Fiber composite material component, and method for producing a fiber composite material component

Abstract

A fiber composite material component has fiber bundles and a matrix of thermoplastic and/or thermosetting material. The fiber bundles are arranged such that they form a profile. Bracing structures are arranged between the fiber bundles. At least two fiber bundles are arranged in a skewed manner with respect to one another and at least one cavity is formed in the region of the intersection of the skewed fiber bundles. Furthermore, a method for producing a fiber composite material component having fiber bundles and a matrix of thermoplastic and/or thermosetting material, is provided.

Claims

1. A fiber composite material component, comprising: fiber bundles arranged so as to form a profile; a matrix of thermoplastic and/or thermosetting material; and bracing structures arranged between the fiber bundles, wherein at least two of the fiber bundles are arranged skewed with respect to one another, and a cavity is formed within a wall of at least one of the bracing structures in a region of an intersection of the skewed fiber bundles.

2. The fiber composite material component according to claim 1, wherein the fiber bundles are arranged so as to form two or more profiles, each of the two or more profiles has at least two fiber bundles arranged skewed and intersecting with respect to each other, and the cavity is formed in the region of the intersection of the skewed fiber bundles.

3. The fiber composite material component according to claim 1, wherein each of the fiber bundles together with the matrix forms a brace in the profile, and the brace is part of the profile.

4. The fiber composite material component according to claim 2, wherein each of the fiber bundles together with the matrix forms a brace in the each of the two or more profiles, and the brace is part of the profile, and the at least two skewed and intersecting fiber bundles are embedded in the matrix in the region of the intersection such that each brace formed by the two skewed fiber bundles has a broadening area in the region of the intersection.

5. The fiber composite material component according to claim 4, wherein at least one opening is provided in a region of the broadening area and is connected to the cavity.

6. The fiber composite material component according to claim 1, wherein at least one of the fiber bundles is a unidirectional (UD) fiber bundle comprising a plurality of unidirectionally arranged fibers.

7. The fiber composite material component according to claim 1, wherein at least one of the fiber bundles consists exclusively of unidirectionally arranged fibers in a direction of a run of the fiber bundles.

8. The fiber composite material component according to claim 1, wherein at least one of the fiber bundles comprises first unidirectionally arranged fibers in a direction of a run of the fiber bundles and second unidirectionally arranged fibers with which the first unidirectionally arranged fibers are interwoven.

9. The fiber composite material component according to claim 1, wherein at least one of the fiber bundles is arranged at an edge of the profile of the fiber composite material component, the fiber bundles and the bracing structures form a three-dimensional profile, and/or the fiber bundles are arranged such that they absorb at least one of flexural stresses, tensile stresses and compressive stresses.

10. The fiber composite material component according to claim 1, wherein the bracing structures comprise ribs or shear surfaces, and/or the bracing structures are arranged such that they transmit or absorb torsional forces or shear forces.

11. The fiber composite material component according to claim 1, wherein at least one of the fiber bundles has at least one exposed segment, where no bracing structure is arranged, wherein the at least one exposed segment is arranged at regular or irregular intervals, and/or the at least one exposed segment is at least partially curved or straight.

12. The fiber composite material component according to claim 1, wherein the bracing structures are formed from shear surfaces, and/or the bracing structures are formed by injecting of thermoplastic and/or thermosetting material, or by fiber bundles.

13. The fiber composite material component according to claim 1, wherein the fiber bundles are offset in a mold-stripping direction such that they are removable from a molding die without a pusher, and/or the fiber bundles include both straight regions and curved regions.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of a basic skeleton of a fiber composite material component according to an exemplary embodiment of the invention;

(2) FIG. 2 is a perspective view of the fiber composite material component according to an exemplary embodiment of the invention;

(3) FIG. 3 is a top view of the fiber composite material component shown in FIG. 2;

(4) FIG. 4 is a sectional view of the fiber composite material component shown in FIG. 2 and FIG. 3 along section A-A of FIG. 3;

(5) FIG. 5 is a top view of a die for manufacturing a fiber composite material component in accordance with an exemplary aspect of the invention;

(6) FIG. 6 is a sectional view along section A-A of FIG. 5;

(7) FIG. 7 is a sectional view along section B-B of FIG. 5;

(8) FIG. 8 is a perspective view of the fiber composite material component according to an exemplary embodiment of the invention;

(9) FIG. 9 is a further perspective view of the fiber composite material component according to an exemplary embodiment of the invention; and

(10) FIG. 10 is a further perspective view of the fiber composite material component according to an exemplary embodiment of the invention.

