sheet with largely flat surfaces ( 12 ) and the deflection sections ( 3 ) are curved. Spring according to one of claims 1 to 5, characterized in that the end sections ( 2 . 6 ) along a transverse axis (Ly) at right angles to the longitudinal axis (Lx) of the spring ( 1 ) are arranged aligned. Spring according to one of claims 1 to 6, characterized in that the end sections ( 2 . 6 ) are cured successively in time. Spring according to one of claims 1 to 7, characterized in that the end sections ( 2 . 6 ) and the winding sections ( 4 . 5 ) over the longitudinal extent of the spring ( 1 ) are each cured in chronological succession. Spring according to claim 8, characterized in that at least one end portion ( 2 . 6 ) and an associated deflection section ( 3 ) are cured at the same time. Spring according to claim 8, characterized in that the winding sections ( 4 . 5 ) each with an associated deflection section ( 3 ) are cured at the same time. Spring according to one of claims 7 to 10, characterized in that the mutually associated portions, namely end portion ( 2 . 6 ) and deflection section ( 3 ) and deflection section ( 3 ) and winding section ( 4 . 5 ) under a tensile load (Fx) of the fibers of the fiber composite material. Spring according to one of claims 1 to 11, characterized in that the fiber volume fraction of the deflection sections ( 3 ) is smaller, equal to or greater than the fiber volume fraction of the end sections ( 2 . 6 ) and the winding sections ( 4 . 5 ). Spring according to one of claims 1 to 11, characterized in that the fiber volume fraction of the deflection sections ( 3 ), the end sections ( 2 . 6 ) and the winding sections ( 4 . 5 ) is different in each case. Spring according to one of claims 1 to 13, characterized in that the material thickness (D2) of the deflection sections ( 3 ) is greater than the material thickness (D1) of the end sections ( 2 . 6 ) and the winding sections ( 4 . 5 ). Spring according to one of claims 1 to 14, characterized in that the peripheral contour ( 3a . 3b . 3c ) the feather ( 1 ) at each end section ( 2 . 6 ) and winding section ( 4 . 5 ) in the area ( 3c ) of the deflection sections ( 3 ) in a straight line and in the intermediate areas ( 3a . 3b ) is formed circular arc-shaped. Spring according to one of claims 1 to 14, characterized in that the spring ( 1 ) due to the selected sine or cosine curve and the selected width of the prepreg layers ( 14 . 15 ) transverse to its longitudinal extent after hardening a central bore ( 7 ) or recess, which has all end sections ( 2 . 6 ) and winding sections ( 4 . 5 ) the feather ( 1 ) penetrates. Spring according to one of claims 1 to 14, characterized in that the winding sections ( 4 . 5 ) at an angle (α) to the end sections ( 2 . 6 ), which is greater than 0 ° and less than 45 °. Method for producing a spring ( 1 ) of a fiber composite material, characterized by the following method steps: S1: feeding of at least two prepreg webs ( 14 . 15 ) to a transport device ( 19 ). S2: alternately discard the at least two Prepreg sheets ( 14 . 15 ) on the transport device ( 19 ) such that a prepreg web ( 14 ) of a sinusoidal curve and the other prepreg sheet ( 15 ) follows a cosine curve that defines a common, uncured fiber composite web ( 8th ) form. S3: feeding the uncured fiber composite web ( 8th ) to a heater ( 10 ) and retraction of the fiber composite web ( 8th ) into a gap ( 9 ) between two heating rollers (W1, W2), seen in the conveying direction behind the heater ( 10 ) are arranged. S4: redirecting the fiber composite web ( 8th ) around one of the two heating rollers (W1, W2) by less than 181 °. S5: Stop the transport of the fiber composite web ( 8th ). S6: Actuating the heater ( 10 ) as well as the heating of the fiber composite web ( 8th ) partially wrapped heat roller (W1, W2). S7: curing of an end section ( 2 . 6 ) or a winding section ( 4 . 5 ) under the heater ( 10 ) and simultaneous curing of a deflection section ( 3 ) on the heating roller (W1, W2). S8: further transport of the hardened end section ( 2 . 6 ) or the hardened turn section ( 4 . 5 ) through the gap ( 9 ) of the two heating rollers (W1, W2) and simultaneous further transport of the hardened deflection section ( 3 ) by lifting off the deflecting section ( 3 ) from the heating roller (W1, W2). S9: feeding and redirecting an uncured section ( 11 ) of the fiber composite web ( 8th ) around the opposite heating roller (W2, W1) by less than 181 °. S10: proceed to step S5 to step S9 until the desired length of the spring (FIG. 1 ) is reached. S11: separating the spring ( 1 ) when reaching a certain length (L). S12: removal of the spring ( 1 ) and continue to step S6. A method according to claim 18, characterized in that below the heater ( 10 ) a plane or only slightly curved portion of the fiber composite web ( 8th ) to an end portion ( 2 . 6 ) or to a winding section ( 4 . 5 ) is cured. A method according to claim 19, characterized in that at the beginning of the manufacturing process exclusively under the heater ( 10 ) and in front of the heating rollers (W1, W2) a flat or only slightly curved section of the fiber composite material web (FIG. 8th ) to an end portion ( 2 . 6 ) is cured. Method according to one of claims 18 to 20, characterized in that the deflection and a pressing of the not yet cured fiber composite web ( 8th ) on the respectively associated heating roller (W1, W2) by means of at least one pressing and deflection roller (W3, W4). Method according to one of claims 18 to 21, characterized in that the under the heater ( 10 ) and the portion of the fiber composite web (FIG. 1) on the heating roller (W1, W2) ( 8th ) is exposed during curing of a tensile force (Fx). Method according to one of claims 18 to 22, characterized in that the guidance and shaping of the not yet cured fiber composite material web ( 8th ) in front of the heater ( 10 ) and / or on the heating rollers (W1, W2) is performed so that the spring ( 1 ) a circumferential geometry with at the deflecting sections ( 3 ) straight course ( 3c ) and between these deflecting sections ( 3 ) a circular section course ( 3a . 