Method for Producing a Composite Fiber Component with an Integrated Screw-In Insert

Abstract

A method is provided for producing a composite fiber component with an integrated screw-in insert. A pressing tool is provided. The pressing tool has a first tool part and a second tool part that can be moved in relation to the first tool part. The parts form a cavity for receiving and forming a fiber preform, when the pressing tool is closed. A screw-in insert is connected to a screw device integrated into the first tool part. The fiber preform is arranged between the first and the second tool parts. The pressing tool is at least partially closed. The screw device is actuated in order to screw the screw-in insert into the fiber preform. The fiber preform is cured.

Claims

1. A method for producing a fiber-composite component having an integrated screw-in insert, the method comprising the acts of: providing a pressing tool having a first tool part and a second tool part that is movable relative to the former, said first tool part and said second tool part in a closed state of the pressing tool forming a cavity for receiving a fibrous semi-finished product in a shape-imparting manner; connecting a screw-in insert to a screw-driving device that is integrated in the first tool part; disposing the fibrous semi-finished product between the first and the second tool part; at least partially closing the pressing tool; activating the screw-driving device for screwing the screw-in insert into the fibrous semi-finished product; and curing the fibrous semi-finished product in order for the fiber-composite component to be generated.

2. The method as claimed in claim 1, wherein the fibrous semi-finished product is disposed in the pressing tool in a state in which said fibrous semi-finished product is impregnated with a matrix and is not cured.

3. The method as claimed in claim 1, wherein the act of at least partially closing comprises completely closing the pressing tool.

4. The method as claimed in claim 1, further comprising the act of: completely closing the pressing tool prior to the act of curing the fibrous semi-finished product.

5. The method as claimed in claim 1, further comprising the act of: reversing at least a screw-driving element of the screw-driving device, prior to the pressing tool being opened.

6. A screw-in insert for screwing into a fibrous semi-finished product, comprising: an activation portion; a screw-in shaft that extends away from the activation shaft; and a linking portion.

7. The screw-in insert as claimed in claim 6, wherein the linking portion comprises an internal thread, an external thread, a ball element, a bayonet element or a clip element.

8. The screw-in insert as claimed in claim 6, wherein the screw-in insert comprises at least one thread blade which is designed for screwing the screw-in insert into the fibrous semi-finished product and anchoring said screw-in insert in the latter.

9. The screw-in insert as claimed in claim 8, wherein the screw-in shaft has a cylindrical portion on which a substantially disk-shaped flange is disposed so as to be spaced apart from the activation portion, the flange, in order for the at least one thread blade to be formed, has at least one flange portion which projects from a flange plane that is defined by the flange.

10. The screw-in insert as claimed in claim 9, wherein the activation portion has a chamfer that faces away from the disk-shaped flange, and/or the disk-shaped flange has a chamfer that faces away from the activation portion.

11. The screw-in insert as claimed in claim 8, wherein the activation portion is configured so as to be disk-shaped, and a receptacle portion for receiving the fibrous semi-finished product is defined between the activation portion and the flange that is disposed so as to be spaced apart.

12. The screw-in insert as claimed in claim 8, wherein the screw-in shaft comprises an external thread for screwing into the fibrous semi-finished product, and the at least one thread blade on the activation portion is disposed so as to be spaced apart in parallel with the screw-in shaft.

13. A pressing tool, comprising: a first tool part and a second tool part, wherein the two tool parts in a closed state form a cavity for receiving a fibrous semi-finished product in a shape-imparting manner, and at least one tool part for screwing a screw-in insert into the fibrous semi-finished product to be disposed in the cavity has a screw-driving device which is activatable in the direction of the cavity.

14. The pressing tool as claimed in claim 13, wherein the screw-driving device comprises a screw-driving element that is movable in a rotational manner and in a longitudinal manner in the direction of the cavity, said screw-driving element for impinging a screw-in insert in a form-fitting manner being configured with a connecting portion that faces the cavity.

15. The pressing tool as claimed in claim 13, wherein the screw-driving device is configured so as to be retractable into the tool part.

16. The pressing tool as claimed in claim 13, wherein the pressing tool is a wet pressing tool.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0048] FIG. 1 shows a side view of a screw-in insert in a first embodiment.

[0049] FIG. 2 shows a plan view of the screw-in insert from FIG. 1.

[0050] FIG. 3 shows a sectional plan view of the screw-in insert from FIG. 1.

[0051] FIG. 4 shows a side view of a screw-in insert in a second embodiment.

[0052] FIG. 5 shows a sectional side view of the screw-in insert from FIG. 4.

