Faserverbund-Bauteilanordnung, Faserverbund-Bauteilsystem und Verfahren zum Herstellen eines Faserverbund-Bauteilsystems

Abstract

A fiber composite component assembly (100) includes a fiber composite component (3) including a base material and a fiber material, and a tolerance compensation layer (5) for joining the fiber composite component (3) to a further component (1), the tolerance compensation layer (5) including a fiber composite portion (17) and/or a further layer portion (7). A fiber composite component system (200) including a fiber composite component assembly (100) and a further component (1) joined to the fiber composite component assembly (100), as well as a method for producing a fiber composite component system (200), is also provided.

Claims

1-15. (canceled)

16. A fiber composite component assembly comprising: a fiber composite component including a base material and a fiber material; and a tolerance compensation layer for joining the fiber composite component to a further component, the tolerance compensation layer including a fiber composite portion or a further layer portion.

17. The fiber composite component assembly as recited in claim 16 wherein the tolerance compensation layer includes a tolerance compensation layer base material the same as the base material, at least in some regions.

18. The fiber composite component assembly as recited in claim 16 wherein the tolerance compensation layer includes a tolerance compensation layer fiber material the same as the fiber material at least in some regions.

19. The fiber composite component assembly as recited in claim 16 wherein the tolerance composition layer includes the fiber composite portion and wherein a structural unit of the fiber composite component and a further structural unit of the fiber composite portion of the tolerance compensation layer are different.

20. The fiber composite component assembly as recited in claim 16 wherein the fiber composite component and the tolerance compensation layer are integrally joined together, at least in some regions.

21. The fiber composite component assembly as recited in claim 16 wherein the tolerance composition layer includes the further layer portion, the further layer portion being a sprayed layer or includes a sprayed layer.

22. The fiber composite component assembly as recited in claim 16 wherein the tolerance compensation layer includes the fiber composite portion and the further layer portion and wherein the further layer portion is joined to the fiber composite portion by a material-to-material bond.

23. The fiber composite component as recited in claim 16 wherein the tolerance composition layer includes the further layer portion, the further layer portion being joined to the fiber composite component by a material-to-material bond.

24. The fiber composite component assembly as recited in claim 16 wherein a thickness of the tolerance compensation layer is greater than a maximum profile depth of surface irregularities of the fiber composite component.

25. A fiber composite component system comprising the fiber composite component assembly as recited in claim 16 and a further component joined to the fiber composite component assembly.

26. The fiber composite component system as recited in claim 25 wherein the tolerance compensation layer of the fiber composite component assembly has a joining surface for joining to the further component.

27. The fiber component system as recited in claim 26 wherein fibers or fiber segments terminate with the joining surface of the tolerance compensation layer.

28. The fiber component system as recited in claim 26 wherein the joining surface is a mechanically machined planar or planarized joining surface.

29. The fiber composite component system as recited in claim 26 wherein the fiber composite component assembly or the further component has an overlap portion.

30. The fiber composite component system as recited in claim 26 wherein the further component is made from or includes a metallic material in a region of the joining surface.

31. A method for producing the fiber composite component system as recited in claim 25, the method comprising the following steps: providing a fiber composite component assembly including a fiber composite component including a base material and a fiber material and a tolerance compensation layer for joining the fiber composite component to a further component, the tolerance compensation layer including a fiber composite portion or a further layer portion; machining the tolerance compensation layer in such a manner that the surface contour of the to-be-joined surface of the further component is adapted to the tolerance compensation layer; joining the fiber composite component assembly to the further component via the adapted tolerance compensation layer.

32. The method as recited in claim 31 wherein the machining of the tolerance compensation layer is accomplished by removal of material or results in the provision of a plane joining surface.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The present invention will now be described, by way of example only, with reference to the accompanying drawings, in which identical or similar components are indicated by the same reference numerals. The figures show in greatly simplified schematic form in:

[0035] FIG. 1 a cross-sectional view of an inventive fiber composite component system including a fiber composite component assembly according to the present invention and an attached flange;

[0036] FIG. 2 a cross-sectional view of an inventive fiber composite component assembly having a tolerance compensation layer before and after mechanical machining; and

[0037] FIG. 3 a cross-sectional view of an inventive fiber composite component assembly having a tolerance compensation layer that includes a fiber composite portion and a further layer portion.

DETAILED DESCRIPTION

[0038] FIG. 1 shows, in cross-sectional view, an inventive fiber composite component system 200 including a fiber composite component assembly 100 according to the present invention and an attached flange 1. Flange 1 may be referred to as a further component.

[0039] Fiber composite component assembly 100 includes a fiber composite component 3 and a tolerance compensation layer 5. Fiber composite component 3 is illustrated by a number of nearly parallel lines, which represent the individual fibers in a base material. The fibers may, for example, have an individual diameter of several m. The fibers may be glass fibers, carbon fibers, ceramic fibers, aramid fibers, boron fibers, basalt fibers, steel fibers, natural fibers, nylon fibers or other fibers. The fibers may contribute significantly to the strength of fiber composite component 3. The base material may be referred to as a substrate or matrix. Polymers such as, for example, thermosetting polymers (other names: thermosetting plastics, synthetic resins), elastomers and thermoplastics are often used as the base material.

