Abstract
A method for manufacturing a component includes a) providing a first, plate-shaped semi-finished product and a second semi-finished product, the first semi-finished product including a first thermosetting reactive resin with non-directionally inserted long-stranded fibers, the second semi-finished product including an oriented network of endless fibers, the endless fibers having a mean length l of at least 80 mm, and the long-stranded fibers having a mean length k which is at least 30 mm shorter than that of the endless fibers; b) placing the second semi-finished product on top of the first semi-finished product so as to form a semi-finished product group; c) inserting the semi-finished group into a first molding part of a multi-part mold of a press, the semi-finished group covering between 70% and 95% of the first molding part after the insertion; d) extrusion forming of the semi-finished product group by the mold resulting in the component; and e) removing the component.
Claims
1. A method for manufacturing a component, the method comprising: a) Providing a first, plate-shaped semi-finished product and a second semi-finished product, wherein the first semi-finished product comprises a first thermosetting reactive resin with non-directionally inserted long-stranded fibers, the second semi-finished product comprises an oriented network of endless fibers, the endless fibers have a mean length l of at least 80 mm, and the long-stranded fibers have a mean length k which is at least 30 mm shorter than the mean length of the endless fibers; b) Placing the second semi-finished product on top of the first semi-finished product so that at least the first semi-finished product and the second semi-finished product form a semi-finished product group; c) Inserting the semi-finished product group into a first molding part of a multi-part mold of a press, wherein the semi-finished product group covers between 70% and 95% of the first molding part after the insertion; d) Extrusion forming of the semi-finished product group by means of the mold resulting in the component; and e) Removing the component.
2. The method according to claim 1, wherein the long-stranded fibers have a mass portion in the first semi-finished product of between 20 m % and 70 m %.
3. The method according to claim 1, wherein the endless fibers have a mass portion in the second semi-finished product of between 20 m % and 95 m %.
4. The method according to claim 1, wherein the semi-finished product group is shaped during the extrusion forming such that the originating component fills out an interior space of the mold.
5. The method according to claim 1, further comprising: c1) firmly bonded fixing of the second semi-finished product on top of the first semi-finished product.
6. The method according to claim 1, further comprising: c2) mechanic fixing of the second semi-finished product with respect to the first molding part and/or the first semi-finished product.
7. The method according to claim 6, wherein a fabric sheet is assigned to the second semi-finished product, on which fabric sheet the endless fibers are affixed.
8. The method according to claim 6, wherein the mechanic fixing comprises in step c2) a fastening, by a fixation means, of the second semi-finished product at the first molding part or at a component which is stationary with respect to the first molding part.
9. The method according to claim 8, wherein the second semi-finished product is fastened by needles as fixation means, the needles being directed from the second semi-finished product to the first molding part or to the component which is stationary thereto.
10. The method according to claim 8, wherein the fabric sheet forms the fixation means.
11. The method according to claim 7, further comprising: c2.1) inserting an insertion part into the semi-finished product group, wherein the mechanic fixing in step c2) comprises a fastening of the second semi-finished product at the insertion part.
12. The method according to claim 1, further comprising: c3) clamping of the second semi-finished product by a clamping device.
13. The method according to claim 12, wherein the clamping device comprises clamping means for detachable clamping of the opposite ends of the fabric sheet, and the clamping of the second semi-finished product happens by tightening the fabric sheet by the clamping means.
14. The method according to claim 1, further comprising: c4) curing of the second semi-finished product by means of microwaves, wherein the second semi-finished product comprises nanoparticles.
15. The method according to claim 6, wherein the extrusion forming happens with the mechanically fixed and/or clamped second semi-finished product.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0065] Further features, advantages and application possibilities of the invention can be derived from the following description of exemplary embodiments and the drawings. Thereby, all described and/or visually depicted features for themselves and in any combination form an advantageous subject matter of the invention independent of their combination in the individual claims or their dependencies. Furthermore, in the drawings, same reference signs indicate same or similar objects.
