METHOD AND SYSTEM FOR PRODUCING A FIBER PREFORM

Abstract

The disclosure relates to a method for producing a fiber preform, wherein: at least one dry and textile fiber material is provided; the fiber material is assembled into a plurality of individual layers; the plurality of individual layers is provided with a binder; the plurality of individual layers is layered to form a package; and a plurality of interconnected fiber preforms is formed by pressing the package. A separation of the plurality of interconnected fiber preforms and activation of the binder occur in a common process step. The disclosure furthermore relates to a corresponding system.

Claims

1. A process for the production of a fiber preform, comprising: providing at least one dry and textile fiber material, wherein the fiber material is dimensioned to have a plurality of individual layers, providing a binder to the plurality of individual layers, wherein the plurality of individual layers is layered to form a package, and where a plurality of interconnected fiber preforms is formed by pressing of the package, wherein a separation of the plurality of interconnected fiber preforms and an activation of the binder are achieved together in a single process step.

2. The process as claimed in claim 1, wherein additionally in the single process step, the plurality of interconnected fiber preforms is formed by pressing of the package.

3. The process as claimed in claim 1, wherein the fiber material comprises carbon fibers and/or glass fibers and/or aramid fibers.

4. The process as claimed in claim 1 to 3, wherein before layering to form the package, the plurality of individual layers is oriented in respect of a fiber orientation of each individual layer.

5. The process as claimed in claim 1, wherein the activation of the binder is achieved by introduction of heat.

6. The process as claimed in claim 5, wherein the introduction of heat is achieved by ultrasound and/or by conductive heat transfer.

7. The process as claimed in claim 6, wherein the introduction of heat is achieved by ultrasound by way of operation of at least one sonotrode, where the at least one sonotrode is passed continuously across the plurality of interconnected fiber preforms.

8. The process as claimed in claim 6, wherein the introduction of heat is achieved by conductive heat transfer by way of at least one contact roll, where the contact roll is heated and is passed across the plurality of interconnected fiber preforms.

9. The process as claimed in claim 1, wherein the separation of the plurality of interconnected fiber preforms is achieved by a cutting procedure, wherein the cutting procedure is achieved by way of a cutting implement, oscillation of which is induced by ultrasound.

10. The process as claimed in claim 9, wherein the oscillation takes place at frequencies in the range of between 20 kHz and 40 kHz.

11. A system for the production of a fiber preform, comprising a first device, which is configured for the dimensioning of dry and textile fiber material provided to give a plurality of individual layers, a second device, which is configured to provide a binder to the plurality of individual layers, and a third device, which is configured for the layering of a package made of the plurality of individual layers, wherein the system comprises a further device that is configured to implement a separation of the plurality of interconnected fiber preforms and an activation of the binder together in a single process step.

12. The system as claimed in claim 11, wherein the further device is also configured to form a plurality of interconnected fiber preforms by pressing the package.

13. The system as claimed in claim 11 wherein the further device comprises a cutting implement which can receive ultrasound, and a sonotrode, where the cutting implement which can receive ultrasound, and the sonotrode are fixedly arranged on the same implement holder.

14. The system as claimed in claim 13, wherein the cutting implement which can receive ultrasound and the sonotrode receive ultrasound from the same ultrasound source.

15. The system as claimed in claim 11 wherein the further device comprises a cutting implement which can receive ultrasound, and a heatable contact roll, wherein the cutting implement which can receive ultrasound, and the heatable contact roll are fixedly arranged on the same implement holder.

16. The system as claimed in claim 15, wherein the contact roll is electrically heatable.

17. (canceled)

18. The process as claimed in claim 6, wherein the introduction of heat is achieved by ultrasound by way of operation of at least one sonotrode, where the at least one sonotrode is applied at regular intervals to the plurality of interconnected fiber preforms.

19. The process as claimed in claim 11, wherein the further device comprises a cutting implement that receives ultrasound, the cutting implement having a first ultrasound source and comprising a sonotrode with a second ultrasound source.

20. The process as claimed in claim 19, wherein the cutting implement is separated from the sonotrode on a common implement holder by a predetermined distance.

