DE102010006805A1 - Method for manufacturing component e.g. shell part of car body, in automobile industry, involves discontinuously manufacturing complex component from preform, and introducing preform into press, and pressing preform - Google Patents

Abstract

The method involves continuously manufacturing a preform (14a) soaked with thermosetting resin (12a), and discontinuously manufacturing a component i.e. complex component (10a), from the preform. The preform is introduced into a press (16a), and is pressed. A reinforcing element (18a) is brought into the press before pressing operation of the preform. The preform is impregnated with the resin by an impregnation device (26a) e.g. injection device and/or spraying device and/or scraper device, and the preform is fixed by heating or cooling. An independent claim is also included for a device for manufacturing a component made of fiber reinforced plastic.

Description

The invention relates to a method for producing a component made of fiber-reinforced plastic according to the preamble of patent claim 1 and an associated apparatus for performing the method.

Components made of fiber-reinforced plastics are becoming increasingly interesting for the automotive industry due to their lightweight construction potential. However, large-scale deployment is currently hampered by the high material and manufacturing costs. The production of components made of fiber-reinforced plastics usually consists of complex, manual work steps, in particular, three methods have high potential for mass production. These are Pultrusion, Resin Transfer Molding (RTM) and pressing of prepregs or thermoplastics.

The pultrusion is usually used for the production of profiles. It is a continuous process in which resin impregnated rovings or semi-finished products are drawn through a tempered tool and cured. Already today large series of, for example, window frame profiles are produced in this process. Originally, only rovings were used for longitudinal reinforcement in this process. With process variants such as the Pullwinding or Pullbraiding or the retraction of textile semifinished product, such as tissue or scrim, and components with multi-axial fiber orientations can be produced. The pultrusion can only produce profiles with longitudinally constant cross sections. Local reinforcements and elements, such as inserts, are difficult or impossible to insert. Also, the maximum dimensions of today produced components are limited. In particular, profiles made of fiber-reinforced plastic, which are produced by pultrusion, especially transversely to the longitudinal direction absorb only limited energy, since after the maximum load usually occurs a rapid failure of the profiles.

In the RTM process textile semi-finished products, such as scrim or tissue, preformed close to the final contour, placed in a tool and then impregnated with a polymeric resin. The method is currently usually used in medium quantities. Even complex components are possible with corresponding preforms, the so-called preforms, and corresponding tool technologies, such as slides. The problem is the near-net shape production of the preform. In this case, complicated procedures are necessary. In addition, thermosetting resins are also necessary for fast cycles, so that, if necessary, thermal cycles must be run.

When forming prepregs or fiber-reinforced thermoplastics, the so-called organic sheets, the corresponding semi-finished products are placed in the press, reshaped and cured in prepregs or cooled in thermoplastics. Especially with thermoplastics very fast cycle times are achieved. Although the method is therefore suitable for the production of large quantities, the disadvantage here is that it is necessary to work with expensive semi-finished products, such as prepregs or organo sheets, and only very simple geometries can be produced.

From the patent EP 1 819 503 B1 is a continuous pultrusion process for the production of structural profiles known. In this case, a semifinished product impregnated with resin is drawn through a tempered tool and cured.

In the published patent application DE 10 2007 018 052 A1 For example, a pultrusion process is described in which an endless reinforcing profile is formed by the edge of at least one prepreg tape of a fiber-reinforced plastic material. The first shaping of the profile takes place in a preforming device, which is followed by a press-forming device for final shaping and precuring.

The publication DE 10 2006 009 345 A1 discloses a method of making a bond between a fiber reinforced, outer or inner plastic part based on resin impregnated fibrous web or fiber mat, and a trim support. In this case, during the pultrusion of the plastic trim part, this is provided with at least one connecting section which can be interlocked in a form-fitting manner with an associated connecting section of the trim support. The connecting portion may consist of a metal body which is formed by pultrusion at least partially in the plastic trim part.

