Process for producing a component which is two-dimensional in regions from a fibre composite material

Abstract

A process is proposed for producing a component, in which at least one first two-dimensional laid scrim is produced from a fibre composite material having a constant thickness, an outer face and an inner face. At least one second two-dimensional laid scrim is arranged with respect to the first two-dimensional laid scrim and then consolidated. The first two-dimensional laid scrim can be provided in a continuous, efficient production process, which increases speed and lowers costs.

Claims

1. A process for producing a component, comprising: producing an even number of first two-dimensional laid scrims from a fibre composite material having a constant thickness, an outer face, and an inner face, where each of the first laid scrims has a two-dimensional extent that determines the two-dimensional extent of the component, and wherein the even number of first laid scrims comprises an outer first laid scrim and an inner first laid scrim; producing at least one second two-dimensional laid scrim from the fibre composite material, where the two-dimensional extent of the second laid scrim is less than that of the first two-dimensional laid scrims; selectively positioning at least a portion of the at least one second laid scrim at discrete regions of the inner face of the outer first laid scrim to increase a local thickness in order to increase local strength; and positioning the inner first laid scrim such that the portion of the at least one second laid scrim is arranged between the outer first laid scrim and the inner first laid scrim, and consolidating the composite composed of the inner first laid scrim, the outer first laid scrim, and the second laid scrim at least under application of pressure.

2. The process according to claim 1, further comprising: providing multiple reinforcement elements; and positioning the reinforcement elements on the inner face of the first laid scrim prior to the consolidating.

3. The process according to claim 1, wherein the inner first laid scrim and the outer first laid scrim have a mutually symmetrical layer structure.

4. The process according to claim 1, further comprising positioning of one or more of the second laid scrims or third laid scrims on an inner face of the inner first laid scrim.

5. The process according to claim 4, wherein the second laid scrim disposed on the inner face of the inner first laid scrim are in symmetric form with respect to the second laid scrims disposed between the two first laid scrims.

6. The process according to claim 1, wherein the producing of the at least one first laid scrim is performed by a twin belt press.

7. The process according to claim 1, wherein: the composite is formed in a forming mould; the composite is then enclosed between the forming mould and a contact pressure block; and the composite is consolidated by action of a mechanical pressure from the contact pressure block in the direction of the forming mould.

8. The process according to claim 1, wherein a shape of the inner first laid scrim is adjusted in three dimensions before the composite is formed in a forming mould.

9. The process according to claim 1, wherein the consolidating is conducted by press consolidation.

10. The process according to claim 1, wherein the component is a fuselage shell, a wing shell, an empennage shell or another two-dimensional component of an aircraft.

11. A component comprising: an even number of first two-dimensional laid scrims comprising a fibre composite material having a constant thickness, an outer face, and an inner face, where each of the first laid scrims has a two-dimensional extent that determines the two-dimensional extent of the component, and wherein the even number of first laid scrims comprises an outer first laid scrim and an inner first laid scrim; and at least one second two-dimensional laid scrim composed of the fibre composite material, wherein the two-dimensional extent of the second laid scrim is less than that of the first two-dimensional laid scrims; wherein at least a portion of the second laid scrims are disposed at discrete regions of the inner face of the outer first laid scrim to increase a local thickness in order to increase local strength; wherein the inner first laid scrim is positioned such that the portion of the at least one second laid scrim is arranged between the outer first laid scrim and the inner first laid scrim; and wherein the composite composed of the inner first laid scrim, the outer first laid scrim, and the second laid scrim has been consolidated at least with application of pressure.

12. The component according to claim 11, wherein the composite is consolidated without any change in a shape of the outer first laid scrim.

13. The process according to claim 1, wherein consolidating the composite composed of the inner first laid scrim, the outer first laid scrim, and the second laid scrim is performed without any change in a shape of the outer first laid scrim.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further features, advantages and possible uses will be apparent from the description below of the working examples and the figures. All features described and/or pictured, on their own and in any combination, form the subject-matter of the disclosure, even irrespective of their composition in the individual claims or their dependency references. In the figures, in addition, identical reference numerals represent identical or similar objects.

(2) FIG. 1 shows a process in a schematic, block-based diagram.

(3) FIG. 2 shows a partial section of a component to be produced.

