Device and method for processing a fibre compound structure

Abstract

In a method for processing a fiber compound structure, an unhardened fiber layer is arranged on a surface section of the fiber compound structure. A pressure cushion is arranged above the surface section. The pressure cushion has a pressure cap and a pressure-tight cap mat pressure-tightly connected to a circumferential border of the pressure cap such that the cap mat limits a pressure area together with the pressure cap. An overpressure in the pressure area is generated. The pressure cushion is pressed onto the fiber compound structure such that the overpressure presses the cap mat against the fiber layer while supporting the fiber compound structure on a side of the fiber compound structure that is opposed to the surface section. The fiber layer is hardened

Claims

1. A processing method for processing a fibre compound structure, the method comprising: arranging at least one unhardened fibre layer on a surface section of the fibre compound structure; arranging a pressure cushion above the surface section, the pressure cushion comprising a pressure cap and a pressure-tight cap mat being pressure-tightly connected to a circumferential border of the pressure cap such that the cap mat limits a pressure area together with the pressure cap; supporting a side of the fibre compound opposed to the surface section with a counter bearing surface; generating an overpressure in the pressure area; pressing the pressure cushion onto the fibre compound structure such that the overpressure presses the cap mat against the at least one fibre layer while supporting the fibre compound structure on a side of the fibre compound structure that is opposed to the surface section; and hardening the at least one fibre layer, wherein the pressure-tight cap mat fills out contours and/or step like sections according to a contour of the fibre compound structure.

2. The processing method according to claim 1, wherein the method further comprises the steps of: covering the at least one fibre layer by the cap mat; sealing of a low-pressuer area limited by the cap mat and the fibre compound structure; and evacuating of the low-pressure area.

3. The processing methond according to claim 2, wherein the sealing of the low pressure area is carried out by pressing the cap mat by means of the pressure cap onto the fibre compound structure.

4. The processing method according to claim 1, wherein the hardening of the at least one fibre layer is carried out by heating, in particular up to a temperature of 125 C to 180 C, in accordance with a resin matrix of the fibre layer.

5. The processing method according to claim 1, where the overpressure being applied is at least 1 bar above atmospheric pressure.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The figures illustrate:

(2) FIG. 1 a schematic cross-sectional view of a connecting device;

(3) FIG. 2 a perspective oblique view of a connecting device according to a second embodiment of the invention;

(4) FIG. 3 a schematic cross-sectional view of a connecting device according to an embodiment of the invention;

(5) FIG. 3A a schematic cross-sectional view of a connecting device according to an embodiment of the invention;

(6) FIG. 3B a schematic cross-sectional view of a connecting device according to an embodiment of the invention;

(7) FIG. 4 a side view of a connecting device according to an embodiment of the invention;

(8) FIG. 5 a side view of a connecting device according to an embodiment of the invention; and

(9) FIG. 6 a flowchart of a processing method according to an embodiment of the invention.

DETAILED DESCRIPTION

(10) In the figures equal references signs identify equal or functionally equal components as far as nothing contrary is indicated.

(11) FIG. 1 shows a schematic cross-sectional view of a connecting device 100 in a state while connecting an initially unhardened fibre layer 104 to a fibre compound component 102. For this purpose the fibre layer 104 has been arranged on a surface section 112 and has been covered by a pressure-tight membrane (for instance a vacuum foil or a rubber mat) 108.

(12) The membrane 108 can also be formed by a section of the hull of a vacuum bag which surrounds the fibre compound component 102 entirely.

(13) A pressure cap 308 is arranged above the surface section 112 which is formed from a flexible cap mat 106 as for instance a rubber mat and from a rigid frame 120 which runs along the border 107 of the cap mat 106 on its upper side. Along with the border 107 of the cap mat 106 the frame 120 is pressed onto the fibre compound component 102 by screw clamps which are arranged in regular distances alongside the circumference of the frame. Furthermore, a circumferential gasket 116 is inserted between the border 107 of the cap mat 106 and the fibre compound component 102 in order that a hermetically closed pressure area 110 is formed between the cap mat 106 and the membrane 108.