[0066] FIG. 1 shows a first schematic flow chart of an embodiment of the method,
[0067] FIG. 2 shows a multitude of first semi-finished products 20 and a multitude of second semi-finished products 22 in a schematic perspective representation,
[0068] FIG. 3 shows an exemplary embodiment of an open mold with a semi-finished product group arranged therein in a schematic cross sectional view,
[0069] FIG. 4 shows a closed mold with a semi-finished product group received therein in a schematic cross sectional view,
[0070] FIG. 5 shows in a schematic cross sectional view the open mold with a component being manufactured in between,
[0071] FIG. 6 shows in a schematic cross sectional view the first semi-finished product along a section in vertical direction,
[0072] FIG. 7 shows in a schematic cross sectional view the first semi-finished product along a section in horizontal direction,
[0073] FIG. 8 shows in a schematic cross sectional view the second semi-finished product along a section in vertical direction,
[0074] FIG. 9 shows in a schematic cross sectional view the second semi-finished product along a section in horizontal direction,
[0075] FIG. 10 shows a schematic top view onto the semi-finished product group which is inserted into the first molding part,
[0076] FIG. 11 shows a second schematic flow chart of a further embodiment of the method,
[0077] FIG. 12 shows a third schematic flow chart of a further embodiment of the method,
[0078] FIG. 13 shows a fourth schematic flow chart of a further embodiment of the method,
[0079] FIG. 14 shows a fifth schematic flow chart of a further embodiment of the method, and
[0080] FIG. 15 shows a sixth schematic flow chart of a further embodiment of the method.
DETAILED DESCRIPTION
[0081] In FIG. 1, a schematic flow chart of a preferred embodiment of the inventive method 8 is shown. The method 8 comprises providing 10 in step a), placing 12 in step b), inserting 14 in step c), extrusion forming 16 in step d), and removing 18 in step e).
[0082] According to step a), providing 10 of a first plate-shaped semi-finished product 20 and a second semi-finished product 22 is provided. The first semi-finished product 20 comprises a first thermosetting reactive resin 24 with undirected inserted long-stranded fibers 26. The second semi-finished product 22 comprises a directed network 28 of endless fibers 30. The endless fibers 30 have a mean length of endless fibers 1 of at least 80 mm. The long-stranded fibers 26 have a mean length of long-stranded fibers k. The mean length of long-stranded fibers k is at least 30 mm shorter than the mean length of endless fibers 1.
[0083] According to step b), placing 12 of the second semi-finished product 22 onto the first semi-finished product 20 is provided so that at least the first semi-finished product 20 and the second semi-finished product 22 form a semi-finished product group 32.
[0084] According to step c), inserting 14 of the semi-finished product group 32 into a first molding part 34 of a multi-part mold 36 of a press 38 is provided, wherein the semi-finished product group 32 covers between 70% and 95% of the first molding part 34 after the insertion.
[0085] According to step d), extrusion forming 16 of the semi-finished product group 32 by means of the mold 36 resulting in the component 40 is provided.
[0086] According to step e), removing 18 of the component 40 is provided.
[0087] In FIG. 2 there are multiple first semi-finished products 20 and multiple second semi-finished products 22 shown, each of which are spaced apart from each other. FIG. 6 shows in a schematic cross sectional view of one of the first semi-finished products 20 along a vertical section. In FIG. 6 there can be recognized the undirected inserted long-stranded fibers 26. The long-stranded fibers 26 are inserted into the first thermosetting reactive resin 24.
[0088] In FIG. 7 there is depicted the previously mentioned first semi-finished product 20 in a further schematic cross sectional representation along a horizontal section through the first semi-finished product 20. The first thermosetting reactive resin 24 as well as the undirected long-stranded fibers 26 inserted into the first thermosetting reactive resin 24 can be recognized. The long-stranded fibers 26 have a length of long-stranded fibers of maximally 70 mm, for example. They may be inserted randomly distributed into the first thermosetting reactive resin 24. Within the first reactive resin 24, the long-stranded fibers 26 are not ordered. The long-stranded fibers 26 may be designed as carbon long-stranded fibers 26, for example.
[0089] In FIG. 8 the second semi-finished product 22 is shown in a schematic cross sectional view along a vertical section through the second semi-finished product 22. The second semi-finished product 22 comprises endless fibers 30. The endless fibers 30 may be inserted into a second reactive resin 42 of the second semi-finished product 22. Alternatively, the endless fibers 30 may be impregnated with the second reactive resin 42.
[0090] In FIG. 9 the second semi-finished product 22 is shown in a schematic cross sectional view along a horizontal section through the second semi-finished product 22. It can be recognized that the endless fibers 30 are formed aligned as network 28. Hence, they have a predetermined direction and/or common shape along the network 28. The network 28 of endless fibers 30 may be applied onto the second reactive resin 42. Alternatively, as shown in FIG. 8, the network 28 of endless fibers 30 may be inserted into the second reactive resin 42 of the second semi-finished product 22.