3b ) having. A method according to claim 23, characterized in that the guidance and shaping of the not yet cured fiber composite material web ( 8th ) in front of the heater ( 10 ) and / or on the heating rollers (W1, W2) is performed so that the fiber volume fraction of the respective deflection sections ( 3 ), End sections 2 . 6 ) and turns sections smaller, equal to or greater than the fiber volume fraction of the respective adjacent deflection sections, end sections and turn sections ( 4 . 5 ). A method according to claim 24, characterized in that the guidance and shaping of the not yet cured fiber composite material web ( 8th ) in front of the heater ( 10 ) and / or on the heating rollers (W1, W2) is carried out so that the fiber volume fraction in the deflecting sections ( 3 ) is greater than the fiber volume fraction in the end sections ( 2 . 6 ) and in the winding sections ( 4 . 5 ). A method according to claim 24, characterized in that the guidance and shaping of the not yet cured fiber composite material web ( 8th ) in front of the heater ( 10 ) and / or on the heating rollers (W1, W2) is carried out so that the fiber volume fraction in the deflecting sections ( 3 ) is smaller than the fiber volume fraction in the end sections ( 2 . 6 ) and in the winding sections ( 4 . 5 ). A method according to claim 24, 25 or 26, characterized in that the setting of the respective fiber volume fraction by a section-wise pressing out of not yet hardened synthetic resin from the supplied fiber composite material web ( 8th ) is achieved. Method according to one of claims 18 to 27, characterized in that the not yet cured fiber composite material web ( 8th ) in front the heater ( 10 ) and / or on the heating rollers (W1, W2) is compressed so transversely to its longitudinal extent that the material thickness (D2) of the deflection sections ( 3 ) is greater than the material thickness (D1) of the end sections ( 2 . 6 ) and the winding sections ( 4 . 5 ). Method according to one of claims 18 to 28, characterized in that the pitch angle (α) of the winding sections ( 4 . 5 ) in the spring ( 1 ) by a pivoting of the heating rollers (W1, W2) about a certain Verschwenkweg (Vα) above or below the plane in which the fiber composite material web ( 8th ) under the heater ( 10 ) lies. Device for producing a spring from a fiber composite material, characterized by - a feed zone (Z) for feeding at least two prepreg webs ( 14 . 15 ) to a transport device ( 19 ), - a depositing and / or forming tool ( 28 ) for depositing and forming the at least two prepreg webs ( 14 . 15 ) on the transport device ( 19 ), with which the prepreg webs ( 14 . 15 ) alternately following the course of a sinusoidal curve or the course of a cosine curve to form a common uncured fiber composite web ( 8th ) are placed vertically one above the other, - one in the transport direction ( 21 ) the following and substantially planar heating zone (H1) with a heater ( 10 ) for shaping and curing straight-sided end sections ( 2 . 6 ) and winding sections ( 4 . 5 ) the feather ( 1 ), - one in the transport direction ( 21 ) after the heating zone (H1) the following deflection zone (U) for shaping and curing curved deflection sections (US Pat. 3 ) the feather ( 1 ), - two in the heating zone (H1) opposite arranged heating rollers (W1, W2), the one gap ( 9 ) for receiving the fiber composite web ( 8th ) form between them, - a pressing and deflecting means (W3, W4) for mutual laying and pressing of not yet cured sections ( 11 ) of the fiber composite web ( 8th ) to one of the two heating rollers (W1, W2), - and a separating device ( 29 ) for separating springs ( 1 ) predetermined length (L) of the continuously produced course of the spring ( 1' ). Apparatus according to claim 30, characterized in that a tensioning device ( 25 ) is present, in conjunction with the feed force of the two driven heating rollers (W1, W2), a tensile force (Fx) on the fiber composite web ( 8th ) is produced during their curing. Apparatus according to claim 30 or 31, characterized in that in the region of the feed zone (Z) and / or immediately before the two heating rollers (W1, W2) and / or on the two heating rollers (W1, W2) a laying and / or mold tool ( 28 ) to the not yet cured fiber composite web ( 8th ), with which the circumferential geometry and / or the fiber volume fraction of sections ( 2 . 3 . 4 . 5 . 6 ) of the spring to be produced ( 1 ). Device according to one of claims 30 to 32, characterized in that the surfaces of the two heating rollers (W1, W2) as molding tools for forming and / or adjusting the fiber volume fraction of the not yet cured fiber composite web ( 8th ) are formed. Device according to one of claims 30 to 33, characterized in that the surfaces of the two heating rollers (W1, W2) and / or the depositing and / or forming tool ( 28 ) are formed in the region of the feed zone (Z) such that with them the fiber composite web ( 8th ) in the region of the later deflection sections ( 3 ) Can be reduced across its longitudinal extent in its width and in its material thickness (D2) is increased, or that the fiber volume fraction in the Umlenkabschnitten ( 3 ) with respect to the adjacent turn sections ( 4 . 5 ) is enlarged. Device according to one of claims 30 to 34, characterized in that the two heating rollers (W1, W2) for adjusting the pitch angle (α) of the winding sections ( 4 . 5 ) the feather ( 1 ) by means of a pivoting device about a pivoting path (Vα) are pivotable above and below the plane in which the fiber composite material web ( 8th ) under the heater ( 10 ) or which by the conveyor belt ( 20 ) of the transport device ( 19 ) is stretched.