(14) However, the membrane 108 can be replaced by a vacuum bag or by a non-adhesive membrane if the gasket 116 runs on this membrane on its whole length because in this case the surface pressure of the frame 120 allows for the sealing of the overpressure area 110 as well as for the sealing of the low pressure area 114.

(15) A valve nozzle 116 is installed in the cap mat 106 for inducing overpressure in the pressure area 110. While the device is in service initially the pressure area 110 is sealed in the described manner. Subsequently the valve nozzle 116 is connected to a compressor which is not shown and the compressor is switched on in order that an overpressure builds up in the pressure area 110.

(16) The overpressure exerts compressive forces on the boundaries which are indicated by arrow symbols. The forces being directed against the cap mat 106 effectuates that the cap mat 106 arches up in the shown manner. The forces being directed against the membrane 108 effectuate that the membrane 108 and the fibre layer 104 being enclosed under the membrane 108 are pressed against the fibre compound component 102 whereby the fibre layer 104 is compressed.

(17) Advantageously the section 114 which is enclosed under the membrane 108 is additionally evacuated, for instance by a vacuum pump 304, which is connected to the low pressure area 114, as shown for instance by a vacuum hose 122 which is guided through the cap mat 106 by means of a duct 124. Alternatively the vacuum hose can be conducted through at a different position, for instance close to the gasket 116 or close to the valve nozzle 118. The duct 124 can also be dispensed with, for instance if the vacuum pump 304 is provided for operation before the sealing of the pressure area 110. The evacuation of the low pressure area causes the application of an effective hardening pressure of approximately 1.8 to 2.2 bar which consists of a low pressure in the low pressure area 114 of approximately 0.8 bar compared to the atmospheric pressure and the overpressure in the pressure area 110 of approximately 1 to 2 bar.

(18) FIG. 2 shows a perspective oblique view of another connecting device 100 comprising a pressure cap 308 which is arranged above a surface section 112 of a fibre compound structure 102 in the shown operating condition of the connecting device 100. Thereby the pressure cap 308 consists of a rubber cap mat 106 as cap cover and a rigid frame 120 for instance made from steel or aluminium which is pressed by a multitude of screw clamps 200 against the rubber mat 106 in order that said rubber mat is jammed between the frame 120 and the fibre compound component 102 at its border 107. For instance, the frame 120 can be firmly connected to the cap mat 106 by means of gluing; however, in the shown arrangement the pressure of the screw clamps 200 causes already a firm connection of the cap mat 106 in order that frame 120 and cap mat 106 can be formed as separate parts.

(19) The screw clamps 200 which carry the frame 120 are held by a bar 202 which is supported on the lower side of the fibre compound structure 102 in a manner not shown here.

(20) FIG. 3 shows a schematic cross-sectional view of a connecting device according to an embodiment of the invention. In the shown operational state in line with FIG. 1 initially an unhardened fibre layer 104 has been arranged on a surface section of a fibre compound component 102 and has been covered by a membrane 108. The membrane 108 and the fibre compound element 102 enclose a low pressure room 114 lying in between which is evacuable by a vacuum pump 304.

(21) Above the such prepared surface section of the fibre compound component 102 a pressure cushion 390 is arranged comprising a rigid pressure cap 308 on the bottom side of which a cap mat 106 is connected by means of fastening elements 310, a circumferential gasket 116 and a frame 120, such that said cap mat encloses a hermetically closed and permanently fixed pressure area 110 inside the pressure cushion 390 along with the plate of the pressure cap 308. An overpressure can be applied to the pressure area 110 by means of a compressor 302 via a pressure induction nozzle 118. Electric heating elements 306 are arranged on the outside or inside of the cap mat 106 or embedded in the cap mat 106. They allow for heating the fibre layers 104 for hardening.