From the publication EP 1 570 976 A1 For example, a method for producing fiber-reinforced sheet material from a polyester is known. A continuously fed web-shaped fiber structure is coated with a reactive starting material in powder form. The applied powder may be heated to improve the adhesive properties. Alternatively, the fiber structure may be preheated and then coated with the powder. Subsequently, cover layers are applied to the fiber structure on both sides. In a continuous press, the reactive Starting material polymerized to form a plastic matrix and in close contact with the outer layers.

The invention is based on the object to provide a method and an apparatus for producing a component made of fiber-reinforced plastic, which allow for simple implementation of a production of complex components in a lightweight design and with good energy absorption behavior.

According to the invention the object is achieved by providing a method for producing a component made of fiber-reinforced plastic having the features of patent claim 1 and by a device for carrying out the method with the features of patent claim 11. Advantageous embodiments and further developments of the invention are specified in the dependent claims.

In order to provide a method for producing a component made of fiber-reinforced plastic, which allows for simple production even complex components in a lightweight design and with good energy absorption behavior, according to the invention is a continuous preparation of a resin-impregnated preform and a discontinuous production of the component from the preform introducing the preform into a press and pressing the preform. Optionally, at least one reinforcing element can additionally be introduced into the press with the preform. In the method according to the invention, the in-line production of a resin-impregnated preform is described, which is formed in a further process step to the final contour. The process according to the invention is a discontinuous process in which the preparation of the resin-impregnated preform is continuous and the production of the actual component by the pressing is discontinuous. In a particularly advantageous manner, the inventive method not only allows the production of profiles, but also the production of large, flat components. The freedom of design in the method according to the invention is significantly greater than, for example, the pure pultrusion method, so that, for example, the integration of force introduction elements such as inserts and / or local wall thickness changes and / or undercuts on the tool design are possible in a simple manner. The inventive design of the method complex components can be produced inexpensively. This is made possible by the use of textile semi-finished products and resins, which are cost-effective compared to the RTM process, as well as by an effective molding process compared to the pultrusion process and by the possible use of resins with short curing times. In this way, complex component geometries can advantageously be produced via the shaping process and the reinforcing elements.

In a refinement of the method according to the invention, a continuous impregnation method is provided, in which already preformed semi-finished products are impregnated. Advantageously, in this method, for example, no prepregs but already shaped semi-finished products impregnated, whereby the limited formability is avoided, for example, by prepregs. The continuous impregnation process and direct further processing eliminates the need for storage at -18 ° C, which would be necessary when using prepregs.

In a further embodiment of the method according to the invention, a thermosetting resins processing impregnation method is provided, which comprises a continuous stripping of semi-finished textile products, preforming the semi-finished at least one Rollformvorrichtung in the desired shape, impregnating the preform with the resin by means of an impregnating device, for example, as an injection device and / or spraying device and / or doctor device, and fixing the preform by heating or cooling comprises. With the method according to the invention, complex components can advantageously be manufactured in an automatable manner. As a result, the lightweight potential of materials can be exploited and the manufacturing costs can be reduced. It is a preform, which has already been impregnated with resin, continuously produced. This preform does not yet have the final contour of the finished component, but the required deformation levels are reduced by a corresponding shape. Subsequently, the preform is cured in a press step and then demolded the finished component. The method can be used for the production of large-area components, such as outer skin parts and structural structural components, such as profiles or floor groups. Advantageously, the handling of the preform is ensured to the press by fixing.

Preferably, the impregnated with the thermosetting resin preform is formed in the press in the final component geometry and cured. Advantageously, the tools of the press can be equipped in advance with the reinforcing elements, such as local reinforcements, inserts, etc. manually or automatically. The impregnated preform is then formed in the press with the appropriate tools in the final component geometry and cured.

In a further embodiment of the method according to the invention, a thermoplastic resins processing impregnation method is provided, which comprises a continuous stripping of textile semi-finished products, a tightening of films of thermoplastic matrix resin by means of the semifinished products, a preforming of the semi-finished products and the films via at least one Rollformvorrichtung in the desired shape and a Fixing the semi-finished products and the films by heating comprises. Advantageously, the method according to the invention makes it possible to produce complex components with a high level of lightweight construction potential, which playfully meet the diverse requirements, for example with regard to installation space, crash requirements and force transmission. The components produced by the method according to the invention can also absorb a higher proportion of energy, especially by using appropriate auxiliaries, especially transversely to the longitudinal direction, since a catastrophic failure of the component is prevented after application of the maximum load. These complex components can be produced by the inventive method in an advantageous manner in automated steps. In particular, this refinement of the method with the illustrated process chain also makes it possible to process highly reactive resins with short cycle times.

