• 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:
    Preformed product with a fiber-reinforced plastic arc shape for the manufacture of arched profiles, comprising. # A structure of choice of fiber layers with an outer arc-shaped contour, where the outer contour has two frontal limitations, an inner edge , oriented towards the center of the arch with its curvature and an outer edge, opposite to the center of the arch with its curvature; # An interior area, whose surface has a relief structure formed along the extension of the arch with ascents and / or descents perpendicular to the lower base; # A central zone as a base zone, without rises or falls, perpendicular to the lower surface; as well as # an outer zone, which has recesses oriented radially and open towards the outer edge. # In addition, the invention relates to a method of manufacturing curved profiles of fiber reinforced plastic with a structure of fiber layers of choice.
    公开号:ES2643755A9
    申请号:ES201730695
    申请日:2017-05-15
    公开日:2018-06-29
    发明作者:Georg Grötzschel
    申请人:COTESA GmbH；
    IPC主号:
    专利说明:

    Preformed arched fiber reinforced plastic product and procedure for the manufacture of arched profiles
    [0001] The invention relates to a preformed arcuate product of fiber reinforced plastic for the manufacture of arched profiles with a structure of choice of fiber layers. In addition, the invention relates to a process for the manufacture of arcuate profiles of fiber reinforced plastic with a structure of choice of fiber layers using a preformed arcuate product of fiber reinforced plastic.
    [0002] The manufacture of arched profiles from fiber reinforced plastic (FVK) with a fiber coordinate system that follows the profile, that is, with an ordinate (90 °) radial to the curvature of the profile and an abscissa ( 0 °) tangential to the profile curvature, represents a high technical challenge. Because of the high demands regarding the fiber content and the quality of the component in the area of primary structure of the aircraft, the use of preformed fiber reinforced plastic (FVK) products is standard for the manufacture of arched profiles. they present either as "pre-impregnated products" or as raw impregnated fiber pieces. These fiber layers can be brought to the desired shape by a thermal transformation process. Pre-impregnated products are textile blanks pre-impregnated with reaction resins, which harden to manufacture components using temperature and pressure.
    [0003] During the remodeling of the fiber layers, due to the change in the radius of the remodeled segments of the arch, the material necessarily "stretches" or "compresses". This necessitates a length compensation within the individual fiber layers. In layers with a fiber angle of ϕ ≠ 0 °, this occurs by an appropriate displacement of the individual fibers. Modifications of the length of the arch are compensated by union or extension with a transverse proportion to the direction of the fiber. In the case of a union, a correspondingly extended settlement of the angular layers must be taken into account. This approach is not applicable for fiber layers with ϕ = 0 °, although these fiber layers that follow the profile are often very relevant in structure components.
    [0004] According to the state of the art, the problem with the remodeling of the fiber layers with ϕ = 0 ° can be avoided or solved in different ways.
    [0005] In a first variant, a replacement of the fiber layers with ϕ = 0 ° by fiber layers with ϕ ≠ 0 ° is carried out increasing the number of layers to achieve the desired strength. Avoiding the fiber angle ϕ = 0 °, however, leads to disadvantageous restrictions in the layered structure of the laminate. With this the necessary resistance of the component can be achieved only with a corresponding increase in the number of layers with a fiber angle of ϕ ≠ 0 °. This, however, necessarily leads to weight gain, which is especially disadvantageous in aeronautical construction. The extension of the fiber layers transversely to the direction of the fiber can eventually result in cleft consequences between the fibers, the so-called "gaps", with inadmissible size.
    [0006] According to a second variant of the state of the art, the settlement of the individual layers of fibers with ϕ = 0 ° is carried out directly in the cross-section of the profile, that is, a three-dimensional settlement, thereby ceasing to be successive remodeling is necessary for these layers. However, the settlement of the fiber layers with ϕ = 0 ° directly in the cross section of the profile implies a high manufacturing cost with a large proportion of manual work phases in the form of placement of individual fiber layers or processes with machinery very complicated A manual lamination process can be reproduced more difficult and is less cost efficient. Therefore, this approach contradicts the objective of manufacturing automation and industrialization.
