Partially fixated semi-finished textile

Abstract

A semi-finished textile for producing a fiber composite component part has a textile structure and a fixation structure so as to provide a semi-finished textile that can be easily handled and that is suitable for use in complex component part shapes. The textile structure includes a first multitude of reinforcement-fiber bundles of high-performance fibers. Displacement sections are formed between adjacent reinforcement-fiber bundles and adjacent reinforcement-fiber bundles can be displaced against each other. The fixation structure fixates the reinforcement-fiber bundles, depending on the textile structure, with a fixation pattern in such a way that the reinforcement-fiber bundles are fixated at least partially and the displacement sections remain at least partially free.

Claims

1. A method for manufacturing a semi-finished textile for producing a fiber composite component part, the method comprising: assembling a textile structure from a first multitude of reinforcement-fiber bundles, wherein bundles displacement sections are formed between adjacent reinforcement-fiber bundles that are displaceable against each other; placing a fixation structure onto the textile structure; fixating the reinforcement-fiber bundles by means of the fixation structure by applying a fixation pattern so that the reinforcement-fiber bundles are at least partially fixated and the displacement sections remain at least partially free, wherein the fixation pattern includes predetermined fixation points on each of the reinforcement-fiber bundles, wherein the predetermined fixation points on each of the reinforcement-fiber bundles is a central zone of each of the reinforcement-fiber bundles, wherein the fixation structure includes a multitude of meltable binder yarns fixated to each of the reinforcement-fiber bundles only in the central zone of each of the reinforcement-fiber bundles, and wherein each meltable binder yarn of the multitude of meltable binder yarns includes a binding material.

2. The method as recited in claim 1, wherein the reinforcement-fiber bundles are connected with each other, and wherein the fixation structure has a binder that at least partially fixates the reinforcement-fiber bundles.

3. The method as recited in claim 1, wherein the fixation structure has a connection structure connecting the reinforcement-fiber bundles with each other, wherein the connection structure includes a second multitude of connection elements having a binder, and wherein the connection elements are connected with the reinforcement-fiber bundles by melting of the binder.

4. The method as recited in claim 1, wherein the fixation pattern is a line pattern or a dot pattern that is formed in relation to the textile structure.

5. The method as recited in claim 1, wherein the fixation pattern extends over an entire surface of the semi-finished textile.

6. The method as recited in claim 1, wherein the fibers of the reinforcement-fiber bundles are carbon fibers or glass fibers.

7. The method as recited in claim 1, wherein the first multitude of reinforcement-fiber bundles of fiber have a flat surface carrying the predetermined fixation points.

8. The method as recited in claim 1, wherein each meltable binder yarn of the multitude of meltable binder yarns includes the binding material extending over an entire length of each meltable binder yarn.

9. The method as recited in claim 1, wherein each meltable binder yarn of the multitude of meltable binder yarns includes the binding material only at positions on each meltable binder yarn overlaying the predetermined fixation points on each of the reinforcement-fiber bundles.

Description

BRIEF SUMMARY OF THE DRAWING FIGURES

(1) In the following, an exemplary embodiment of the invention is described in further detail with the aid of the enclosed drawings. Shown are:

(2) FIG. 1 shows a cross section through a semi-finished textile according to the invention;

(3) FIG. 2 shows a schematic top view of the semi-finished textile according to FIG. 1;

(4) FIG. 3 shows a cross section through a further exemplary embodiment of a semi-finished textile according to the invention;

(5) FIG. 4 shows a schematic top view of the semi-finished textile according to FIG. 3;

(6) FIG. 5 shows a further exemplary embodiment of a fixation pattern according to the invention;

(7) FIG. 6 shows a further exemplary embodiment of a fixation pattern according to the invention;

(8) FIG. 7 shows a further exemplary embodiment of a fixation pattern according to the invention;

(9) FIG. 8 shows a device for producing a semi-finished textile according to the invention; and

(10) FIG. 9 shows the method steps of a method according to the invention for producing a semi-finished textile.