21. The process as claimed in claim 20, wherein the system has a flowpath for the production of the fiber preforms, and the cutting implement is arranged in the flowpath of the system such that the cutting implement is utilized before the sonotrode.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0040] The disclosure is explained by way of example below with reference to various exemplary arrangements depicted in the figures.

[0041] FIG. 1 shows by way of example and diagrammatically a sequence of a process of the disclosure in comparison with a process known in the prior art,

[0042] FIG. 2 shows by way of example and diagrammatically a possible exemplary arrangement of a device which is configured to implement separation of a plurality of interconnected fiber preforms and to implement activation of a binder in a single process step,

[0043] FIG. 3 shows by way of example and diagrammatically another possible exemplary arrangement of a device which is configured to implement separation of a plurality of interconnected fiber preforms and to implement activation of the binder in a single process step,

[0044] FIG. 4 shows by way of example and diagrammatically the arrangement depicted in FIG. 2 of the device during an implementation of the process of the disclosure and

[0045] FIG. 5 likewise shows by way of example and diagrammatically the arrangement depicted in FIG. 2 of the device during implementation of the process of the disclosure.

[0046] Identical items and functional units, and comparable components, are designated with identical reference signs in all of the figures. These items and functional units, and comparable components, are designed identically in respect of their technical features unless the description explicitly or implicitly indicates otherwise.

DETAILED DESCRIPTION

[0047] FIG. 1 shows by way of example and diagrammatically a sequence of a process of the disclosure (FIG. 1b) in comparison with a process known in the prior art (FIG. 1a). Not only in the process of the disclosure but also in the known process, a dry and textile fiber material 1 is first provided in a first process step 20. The fiber material 1 in the example is configured as carbon fiber material 1, and is introduced into a first device 2, which in the example is configured as cutting device 2. In process step 21, the fiber material 1 is dimensioned by the cutting device 2 to give a plurality of individual layers 3 of the fiber material 1. The individual layers 3 in the example are all configured with identical shape. In the following process step 22, a binder 5 comprising a thermoplastic substance is provided to the plurality of individual layers 3 by a second device 4. To this end, the second device 4 is configured in the example as scattering device 4 which applies the binder 5 in powder form to the plurality of individual layers 3. In step 23, the plurality of individual layers 3 is now layered to give a package 7, while consideration is given to a fiber orientation of each individual layer. The package 7 therefore includes the plurality of individual layers 3. The layering of the plurality of individual layers 3 to create the package 7 is achieved by a third device 6, which is configured in the example as lay-up device 6, and which can grip, orientate and place the plurality of individual layers 3. Up to process step 23 there is no difference in the example between the known process and the process of the disclosure.

[0048] In step 24 in the known process, a plurality of interconnected fiber preforms 8 is now formed by pressing of the package 7, where the pressing is achieved in the example by a fourth device 9 configured as hydraulic press 9. In step 25 in the known process, the binder 5 is activated by a contact heating system 10, so that the binder 5 develops an adhesive action between the individual layers 3 of the package 7 and, respectively, of the plurality of interconnected fiber preforms 8. In process step 26, the plurality of interconnected fiber preforms 8 is then separated by a punching device 11. In step 28, the separated fiber preforms 8 are transferred to another device not depicted in FIG. 1 for their further processing.

[0049] The process of the disclosure differs from the known process steps 24, 25 and 26 in that process step 27 simultaneously achieves formation of the plurality of interconnected fiber preforms 8, the activation of the binder 5 and, likewise simultaneously, the separation of the plurality of interconnected fiber preforms 8. The further device 12 here in the example comprises a cutting implement 13 which can receive ultrasound, and a sonotrode 14, where the cutting implement 13 which can receive ultrasound, and the sonotrode 14, are fixedly arranged on a single implement holder 15. Because the shaping procedure, the separation of the plurality of interconnected fiber preforms 8 and the activation of the binder 5 are achieved simultaneously, it is possible to achieve, in comparison with the known process, a reduction of the required production time. The capital expenditure necessary can moreover be reduced, because purchase of the separate components of the hydraulic press 9, of the contact heating system 10, and also of the punching device 11, can be omitted. Instead, it is merely necessary to purchase the further device 12. In step 28, here again the separated fiber preforms 8 are transferred to another device for their further processing.