    [0007] US 7 943 076 B1 describes a process for manufacturing a curved composite component, comprising the following process steps:
    -  Making available a multiplicity of segments of composite tapes;
    -  Union of a group of tape segments in one layer, which keeps this group in a flexible framework;
    -  Positioning of the joined group of belt segments against a first curved surface of the tool of the molding tool;
    -  Adaptation of the joined group of belt segments to a second, generally flat surface of the tool of the molding tool;
    -  Adaptation of the joined group of belt segments to a third curved surface of the molding tool tool; Y
    -  Position hardening.
    [0008] In this case the group of the tape segments, starting from a smaller radius of the curvature, can be molded into a radius of greater curvature. The method uses a corrugated tool surface of a supplementary intermediate molding tool, to bring the group of belt segments to an intermediate shape. For this, the intermediate molding tool comprises different tool surfaces, of which some are provided with waves, which are formed by alternating projections and depressions. The waves are used to pre-mold the prepreg product to an intermediate form, where this intermediate form can be lightly molded using a molding machine with the molding tool. The area of the prepreg, which is pre-molded by a first tool surface of the intermediate molding tool, is placed against the smallest inner radius of the molding tool, the first curved surface of the tool. A contiguous zone, which is pre-molded by a second tool surface of the intermediate molding tool, and an outer cover, which is pre-molded by a third tool surface of the intermediate molding tool, is formed by the through molding tool of the molding machine.
    [0009] With this variant the cost of remodeling is relatively large, since depending on the profile shape, more than one edge can be remodeled successively. A special remodeling tool is needed, which has a disadvantage in manufacturing costs. In addition, a multi-stage remodeling process will result in unwanted displacements of the fiber layers, and will have a disadvantageous effect on the reproducibility of the process as well as the quality of the component. Because of the high degree of remodeling, a corrugated structure with very marked waves is required for this purpose, which is unfavorable from the point of view of the manufacturing technique. During the placement of the linked groups of belt segments against the first curved tool surface of a molding tool, especially in case of large thickness groups and a tool surface with a small radius of curvature, inadmissible compressions of fiber.
    [0010] Document DE 10 250 826 A1 describes a method for manufacturing a three-dimensional preformed product from textile starting materials such as fibers, fiber bundles
    or tapes The starting textile materials are placed two-dimensionally at the same level, where the orientation of the fibers and the geometry of the two-dimensional laying has been determined by recalculation from the three-dimensional objective form. The desired three-dimensional shape is manufactured by remodeling / covering the two-dimensional setting. However, with this method, arc-shaped preformed products with any fiber layer structure cannot be transformed into non-curved profiles. This is particularly true for fiber orientations with ϕ = 0 °.
    [0011] From US 2007/0 138 695 A1, a reinforcing element and a known method for its manufacture are known. The reinforcing element consists of a compound, which is intended for fixing to a curved surface of the cover and comprising a flange with a first longitudinal edge and a fixing flange, whose outer surface has a radius of curvature corresponding to the curved surface of the roof. The flange comprises at least one rounded conical bulge, which from a basic section essentially connected to the first longitudinal edge narrows to a first folding line and to the fixing flange. In addition, to provide rigidity to the element an internal flange is provided in the flange. In the method for manufacturing the reinforcing element, an essentially flat blank of composite material is first made available, having an essentially parallel first and second longitudinal edge. In a second step, the formation of the blank and the hardening of the formed blank takes place. The formation step comprises the formation of at least one rounded bulge with a conical shape in the flange, which narrows from the first edge to a first folding line, to receive the flange, and the formation of the flange, which essentially joins with a vertex of rounded bulge.
    [0012] EP 2 596 942 A1 describes a method for manufacturing a rolling component. This method comprises the following steps: a) making available a tool with a molding surface; b) arrangement of a stack of layers of layers on the molding surface of the tool and c) formation of the stack of layers of layers on the molding surface in a forming process. The tool has a fold control element on its molding surface for performing wrinkle formation in the layer sheets during the molding process. In this case, the fold control element acts together with the layer sheet pile during the molding process, to produce a local undulation on the surface on a surface of the laminate component to be generated, which is closer to the tool . In this way, a folding in the layers of layers or a formation of wrinkles in one or several layers of layers at a predetermined point should be avoided.