DETAILED DESCRIPTION OF THE DRAWINGS

(11) FIG. 1 shows a basic skeleton of a fiber composite material component 10 according to an exemplary embodiment of the invention without surrounding material, which is obtained by a method according to the invention for manufacturing the fiber composite material component 10.

(12) In a manufacturing method for producing the fiber composite material component 10 shown in FIG. 1, fiber bundles 20 are, first of all, arranged three-dimensionally according to a profile P.

(13) The profile P here has four substantially parallel arranged fiber bundles 20 with fibers 25. Between the fiber bundles 20 there are provided several bracing structures 30.

(14) By means of a matrix M of thermoplastic and/or thermosetting material, the fiber bundles 20 and the bracing structures 30 are joined together (see FIG. 2 for example). The bracing structures 30 can here be part of the matrix M.

(15) The finished fiber composite material component 10 thus comprises fiber bundles 20 and a matrix M. The fiber bundles 20 are arranged such that they form a profile P, while the bracing structures 30 is arranged between the fiber bundles 20.

(16) The fiber bundles 20 here are unidirectional (UD) fiber bundles and include several unidirectionally arranged fibers 25.

(17) It is possible for the fiber bundles 20 to consist exclusively of unidirectionally arranged fibers in the direction of the run of the fiber bundles.

(18) Alternatively, however, it is also contemplated for the fiber bundles 20 to have first unidirectionally arranged fibers in the direction of the run of the fiber bundles 20 and second unidirectionally arranged fibers with which the first fibers are interwoven.

(19) In this context, it can also be provided that at least one fiber bundle consists exclusively of unidirectionally arranged fibers in the direction of the run of the fiber bundles 20 and at least one additional fiber bundle has first unidirectionally arranged fibers in the direction of the run of the fiber bundles 20 and second unidirectionally arranged fibers with which the first fibers are interwoven.

(20) FIG. 2 shows a top view of a fiber composite material component 10 according to the invention, which has been produced by a method according to the invention for manufacturing the fiber composite material component 10 and which has the above-described structural and functional features.

(21) FIG. 3 shows a top view of the fiber composite material component 10 of FIG. 2.

(22) FIG. 4 shows a sectional view of the fiber composite material component 10 shown in FIG. 2 and FIG. 3, taken along section A-A of FIG. 3.

(23) In the profile P, several fiber bundles 20 are arranged skewed with respect to one another.

(24) The skewed fiber bundles 20 are disposed perpendicular to each other.

(25) Each one of these fiber bundles 20 forms, together with the matrix M in the profile P, a brace 32, which is part of the profile P.

(26) In the region of an intersection K of every two skewed fiber bundles 20 or in the region of an intersection K of the respective braces 32, there is formed at least one cavity H.

(27) The braces 32 each has a broadening area 34 in the region of their intersection K.

(28) In the region of the broadening area 34, at least one opening 36 is provided. The opening 36 is connected to the cavity H, as shown in FIG. 4.

(29) On either of the longitudinal ends of the cavity H there is provided an opening 36.

(30) The profile P shown in FIG. 2 can be part of a larger profile, or already be its own part.

(31) The profile P has two frame-like lattices 38 each and each of them is formed from four skewed braces 32, as shown in FIG. 2.

(32) The lattices 38 are here substantially identical in construction. They are disposed at two opposite sides of the profile P and tighten the profile P or serve as a skeleton for the profile P.

(33) In each lattice 38, two parallel braces 32 are provided in a first plane and two other parallel braces 32 are provided in a plane spaced apart from the plane.

(34) The parallel braces 32 of the first plane intersect, and are arranged skewed against and perpendicular to the parallel braces 32 of the second plane. A cavity H is formed in the region of each intersection K.

(35) The two lattices 38 are joined together by several bracing structures 30.

(36) The function and manufacture of the fiber composite material component 10 shown in FIGS. 1-3 are described below.