[0040] In this specific embodiment, tolerance compensation layer 5 includes a further layer portion 7 that compensates for the uneven surface 9 of fiber composite component 3 and the smooth surface 11 of flange 1. Further layer portion 5 may be, for example, a sprayed layer. Further layer portion 5 may, merely by way of example, be a polymer or include a polymer. Alternatively, further layer portion 5 may be composed of a different material, be a composite material, for example one including a polymer. After applying further layer portion 5 to uneven surface 9 of fiber composite component 3, further layer portion 5 may, in a subsequent machining step, be machined on the side that is to be joined to the flange. This machining may be mechanical machining by milling, another material-removal method, such as a laser ablation process, or any other method. This machining step may optionally be followed by one or more further steps, for example for smoothing, polishing or surface treatment. A surface treatment may be a plasma process to prepare for a subsequent adhesive bonding step.

[0041] Flange 1 may also be machined on the side that is to be joined to fiber composite component assembly 100, for example by milling, polishing, etc.

[0042] The connection between flange 1 and tolerance compensation layer 5, which, in this embodiment, exemplarily takes the form of a further layer 7, may be a material-to-material bond, for example an adhesive bond or a weld.

[0043] In this specific embodiment, the connection between flange 1 and fiber composite component assembly 100 is accomplished by means of two end regions or overlap regions of the two mentioned components. Thus, tolerance compensation layer 5 has been applied to fiber composite component 3 only in the region of this overlap.

[0044] The connection of the individual components is indicated by a connecting line 13. As an alternative to a material-to-material bond, the connection may be a force-fit connection or a form-fitting connection or a combination of a material-to-material bond, a force-fit connection and a form-fitting connection. Merely by way of example, the connection may be screwed or riveted.

[0045] FIG. 2 shows, in cross-sectional view, an inventive fiber composite component assembly 100 having a tolerance compensation layer 5 before and after, in particular mechanical, machining. Before machining, tolerance compensation layer 5 additionally includes removal layer 15, which has an uneven surface (to the left in FIG. 2). In the specific embodiment shown here, the surface is undulated or wavy. Removal layer 15 is reduced to its final surface shape using a material-removal process, such as a milling process. This final surface shape is dependent on the surface shape of the component to which fiber composite component assembly 100 is to be joined. If this component has, for example, a smooth surface, the shape of tolerance compensation layer 5 may be adapted accordingly.

[0046] The shape of removal layer 15 may be referred to as a layer contour before an exemplary mechanical machining operation.

[0047] The wavy shape of fiber composite component 3 may be due to the manufacturing process. Material removal directly from the surface of fiber composite component 3; i.e., without tolerance compensation layer 5, could damage the subsurface fibers in fiber composite component 3 and significantly weaken the strength of the component.

[0048] The maximum profile depth 21 of the wavy surface of fiber composite component 3 is less than the maximum thickness 23 of tolerance compensation layer 5. Thus, fiber composite component 3, in particular its subsurface layers including fibers of the fiber composite material, may remain unmachined or undamaged when material is removed from removal layer 15 by mechanical machining.

[0049] FIG. 3 shows, in cross-sectional view, an inventive fiber composite component assembly 100 having a tolerance compensation layer 5 that includes a fiber composite portion 17 and a further layer portion 7.

[0050] The fiber composite portion 17 is, merely by way of example, configured as an integral portion that forms as a unit with the fiber composite component 3 in terms of material. Thus, the fibers of fiber composite portion 17 as well as the base material of fiber composite portion 17 may be identical to those of fiber composite component 3. The fibers of fiber composite portion 17, which are shown as vertical, nearly parallel lines, preferably extend only over joint region 19. These fibers are not needed for structurally stabilizing fiber composite component assembly 100 outside the joint region 19. The fibers of fiber composite portion 17 do not form a structural unit with the fibers of fiber composite component 3. Therefore, if no further layer 7 were applied (not shown in FIG. 3), this fiber composite portion 17 could be mechanically machined and at least partially removed without affecting or weakening the structural stability and strength of fiber composite component 3. The fibers of fiber composite component 3 may extend beyond the joint region and, for example, follow or define a curved component contour.

[0051] Further layer portion 7 may be a sprayed layer. The corresponding descriptions for FIGS. 1 and 2 may be considered analogously.

LIST OF REFERENCE NUMERALS

[0052] 100 fiber composite component assembly
200 fiber composite component system
1 flange; further component
3 fiber composite component
5 tolerance compensation layer
7 further layer portion
9 surface; uneven surface
11 surface; smooth surface
13 connecting line
15 removal layer
17 fiber composite portion
19 joint region; region of the joining surface
21 maximum profile depth
23 thickness of the tolerance compensation layer