    [0013] The object of the invention is to overcome the aforementioned disadvantages of the state of the art and allow an advantageous, efficient and reproducible manufacture of high-quality arc-shaped profiles of fiber reinforced compound using simple manufacturing methods and standard with all freedoms with respect to the structure of the layers.
    [0014] The task is solved with a preformed arc-shaped product with the features according to claim 1 and a method according to claim 7. Other developments are indicated in the dependent claims.
    [0015] The preformed fiber reinforced plastic product according to the invention, which is suitable for the manufacture of arc profiles of fiber reinforced plastic (FVK), comprises
    -  A flat or slightly bulged base;
    -  A structure of choice of fiber layers with an arc-shaped outer contour, which has two frontal limitations, an inner edge, which is oriented towards the center of the arch and an outer edge, opposite the center of the arch;
    - Three zones: A first zone located inside - which is formed from the inner edge - as an expansion zone, whose surface has a relief structure formed along the length of the arch with elevations and / or subsidence, perpendicular to the base and in this way as an expansion zone allows the necessary expansion for the subsequent molding of this zone through the exact preparation of the necessary fiber lengths; A second zone, in the middle, - that starts from the first zone located in the interior, adjacent to the outside -, as a base area, which as a placement zone does not undergo any deformation during the subsequent formation of the profile; as well as a third zone, located on the outside, - which starts from the area of the base, adjacent to the outside and extends to the outer edge, –which has radially extending recesses and is open towards the outer edge and This way as a compression zone allows the compression necessary for the subsequent molding of this zone.
    [0016] According to an advantageous embodiment of the invention, the first area, located inside, is adjusted in such a way to the objective profile to be manufactured, that exactly one surface is maintained through the relief structure, corresponding to a surface that is formed by the area located inside, and that extends by closing the relief structure in the curved target profile. Particularly preferred is a relief structure formed in an undulating manner with elevations and subsidence.
    [0017] Preferably the recesses are arranged with regular distance along the outer edge. According to an advantageous configuration, the recesses are wedge-shaped
    [0018] The invention therefore comprises a prefabricated preformed product, which has the complete structure of fiber layers of the rear profile and through the characteristic configuration of the zones according to the invention, this profile can be advantageously carried in a process stage.
    [0019] Advantageously, the fiber layer structure may comprise fiber layers with fiber orientations at the free choice of small unidirectional fiber tapes. Particularly possible is the unlimited combination of the most relevant fiber angles from the point of view of the mechanical structure of ϕ = 0 ° with ϕ = 45 °, ϕ = - 45 ° and ϕ = 90 °, also of partial fiber layers .
    [0020] Another aspect of the invention relates to a process for the manufacture of a curved profile of fiber reinforced plastic (FVK) using a preformed curved product of FVK fiber reinforced plastic using a preformed FVK product according to the invention and a molding tool The molding tool represents the surface located inside the molded profile, which consists of an arcuate cover surface and adjacent flange surfaces that are joined perpendicularly or obliquely. In this case the surface of the inner flange is concavely curved and the surface of the outer flange is convexly curved. Instead of a separate molding tool, the hardening molding tool can be advantageously used directly for molding.
    [0021] The method comprises the following steps of the method that follow one another: In a first stage of the procedure a) a placement of the preformed FVK product is performed such that the base area is positioned exactly flush on the covering surface of the molding tool. In this case the adjacent areas - the expansion zone located inside and the compression zone located outside - protrude above the covering surface of the molding tool.
    [0022] In a successive stage of the procedure b) an adjustment of the external compression zone protruding from the preformed FVK product is made to the outer surface of the molding tool flange, where the wedge-shaped recesses of the area of compression are closed, as well as an adjustment of the expansion zone located inside, protruding from the preformed FVK product to the surface of the inner flange of the molding tool, where the expansion zone located inside, in the form of relief , extends by completely closing the relief structure. The adjustment to the two flange surfaces is done simultaneously in one step or successively regardless of the order.
