Manufacture of objects having a fiber-reinforced region

Abstract

A method suitable for manufacturing complex and stable objects of a wide range of sizes. The method involves producing an object structure by a generative production method and/or by an injection molding method, and producing a fiber-reinforced resin layer in at least one sub-region of the object structure.

Claims

1. A method for manufacturing objects, the method comprising: producing a first substructure by a generative production method and/or by an injection molding method; producing, after the first substructure is produced, a second substructure by the generative production method and/or by the injection molding method, wherein the first substructure and/or the second substructure comprise a recess; covering the first substructure with the second substructure, so that the recess of the first substructure and/or the recess of the second substructure define a cavity, at least in part, to form an object structure; introducing a resin material and a fiber material into the cavity of the object structure; and curing the resin material within the cavity to form a fiber-reinforced resin layer in the object structure; wherein the object structure has at least first and second sub-regions, wherein the fiber-reinforced resin layer is produced to have a different thickness in the first sub-region, using a different resin material and/or a different fiber material from the resin material and/or fiber material, respectively, than in the second sub-region, and/or wherein the fiber-reinforced resin layer is produced to have a different fiber density in the first sub-region than in the second sub-region.

2. The method of claim 1, wherein the first substructure and the second substructure each comprise a recess, and wherein the cavity is formed by the recess of the first substructure and the recess of the second substructure.

3. The method of claim 1, wherein the fiber material is introduced into the cavity before the resin material is introduced into the cavity.

4. The method of claim 1, wherein, when the first substructure is covered by the second substructure, an infusion system is formed integrally with the object structure, and wherein the resin material is injected using the infusion system.

5. The method of claim 1, wherein the fiber material is introduced into the cavity using pressurized gas and/or together with the resin material.

6. The method of claim 1, comprising applying the fiber material within the recess of the first substructure and/or the second substructure before the first substructure is covered by the second substructure, wherein the second substructure comprises a film.

7. The method of claim 1, comprising polymerizing the resin material.

8. The method of claim 7, wherein polymerizing the resin material is performed by one of heat treatment, irradiation with ultraviolet light, and irradiation with gamma radiation.

9. The method of claim 1, wherein the generative production method comprises 3D printing by fused deposition modelling using plastics material, synthetic resin, and/or composite material.

10. The method of claim 1, wherein the object structure and the fiber-reinforced resin layer interconnect two or more object components and/or stabilize at least one region of an object component.

11. The method of claim 1, wherein introducing the resin material into the cavity of the object structure comprises injection pressing and/or vacuum-assisted infusion of the resin material into a shaping tool, wherein the object structure is a structure that distributes the resin material.

12. The method of claim 1, wherein the object structure and the fiber-reinforced resin layer adhere to each other in at least one contact region and/or do not adhere to each other in at least one contact region.

13. The method of claim 1, comprising, after the resin material is cured within the cavity, removing at least part of the object structure from the fiber-reinforced resin layer.

14. An object manufactured by a method comprising: producing a first substructure by a generative production method and/or by an injection molding method; producing, after the first substructure is produced, a second substructure by the generative production method and/or by the injection molding method, wherein the first substructure and/or the second substructure comprise a recess; covering the first substructure with the second substructure, so that the recess of the first substructure and/or the recess of the second substructure define a cavity, at least in part, to form an object structure; introducing a resin material and a fiber material into the cavity of the object structure; and curing the resin material within the cavity to form a fiber-reinforced resin layer in the object structure; wherein the object structure has at least first and second sub-regions, wherein the fiber-reinforced resin layer is produced to have a different thickness in the first sub-region, using a different resin material and/or a different fiber material from the resin material and/or fiber material, respectively, than in the second sub-region, and/or wherein the fiber-reinforced resin layer is produced to have a different fiber density in the first sub-region than in the second sub-region.

15. The method of claim 1, wherein the fiber material is introduced into the cavity at a same time as injected resin material.

16. The method of claim 1, wherein introducing the fiber material into the cavity of the object structure comprises applying fiber material to the first substructure, after which the first substructure is covered by the second substructure.

