Hybrid component and production method

Abstract

The present application relates to a hybrid component and a method for producing the same. The proposed hybrid component comprises a basic element (2) having at least one portion which is formed as a laminate (3) from a plastics foam and a fiber composite plastic.

Claims

1. A hybrid component for an aircraft, comprising: a tubular basic element extending axially between a first axial end of the tubular basic element and a second axial end of the tubular basic element, wherein the tubular basic element comprises a first portion and a second portion both extending axially between the first axial end and the second axial end of the tubular basic element, wherein the first portion is formed of a plastics foam and has a first contact surface and a second contact surface both extending axially between the first axial end and the second axial end of the tubular basic element, wherein the first portion extends circumferentially between the first contact surface and the second contact surface, wherein the second portion is formed of a fiber composite plastic, and the second portion is bonded to both the first contact surface and the second contact surface of the first portion to be circumferentially interposed between the first contact surface and the second contact surface, wherein the first portion is of a single-layer structure and provides an airtight configuration.

2. The hybrid component as claimed in claim 1, wherein the plastics foam is formed from a plastomer.

3. The hybrid component as claimed in claim 1, wherein the fiber composite plastic comprises a duromer and at least one of glass fibers, carbon fibers and aramid fibers, and wherein the fibers exist in the form of at least one of woven fabric, bonded fabric, knitted fabric, lattice fabric and nonwoven fabric.

4. The hybrid component as claimed in claim 3, wherein the melting temperature of the plastics foam is greater than a curing temperature of the duromer.

5. The hybrid component as claimed in claim 1, wherein the plastics foam is constituted by a closed-cell foam material.

6. The hybrid component as claimed in claim 1, wherein the plastics foam has a density between 30 kg/m.sup.3 and 75 kg/m.sup.3.

7. The hybrid component as claimed in claim 1, wherein the first portion of the tubular basic element comprises two half shells, wherein the first half shell has a third contact surface extending axially between the first axial end and the second axial end of the tubular basic element, such that the first half shell circumferentially extends between the first contact surface and the third contact surface; wherein the second half shell has a fourth contact surface extending axially between the first axial end and the second axial end of the tubular basic element, such that the second half shell circumferentially extends between the second contact surface and the fourth contact surface; and wherein the first portion further comprises a fiber composite plastic bonded to both the third contact surface and the fourth contact surface to be circumferentially interposed between the third contact surface and the fourth contact surface.

8. The hybrid component as claimed in claim 1, wherein the fiber composite material of the second portion varies in thickness in the normal direction of the tubular basic element, and the plastics foam is compressed.

9. A hybrid pipe for air conditioning applications, configured as a hybrid component as claimed in claim 1.

10. A cabin trim element for aircraft cabins, configured as a hybrid component as claimed in claim 1.

11. A method for producing a hybrid component as claimed in claim 1, wherein a plastics foam element and a fiber composite plastics element are connected to each other in a lamination process.

12. The hybrid component as claimed in claim 2, wherein the plastomer comprises at least one of PVDF and PPSU.

13. The hybrid component as claimed in claim 1, wherein the plastics foam has a density between 30 kg/m.sup.3 and 40 kg/m.sup.3.

Description

(1) Illustrative embodiments of the invention are described in greater detail below with reference to the figures, wherein:

(2) FIG. 1 shows a perspective view of a hybrid pipe;

(3) FIG. 2 shows a cross-sectional representation of the hybrid pipe;

(4) FIG. 3 shows a cross-sectional representation of a variant of the hybrid pipe;

(5) FIG. 4 shows a seam portion of the hybrid pipe;

(6) FIG. 5 shows a further seam portion of a further variant of the hybrid pipe;

(7) FIG. 6 shows a side view of a portion of a further variant of the hybrid pipe;

(8) FIG. 7 shows a side view of a portion of a still further variant of the hybrid pipe;

(9) FIG. 8 shows a perspective view of a hybrid component; and

(10) FIG. 9 a sectional representation of the hybrid component of FIG. 8.