    [0023] Through the use of the invention in an industrial manufacturing process several advantages result from the manufacturing methods of the prior art:
    -  Placing the complete structure of fiber layers in a single preformed FVK product,
    -  An advantageous manufacture of the preformed FVK product with simple standard manufacturing procedures on a flat or slightly bulged basic surface, for example, in an automated way with an automated fiber positioning installation (AFP Installation),
    -  Surprisingly simple further processing modeling with standard molding process, where the complete structure of fiber layers can be molded in one step without using expensive molding tools or machines,
    -  a structure of fiber layers completely to election without conditions imposed by manufacturing technique and therefore an optimal use of the characteristics related to the mechanical structure of fiber reinforced compounds and
    -  Surprisingly good remodeling results without unwanted influence on fiber orientation, such as a distortion of the fiber angle.
    [0024] Other details, features and advantages of configurations of the invention result from the following description of embodiments with reference to the corresponding drawings. Shows:
    [0025] Fig. 1: a preformed FVK product for the manufacture of arc profiles of fiber reinforced plastic (FVK) with fiber coordinate system following the profile,
    [0026] Fig. 2: FVK's preformed product for the manufacture of arc profiles of fiber reinforced plastic (FVK) in a schematic representation in a polar coordinate system,
    [0027] Fig. 3: a schematic representation of a three-dimensional, curved profile of fiber reinforced plastic (FVK) with exemplary objective geometry after molding and
    [0028] Fig. 4: a schematic representation of the layer structure of a three-dimensional curved profile.
    [0029] Fig. 1 shows a preformed arc-shaped FVK 1 product for the manufacture of arc profiles of fiber reinforced plastic (FVK) with fiber coordinate system following the profile. By a fiber coordinate system that follows the profile, it is understood that the abscissa of the fiber coordinate system is oriented parallel to the tangent of the profile line, in the example shown, the curvature of the arched preformed product 1, and the correspondingly arranged in perpendicular, that is, it extends by 90 °, both being respectively at the lower base 2.
    [0030] In this case the preformed arc-shaped product 1 has a structure of choice of fiber layer, which forms a lower base 2 with an arc-shaped outer contour. The lower base 2 can be formed flat or domed. Thus, the lower base 2 can bulge, for example, as a section of a cone surface.
    [0031] The outer arc-shaped contour has two frontal limitations 3a 3b as well as an inner edge 4, oriented towards the center of the arc with its curvature and an outer edge 5, opposite the center of the arc with its curvature. The preformed product 1 comprises three different zones. A first zone 6 located inside is formed from the inner edge 4, where the surface of this zone 6 located inside has a wavy relief structure 7 along the length of the arch with elevations 7a and / or subsidence 7b perpendicular to the lower base 2. Starting from the first zone 6, located inside, a second central zone is formed, adjacent outwards, as a base zone 8 without elevations 7a and subsidence 7b, perpendicular to the lower base 2. The base zone 8 of the preformed product 1 is formed in the example shown in essentially two-dimensional form, that is, it corresponds to a flat bottom base 2. However, the base zone can also have a bulged shape, such as a section of the lateral surface of a cone. Starting from the base zone 8, a third zone 9 is formed outside, adjacent outwardly, extending to the outer edge and having radially oriented, 10-shaped recesses, open towards the outer edge 5. The cuneiform recesses 10 10 are preferably distanced from each other regularly.
    [0032] Alternatively to the representation in a fiber coordinate system that follows the profile, arcuate preformed FVK products, as shown in Fig. 2, can also be represented in a polar coordinate system. The definition of a local fiber angle depends on the position of the point respectively contemplated P in the polar fiber coordinate system, which in turn defines a polar angle α and a radius r. A fiber angle ϕ of ϕ = 0 ° corresponds to the tangential direction at the respective point P, a fiber angle of 90 ° corresponds to the point P of the radial direction at point P of the polar coordinate system. All other fiber orientations are deduced accordingly. The description model of the polar fiber coordinate system can be used at least locally, where the same polar coordinate system does not have to be valid for the total position of the arc-shaped fiber, for example in the case of jumps in the radius of the arc shape.