(4) FIG. 3 shows an aircraft and a fuselage shell of the aircraft as the component to be produced.

(5) FIGS. 4, 4A, 5 and 5A show the use of different forming moulds.

DETAILED DESCRIPTION

(6) The following detailed description is merely illustrative in nature and is not intended to limit the embodiments of the subject matter or the application and uses of such embodiments. As used herein, the word “exemplary” means “serving as an example, instance, or illustration.” Any implementation described herein as exemplary is not necessarily to be construed as preferred or advantageous over other implementations. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description.

(7) FIG. 1 shows a process 2 for producing a component in a schematic, block-based diagram. The process 2 begins, by way of example, with the production 4 of at least a first two-dimensional laid scrim from a fibre composite material having a constant thickness, wherein the first laid scrim has a two-dimensional extent that determines the two-dimensional extent of the component. Subsequently, simultaneously or in a preceding step, multiple second two-dimensional laid scrims are produced 6 from the fibre composite material, wherein the two-dimensional extents of the second laid scrim are less than that of the first two-dimensional laid scrim. Subsequently, simultaneously or in a preceding step, multiple reinforcing elements are provided 8.

(8) For the sake of simplicity, these three steps 4, 6 and 8 are identified as successive steps. As stated, however, these can also be implemented in a different sequence.

(9) If these components, i.e. the at least one first two-dimensional laid scrim, the second two-dimensional laid scrims and the reinforcing elements, are present, these are positioned appropriately in order to form a composite of components. The second laid scrims are positioned 10 in those areas of an inner face of the first laid scrim where there is a need to increase a local thickness to increase the local strength.

(10) Subsequently or in a preceding step, reinforcing elements are positioned 12 on the inner face of the first laid scrim, followed by consolidating 14 of the composite composed of the first laid scrim, the second laid scrims and the reinforcing elements at least with application of pressure. Here too, for the sake of simplicity, process steps 10 and 12 are identified as successive steps. However, the sequence in which these steps are conducted may especially depend on the shape of the forming mould.

(11) The producing 4 of the at least one first two-dimensional laid scrim may comprise the producing 16 of an outer first laid scrim and the producing 18 of an inner first laid scrim. The positioning 10 of the second laid scrims may then consequently comprise the introducing 20 of at least a portion of the second laid scrims between the outer first laid scrim and the inner first laid scrim.

(12) In addition, it is also possible to position 22 one or more of the second laid scrims on the inner face of the inner first laid scrim in order to achieve further local reinforcement. These may also be provided with stronger shape transitions than the second laid scrims disposed between the first laid scrims.

(13) FIG. 2 shows an illustrative layer structure of a component 42 to be produced in a partial section. What is shown here, at the bottom in the plane of the drawing, is an outer first laid scrim 24 provided with a number of layers 24a, 24b, . . . , 24f. At a distance from this is provided an inner first laid scrim 26 having multiple layers 26a, 26b, . . . , 26f. It is envisaged that the layers 24a to 24f and the layers 26a to 26f are symmetric with respect to one another. This means that the fibre directions of the individual layers are the same as with increasing separation of the first laid scrims 24 and 26 from one another.

(14) Between the two first laid scrims 24 and 26 is disposed a second laid scrim 28 which, by way of example, has a number of layers 28a, 28b, 28c and 28d. It is preferable that surface transitions in the second laid scrim 28 run very harmonically, such that surface slopes of not more than 1:200 are achieved. By pressing on the inner first laid scrim 26 or the outer first laid scrim 24, the second laid scrim 28 is incorporated flush.

(15) In this connection, the side of a composite 30 made from the laid scrims shown should be identified as follows. A side 32 of the outer first laid scrim 24 remote from the inner first laid scrim 26 should be identified as the outer face 32. The opposite side is the inner face 34. A side of the inner first laid scrim 26 facing the outer first laid scrim 24 is an outer face 36, and an opposite side an inner face 38. On the inner face 38 of the inner first laid scrim 26 is disposed, by way of example, a number of further second laid scrims 40 that cause additional reinforcement of the component. In the case of these non-incorporated second laid scrims 40, greater surface slopes of, for example, up to 1:20 may be achieved.