17. The method of claim 1, wherein introducing the resin material into the cavity of the object structure comprises injection pressing the resin material into a shaping tool, wherein the object structure is a structure that distributes the resin material.

18. The method of claim 1, wherein the object structure and the fiber-reinforced resin layer do not adhere to each other in at least one contact region.

19. A method for manufacturing objects, the method comprising: producing a first substructure by a generative production method and/or by an injection molding method; producing, after the first substructure is produced, a second substructure by the generative production method and/or by the injection molding method, wherein the first substructure and/or the second substructure comprise first and second recesses; covering the first substructure with the second substructure, so that the first recess of the first substructure and/or the first recess of the second substructure define a first cavity, at least in part, and so that the second recess of the first substructure and/or the second recess of the second substructure define a second cavity, thereby forming an object structure, wherein the first cavity is in a first sub-region of the object structure and the second cavity is in a second sub-region of the object structure; and introducing a first resin material and a first fiber material into the first cavity of the object structure; introducing a second resin material and a second fiber material into the second cavity of the object structure; curing the first resin material within the first cavity to form a first fiber-reinforced resin layer in the first sub-region of the object structure; and curing the second resin material within the first cavity to form a second fiber-reinforced resin layer in the second sub-region of the object structure; wherein, when the first resin material is different from the second resin material and/or the first fiber material is different from the second fiber material, the first fiber-reinforced resin layer has a thickness that is different from a thickness of the second fiber-reinforced resin layer; and/or wherein the first fiber-reinforced resin layer has a fiber density that is different from a fiber density of the second fiber-reinforced resin layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the following, features of some embodiments of the disclosure herein are described in greater detail by way of drawings. It will be appreciated that the schematically shown individual elements and components may also be combined and/or formed differently from shown and that the present disclosure is not limited to the features shown.

(2) In the drawings, schematically:

(3) FIG. 1a-1c show manners of production according to the disclosure herein of fiber-containing resin layers in various example object structures;

(4) FIG. 2 shows four steps A-D of an example method according to the disclosure herein;

(5) FIG. 3 shows an example object according to the disclosure herein; and

(6) FIG. 4 shows a further example object according to the disclosure herein.

DETAILED DESCRIPTION

(7) FIG. 1a is a schematic cross section of an object structure 110 which has been produced according to the disclosure herein (in a step not shown) by a generative production method and/or by an injection molding method. The object structure comprises a cavity 112, which extends in a sub-region 111 of the object structure, and additionally comprises an infusion system 114a, 114b for introducing resin material into the cavity or for letting air out of the cavity. In the example shown in FIG. 1a, the infusion system 114a, 114b is arranged at a periphery of the sub-region 111 in such a way that introduced material can be introduced from an outer edge of the sub-region (or of the cavity). The connecting portions 114a, 114b shown between the cavity 112 and surroundings of the object structure may be mutually separated openings or be connected by an annular gap which passes around the cavity at least in part.

(8) FIG. 1a shows introduction of resin material 20 in this manner along with fibers 22 contained therein in accordance with an embodiment of the method according to the disclosure herein. The introduction takes place through a connecting portion 114a of the infusion system, for example by applied pressure; air or other gas can escape from cavity through an outlet 114b in the infusion system.

(9) FIG. 1b is a cross section of an object structure 210 which analogously comprises a cavity 212 in a sub-region 211 and has been produced (in a step not shown) by a generative production method and/or by an injection molding method. The object structure 210 comprises an alternative infusion system 214a, 214b, 214c comprising connecting portions 214a, 214b which are arranged at the periphery of the cavity 212 (or of the sub-region 211) (and which connect the cavity 212 to surroundings of the object structure) and additionally comprising a connecting portion 214c in the centre of the cavity (or of the largest extension thereof). The connecting portions 214a, 214b shown may be separated from one another or be connected by an annular gap which passes around the cavity at least in part.

(10) FIG. 1b shows simultaneous introduction of resin material 20 (having fibers 22 contained therein) in accordance with an embodiment of the method according to the disclosure herein through the peripheral connecting portions 214a, 214b of the infusion system. As indicated by the arrows, the resin material 20 propagates in the cavity 210. Meanwhile, air can escape through the connecting portion 214c.