(37) The fiber bundles 20, as shown in FIGS. 1-3, are arranged at least at the outer edges of the profile P of the fiber composite material component 10 and between the fiber bundles 20 there are provided bracing structures 30, such as ribs and shear surfaces, and arranged so that a truss-like profile structure can be produced. The fiber bundles 20 and the bracing structures 30 are extrusion coated thermoplastic or thermosetting material, or the bracing structures 30 are created by being injected onto the fiber bundles 20.

(38) The forces are then transmitted by the fibers 25, wherein the thermoplastic or thermosetting material provides the connection between the fiber bundles 20. Thanks to the three-dimensional arrangement, profiles P with good stiffness and good stability can be produced at minimal weight. Thanks to the free arrangement of the fiber bundles 20 in the space, any given profile shapes are made possible, which can be used, for example, for B-columns, load-bearing structures, window frames, and so on.

(39) The fibers 25 can be arranged such that they absorb flexural stresses and/or tensile stresses and/or compressive stresses.

(40) The bracing structures 30 are arranged such that they can transmit and/or absorb torsional forces and/or shear forces.

(41) It is contemplated to use the fiber bundles 20 in the dry state. However, it is also contemplated to use them pre-impregnated.

(42) The bracing structures 30 can be formed from braces or shear surfaces and it is further contemplated for the bracing structures to be formed by injecting of thermoplastic or thermosetting material onto them, or by fiber bundles 20.

(43) It is contemplated to arrange the fiber bundles 20 offset in the mold-stripping direction, so that they can be removed from the molding die without a pusher.

(44) Furthermore, it can be provided that the fiber bundles 20 are designed so as to consist of straight regions and short curved regions and thus can follow approximately any given curve.

(45) The cavity H is formed by internal-pressure injection molding during the manufacturing of the fiber composite material component 10 according to the invention.

(46) The internal-pressure injection molding can be a gas internal-pressure injection molding or an internal-pressure injection molding using fluid injection technique, especially a water internal-pressure injection molding.

(47) The method according to the invention and the fiber composite material component 10 according to the invention make it possible to accomplish three-dimensional arrangements of the UD fiber bundles 20 with endless fibers 25, enabling practically any given configuration. One can achieve rigid and stable profiles P which furthermore can be much lighter than comparable known profiles. Thus, a very good lightweight construction is possible. Furthermore, any desired profile geometries or any desired component configurations can be created and a lower material requirement is achieved. In particular, there is little or no waste.

(48) The cavities H serve to prevent material clustering. Thanks to internal-pressure injection molding, the use of pushers or cores is unnecessary and the manufacturing is simplified.

(49) The skeletal structure of the profile P advantageously enables a high torsional strength of the fiber composite material component 10.

(50) FIG. 5 shows a top view of the die W for manufacturing a fiber composite material component 10 according to the invention, particularly, a roof cross member for a motor vehicle, namely a cowl. FIG. 6 is a sectional view along section A-A of FIG. 5 and FIG. 7 is a sectional view along section B-B of FIG. 5.

(51) The fiber composite material component 10 according to FIG. 5 has all of the features illustrated and described above in connection with FIG. 1. Here again, fiber bundles 20 are arranged three-dimensionally as a profile P and bracing structures 30 are arranged between the fiber bundles 20, joining the fiber bundles 20 to each other. The fiber bundles 20 can be UD fiber bundles as described above in connection with FIG. 1.

(52) As can be seen from FIGS. 5-7, exposed segments 22 are provided at regular intervals where no bracing structures 30 are arranged. In these exposed segments 22, the fiber bundles 20 are placed directly in the die W, as is shown in FIGS. 6-7. Consequently, the fiber bundles 20 upon injecting of thermoplastic or thermosetting material are fixed at this point in the die and do not move out from the mold. A good shaping precision is therefore possible.

(53) The fiber bundles 20 can have exposed segments 22 at regular or irregular intervals. Basically, the exposed segment 22 can be at least partially curved or straight.

(54) FIG. 8 shows a perspective view of the fiber composite material component 10 according to the invention, as illustrated in FIGS. 5 to 7. FIGS. 9-10 are broken views of the fiber composite material component 10 shown in FIG. 8.

(55) The fiber bundles 20 are arranged respectively in the edge regions of the fiber composite material component 10. In this way, the fibers of the fiber bundles 20 can absorb flexural stresses, tensile stresses and compressive stresses.

(56) On the other hand, the bracing structures 30 are arranged so that they can transmit and/or absorb torsional forces and/or shear forces.

(57) 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.