[0053] FIG. 6 shows a side view of a screw-in insert in a third embodiment.

[0054] FIGS. 7A, 7B, 7C, and 7D show the steps of a method for producing a fiber-composite component having an integrated screw-in insert.

[0055] FIG. 8 shows a side view of a screw-in insert in a fourth embodiment.

[0056] FIGS. 9A, 9B, 9C, and 9D show the steps of a method for producing a fiber-composite component having an integrated screw-in insert according to FIG. 8.

DETAILED DESCRIPTION OF THE DRAWINGS

[0057] A side view of a screw-in insert 10 in a first embodiment is illustrated in FIG. 1. The screw-in insert 10 is provided for screwing into a fibrous semi-finished product 80 (cf. FIGS. 7A to 7D) and to this end has an activation portion 11 with the aid of which the screw-in insert 10, for example by a screw-driving device (cf. FIGS. 7A to 7C) can be impinged so as to be capable of transmitting a torque and be screwed into the fibrous semi-finished product 80. Moreover, a screw-in shaft 12 that extends away from the activation potion 11 and a linking portion 13 are provided.

[0058] The screw-in shaft 12 is provided for penetrating the fibrous semi-finished product 80 and for displacing fibrous material, and to this end has a substantially cylindrical pin having a tapered point. The screw-in shaft 12 can optionally also be embodied for at least partially anchoring the screw-in insert 10 in the fibrous semi-finished product 80. A linking portion 13 is to be understood as a portion of the screw-in insert 10 which is provided for linking further components (not illustrated).

[0059] To this end, the linking portion 13 can be an internal thread, for example, which can be seen in particular in FIG. 2 (plan view of the screw-in insert 10). Alternatively however (and thus not illustrated), the linking portion 13 can also be an external thread, a ball element, or a clip element.

[0060] The screw-in insert 10 additionally has a thread blade 14 which is designed for screwing the screw-in insert 10 into the fibrous semi-finished product 80. To this end, the screw-in shaft 12 has a cylindrical portion on which a substantially disk-shaped flange 15 is disposed so as to be spaced apart from the activation portion 11. As can be seen in particular from FIG. 1 and from the sectional view A-A illustrated in FIG. 3, the flange 15 has a flange portion 15a which on a side that faces away from the activation portion 11 projects from a flange plane F (perpendicular to the image plane) that is defined by the flange 15, in order for the thread blade 14 to be formed. Additionally, an external edge 14a of the thread blade 14 is shaped so as to be bent in the direction of the screw-in shaft 12, in order for the fibrous semi-finished product 80 to be penetrated more easily.

[0061] The activation portion 11 is additionally configured so as to be disk-shaped such that a receptacle portion 16 for receiving the fibrous semi-finished product 80 is defined between the activation portion 11 and the flange 15 that is disposed so as to be spaced apart.

[0062] The thread blade 14, formed by the projecting flange portion 14, when being screwed into the fibrous semi-finished product 80 thus penetrates the fibrous structure of the fibrous semi-finished product 80 such that said fibrous structure is displaced in the direction of the activation portion 11 and, by virtue of the rotating movement of the screw-in insert 10, is driven into the receptacle portion 16, as is illustrated and described in FIGS. 7A to 7D.

[0063] A side view of a screw-in insert 20 in a second embodiment is illustrated in FIG. 4, said second embodiment corresponding substantially to the screw-in insert 10 of the first embodiment that has already been illustrated in FIGS. 1, 2, and 3, such that reference is made to the respective description, and the respective elements, to the extent of being identical, are identified by the same reference signs.

[0064] By contrast to the first embodiment, the screw-in insert 20 according to the second embodiment has an activation portion 21 which includes a chamfer 21a that faces the first tool part. The chamfer 21a is consequently disposed so as to face away from the disk-shaped flange 25. Moreover, a chamfer 25a that faces the second tool part is also disposed on the disk-shaped flange 25. The chamfer 25a is consequently disposed so as to face away from the activation portion 21.

[0065] A sectional view of the screw-in insert 20 from FIG. 4 is additionally illustrated in FIG. 5. With the exception of the chamfers 21a, 25a, said view of insert element 20 from FIG. 4 likewise applies to the first embodiment according to FIGS. 1 to 3, showing the linking portion 13 that is embodied as an internal thread.

[0066] FIG. 6 shows a side view of a screw-in insert 30 according to a third embodiment. Accordingly, the screw-in insert 30 likewise has an activation portion 31, a screw-in shaft 32 that extends away from the activation portion 31, and a linking portion 33.