(11) In the figures, same or functionally same elements are labeled, as far as possible, with the same reference symbols.

(12) FIG. 1 shows a perspective view of a hybrid pipe 1. The hybrid pipe 1 comprises a basic element 2, which has at least one portion which is formed as a laminate 3 from a plastics foam material and a fiber composite plastic.

(13) The hybrid 1, hereinafter also referred to, in short, as a pipe 1, or the basic element 2, is substantially formed from a plastics foam sheet, or flat plastics foam body, which has been curved into a cylindrical hollow body and forms the wall 4 of the hybrid pipe 1.

(14) Along the butt edge which runs axially on the wall 4 and at which the ends or side edges of the curved plastics foam body butt one against another or one upon another is formed the laminate 3 or the portion configured as a laminate, in which portion the side edges of the bent plastics foam body are bonded together by the fiber composite plastic. As the fiber composite plastic can be used, for instance, so-called prepregs, which can be cured under subjection to pressure and temperature and thus, by virtue of the configuration of the laminate 3, bond together the ends of the plastics foam body.

(15) The configuration of the laminate 3 allows, on the one hand, a fixed connection of the ends of the plastics foam body to be achieved and, on the other hand, the mechanical strength, the viscoelastic properties, like the dimensional stability, in particular the dimensional stability in the longitudinal direction of the basic element, to be improved.

(16) The shown hybrid pipe 1 is suitable, in particular, for applications in air conditioning systems and aircraft air conditioning pipe installations in aircraft, for, in particular through the use of the plastics foam material, the hybrid pipe 1 has a markedly reduced weight in comparison to conventional pipes. This latter is based, in particular, also on the fact that the basic element can be configured in a laminate-free manner outside of the region configured as a laminate 3, i.e. can have laminate-free surface portions O. Laminate-free surface regions O are labeled consistently in the figures with the reference symbol O, though respectively not all laminate-free surface regions are labeled in the figures.

(17) Furthermore, the wall 4 produced from the plastics foam material exhibits heat insulating properties, so that an additional measure for thermal insulation of the hybrid pipe can be waived.

(18) FIG. 2 shows a cross-sectional representation of the hybrid pipe 1. From the cross-sectional representation, the structure and shape of the portion formed as a laminate 3 is more clearly apparent. In the present embodiment, the ends or edges of the tubularly curved plastics foam body are butted squarely one against the other, wherein the fiber composite plastics material is disposed between the ends or edges. As can be seen, the fiber composite material, and thus the forming or formed laminate 3, is found merely between the ends of the plastics foam body. Outside of the laminate or the portion configured as the laminate 3, the basic element 2 is formed from the plastics material.

(19) By virtue of the laminate 3, the ends or edges are in the bonded state or are bonded together. An appropriate bonding is absolutely sufficiently stable for air conditioning and/or ventilation applications. Where necessary, however, the bonding can be made yet more stable and firmer, which is discussed in still further detail below in connection with FIGS. 3 to 5.

(20) FIG. 3 shows a cross-sectional representation of a variant of the hybrid pipe 1, and FIG. 4 shows a seam portion, i.e. an enlarged representation of the seam N or joint of the hybrid pipe 1. In this variant, the basic element 2 or the wall 4 is formed by two half shells 5. In the present example, the side edges of the half shells 5 are butted squarely one against the other and are mutually connected into a tubular body. In the present case, the connection of the side edges of the half shells comprises a plurality of portions configured as a laminate 3, which portions, depending on the configuration, can also be regarded however as a continuous laminated portion.

(21) In the example of FIG. 3, fiber composite plastics material is found between the mutually abutting side edges of the plastics foam material. Additionally, and unlike in FIG. 2, the fiber composite plastics material is found on the inside and outside of the wall 4 along the butt edges of the half shells 5, the fiber composite plastics material overlapping the butt edges by a predefined width. In this respect, the portions which are configured as a laminate 3 and join together the plastics foam bodies are located between the butt edges, and with respectively predefined, and substantially freely selectable widths, along the inside and outside of the butt edges. In the present example, the portions configured as a laminate 3 are chosen such that a substantially symmetrical arrangement is obtained. This is particularly advantageous for the dimensional stability, in particular in connection with the production of the laminates 3, since the occurrence of anisotropic tensions or stresses in the region of the laminates 3 can be avoided.