DETAILED DESCRIPTION

(11) FIG. 1 shows a semi-finished textile 10 for producing a fiber composite component part. The semi-finished textile has a textile structure 12 and a fixation structure 14.

(12) As shown schematically in FIG. 1, textile structure 12 has a first multitude of reinforcement-fiber bundles 16 consisting of high-performance fibers. The high-performance fibers, for example, carbon fibers or glass fibers are shown schematically in a rectangular cross sectional form. It should be noted that reinforcement-fiber bundles 16 can also have a significantly flatter cross section and in particular, a cross sectional form that is different than a rectangle.

(13) The reinforcement-fiber bundles are, for example, located essentially parallel to each other. For example, the location is at a regular distance or distance dimension.

(14) According to a further aspect (not shown) the reinforcement-fiber bundles can also be woven together or lie in several internally parallel layers with different orientation on top of each other, for example, as non-crimp fabric.

(15) Fixation structure 14 connects reinforcement-fiber bundles 16 with each other.

(16) In the exemplary embodiment shown in FIG. 1, fixation structure 14 is fixated at reinforcement-fiber bundles 16 with a fixation pattern 18depending on textile structure 12in a way that it will be explained in more detail in FIG. 2. The fixation is provided in such a way that displacement sections 20 are formed between adjacent reinforcement-fiber bundles and adjacent reinforcement-fiber bundles 16 are displaceable against each other.

(17) In FIG. 1 and also in FIGS. 2 to 4, displacement sections 20 are shown as free displacement zones. These displacement sections 20 can, however, also be arranged so that they are not directly visible, for example, then, when reinforcement-fiber bundles 16 lie directly against each other, whereby then, however, a displacement to each other is still possible.

(18) According to a further aspect of the invention, textile structure 12 can be located in a first layer 22 and fixation structure 14 in a second layer 24 that is adjacent to first layer 22. For example, the fixation structure lies two-dimensionally at the textile structure.

(19) In the exemplary embodiment shown in cross section in FIG. 1, fixation structure 14 is fixated at reinforcement-fiber bundles 16 approximately in the centeridentified with reference number 26of reinforcement-fiber bundle 16. As can be seen, the term center relates to the center of the lateral surface. Thereby, it is achieved that the reinforcement-fiber bundles can be displaced to each other as freely as possible, to ensure the deformability of semi-finished textile 10.

(20) FIG. 2, which is a top view of semi-finished textile 10 from FIG. 1, illustrates that the connection between textile structure 12 and fixation structure 14 is provided in a line pattern 28. As can be seen, line pattern 28 is defined by textile structure 12 that lies underneath. Line pattern 28 is formed relative to textile structure 12.

(21) According to a further exemplary embodiment, fixation pattern 18 is a dot pattern 30 that is likewise formed relative to textile structure 12.

(22) According to a further aspect of the invention, the fixation structure has a number of connection elements 31.

(23) According to the exemplary embodiment illustrated in FIGS. 1 and 2, fixation structure 14 has a multitude of meltable binder yarns 32 as connection elements 31. Binder yarns 32 are located perpendicular to the fiber direction of reinforcement-fiber bundles 16 in the exemplary embodiment shown. Because binder yarns 32 fixate reinforcement-fiber bundles 16 only in their central zone 26, reinforcement-fiber bundles 16 can be displaced against each other, as a result of which, good deformability of the semi-finished textile is provided. The displacement possibility is indicated by arrows 33.

(24) In FIG. 2, the binder yarns are shown with a clear distance to each other. This results, strictly speaking, in a dot-shaped fixation pattern. If the binder yarns are located narrower, the points wonder to coincide with the lines, which are identified in FIG. 2 with reference number 26.