Preferably, the preform comprising the semifinished products and the films is shaped in the press into the final component geometry and the semifinished products are joined to the films. Advantageously, two tasks are performed in the press at the same time, namely the formation of the preform in the final component geometry and the connection of the reinforcing semi-finished products with the thermoplastics, resulting in both a time savings and a cost savings. Again, the tools of the press in advance with the reinforcing elements, such as local reinforcements, inserts, etc. can be equipped manually or automatically.

In an embodiment of the method according to the invention, at least one additional auxiliary substance is supplied to the preform. In this way, components with new functionalities can advantageously also be produced by modifying the functionality of the component to be produced in a simple and cost-effective manner by supplying the at least one additional auxiliary substance. Depending on the nature of the excipient, for example, the impact strengths or the energy absorption or also the surface quality can be improved.

In a further embodiment of the method according to the invention, the at least one additional excipient is supplied when the semifinished products are removed. Advantageously, the continuous production process allows removal of the at least one additional auxiliary material together with the semi-finished products.

It is further proposed that the at least one additional adjuvant comprises an elastomer and / or a sandwich core of a moldable foam and / or a reactive foam and / or honeycomb. The method according to the invention enables a supply of these auxiliaries, which can produce an extended functionality, such as, for example, increased mechanical properties and / or improved energy absorption of the components. Thus, in addition to the cost reduction, an improvement of the property profile is possible. For example, elastomers can advantageously increase the energy absorption capability of the component, improve the acoustics and / or the impact behavior of the component. Sandwich cores of moldable foams or of reactive foams which foam in the press or sandwich cores with honeycombs can improve mechanical properties, especially rigidity. As further auxiliaries, it is also possible to use films and / or nonwovens which improve the surface quality of the component, so that any subsequent coating can be dispensed with or at least simplified.

A preferred realization of the method according to the invention provides that the preform soaked with the resin is processed in the press and / or in a subsequent step with a punching tool. This means that the component can be processed via the punching tool either directly in the tool of the press or in a subsequent step. Advantageously, this makes possible a direct final contour machining by means of the punching tools integrated into the method. In particular, highly reactive resins with short cycle times can be processed with the process chain shown.

Advantageous embodiments of the invention are illustrated in the drawings and will be described below.

Showing:

1 a schematic block diagram of a first embodiment of an apparatus for performing a method according to the invention for producing a component made of fiber-reinforced plastic, in which thermosetting resins are processed, and

2 a schematic block diagram of a second embodiment of an apparatus for performing the inventive Process in which thermoplastic resins are processed.

1 and 2 each show a device for carrying out a method according to the invention for producing a component 10a . 10b made of fiber-reinforced plastic.

To a method for manufacturing a component 10a . 10b specify fiber-reinforced plastic, which in simple implementation, a production of complex components 10a . 10b lightweight and with good energy absorption performance, the process involves continuous production of one with resin 12a . 12b impregnated preform 14a . 14b and a discontinuous production of the component 10a . 10b from the preform 14a . 14b by introducing a preform 14a . 14b in a press 16a . 16b , An introduction of at least one reinforcing element 18a . 18b ; 20a . 20b in the press 16a . 16b and pressing the preform 14a . 14b and the at least one reinforcing element 18a . 18b ; 20a . 20b is provided. Advantageously, the press 16a . 16b have an isothermal tool heating, whereby resins 12a . 12b can be used with short curing times. Likewise, the press 16a . 16b Have at least one slide tool, which also complex component geometries can be produced in an advantageous manner.

