Abstract
A method of producing a fibre composite component having an elastomer seal disposed on a top side at the edge in annular manner around an opening, includes: providing a first, laminar semifinished product having fibres preimpregnated with a first thermoset, incompletely crosslinked matrix material; applying a sealing compound to a particular deposition region at a top side of the first semifinished product so as to form a semifinished composite product including the first semifinished product and the sealing compound applied, the sealing compound being formed by an elastomeric semifinished product; and extrusion-forming the semifinished composite product to give the fully crosslinked fibre composite component having the elastomer seal. The fibre composite component results from crosslinking of the first semifinished product, and the elastomer seal from crosslinking of the sealing compound. The fibre composite component and the elastomer seal are cohesively bonded to one another by a common extrusion-forming operation.
Claims
1. A method of producing a fibre composite component having an elastomer seal, comprising: a) providing a first, laminar semifinished product having fibres preimpregnated with a first thermoset, incompletely crosslinked matrix material; b) applying a sealing compound to a predetermined deposition region at a top side of the first semifinished product so as to form a semifinished composite product composed of the first semifinished product and the sealing compound applied, the sealing compound being formed by an elastomeric semifinished product; and c) extrusion-forming the semifinished composite product to give the fully crosslinked fibre composite component having the elastomer seal, wherein the fibre composite component results from crosslinking of the first semifinished product, and the elastomer seal from crosslinking of the sealing compound.
2. The method according to claim 1, wherein the first semifinished product includes the fibres preimpregnated with the first thermoset, incompletely crosslinked matrix material.
3. The method according to claim 1, wherein the first semifinished product has a first outer layer, a second outer layer and a core layer arranged between the first outer layer and the second outer layer, the first outer layer and the second outer layer each includes the fibres preimpregnated with the first thermoset, incompletely crosslinked matrix material, and the core layer has a multitude of voids.
4. The method according to claim 1, wherein an opening through the fibre composite component is established for the elastomer seal, such that the elastomer seal surrounds the opening at the edge in an annular manner.
5. The method according to claim 4, wherein the opening is established after step c).
6. The method according to claim 4, wherein the opening is established during step c).
7. The method according to claim 1, wherein each elastomer seal in step c) takes the form of an annular elastomer seal.
8. The method according to claim 1, wherein each deposition region is configured as an annular deposition region.
9. The method according to claim 1, wherein a first press mould and a second press mould are used for the extrusion-forming operation, wherein the first press mould has a first press side configured for shaping of a front side of the fibre composite component, wherein the first press side has a first mould section projecting into the first press mould, such that the first mould section forms a first cavity open toward the first press side, and wherein the sealing compound is applied in step b) in such a way that the sealing compound, in the extrusion-forming operation in step c), flows into and fills the first cavity.
10. The method according to claim 1, wherein each section of the first semifinished product bounded on the top side by a deposition region is reinforced by further fibres and/or metallic anchoring elements.
11. The method according to claim 1, wherein a cohesive bond forms in step c) between the fibre composite component and the elastomer seal.
12. The method according to claim 1, wherein a depression has been formed on the top side of each deposition region of the first semifinished product, and wherein the sealing compound in step c) is introduced at least partly into the respective depression.
13. The method according to claim 1, wherein the first semifinished product has a section with an integrated heat shield.
14. A fibre composite component having an elastomer seal disposed on a top side of the fibre composite component at the edge in an annular manner around an opening through the fibre composite component, wherein the fibre composite component and the elastomer seal are cohesively bonded to one another by a common extrusion-forming operation.
15. The fibre composite component according to claim 14, wherein the fibre composite component has been formed from a thermoset material admixed with fibres, and the elastomer of the elastomer seal has been crosslinked with the thermoset material at the bond to the fibre composite component.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] Further features, advantages and possible uses of the present invention will be apparent from the description of the working examples which follows and the figures. All features that are described and/or represented in images here, independently and in any combination, form the subject-matter of the invention independently of their composition in the individual claims or their dependency references. In the figures, identical reference numerals still represent identical or similar objects.
[0049] The figures show:
[0050] FIG. 1 a schematic flow diagram of one configuration variant of the method;
[0051] FIG. 2 a flow diagram of a further advantageous configuration of the method;
[0052] FIGS. 3a-3e the schematic cycle from the use of the first laminar semifinished product and the sealing compound as far as the extrusion-forming to produce the fibre composite component having an elastomer seal;
[0053] FIG. 4 a schematic cross-sectional diagram of a configuration variant of the fibre composite component having an elastomer seal;
[0054] FIG. 5 a schematic diagram of a fibre composite component having a securing element that has been guided through an opening in the fibre composite component such that the elastomer seal has a sealing effect between the fibre composite component and the securing element;
[0055] FIG. 6 a further configuration of a fibre composite component having an elastomer seal in a schematic cross-sectional view; and
[0056] FIG. 7 a further advantageous configuration of a fibre composite component having an opening in which a securing element has been inserted such that the elastomer seal has a sealing effect between the securing element and the fibre composite component.