(25) As, however, according to one aspect of the invention it can be provided that the fixation pattern is applied with rollers, a reaction takes place extending along the strips identified in FIG. 2 by reference number 26.

(26) According to a aspect of the invention (not shown in further detail), the connection elements, for example, the binder yarns, can also run diagonal to the fiber direction of the reinforcement-fiber bundles.

(27) According to the exemplary embodiment shown in FIG. 3 and FIG. 4, fixation structure 14 has a meltable fibrous web binder 35.

(28) The top view of FIG. 4 schematically illustrates that the fibrous web binder 34 has a multitude of non-directional fiber elements 36 as connection elements 31. Fiber elements 36 of fibrous web binder 34 are connected with textile structure 12 by a linear fixation pattern that corresponds to fixation pattern 18 from FIG. 2. Even in this exemplary embodiment, deformability of semi-finished textile 10 with simultaneous simple handling is ensured, as a result of displacement sections 20.

(29) Of course, a dot-shaped fixation pattern would also be possible when using a fibrous web binder, which is, however, not shown in further detail.

(30) FIG. 5 is a schematic top view of a fixation pattern 18 designed as a dot pattern 30.

(31) FIG. 6 shows a further exemplary embodiment for a line pattern 128 that is designed relative to textile structure 12. As schematically illustrated, textile structure 12 is located at an angle W to the direction of production, for example, having an angle W of 45. To ensure the displaceability of reinforcement-fiber bundles 16, here also textile structure 112 has displacement sections 120. The connection is ensured and fixation structure 14 that is likewise located in angle W, connects the reinforcement-fiber bundles with each other in the central section 126, for example by using meltable binder yarns 132.

(32) FIG. 7 illustrates a further dot pattern 230 that is likewise formed in relation to the textile structure. As can be seen, a textile structure 212 is provided that is formed at an angle W of approximately 30 to the direction of production. Accordingly, displacement sections 220 also have such an angle. The connection takes place, for example, by using binder yarns 232, which run perpendicular to the direction of production in the example shown, i.e., at an angle to displacement sections 220.

(33) It should be noted that the exemplary embodiments shown in FIGS. 5 through 7 can be designed for additional fixation patterns in addition to the binder yarns shown, also with a meltable fibrous web binder.

(34) According to an exemplary embodiment that is not shown, the fixation structure is an applied binder powder.

(35) FIG. 8 is a perspective illustration of a device 50 for producing a semi-finished textile for making a fiber composite component part. Device 50 shows a system 52 for feeding a semi-finished textile 54 having a textile structure and a fixation structure. Semi-finished textile 54 is designed as semi-finished textile according to one of the preceding exemplary embodiments. The textile structure has a first multitude of reinforcement-fiber bundles consisting of high-performance fibers that are located parallel to each other. Moreover, a system 56 is provided for applying a fixation pattern 58 for connecting the fixation structure with the reinforcement-fiber bundles. Fixation pattern 58 is formed depending on the textile structure, in order to fixate the fixation structure at the reinforcement-fiber bundles in such a way that displacement sections are formed between adjacent reinforcement-fiber bundles, so that adjacent reinforcement-fiber bundles are displaceable against each other.

(36) According to one aspect of the invention, the system for applying the fixation pattern has sections 60 having different temperatures. Accordingly, first sections 62 are provided with higher temperatures, which effect a melting of a binder, which is in the connection elements. Moreover, two sections 64 are provided, which have lower temperatures, which prevent a melting of the binder.

(37) For example, system 56 for applying fixation pattern 58 is a roller 66 with some hotter and some cooler sections.

(38) In the exemplary embodiment shown in FIG. 8, the fixation pattern is a line pattern, and roller 66 has a linear pattern of hotter and cooler sections, which is located radially in the circumferential direction.