[0067] However, the screw-in shaft 32 in the embodiment illustrated comprises an external thread for screwing into the fibrous semi-finished product 80. Additionally, four thread blades 34 (merely three thread blades are illustrated) which are designed for screwing the screw-in insert 30 into the fibrous semi-finished product 80 and anchoring said screw-in insert 30 in the latter are provided. The thread blades 34 on the activation portion 31 are disposed so as to be spaced apart in parallel to the screw-in shaft 32, and in the circumferential direction of the activation portion 31 are disposed so as to be mutually spaced apart at equal spacings.

[0068] FIGS. 7A, 7B, 7C, and 7D show four steps of a method for producing a fiber-composite component 81 having an integrated screw-in insert 20, according to the second embodiment. However, it is understood that other screw-in inserts 10, 30, in particular the screw-in inserts 10, 30 according to the first or the third embodiment that are illustrated in FIGS. 1 to 6 can also be employed in the same manner.

[0069] An initial position in which a provided pressing tool 70 (illustrated in a merely fragmented and heavily simplified manner) comprises a first tool part 71, embodied as the upper tool, and a second tool part 72, movable in relation to said first tool part 71 and embodied as the lower tool, is illustrated in FIG. 7A. Of course, the first tool part can however also be provided as the lower tool, and the second tool part can be provided as the upper tool.

[0070] Both tool parts 71, 72 are movable in relation to one another in order for a cavity 74 for receiving the fiber-composite component 81 in a shape-imparting manner to be formed in a closed state of the pressing tool 70.

[0071] The screw-in insert 20 according to the second embodiment described in FIGS. 4 and 5 is connected to a screw-driving device 73 that is integrated in the first tool part 71, and the fibrous semi-finished product 80 is disposed between the first 71 and the second tool part 72, wherein the fibrous semi-finished product 80 is provided in a state in which the latter is impregnated with a matrix and is not cured.

[0072] The pressing tool 70 according to FIG. 7B is at least partially closed. Additionally, an activation of the screw-driving device 73 for screwing the screw-in insert 20 into the fibrous semi-finished product 80 by means of a screw-driving element 73a which with the aid of a thread (not illustrated) is movable in a rotational manner and in a longitudinal manner in the direction of the cavity 74.

[0073] The screw-driving element 73a is embodied in a pin-shaped manner and on an end side is embodied for impinging the screw-in insert in a corresponding manner, in the embodiment illustrated by way of a merely optional appendage 73b in order for the form-fitting impingement to be achieved.

[0074] First, the screw-in shaft 12 by way of the tip thereof penetrates the fibrous semi-finished product 80 and displaces part of the fibrous structure. As the depth increases, the projecting flange portion 15a reaches the fibrous semi-finished product 80 and is screwed into the fibrous structure. As has already been described, the fibrous semi-finished product 80 is displaced in the direction of the activation portion 21, and by virtue of the rotating movement of the screw-in insert 20 is driven into the receptacle portion 16.

[0075] The fibrous semi-finished product 80 herein in a localized manner is displaced and on a rear side of the disk-shaped flange 25 slides into the defined receptacle portion 16, as is illustrated in FIG. 7C. The screw-in insert 20 in this state by way of the disk-shaped activation portion 21, on the one hand, and by way of the disk-shaped flange 25, on the other hand, is fixed to and held on the fibrous semi-finished product 80, or is supported thereon, respectively, such that a transmission of high forces becomes possible.

[0076] The pressing tool 70 can optionally be designed in such a manner that the projecting flange portion 15a (cf. FIG. 4), subsequent to screwing in that is performed in this manner, is deformed in that the screw-in insert 20 is pressed against the opposite tool part, presently the lower tool part 72, for example by means of the screw-driving element 73a, and/or in that the pressing tool 70 is closed to a further degree. In this way, a level lower side of the screw-in insert 20 which is defined by that surface of the disk-shaped flange 25 that faces the second tool part 72, is produced, thus preventing the screw-in insert 20 from being released from the fibrous semi-finished product 80.

[0077] Subsequent to incorporating the screw-in insert 20 in the fibrous semi-finished product 80 as described, curing of the fibrous semi-finished product 80 under an impingement with temperature and/or pressure is performed in the pressing tool 70 in order for the fiber-composite component 81 to be produced.

[0078] Preferably, the screw-driving device 73 or at least the screw-driving element 73a should be moved back prior to opening the pressing tool 70, in order for an engagement in the screw-in insert 20 to be released and a removal of the fiber-composite component 81 that has been produced in the manner described to be facilitated. It is understood that the step of moving back the screw-driving device 73 or at least the screw-driving element 73a can alternatively be performed already prior to curing.