DETAILED DESCRIPTION
[0057] FIG. 1 shows a schematic flow diagram for the method of producing a fibre composite component 2 having an elastomer seal 4. In a first step a) of the method, the provision of a first laminar semifinished product 6 having a first thermoset, incompletely crosslinked matrix material is envisaged. In a second step b) of the method, application of a sealing compound 8 to a predetermined region 10 of a top side 12 of the first semifinished product 6 is envisaged, so as to give rise to a semifinished composite product 14 composed of the first semifinished product 6 and the sealing compound 8 applied, where the sealing compound 8 has been formed by an elastomeric semifinished product. In a third step c) of the method, extrusion-forming of the semifinished composite product 14 to form the fully crosslinked fibre composite component having the elastomer seal 4 is envisaged, wherein the fibre composite component 2 forms as a result of crosslinking of the first semifinished product 6 and the elastomer seal 4 through crosslinking of the sealing compound 8.
[0058] One example of a first laminar semifinished product 6, which is also referred to hereinafter as first semifinished product 6, is shown in schematic form in FIG. 2. The first semifinished product 6 is shown here from the top side 12. Laminar semifinished products 6 of this kind are often used to produce larger-area fibre composite components 2. However, it is by no means a rare requirement for fibre composite components 2 of this kind to have to be bonded to other components. For this purpose, the fibre composite component 2 may have an opening 38. By means of this opening 38, the fibre composite component 2 can be bonded to another component. If the fibre composite component 2 is additionally used in a region where there is to be no exchange of gas and/or fluid with the environment through the aforementioned opening 38, a seal suitable for the purpose is required in the region of the opening 38. In practice, however, a task that has frequently been faced in this case is that of disposing the seal with maximum precision and predictability in such a way that the opening 38 is closed on securing of the fibre composite component 2. This can especially be assured in that the seal has been disposed with particular precision and accuracy around the opening 38 beforehand. But even if this is the case at one juncture, what can happen in the course of assembly is that such a seal can slip again. Thus, further measures are required to assure the predictable arrangement of the seal in the region of the opening 38, such that the sealing effect is indeed achieved at a later stage.
[0059] FIG. 2 shows the first semifinished product 6 in schematic form in a top view. Therefore, FIG. 2 also indicates the opening 16 provided at a later stage for the fibre composite component 2 with a dotted line. It thus identifies the region of the first semifinished product 6 where, at a later stage, in the extrusion-forming operation, the opening 38 is formed in the semifinished fibre composite product 2. Alternatively, it may be the case that the opening 38 is established subsequently in the corresponding region, for example by drilling or machining.
[0060] In order to achieve a very good sealing effect, a seal should be disposed around the circumference of the opening 16 provided. It is therefore the case that there is a predetermined deposition region 10 of the top side 12 of the first semifinished product 6 where a sealing compound 8 is applied. On application, the sealing compound 8 may also cover the region of the opening 16. Nevertheless, the sealing compound (8) (also) covers the region of the opening 16 in a circumferential or annular manner. In other words, the sealing compound 8 is in annular form around the opening 16 envisaged on the top side 12 of the semifinished product 6.
[0061] The first semifinished product 6 includes a thermoset, incompletely crosslinked matrix material in which fibres have been distributed. This can be formed in that fibres are preimpregnated with the matrix material mentioned. In addition, the fibres preimpregnated with the incompletely crosslinked, thermoset matrix material have been arranged in laminar form. This may preferably be what is called a sheet moulding compound (SMC). However, it is also possible that the first semifinished product 6 has at least one laminar outer layer formed by fibres preimpregnated with the first thermoset, incompletely crosslinked matrix material. In other words, the first outer layer may be formed by a sheet moulding compound.
[0062] FIG. 3a shows a first laminar semifinished product 6. This is preferably a first outer layer of a semifinished sandwich product 24. The first semifinished product 6 here takes the form of a sheet moulding compound. As shown in schematic form in FIG. 3a, the semifinished product 24 in sandwich form includes the first laminar semifinished product 6 and a second laminar semifinished product 20 that are arranged one on top of the other, especially parallel to one another. The first semifinished product 6 may thus form a first outer layer 18 of the semifinished product 24 in sandwich form and the second laminar semifinished product 20 a second outer layer 22 of the semifinished product 24 in sandwich form. Between these is disposed a core layer (not shown). In principle, it is also possible to dispense with this core layer. If the core layer is provided, this may be a porous core layer and/or a core layer in foam form. More particularly, it is a feature of the core layer that it has a multitude of voids.