[0050] FIG. 2 shows by way of example and diagrammatically a possible arrangement of the device 12, which is configured to implement the separation of the plurality of interconnected fiber preforms 8 and the activation of the binder 5 in a single process step. To this end, the further device 12 shown by way of example in FIG. 2 comprises a cutting implement 13 which can receive ultrasound, configured as blade 13, and also comprises a sonotrode 14, these being fixedly arranged with a prescribed separation on a single implement holder 15. By the blade 13, the plurality of interconnected fiber preforms 8 can be cut and thus separated. At the same time, ultrasound waves are introduced by way of the sonotrode 14 into the plurality of interconnected fiber preforms 8, and these activate the binder 5, which thus develops its adhesive action. The application of ultrasound to the blade 13 permits comparatively easy and precise cutting of the fiber material 1 of the plurality of interconnected fiber preforms 8. In order to generate the ultrasound waves, there is an ultrasound source 17 allocated to the blade 13, and an ultrasound source 18 allocated to the sonotrode 14. As a result of the depicted separation of the blade 13 from the sonotrode 14, although the separation and the activation are achieved simultaneously, they are achieved at different locations within the plurality of interconnected fiber preforms 8. It is thus possible to determine, via the orientation of the further device 12, whether an individual fiber preform 8 is to be first divided off or cut off or separated by the blade 13 from the plurality of interconnected fiber preforms 8 or whether the binder 5 is first to be activated in the region of the individual fiber preform 8 by the sonotrode 14. The single implement holder 15 in the example can be linked to an industrial robot, not depicted, or to a CNC milling machine, likewise not depicted; said robot or said machine then, during the course of implementation of the process of the disclosure, guides and activates the further implement 12 across the plurality of interconnected fiber preforms 8.

[0051] FIG. 3 shows by way of example and diagrammatically another possible exemplary arrangement of the device 12, which is configured to implement the separation of the plurality of interconnected fiber preforms 8 and the activation of the binder 5 in a single process step. The device 12 of FIG. 3 differs from the device 12 of FIG. 2 in that it comprises an electrically heatable contact roll 16 instead of the sonotrode 14. The heatable contact roll 16 is likewise fixedly arranged with the blade 13 on the single implement holder 15.

[0052] FIG. 4 shows by way of example and diagrammatically the exemplary arrangement already depicted in FIG. 2 of the device 12 during the implementation of the process of the disclosure. The device 12 comprises a cutting implement 13 which can receive ultrasound, configured as blade 13, with an ultrasound source 17, and comprises a sonotrode 14 with an ultrasound source 18, these being fixedly arranged with a prescribed separation on a single implement holder 15. The single implement holder 15 in the example is passed by an industrial robot, which is not depicted, across a plurality of interconnected fiber preforms 8. The plurality of interconnected fiber preforms 8 has been placed on holders 19. As can be seen, the device 12 in FIG. 4 is oriented in a manner such that a fiber preform 8 is first divided off or cut off or separated by the blade 13 from the plurality of interconnected fiber preforms 8 before ultrasound is applied thereto by the sonotrode 14, this then leading to the activation of the binder 5. The effect of this is therefore that although in the depiction of FIG. 4 the separation and activation are achieved simultaneously in a single process step, by virtue of the separation of the blade 13 from the sonotrode 14 they are achieved at separate locations, such that the fiber preforms 8 are separated before the binder 5 of the separated fiber preforms 8 is activated.

[0053] FIG. 5 likewise shows by way of example and diagrammatically the arrangement depicted in FIG. 2 of the device 12 during the implementation of the process of the disclosure. The depiction of FIG. 5 differs from the depiction of FIG. 4 via the orientation of the device 12: in FIG. 5, the orientation of the device 12 is specifically such that ultrasound is first applied to the plurality of interconnected fiber preforms 8 by the sonotrode 14, so that activation of the binder 5 is therefore achieved before the plurality of interconnected fiber preforms 8 is separated by the blade 13. In this case again, although the separation and activation are achieved simultaneously in a single process step, by virtue of the separation of the blade 13 from the sonotrode 14 they are achieved at separate locations, such that the binder 5 is activated before the fiber preforms 8 are separated.