(22) During the operation of the device 100 the low pressure area 114 is evacuated by the vacuum pump 304. In the pressure area 110 an overpressure being indicated by arrow symbols is built up by means of the compressor 302 which inflates the cap mat 106. If the screw clamps 200 (or other devices as for instance pressure spindles or pressure cylinders which serve the purpose) are adjusted in a suitable manner the overpressure presses the cap mat 106 against the fibre layer 104 which is covered by the membrane 108 and compresses the fibre layer. The heating elements 306 are activated for the final hardening of the fibre layers 104.

(23) FIG. 3A shows view of a connecting device according to a further embodiment, which differs from the embodiment of FIG. 3 in that the pressure cap 308 and the cap mat 106 have been integrally formed from an elastic material such as rubber. In other words, the pressure cushion 390 that contains the pressure area 110 is formed as a single piece, which reduces the cost of providing the connecting device and greatly facilitates handling. The pressure cushion 390 can be formed such that it exhibits the form of a flat, hollow mat in a state when it is not in use and the pressure area 110, located inside this hollow mat, is deflated, thus allowing efficient storage of the pressure cushion 390.

(24) FIG. 3B shows a view of a connecting device according to a further embodiment, in which as in the embodiment of FIG. 3A the pressure cushion 390 comprising the pressure cap 308 and the cap mat 106 has been integrally formed from an elastic material such as rubber. In addition, the pressure cushion 390 comprises a sealing area 392 that during use of the connecting device touches the fibre compound structure 102 along a circumference enclosing the surface section 112. Due to the presence of the sealing area 392, a low pressure area 114 can be formed at the location of the fibre layer 104 without having to separately provide a pressure-tight membrane for covering the surface area 112. At the location where the low-pressure area 114 is to be formed, the pressure cushion comprises a shallow recess 398. An evacuation duct 394 runs from the low-pressure area 114 to the circumference of the pressure cushion 390, thus allowing the low-pressure area 114 to be evacuated by a vacuum pump 304 after the pressure cushion 390 has been pressed onto the fibre compound structure 102. For improved sealing performance, gaskets 396 e.g. from a softer material that run around the circumference enclosing the surface section 112 have been provided in the sealing area.

(25) FIG. 4 shows a side view of a connecting device according to an embodiment of the invention in which a cap mat 106 (in line with FIG. 3) is permanently connected to a pressure cap 308 constituting an integral pressure cushion 390 and being supported by a bar 202. The bar 202 allows for pressing the pressure cap 308 along with the cap mat 106 onto a surface section 112 of a fibre compound structure 102 which is to be processed so as to indirectly apply the overpressure prevailing between the pressure cap 308 and the cap mat 106 to the surface section by this means.

(26) The bar 202 has a C-shaped form and has a counter bearing 400 on the other end which has a profile which is suitable for supporting the fibre compound structure 102 on a back side 402 which is opposed to the surface section 112 to be processed. The exemplary shown fibre compound structure 102 has a multitude of stringers 406 on its back side which fit into according cavities of the counter bearing 400. A height adjustment 404 allows for adapting the height of the counter bearing to the thickness of the fibre compound structure 102 and for adapting the desired surface pressure of the cap mat 106.

(27) In a similar manner as the counter bearing 400 the cap mat 106 can also be designed in a contoured manner according to the shape of the surface section 112 to be processed so as to improve the pressure distribution and to optimally use the strechability of the cap mat 106. A such contoured cap mat 106 can be produced for instance on an accordingly shaped master pattern.

(28) FIG. 5 shows a side view of a connecting device according to an embodiment of the invention which also comprises a pressure cushion 390 constituted as an integral unit from a pressure cup 308 and from a cap mat 106 and which is held by a bar 202 above the surface section 112 of a fibre compound structure 102 to be processed. However, in this embodiment the bar 202 is supported by means of suction cups 500 on supporting sections 502 of the surface of the fibre compound structure 102 which are adjacent to the surface section 112 that is to be processed.