[0063] As indicated in FIG. 3a, the sealing compound 8 is applied to the predetermined deposition region 10 on the top side 12 of the first semifinished product 6, which is shown in schematic form in FIG. 2. This gives rise to a semifinished composite product 14 composed of the first semifinished product 6 and the sealing compound 8 applied. This is in turn shown in schematic form in FIG. 3b. It is also apparent from FIG. 3b that the first semifinished product 6 has also been bonded at least indirectly to the second laminar semifinished product 20, especially via the core layer (not shown). In this case, the second laminar semifinished product 20 also forms part of the semifinished composite product 14. The sealing compound 8 is formed by an elastomeric semifinished product.
[0064] For the extrusion-forming of the semifinished composite product 14 to give the fully crosslinked fibre composite component 2 having the elastomer seal 4, it is possible to use, for example, an extrusion-forming apparatus 26 as shown schematically by way of example in FIGS. 3b to 3e.
[0065] FIG. 3b shows a schematic of a first press mould 28 of the extrusion-forming apparatus 26. The first press mould 28 has a first press side 30. The first press side 30 has preferably been configured for shaping of a front side of the fibre composite component 2 to be produced. The first press side 30 has a first mould section 32 that extends into the first press mould 28, such that the first mould section 32 forms a first cavity 34 open to the first press side 30.
[0066] As shown in schematic form in FIG. 3b, the sealing compound 8 has been applied on the top side 12 of the first semifinished product 6 in such a way that the sealing compound 8, when the semifinished composite product 14 is disposed in an accommodation space of the extrusion-forming apparatus 26, is disposed opposite the first cavity 34. If the semifinished composite product 14, as shown in schematic form in FIG. 3c, is placed onto the first press side 30, the sealing compound 8 projects at least partly into the first cavity 34. It is preferably the case here that the sealing compound 8 is applied in such a way, especially with regard to the application to the predetermined deposition region 10 and/or with regard to the amount of the sealing compound 8, such that the sealing compound 8 flows into and fills the cavity 34 in an extrusion-forming operation. This prevents the first semifinished product 6 and/or second semifinished product 20 from being affected with regard to their shape by the first cavity 34. Instead, the first cavity 34 serves exclusively to shape the sealing compound 8 or the elastomer seal 4 to be produced therefrom.
[0067] For the extrusion-forming operation, the second press mould 36 already shown in FIG. 3c is moved in the direction of the first press mould 28 such that the semifinished composite product 14 is extrusion-formed under pressure and/or at high temperature, such that the sealing compound 8 gives rise to an elastomer seal 4 through crosslinking of the sealing compound. In the extrusion-forming operation, in addition, the first semifinished product 6 and, if appropriate, any further semifinished thermoset product, such as the second semifinished product 20 as well are crosslinked. This may also be correspondingly applicable to the core layer. Thus, the fibre composite component 2 is formed at least from the first semifinished product 6, preferably from the first semifinished product 6, the second semifinished product 20 and, if appropriate, the core layer. In the extrusion-forming operation, the sealing compound 8 and the thermoset matrix material are then preferably crosslinked simultaneously, such that the extrusion-forming operation preferably gives rise to a cohesive bond between the fibre composite component 2 and the elastomer seal 4.
[0068] After the extrusion-forming operation, the second press mould 36 can be removed again from the first press mould 28, such that the fibre composite component 2 having the elastomer seal 4 that has now been produced can be removed from the accommodation space of the extrusion-forming apparatus 26.
[0069] FIG. 4 shows the fibre composite component 2 having the elastomer seal 4 in a schematic cross-sectional view. This is an advantageous configuration. The fibre composite component 2 has an opening 38 that extends through the fibre composite component 2. The opening 38 extends from a first top side 40 of the fibre composite component 2 to an opposite top side 42 of the fibre composite component 2. The opening 38 of the fibre composite component 2 may already have been produced during the extrusion-forming operation. The extrusion-forming apparatus 26 may have been designed correspondingly for the purpose. For instance, a ram section may have been assigned to the first press mould 28 and/or second press mould 36, which establishes the opening 38 in the fibre composite component 2 when the two press moulds 28, 36 are moved into the closed position. The elastomer seal 4 extends around the circumference, especially in an annular manner, around the edge at the first top side 40 of the fibre composite component 2. It is preferably the case here that the elastomer seal 4 likewise has an opening section 44 flush with the opening 38. Thus, the elastomer seal 4 may extend directly up to the edge of the opening 38 of the fibre composite component 2. This gives the advantage that a securing element 46 which is guided through the opening 38 of the fibre composite component 2 in order to secure the fibre composite component 2 can be sealed with respect to the fibre composite component 2 in a particularly reliable and effective manner by means of the elastomer seal 4.