    [0033] The preformed arc-shaped FVK product 1 comprises a first zone 6 located inside, which starts from the inner edge 4, which corresponds to a radius r1 in the polar coordinate system, where the inner surface has a structure of relief 7 corrugated along the extension of the arc of the preformed FVK product 1 with elevations 7a and / or subsidence 7b in relation to the lower base 2, in the example shown of the plane of the polar coordinate system. A zone 6 located in the center as a base zone 8, adjacent outwards with the first zone, located inside, is formed essentially two-dimensional. In the outside area 9, which is adjacent to the base area 8, the preformed product 1 has cuneiform recesses 10, radially oriented and open towards the outer edge 5. The outer edge itself has a radius outside the recesses 10 R2.
    [0034] Fig. 3 shows a three-dimensional arched profile of fiber-reinforced plastic (FVK) with exemplary objective geometry, which can be obtained by molding the preformed arc-shaped FVK 1 product shown in Fig. 1. This can be obtained through a process for manufacturing a curved profile of fiber reinforced plastic (FVK) using a preformed arcuate FVK 1 product, shown in Figs. 1 and Fig. 2, and a tool for molding not shown. The molding tool has an arched surface in the form of a flat arch with an outer edge with a larger radius and longer arc length and an inner folded edge with a smaller radius and smaller arc lengths. In this case, each of the two edges of the curved surface of the molding tool respectively follows a curved flange surface oriented downwardly perpendicularly, where the outer flange surface is convexly curved in the outer edge and the surface of the inner flange is concavely curved in the inner edge.
    [0035] The method for manufacturing a curved profile of fiber reinforced plastic (FVK) according to Fig. 3 comprises the following successive steps of the method: a) Positioning of an area for placement 12, corresponding to the base area 8 of the preformed arc-shaped FVK 1 product shown in Figs. 1 and Fig. 2 and which lies between the area 6 located inside with the relief structure 7 and the area located outside 9 with the Cuneiform radial recesses 10, on the curved surface of the molding tool, formed in the form of a flat arc, b) Adaptation of an expansion zone 13 of the preformed FVK product 1, corresponding to the zone 6 located inside with the relief structure 7, to the inner surface of the flange forming a ridge 14 between the placement zone 12 and the expansion zone 13 in the inner edge of the molding and adaptation tool of a compression zone 15, corresponding to the a zone located on the outside 9 with the cuneiform radial recesses 10, to the surface of the outer flange forming a ridge 16 between the positioning zone 12 and the compression zone 15, where the adaptation to both flange surfaces is carried out in one step
    5 simultaneously or successively in any order.
    [0036] In this way an arcuate profile 11 arises, three-dimensional, which has an essentially inverted U-shaped cross section.
    [0037] Fig. 4 contains a schematic representation of the structure of layers of a curved profile 11, three-dimensional, after modeling the preformed arcuate FVK 1 product. An advantage of the invention is that the preformed product of FVK 1 can be made with a structure of fiber layers of choice without conditions imposed by manufacturing techniques and in this way it is possible to take advantage of the characteristics of the
    15 mechanical structure of fiber reinforced materials. Thus, the arcuate, three-dimensional profile 11, as schematically represented in Fig. 4, can be made with both fiber layers of small unidirectional fiber tapes 17 with a fiber angle ϕ = 0 °, as well as fiber layers of small unidirectional fiber tapes 18 with a fiber angle ϕ ≠ 0 °. Different layers of fiber are schematically represented in Fig. 4,
    20 respectively unidirectional. The indications for the fiber angle ϕ refer to a fiber coordinate system that follows the profile.