Thus, the process of the invention discloses the in-line production of resin 12a . 12b impregnated preform 14a . 14b , which in a further process step to the final contour, possibly taking into account additional auxiliaries 30a . 30b is formed. This is a batch process wherein the preparation of resin 12a . 12b impregnated preform 14a . 14b continuously and the production of the actual component 10a . 10b is discontinuous by pressing. This means it will be a preform 14a . 14b , which already with resin 12a . 12b was impregnated, continuously produced. This preform 14a . 14b does not yet have the final contour of the finished component 10a . 10b on, but the required degrees of deformation are reduced by an appropriate design. Subsequently, the preform 14a . 14b hardened in a press step and then the finished component 10a . 10b removed from the mold. Advantageously, the inventive method can also be used for the production of large-area components, such as body panels of a vehicle body and structural structural components, such as profiles or ground groups of a vehicle body.

The method according to the invention comprises a continuous impregnation method in which already preformed semi-finished products 22a . 22b be impregnated, which advantageously a limited formability is bypassed. Through the continuous impregnation process and the direct further processing of the semi-finished products 22a . 22b preferably eliminates the storage of semi-finished products 22a . 22b at -18 ° C, which is necessary for example in prepregs.

1 shows an apparatus for performing a method in which a thermosetting resins 12a processing impregnation method is provided. The process comprises a continuous stripping of textile semifinished products 22a , a preforming of the semi-finished products 22a via at least one rollforming device 24a in the desired shape, an impregnation of the preform 14a with the resin 12a by means of an injection device 26a and fixing the preform 14a by heating or cooling. For this purpose, the injection device 26a preferably a not visible here heating and / or cooling unit. In the process, the textile semifinished products, which are preferably designed as rovings, are used 22a withdrawn continuously and then via one or more Rollformvorrichtungen 24a brought into the desired shape. The fibers of semi-finished products 22a be with the resin 12a via the injection device 26a impregnated and then fixed in their shape by heating or cooling. This resulting preform 14a then gets to the press 16a transported, with the handling of the preform 14a to the press 16a over the fixation is ensured. Alternatively to the described injection device 26a For example, a spray and / or doctor device can be used for the impregnation process.

In the press 16a becomes the one with the thermosetting resin 12a soaked preform 14a molded into the final component geometry and cured. The tools of the press 16a are preferably in advance with at least one additional reinforcing element 18a . 20a or insert, such as a local reinforcement and / or an insert, manually or automatically populated. The impregnated preform 14a will then be in the press 16a molded and cured with the appropriate tools in the final component geometry.

2 shows an apparatus for performing a method in which a thermoplastic resins 12b processing impregnation method is provided. The process comprises a continuous stripping of textile semifinished products 22b , Tightening of thermoplastic matrix resin films 12b by means of the semi-finished products 22b , a preforming of the semi-finished products 22b and the slides 12b via at least one rollforming device 24b in the desired shape and fixing the semi-finished products 22b and the slides 12b by heating. In this process step, the semi-finished product 22b not yet with that Thermoplastics or the thermoplastic matrix resin 12b connected, but only the shape fixed.

In the press 16b become the semi-finished products 22b and the slides 12b comprehensive preform 14b molded into the final component geometry and the semi-finished products 22b with the slides 12b connected. The tools of the press 16b are preferably in advance with at least one additional reinforcing element 18b . 20b or insert, such as a local reinforcement and / or an insert, manually or automatically populated. The impregnated preform 14b will then be in the press 16b molded and cured with the appropriate tools in the final component geometry.

Both in the process for thermoset systems according to 1 as well as in the process for thermoplastic systems according to 2 is it possible for the preform 14a . 14b at least one additional excipient 30a . 30b is supplied. Advantageously, this means components 10a . 10b can be produced with new functionalities by adding at least one additional excipient 30a . 30b the functionality of the component to be manufactured 10a . 10b is modified in a simple and cost-effective manner. Preferably, the at least one additional excipient 30a . 30b when removing the semi-finished products 22a . 22b fed. Here, the at least one additional adjuvant 30a . 30b an elastomer and / or a sandwich core of a moldable foam and / or a reactive foam and / or with honeycombs.