(11) FIG. 1c shows the same object structure 210 as in FIG. 1b, into which resin material 20 (having fibers 22 contained therein) is introduced in accordance with an alternative embodiment of a method according to the disclosure herein. In this case, the introduction takes place through the connecting portion 214c in such a way that the resin material propagates outwards from the centre of the cavity (as indicated by the arrows). Air can escape from the cavity through the connecting portions 214a, 214b.

(12) The infusion systems shown in the drawings may each be integrated into the object for manufacture as part thereof or be removed at least in part after the resin material is introduced or after it is cured.

(13) FIG. 2 shows method steps A-D of an example method according to the present disclosure; the steps A-C are each shown after completion. In step A, a first substructure 310a of an object structure has been produced by a generative production method and/or by an injection molding method. The substructure 310a comprises a depression (or recess) 312a, in which (for example dry) fiber material 32 has been arranged in step B. In step C, the depression 312a of the first substructure 310a having the fiber material 32 arranged therein has been covered by a second substructure 310b; together, the substructures 310a, 310b form an object structure 310 having a cavity 312 in the interior thereof which is formed in part by the depression 312a. When covering the depression by the second substructure 310a, an infusion system 314 was formed through which resin material can be injected into the cavity.

(14) The second substructure 310b may be prefabricated, for example in a standardised mold suitable for manufacturing objects of various types. As a result, rapid manufacture of the object can be provided. It may be or have been generated by a non-generative production method, for example by casting, extrusion, calendering or blow molding.

(15) Alternatively, the second substructure may be constructed on the first substructure 310a in layers by a generative production method after the fiber material is arranged in the depression 312a; this makes possible, in a simple manner, a specific geometric shaping of the second substructure and low-wear manufacture. The generative production method for the second substructure 310a may be the same as that used for producing the first substructure 310a or a different method, for example it can comprise use of a different material from that used for producing the first substructure.

(16) In step D, resin material 30 is introduced or pressed into the cavity 312 of the object structure 310 having the fiber material 32 located therein through the infusion system 314. After the resin material is cured, this results in a fiber-reinforced resin layer in the cavity.

(17) FIG. 3 is a schematic cross section of an object 400 according to an embodiment of the present disclosure. The object 400 comprises an object structure 410, which has been produced by a generative production method and/or an injection molding method. The object structure 410 comprises a first substructure 410a, which comprises depressions that are covered by a second substructure 410b, which also comprises depressions. In this way, there are two cavities 412, 415 formed in the object structure 410.

(18) A first cavity 412 is filled with fibers and a resin material, and as a result a fiber-reinforced resin layer 40 has been produced in a first sub-region 411 of the object structure 410. Thus, the object 400 has increased stability and rigidity in the first sub-region 411. By contrast, the second cavity 415 is filled with gas, for example, air, and this may be expedient in particular if the second sub-region 413 is not exposed to any particular stress in an intended use of the object 400. As a result of the gas filling, the object 400 has a relatively low weight.

(19) FIG. 4 is a cross section of an alternative object 500 in accordance with an embodiment of the present disclosure. The object 500 comprises object components 501, 502 which are stably interconnected by an object structure 510 and a fiber-reinforced resin layer 50. The object structure 510 is produced by a generative production method and/or an injection molding method. It comprises regions 515a, 515b in which it is positioned against the object components 501, 502. For example, the object structure 510 may at least in part comprise a thermoplastic material, which, when heated and soft, is adapted to and welded to the object components 501, 502 in the regions 515a, 515b. Alternatively or in addition, the resin material in the fiber-reinforced resin layer 50 may be used for gluing the object structure 510 to the object components 501, 502. In the embodiment shown, the fiber-reinforced resin layer 50 is arranged between the object components 501, 502 and the object structure 510, forming a cavity filled with the fiber-reinforced resin layer 50.

(20) While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms comprise or comprising do not exclude other elements or steps, the terms a, an or one do not exclude a plural number, and the term or means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.