[0091] The endless fibers 30 have a mean length of endless fibers 1 of at least 80 mm. This preferably corresponds to at least 60%, 70%, 80%, 90% of a diagonal length of a component 40 to be manufactured.
[0092] As can be recognized in FIG. 3, at least one of the second semi-finished products 22 is laid onto at least one of the first semi-finished products 20 during placing 12 according to step b) so that the at least one first semi-finished product 20 and the at least one second semi-finished product 22 form a semi-finished product group 32. Additional first semi-finished products 20 and/or further second semi-finished products 22 may be laid upon the semi-finished product group 32. Hence, these may also form the semi-finished product group 32.
[0093] As also indicated in FIG. 3, the semi-finished product group 32 is inserted into a first molding part 34 of a multi-part mold 36 of a press 38 during step c), that is during insertion 14.
[0094] In FIG. 10, a schematic top view onto the semi-finished product group 32 and the first molding part 34 arranged underneath can be seen. The cross sectional area of the semi-finished product group 32 is smaller than a cross sectional area of an opening of the first molding part 34. Here, it is provided that after the insertion 14 the semi-finished product group 32 covers between 70% and 95% of the first molding part 34, namely preferably the opening of the first molding part 34. Thereby, the coverage preferably refers to the cross sectional areas of the semi-finished product group 32 or of the opening of the first molding part 34, respectively.
[0095] In FIG. 4, step d) is shown, that is the extrusion forming 16 of the semi-finished product group 32 by means of the mold 36 resulting in a component 40. Therefrom, it is evident that due to the high coverage of the first molding part 34 by the semi-finished product group 32 only a small flow path occurs, namely primarily relating to the first reactive resin 24 and/or the second reactive resin 42. This is because the semi-finished product group 32 almost completely projects up to an inner casing wall of the first molding part 34. The remaining flow path is suitable as to reduce pores and/or air inclusions. Moreover, a consolidation and/or rest impregnation of the endless fibers 30 and/or of the long-stranded fibers 26 happens due to the remaining flowing. Due to the high coverage, almost no moving of the network 28 of the endless fibers 30 happens. Rather, the alignment and/or design of the network 28 of endless fibers 30 is maintained as it is provided for the second semi-finished product 22.
[0096] If the component 40 is created by means of the extrusion forming 16, wherein preferably the first and/or the second reactive resin 24, 42 are polymerized or cured, the component may be removed according to step e). Removing of the component is schematically shown in FIG. 5.
[0097] In FIG. 11, a schematic flow chart of a preferred embodiment of the method 8 is shown. In contrast to the flow chart shown in FIG. 1, the method as for now also comprises the step c1). According to step c1), a firmly bonded fixing 44 of the second semi-finished product 22 onto the first semi-finished product 20 is provided. The step c1) is executed prior to the step c), that is the insertion of the semi-finished product group 32 into the first molding part 34. According to step b), the second semi-finished product 22 is already laid onto the first semi-finished product 20 as to thereby form the semi-finished product group 32. According to step c1) which is subsequent to the step b), as for now also a firmly bonded fixing 44 happens. For this purpose, an adhesive means, in particular a binder, may be provided. This may preferably be a thermoplastic adhesive means which was previously applied or preferably sprayed onto the first semi-finished product 20 and/or the second semi-finished product 22. As to gain the firmly bonded fixation now, the thermoplastic adhesive means is heated and subsequently cooled. This results in a firmly bonded connection of the adhesive means with the thermosetting reactive resin 24 of the first semi-finished product 20 as well as with the endless fibers 30 of the second semi-finished product 22 and/or with the second reactive resin 42 of the second semi-finished product 22. Due to the firmly bonded fixation, a pre-positioning of the endless fibers 30 relative to the first semi-finished product 20 happens. Furthermore, due to this also a pre-positioning of the endless fibers 30 within the semi-finished product group 32 happens. This ensures that the component 40 to be manufactured has the endless fibers 30 or the network 28 of the endless fibers 30 at the desired position.