(29) FIG. 6 shows a flow chart of a processing method for processing a fibre compound structure according to an embodiment of the invention which can be carried out for instance by means of one of the above described connecting devices.

(30) Thereby in a first step 600 the unhardened fibre layers are arranged on a surface section of the fibre compound structure. Subsequently, in a further step 602 the fibre layers are covered by a pressure tight membrane for instance by a single serving vacuum foil or by a reusable rubber mat. In a step 614 a low pressure area which is bounded by the membrane and by the fibre compound structure is sealed. Subsequently, the low pressure area is evacuated in a step 616.

(31) In a further step 604 a pressure cushion is arranged above the surface section, which comprises a pressure cap and a pressure tight cap mat connected pressure tightly to a circumferential border of the pressure cap such that the cap mat limits a pressure area together with the pressure cap. The arranging of the pressure cap 604 and of the membrane 602 is carried out in such a manner that the pressure cap is pressed against the fibre compound structure so that partial areas of the pressure cap or of the cap mat like the border of the pressure cap or the centre of the cap mat press against the fibre compound structure.

(32) In a further step 608 an overpressure is generated in the pressure area which presses the membrane against the fibre layers. The step 606 and farther 608 can also be carried out at the beginning of the method, for instance by prefilling the pressure cushion with a pressure medium as compressed air.

(33) The arranging of the pressure cap 604 and the generating 608 of the overpressure cooperate to that effect that the pressure cap together with the cap mat is pressed onto the fibre compound structure 612 which is covered by the membrane so that partial sections of the cap mat as the centre of the cap mat press against the fibre compound structure.

(34) An evacuation of the low pressure area in step 616 and the generation of the overpressure result in the application of an effective hardening pressure of approximately 1.8 to 2.8 bar which is composed of a low pressure in the low pressure area of approximately 0.8 bar compared to the atmospheric pressure and of the overpressure in the pressure area of approximately 1 to 2 bar.

(35) As an alternative to steps 602 and 614, the low pressure area may be sealed together with step 608 by pressing a sealing area provided on the cap mat against the fibre compound structure, such that the resulting low pressure area is bounded by the cap mat and the fibre compound structure. In this case, step 616 may also be performed after step 608.

(36) In a terminal step 610 the fibre layers are hardened, for instance by heating by means of heating elements which can be integrated in the membrane or in the cap mat or can be attached to these.

(37) Although the present invention has been described by means of preferred embodiments it is not restricted thereto, but it is modifiable in a versatile fashion.

(38) For instance, unhardened fibre layers can also be connected to structures and components of a different type. Thus, it is possible to connect layers of fibre glass reinforced plastic to components of aluminium in the described manner. Furthermore, the fibre layers can be replaced by materials of a different type as for instance granulates. Also connecting of a hard element to the basic structure by means of an inlaid adhesive film layer is possible.

LIST OF REFERENCE SIGNS

(39) 100 connecting device

(40) 102 fibre compound structure

(41) 104 fibre layer

(42) 106 cap mat

(43) 107 border

(44) 108 pressure tight membrane

(45) 110 pressure area

(46) 112 surface section

(47) 114 low pressure area

(48) 116 gasket

(49) 118 valve nozzle

(50) 120 frame

(51) 200 screw clamps

(52) 202 bar

(53) 300 middle section

(54) 302 compressor

(55) 304 vacuum pump

(56) 306 heating element

(57) 308 cap plate

(58) 310 fastening element

(59) 390 pressure cushion

(60) 392 sealing area

(61) 394 evacuation duct

(62) 396 gasket

(63) 398 recess

(64) 400 counter bearing

(65) 402 back side

(66) 404 height adjustment

(67) 406 stringer

(68) 500 vacuum cup

(69) 502 support section

(70) 600 arranging of the fibre layers

(71) 602 covering of the fibre layers

(72) 604 arranging of the pressure cap

(73) 608 generating an overpressure

(74) 610 hardening of the fibre layers

(75) 612 pressing on of the pressure cap