(16) It is preferable that the second laid scrims 40 on the inner face 38 of the inner first laid scrim 26 are in symmetric form with respect to the second laid scrims 28 between the first laid scrims 24 and 26.

(17) An example of a component 42 to be produced is the illustration of an aircraft 44 in FIG. 3. The component 42 could be a fuselage shell having multiple window cutouts 46 and a door cutout 48. In regions around the window cutouts 46 and the door cutout 48, there may be areas of local thickening that could be achieved, for example, with second laid scrims 28 and 40. By virtue of the topology shown in FIG. 2, it is possible to achieve areas of local thickening with the aid of second laid scrims 28 and nevertheless to provide large-scale components in efficient and rapid production processes as two-dimensional components with a uniform thickness.

(18) FIGS. 4 and 4A show a first variant of a forming mould 50 having a rigid base 52 on which there are firstly disposed reinforcing elements 54 in the form of stringers. These are directed later toward an inner face of the component 42. The inner first laid scrim 26, the outline of which has been adjusted in three dimensions in some sub-regions 56, is positioned onto the stringers 54. This makes it possible to arrange the incorporated second laid scrims 28 between the stringers 54 or both beneath and between the stringers 54, such that they lead to local thickening.

(19) Subsequently, the outer first laid scrim 24 is arranged. By virtue of the prior adjustment of the outline of the inner first laid scrim 26, the outer face 32 of the outer first laid scrim 24 remains in its planned form. The outer face 32 which constitutes an outer face of the fuselage shell 42, for example, can thus be placed flush onto the other components. By the subsequent pressing-on of the outer first laid scrim 24 by way of a contact pressure block 58, it is possible to perform a consolidation without any change in the shape of the outer first laid scrim 24. The incorporated second laid scrims 28 may likewise have been provided with a final three-dimensional outline or they are placed on in largely flat form and only converted to their envisaged form by the pressing-on of the contact pressure block 58.

(20) The diagrams in FIGS. 4 and 4A should merely be understood by way of example; further laid scrims are also possible and, in addition, it would also be possible to integrate a lightning guard layer (not shown). In addition, rather than a contact pressure block 58, it would also be possible to apply a vacuum foil such that air is sucked out between the vacuum foil and the rigid base 52, such that the air pressure surrounding the forming mould 50 acts on the composite 30.

(21) FIGS. 5 and 5A show a different forming mould 60. This has a rigid base 62 on which the outer face 32 of the outer first laid scrim 24 is positioned. This is followed by the incorporated second laid scrims 28, on which the inner first laid scrim 26 is positioned. Subsequently, the reinforcing components 54 are mounted. A contact pressure block 64 then serves to press on the reinforcing elements 54 and the inner first laid scrim 26, especially with simultaneous heating for consolidation of the component.

(22) It should additionally be pointed out that “including” does not exclude any other elements or steps, and “a” or “an” does not exclude a multitude. Moreover, it should be pointed out that features that have been described with reference to one of the above working examples can also be used in combination with other features of other working examples described above. Reference numerals in the claims should not be regarded as a restriction.

REFERENCE NUMERALS

(23) 2 process 4 producing a first two-dimensional laid scrim 6 producing second two-dimensional laid scrims 8 providing reinforcing elements 10 positioning second laid scrims 12 positioning reinforcing elements 14 consolidating 16 producing of outer first laid scrim 18 producing of inner first laid scrim 20 introducing of second laid scrims between first laid scrim 22 positioning of second laid scrims 24 outer first laid scrim 26 inner first laid scrim 28 (incorporated) second laid scrim 30 composite 32 outer face of the outer first laid scrim 34 inner face of the outer first laid scrim 36 outer face of the inner first laid scrim 38 inner face of the inner first laid scrim 40 second laid scrim 42 component 44 aircraft 46 window cutout 48 door cutout 50 forming mould 52 rigid base 54 reinforcing elements 56 sub-regions of the inner first laid scrim 58 contact pressure block 60 forming mould 62 rigid base 64 contact pressure block

(24) While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or embodiments described herein are not intended to limit the scope, applicability, or configuration of the claimed subject matter in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing the described embodiment or embodiments. It should be understood that various changes can be made in the function and arrangement of elements without departing from the scope defined by the claims, which includes known equivalents and foreseeable equivalents at the time of filing this patent application.