[0070] The opening section 44 of the elastomer seal 4 may have been produced simultaneously with the opening 38 of the fibre composite component 2 during the extrusion-forming operation. In principle, however, it is also possible that the opening 38 and the opening section 44 of the elastomer seal 4 are established subsequently. For instance, this may be formed by a corresponding drilling and/or machining operation. In other words, in a further step of the method, the opening 38 and/or the opening section 44 in the elastomer seal 4 may be produced subsequently by drilling or machining.
[0071] FIG. 5 shows the fibre composite component 2 with the elastomer seal 4 in such a schematic form as can be employed in practice. For this purpose, a securing element 46 fits through the opening 38, such that the section of the securing element 46 that projects through the opening 38 beyond the second top side 42 is suitable for mounting on a further component, such that the fibre composite component 2 can be secured via the securing element 46, especially to the further component. The securing element 46 has a flange section 48 in disc form that extends in transverse direction. The flange section 48 extends in transverse direction beyond the edge of the opening 38, such that the flange section 48 reaches through the fibre composite component 2 at the first top side 40. Therefore, the flange section 48 firstly presses against the elastomer seal 4 which is now disposed between the fibre composite component 2 and the flange section 48. The flange section 48 in disc form and the elastomer seal 4 that extends around the circumference of the opening 38 therefore ensure that a sealing effect between the flange section 48 and the fibre composite component 2 is achieved. As elucidated above, in the extrusion-forming operation, cohesive bonding preferably takes place between the elastomer seal 4 and the fibre composite component 2. In the securing of the fibre composite component 2 by means of the securing element 46 thereof, it is therefore possible to ensure that the elastomer seal 4 does not slip unintentionally.
[0072] It has therefore been found to be advantageous when a depression on the first top side 12 of the first semifinished product 6 has been provided such that it is disposed in the region of the deposition region 10, and preferably around the circumference of the opening 16 or 38 to be provided. Correspondingly, for this purpose, the fibre composite component 2 therefore also has a depression 50 on the first top side 40 that extends in an annular manner around the opening 38. The depression 50 and the elastomer seal 4 may be designed with respect to one another such that the elastomer seal 4 can be compressed such that the elastomer seal 4 is disposed completely in the depression 50, as shown in schematic form, for example, in FIG. 5, when the securing element 6 has been pressed against the fibre composite component 2 in the longitudinal axial direction of the opening 38.
[0073] FIG. 6 shows the fibre composite component 2 having the elastomer seal 4 in a further advantageous configuration in a schematic cross-sectional view. A preferred feature here of the fibre composite component 2 is that at least one section 52 is or, as shown in FIG. 2, multiple sections 52 are formed in a multilayer sandwich arrangement. Such a section 52 may have a core layer 54 covered by an outer layer on each of the opposite outer faces. The lower outer layer is formed here by the crosslinked first laminar semifinished product 6 or the first outer layer 18. The opposite second layer is formed by the crosslinked second laminar semifinished product 20 or the second outer layer 22. In this region too, an opening 38 may be provided, in which case a correspondingly formed elastomer seal 4 that extends in an annular manner around the edge of the opening 38 is disposed on the first top side 40.
[0074] From FIG. 7 is possible to infer further advantageous details which may be provided in relation to the fibre composite component 2 or the sandwich section 52 of the fibre composite component 2. In principle, the elucidations which follow, however, are also applicable to the construction of the fibre composite component 2 with just one layer, and so the fibre composite component 2 may also take the form of monolithic bodies.
[0075] It is apparent from FIG. 7 by way of example that, for the provision of the first laminar semifinished product 6, a region around the envisaged opening 38 in the first laminar semifinished product 6 may have reinforcing elements, for example a higher amount of fibres impregnated with the incompletely crosslinked matrix material and/or metallic reinforcing elements. These may especially be disposed on the reverse side from the deposition region 10 and/or in the deposition region 10 on the top side 12 of the first laminar semifinished product 6. If such a first laminar semifinished product 6 is used to produce the fibre composite component 2, this results in a reinforced section 56 as shown in schematic form for the fibre composite component 2 in FIG. 7. This reinforcement section 56 preferably extends in an annular and/or circumferential manner around the opening 38. The reinforcing section may be provided by means of crosslinked matrix material with introduced fibres and/or with at least one metal element. Forces that act on the fibre composite component 2 in normal direction from the securing element 46, for example, can thus be passed onward particularly efficiently to adjacent regions of the fibre composite component 2.
[0076] It should additionally be pointed out that having does not rule out any other elements or steps and a or one does not exclude a multitude. It should also 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 above-described working examples.
[0077] 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 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.