(22) It should here be mentioned that, in one variant, the laminate 3 present between the butt edges of the half shells can be replaced or supplemented by another type of connection, in particular by a bonding or a bond seam with adhesive and/or by a welding or weld seam.

(23) It should be noted that the type of connection which is shown in FIG. 3 can also be used if the hybrid pipe comprises, apart from the seam N, only a continuous plastics foam body or if the hybrid pipe 1 comprises a plurality of plastics foam bodies which respectively form part-shells. It should further be noted that corresponding connections, in particular connections which overlap the butt joints and or the butt seams, can be used in hybrid components different from pipes.

(24) FIG. 5 shows a seam portion or the seam N of a further variant of the hybrid pipe 1. Unlike in FIG. 3 and FIG. 4, on one side of the basic element, in the region of the seam N, is provided a further layer L of fiber plastics material, which overlaps the layers of fiber plastics material which are already present in accordance with the embodiments of FIG. 3 and FIG. 4. By virtue of the further layer L of fiber plastics material, the connection in the region of the seam N can be further stabilized and strengthened. The further layer L can be provided either on an inner side of the basic element 2 or on an outer side of the basic element 2. Alternatively, it is possible for respectively a further layer L to be present or provided on the inner and also on the outer side.

(25) FIG. 6 shows a side view of a portion of a further variant of the hybrid pipe 1. In the present hybrid pipe 1, the portion configured as a laminate 3 can be configured in the region of the seam N, in accordance with the hybrid pipes 1 shown in FIGS. 3 to 5. An embodiment in accordance with the variant according to FIG. 2 is also possible. Contrary or in addition to the previously shown laminate regions 3, the hybrid pipe 1 of FIG. 6 has further portions configured as a laminate, i.e. further laminates 6. In the present example, the further laminates 6 are configured such that they radially encompass the basic element 2, and serve substantially as mechanical reinforcements and stiffenings of the basic element in the peripheral direction. In the regions of the laminates 3 and further laminates 6, the flexibility of the basic element is restricted in favor of mechanical stability and strength, while, outside of the laminates 3 and further laminates 6, the flexibility of the plastics foam material is between less and not at all restricted. For these reasons in particular, a sufficiently mechanically stable and dimensionally stable hybrid component, which, with regard to the end shape and end geometry, is not entirely stiff, but is still flexible within certain boundaries, can be provided.

(26) FIG. 7 shows a side view of a portion of a further variant of the hybrid pipe 1. It is here pointed out that, in the further variant according to FIG. 7, those details and features which are described in connection with FIG. 2 to FIG. 6, yet are not represented and shown in FIG. 7, can be implemented singly or in combination, according to requirement.

(27) The hybrid pipe 1 of FIG. 7 differs from the previously shown hybrid pipes 1 substantially in that, at the two ends of the basic element 2, an axial flange 7 is respectively present. The axial flanges 7 are formed from fiber composite plastics materials in cured form. The axial flanges 7 project beyond the axial ends of the basic element 2, the protruding flange portions being able to be connected to further pipes or pipeline elements. Apart from providing a connection option to further pipes or pipeline elements, the axial flanges 7 also provide a mechanical stiffening or reinforcement of the axial ends of the plastics foam material.

(28) In the present example, the axial flanges 7 are connected to the inner side of the wall 4, to be precise by virtue of the fact that the fiber composite material of the axial flanges 7 with the plastics foam material are mutually connected by lamination. In this respect, in the present example, portions configured as a laminate are present at the ends of the plastics foam body in the region of the overlap with the fiber plastics material of the axial flanges 7. It should be noted that, in place of an axial flange 7, a radial flange (not shown) can also be present.