Advantageously, the with the resin 12a . 12b soaked preform 14a . 14b in the press 16a . 16b and / or processed in a subsequent step with a punching tool. About the punching tool, the component 10a . 10b either directly in the tool of the press 16a . 16b or edited in a subsequent step.

LIST OF REFERENCE NUMBERS

10a, 10b

Component made of fiber-reinforced plastic

12a

thermosetting resin

12b

thermoplastic resin

14a, 14b

preform

16a, 16b

Press

18a, 18b

reinforcing element

20a, 20b

reinforcing element

22a, 22b

Workpiece

24a, 24b

Roll forming apparatus

26a

injection device

28b

heater

30a, 30b

excipient

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 1819503 B1 [0006]
• DE 102007018052 A1 [0007]
• DE 102006009345 A1 [0008]
• EP 1570976 A1 [0009]

Claims (13)

Process for producing a fiber-reinforced plastic component, characterized by the following steps: a) continuous production of a resin ( 12a . 12b ) impregnated preform ( 14a . 14b ); b) discontinuous production of the component ( 10a . 10b ) from the preform ( 14a . 14b ) by: - introducing the preform ( 14a . 14b ) in a press ( 16a . 16b ); - pressing the preform ( 14a . 14b ). A method according to claim 1, characterized in that prior to the pressing operation at least one reinforcing element ( 18a . 18b ; 20a . 20b ) additionally in the press ( 16a . 16b ) is introduced. Process according to claim 1 or 2, characterized by a continuous impregnation process in which already preformed semi-finished products ( 22a . 22b ) are impregnated. Method according to one of claims 1 to 3, characterized in that a thermosetting resins ( 12a ) is provided, comprising the following steps: - continuous stripping of textile semifinished products ( 22a ); - preforming of semi-finished products ( 22a ) via at least one rollforming device ( 24a ) in the desired shape; Impregnating the preform ( 14a ) with the resin ( 12a ) by means of an impregnation device ( 26a ); and - fixing the preform ( 14a ) by heating or cooling. A method according to claim 4, characterized in that the impregnation device is designed as injection and / or spray and / or doctor device. Method according to one of claims 1 to 5, characterized in that the with the thermosetting resin ( 12a ) soaked preform ( 14a ) in the press ( 16a ) is molded into the final component geometry and cured. Method according to one of claims 1 to 3, characterized in that a thermoplastic resins ( 12b ) is provided, comprising the following steps: - continuous stripping of textile semifinished products ( 22b ); - Tightening of films of thermoplastic matrix resin ( 12b ) by means of the semi-finished products ( 22b ); - preforming of semi-finished products ( 22b ) and the films ( 12b ) via at least one rollforming device ( 24b ) in the desired shape; and - fixing the semi-finished products ( 22b ) and the films by heating in a heating device ( 28b ). Method according to one of claims 1 to 3 or 7, characterized in that the semifinished products ( 22b ) and the films ( 12b ) comprehensive preform ( 14b ) in the press ( 16b ) into the final component geometry and the semi-finished products ( 22b ) with the films ( 12b ) get connected. Method according to one of claims 1 to 8, characterized in that the preform ( 14a . 14b ) at least one additional excipient ( 30a . 30b ) is supplied. A method according to claim 9, characterized in that the at least one additional excipient ( 30a . 30b ) when removing the semi-finished products ( 22a . 22b ) is supplied. A method according to claim 9 or 10, characterized in that the at least one additional excipient ( 30a . 30b ) comprises an elastomer and / or a film and / or a nonwoven fabric and / or a sandwich core of a moldable foam and / or a reactive foam and / or honeycomb. Method according to one of claims 1 to 11, characterized in that the with the resin ( 12a . 12b ) soaked preform ( 14a . 14b ) in the press ( 16a . 16b ) and / or processed in a subsequent step with a punching tool. Device for producing a component of fiber-reinforced plastic characterized by means ( 24a . 24b . 26a . 28b ) for the continuous production of a preform ( 14a . 14b ) and a press ( 16a . 16b ) for the discontinuous production of the component ( 10a . 10b ) by carrying out a method according to any one of claims 1 to 12.

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