[0079] A side view of a screw-in insert 40 in a fourth embodiment which corresponds substantially to the screw-in insert 20 of the second embodiment that has already been illustrated in FIG. 4 is illustrated in FIG. 8, such that reference is made to the respective description, and the respective elements, to the extent of being identical, are identified by the same reference signs.

[0080] By contrast to said second embodiment illustrated in FIG. 4, the screw-in insert 40 according to the fourth embodiment has a linking portion 43 which comprises a cylindrical portion which has an external thread 44 for connecting to other components and connecting means (not illustrated).

[0081] Additionally, a diameter d1 of the disk-shaped flange 25 is smaller than a diameter d4 of the activation portion 21. In the case of the chamfers 21a, 25a that are optionally provided, this is to be understood in such a manner that the respective largest diameter d1 of the disk-shaped flange 25 is smaller than the largest diameter d4 of the activation portion 21, and the smallest diameter d2 of the disk-shaped flange 25 is smaller than the smallest diameter d3 of the activation portion 21. Moreover, in a merely optional manner, the largest diameter d1 of the disk-shaped flange 25 can be dimensioned so as to be smaller or equal to the smallest diameter d3 of the activation portion 21.

[0082] FIGS. 9A, 9B, 9C, and 9D show four steps of a method for producing a fiber-composite component 81 having an integrated screw-in insert 40, according to the fourth embodiment. The individual steps correspond substantially to the steps that have already been described in the context of FIGS. 7A to 7D, such that reference is made to the description that has already been offered in the context of said FIGS. 7A to 7D. The latter thus also applies to the steps of FIGS. 9A to 9D such that only the points of differentiation and the particularities which result from the use of the screw-in insert 40 of the fourth embodiment are described hereunder. However, it is understood that other screw-in inserts 10, 20, 30, in particular the screw-in inserts 10, 20, 30 according to the first, second, or third embodiment that are illustrated in FIGS. 1 to 6 can also be employed in the same manner.

[0083] The screw-in insert 40 in FIG. 9A is connected to the screw-driving device 73 that is integrated in the first tool part 71, and the fibrous semi-finished product 80 is disposed between the first 71 and the second tool part 72, wherein the fibrous semi-finished product 80 is provided in a state in which the latter is impregnated with a matrix and not cured.

[0084] The pressing tool 70 according to FIG. 9B is at least partially closed. An activation of the screw-driving device 73 for screwing the screw-in insert 40 into the fibrous semi-finished product 80 by means of the screw-driving element 73a which with the aid of a thread (not illustrated) is movable in a rotational manner and in a longitudinal manner in the direction of the cavity 74 is additionally performed. The screw-driving element 73a is embodied so as to be pin-shaped and in the region of an end side is provided with an internal thread 73b for connecting to the external thread 44 of the screw-in insert 40.

[0085] The screw-in insert 40 by way of the tip of the screw-in shaft 12 is first incorporated into the fibrous semi-finished product 80, and displaces part of the fibrous structure. As the depth increases, the projecting flange portion 15a (cf. FIG. 8) reaches the fibrous semi-finished product 80 and is screwed into the fibrous structure. The fibrous semi-finished product 80 is displaced in the direction of the activation portion 21 and by virtue of the rotating movement of the screw-in insert 40 is driven into the receptacle portion 16.

[0086] The diameter d1 of the flange 25 is optionally chosen so as to be smaller than the diameter d3 of the activation element 21 such that a gap 91a is generated between the first tool part 71 and the flange 25, on account of which the fibrous semi-finished product 80 can be more easily and readily incorporated into the receptacle portion 16. Tearing of the fibrous structure is avoided in this way.

[0087] Additionally or alternatively to this choice of the diameters, on the surface of the first tool part 71 that delimits the cavity 74, a clearance 93, for example in the form of a chamfer or of a rounded feature, can be provided in the first tool part 71 in the region of a mouth 93 of the screw-driving device 73, in order to likewise generate a gap 91b between the first tool part 71 and the flange 25, or for the existing gap 91a that is provided by the choice of diameter mentioned to be enlarged such that the fibrous semi-finished product 80 can more easily and reliably be incorporated into the receptacle portion 16. Tearing of the fibrous structure is likewise reliably avoided.

[0088] The steps carried out in FIGS. 9C and 9D correspond to the steps illustrated in FIGS. 7C and 7D.

[0089] 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.