(39) Because fixation pattern 54 is always formed relative to the textile structure, according to an additional exemplary embodiment (not shown) it is provided that in a textile structure 12perpendicular to the direction of textile production, which is indicated by an arrow 68i.e., when reinforcement-fiber bundles 16 run perpendicular to the direction of textile production 68, roller 66 has a line structure that is located axially on the circumferential surface, i.e., perpendicular to the direction of rotation.

(40) According to a further exemplary embodiment of the invention (not shown) the roller has a dot pattern of hotter and cooler sections, i.e., the hotter sections are located distributed dot-shaped, in order to apply a dot-shaped fixation pattern.

(41) According to a further aspect of the invention, instead of a roller, a device can also be used that has a multitude of smaller rollers, to provide a corresponding fixation pattern.

(42) According to a further aspect of the invention, instead of rollers, different suitable devices for the application of a fixation pattern can also be provided; for example, dies with a dot-shaped impact that move along in sections with a continuously evenly moving semi-finished textile or, in the case of a textile that moves haltingly, i.e., in a progression of motion that is stopped briefly, when the semi-finished textile is passed through, a die that impacts stationary.

(43) In FIG. 9, a method 500 for the production of a semi-finished textile for producing a fiber composite component part is shown. In a first assembly step 510, textile structure 512 is assembled from a first multitude of reinforcement-fiber bundles consisting of high-performance fibers, whereby the reinforcement-fiber bundles are, for example, located parallel to each other. Subsequently, a fixation structure 516 is placed onto the textile structure in second assembly step 514. After that, in a fixation step 518, the reinforcement-fiber bundles are fixated with the fixation structure by applying a fixation pattern 520 depending on the textile structure, whereby the fixation structure is fixated at the reinforcement-fiber bundles in such a way, that the reinforcement-fiber bundles are at least partially fixated, and the displacement sections remain at least partially free.

(44) Assembly step 510 is also described as step a), placement step 514 as step b) and fixation step 518 as step c).

(45) According to one aspect of the invention, a binder is fixated locally on the semi-finished textile, i.e., the textile structure in such a way that it least hinders possible displacement for deformation. According to the invention, this is provided primarily in the center of the reinforcement-fiber bundles. As has already been shown, the two sections between fiber bundles, at which displacements take place are not conglutinated, i.e., no binder is applied there, or a binder element that extends above it, for example, a binder yarn or a fibrous web binder, it is not connected at these positions, for example, by melting, in order to prevent a conglutination at these positions. The melt pattern or fixation pattern thereby orients itself not at the component part geometries or precut geometries, but at the semi-finished material structure and is, according to the invention, identical everywhere on the semi-finished material. Perhaps the outer edges of the web-like material and the beginning and end cut selvedges are designed differently for handling during storage and transport, for example, stiffer.

(46) Consequently, stabilization is a feature of the semi-finished textile according to the invention and does not require to be applied at a later point in time, for example, in any form during the production process that is dedicated to a component part.

(47) It should be noted that the definition that the fixation pattern must be formed in relation to the textile structure also covers those cases in whichdue to imprecisions that occur in any production processoffsets or a non-agreement between the fixation pattern and the textile structure occur. For example, in a line pattern that is not very precisely coordinated, a successive offset can cause a deviation from the central position. After a certain number, the connection sections then become arranged in the intermediate area that is actually provided as displacement section and subsequently, as a consequence in turn to an approximation to the central position. Even in the case of imprecisions of this type, however, it is ensured that in the case of a multitude of adjacent zones between the reinforcement-fiber bundles a displacement section will be formed, so that the fundamental deformability is ensured, even if there is a fixation in one or another displacement section and there, a displacement is then actually no longer possible.

(48) In addition it is to be pointed out that including does not preclude any other elements or steps and one or a does not preclude a multitude. Furthermore, let it be pointed out that characteristics or steps that have been described by referring to one of the above exemplary embodiments, can also be used in combination with other characteristics or steps of other exemplary embodiments described above. Reference numbers in the claims are not to be viewed as limitation.

(49) The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.