[0098] In FIG. 12, an additional schematic flow chart of a preferred embodiment of the method 8 is shown. Thereby, the method 8 comprises steps as being elucidated with reference to FIG. 1. Moreover, step c2) is provided for the method: mechanic fixation 46 of the second semi-finished product 22 with respect to the first molding part 34 and/or the first semi-finished product 20. The mechanic fixation 46 according to step c2) preferably happens prior to insertion 14 according to step c). Moreover, it is provided that the mechanic fixation 46 according to step c2) happens after the placing 12 according to step b). The second semi-finished product 22 may be fastened with respect to the first molding part 36 and/or to a component which is stationary with respect to the first molding part 36 for the purpose of the mechanic fixation 46. Preferably, a fixation means may be provided for this purpose. These are needles, for example. Alternatively or additionally, the second semi-finished product 22 may be mechanically fixed 46 with respect to the first semi-finished product 20. For example, this may be described by the mechanic fixation of the second semi-finished product 22 at and/or on the first semi-finished product 20. For example, the second semi-finished product 22 may be fastened on the first semi-finished product 20 for mechanic fixation. This may happen by means of a fixation means which is, for example, a fabric sheet of the second semi-finished product 22. The network 28 of the endless fibers 30 may be fasted at the fabric sheet which is designed as a seam base, for example, so that a placing of the fabric sheet onto the first semi-finished product 20 already ensures a pre-arrangement of the endless fibers 30 on the first semi-finished product 20. The fabric sheet may have a roughness which ensures a mechanic fixation with respect to the first semi-finished product 20. Further preferred, the fabric sheet may be sprayed and/or otherwise impregnated with a thermoplastic adhesive means. However, if the fabric sheet is now heated and finally cooled, a bonding effect between the fabric sheet and the first semi-finished product 20 is generated by the thermoplastic adhesive means. For example, the fabric sheet may be a glass fiber fabric, a non-woven fabric and/or a fiber mat.
[0099] In FIG. 13, a flow chart of a further advantageous embodiment of the inventive method is schematically shown. The method corresponds to the previously elucidated method with reference to FIG. 12, however, with the exception that between the step b) and c2) a further step c2.1) is provided, namely the insertion 48 of an insertion part into the semi-finished product group 32, wherein the mechanic fixation 46 in step c2) comprises a fastening of the second semi-finished product 22 at the insertion part. The insertion part may be detachably fastened at the first molding part 34 of at another molding part of the mold 36. For example, the insertion part may be a thread insert, a bushing, a bearing ring or another metallic part. The insertion part serves as fixation basis when being inserted into the semi-finished product group 32. Therefore, the second semi-finished product 22 may be fastened and/or positioned at the insertion part. This ensures a very precise alignment of the endless fibers 30 with respect to the insertion part, wherein at the component 40 to be manufactured especially strong forces may be transmitted by the insertion part to the component 40. Thereupon, these forces may be distributed particularly well in the component 40 due to the purposeful arrangement of the endless fibers 30.
[0100] In FIG. 14, a schematic flow chart of a further advantageous embodiment of the method is shown, wherein the method steps correspond to those of the explanations given with reference to FIG. 1, however, with the exception that between the method step c) and the method step d) a further method step c3) is provided: clamping 50 of the second semi-finished product 22 by means of a clamping device. For example, nails may be used as clamping device as to tighten the endless fibers 30 of the second semi-finished product 22 so that the network 28 of the endless fibers 30 has a preferred alignment. Alternatively or additionally, a fabric sheet of the second semi-finished product 22 at which fabric sheet the endless fibers 30 are fastened may be clamped as the obtain a preferred alignment of the network 28 of the endless fibers 30. The extrusion forming 16 may thereupon happen with the clamped second semi-finished product 22.
[0101] In FIG. 15, a schematic flow chart of a further advantageous embodiment of the method is shown, which comprises the steps which also have been previously explained with reference to FIG. 1, however, there is provided a further method step c4) between the method step c) and d): curing 52 of the second semi-finished product 22 by means of microwaves, wherein the second semi-finished product 22 comprises nanoparticles. Curing 52 may mean increasing a viscosity of the second semi-finished product 22, in particular of the related second reactive resin 42. Stiffening of the second reactive resin 42 may happen due to using of the microwaves so that the second semi-finished product 22 has the increased viscosity. During the curing 52, the second semi-finished product may be in direct or indirect contact with the first molding part 34 or a correspondingly designed pre-mold, so that the second semi-finished product 22 undergoes the curing 52 in a pre-shaped design. The contact of the second semi-finished product 22 to the pre-mold or the first molding part 34 may happen with the semi-finished product group 32 of which the second semi-finished product 22 forms apart.
[0102] Additionally, it is noted that comprising does not exclude any other elements and a or an does not exclude a plurality. It is further noted that features which are described with reference to one of the above exemplary embodiments may also be used in combination with other features of other exemplary embodiments described above. Reference signs in the claims are not to be construed as a limitation.
[0103] 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.