    Reference List
    one Preformed fiber reinforced plastic product
    2  Bottom base
    3rd Frontal limitation
    3b Frontal limitation
    4 Inner edge
    5 Outer edge
    6 Inside area
    7 Relief structure
    7a Elevations
    7b Sinking
    8 Base area
    9 Outside area
    10 Recesses
    eleven Profile
    12 Placement area
    13 Dilation zone
    14 Edge between placement zone 12 and expansion zone 13
    fifteen Compression zone
    16 Edge between placement zone 12 and compression zone 15
    17 Small fiber tape
    18 Small fiber tape
    P Polar coordinate system point
    r1 Radius (internal edge 4)
    r2 Radius (outer edge 5)
    α Polar angle
    ϕ Fiber angle, fiber orientation
    权利要求:
    Claims (7)
    [1]
    one. Preformed product in the form of a fiber reinforced plastic arch (1) for the manufacture of arched profiles, comprising a structure of fiber layers with an external contour in the form of an arc, which forms a flat or domed bottom base (2), where the outer contour has two frontal limitations (3a, 3b), an inner edge (4), oriented towards the center of the arch with its curvature and an outer edge (5), opposite to the center of the arch with its curvature; A first zone (6) located inside, - formed from the inner edge - whose surface has a relief structure (7) formed along the length of the arch with rises (7a) and / or descents (7b) perpendicular to the bottom base (2); A second central zone as the base zone (8) - which starts from the first zone, located inside (6), adjacent to the outside -, without rises or descents, perpendicular to the lower surface; as well as a third zone, located on the outside (9), which starts from the base area (8) and being adjacent outwards extends to the outer edge (5), where the outer zone (9) has recesses (10 ) oriented radially and open towards the outer edge (5).
    [2]
    2. Preformed product in the form of a fiber reinforced plastic arch (1) according to claim 1, characterized in that the first area (6) located inside is adapted in such a way to the objective profile, that through the structure Relief (7) exactly maintains a surface that corresponds to a surface formed by the area (6) located inside, which extends by closing the relief structure (7) in the curved objective profile (11)
    [3]
    3. Preformed product in the form of a fiber reinforced plastic arch (1) according to claim 1 or 2, characterized in that the relief structure (7) is formed in a wavy shape with rises (7a) and descents (7b).
    [4]
    Four. Preformed product in the form of a fiber reinforced plastic arch (1) according to one of claims 1 to 3, characterized in that the recesses (10) are arranged along the outer edge (5) spaced regularly.
    [5]
    5. Preformed product in the form of a fiber reinforced plastic arch (1) according to one of claims 1 to 4, characterized in that the recesses (10) are wedge-shaped.
    [6]
    6. Preformed product in the form of a fiber reinforced plastic arch (1) according to one of claims 1 to 5, characterized in that the preformed fiber reinforced plastic product (1) consists of several layers of fiber with small ribbons of fiber (17,18) respectively unidirectional with a fiber angle ϕ = 0 ° or with a fiber angle ϕ ≠ 0 °.
    [7]
    7.  Method for manufacturing a curved profile of fiber-reinforced plastic (FVK) using a preformed fiber-reinforced plastic arc-shaped product (1) according to one of claims 1 to 6 and a molding tool, which has a surface of flat or domed coverage in the form of an arch with an outer edge with a larger radius and a longer arc length and a folded inward edge with smaller radius and smaller arc length, where each of the two The edges of the cover surface are joined respectively by a curved flange surface oriented obliquely or perpendicularly, where an outer surface of the flange is convexly curved in the outer edge and an inner surface of the flange is concavely curved in the inner edge, which comprises the following steps of the method, which follow one after the other: a) Placing the preformed product of reinforced plastic zado with fiber (1) in such a way that the base area (8) is positioned as a zone for placement (12) flush over the covering surface of the molding tool, where adjacent areas - the area located inside (6), as an expansion zone (13) that has a relief structure (7) and the area located outside (9) as a compression zone (15), which has cuneiform recesses
    (10) - protrude above the covering surface of the molding tool; b) Adjustment of the compression zone (15) that is outside, which protrudes, from the preformed fiber reinforced plastic product (1) to the outer surface of the molding tool flange, where the cuneiform recesses (10) of the compression zone (15) are closed, as well as the adjustment of the expansion zone (13) located inside, which protrudes, from the preformed fiber reinforced plastic product (1) to the inner surface of the flange of
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