(29) FIG. 8 shows a perspective view of a hybrid component 8. The hybrid component 8 is configured as a half shell for the production of an air outlet of an aircraft cabin air conditioning system. The hybrid component comprises a first segment 9, which forms a pipe half shell, and a second segment 10, which adjoins a longitudinal side of the first segment 9 and is of roughly plate-like configuration. On outer edges of the second segment 10 mounting flanges 11 are present, while on the longitudinal side of the second segment 10 an airflow edge 12 is configured.

(30) As can be seen, in particular, from FIG. 9, which is shown a sectional representation of the hybrid component 8 of FIG. 8, the first segment 9 and the second segment 10 are mutually connected by a laminate 3 with a fiber composite plastic. Regarding this connection, reference is made to the above statements, which apply analogously here. Connection variants as shown and described in connection with the hybrid pipe 1 can likewise find application here.

(31) The second segment 10 has a layer structure 2 comprising two outer plastics foam layers and an intervening intermediate layer 12 of fiber composite plastic. The plastics foam layers and the intermediate layer are mutually connected through the use of a lamination process. That is to say, in the region of the layer structure a region is present which is configured as a laminate and provides a mechanical reinforcement of the flat, plate-like second segment 10.

(32) Based on the structure of the second segment 10, which is of plate-like construction, it is conceivable within the scope of the invention for laminar hybrid components to be produced with corresponding laminated reinforcement regions. Laminar hybrid components of this kind can be constituted, for instance, by internal trim elements, in particular ceiling trim elements for aircraft cabins. Other interior fitting elements can also be similarly produced, i.e. with a plastics foam body which has laminated reinforcing and/or connecting layers of fiber composite plastics. An advantage of using a plastics foam material also consists in the possibility of produce substantially optionally curved and optionally shaped regions or components which are already thermally insulated by the plastics foam material.

(33) From FIG. 9 it can further be seen that that longitudinal side of the second segment 10 which is facing away from the first segment 9 has a marginal region R which is compressed in comparison to the rest of the hybrid component 8, whereby the thickness of the second segment 10 is locally reduced, in the marginal region R. The reduction in thickness is achieved substantially by a compression of the plastics foam material, wherein the plastics foam material is compressed in the course of the lamination process and, following curing of the fiber composite material, maintains the reduced thickness.

(34) The compressed marginal region R configured as a laminate is adjoined by an edge region K formed solely from fiber composite plastic. This means that the compressed region, in which a hybrid structure of plastics foam and fiber composite plastic still exists, merges in the direction of the margin of the second segment 10 into the edge region K formed purely from fiber composite plastic, which edge region, in contrast to the hybrid structure, can also be termed monolithic. In the present example, the edge region K serves as an air discharge edge.

(35) The plastics foam which is used for the described hybrid components 1, 8 can be constituted by a thermoplastic foam. This can be inserted in one or more blanks into a mold, in particular a low-pressure hose mold, shaped in accordance with the end contour of the hybrid component, together with the fiber composite plastic, in particular prepregs, and following closure of the mold can be pressed against the mold with a suitable pressure hose. By subjecting the arrangement to temperature, the fiber composite plastic can be cured, while, at the same time, the plastics foam is shaped into the end contour given by the mold.

(36) The connection of the plastics foam material can be activated by the fiber composite plastic, by adhesive and/or adhesive strips, which preferably takes place during the subjection to temperature. It is also possible for blanks of plastics foam material to be connected beforehand by means of welding or bonding, and for the thus formed plastics foam body to be brought in a subsequent process into the end shape and be provided with the reinforcements consisting of fiber composite plastic.

REFERENCE SYMBOL LIST

(37) 1 hybrid pipe 2 basic element 3 laminate 4 wall 5 half shell 6 further laminate 7 axial flange 8 hybrid component 9 first segment 10 second segment 11 flange 12 intermediate layer N seam L further layer R marginal region K edge region O laminate-free surface portion