PROCESS FOR MANUFACTURING A FIBRE-PLASTIC COMPOSITE

Abstract

A process for manufacturing a fibre-plastic composite with a secured fibre orientation, wherein continuous fibres or long fibres are oriented and sheathed with a matrix, characterized by the steps of (a) providing a mold comprising at least one flow channel, (b) introducing the continuous fibres or long fibres into the at least one flow channel, (c) positioning and orienting the continuous fibres or long fibres in the at least one flow channel by way of a pressure gradient in the flow channel, (d) sheathing the continuous fibres or long fibres with a matrix.

Claims

1. A process for manufacturing a fibre-plastic composite with a secured fibre orientation, wherein continuous fibres (16) or long fibres are oriented and sheathed with a matrix, the process comprising the steps of: a) providing a mold (2) comprising at least one flow channel (10), b) introducing the continuous fibres (16) or long fibres into the at least one flow channel (10), c) positioning and orienting the continuous fibres (10) or long fibres in the at least one flow channel (10) by way of a pressure gradient (Δp) in the flow channel (10),and d) sheathing the continuous fibres (16) or long fibres with a matrix.

2. A process according to claim 1, wherein the continuous fibres (16) or long fibres are positioned in the flow channel (10) by a fluid stream.

3. A process according to claim 1 or claim 2, characterized in that securing of the fibre orientation occurs inside of the mold (2) or outside of the mold (2) on a carrier substrate.

4. A machining tool (1), comprising a mold (2) and at least one flow channel (10) inserted into the mold (2), wherein at least one fluid nozzle (12) is allocated to each flow channel (10), the fluid nozzle (12) having a fibre reservoir (14) for continuous fibres (16) or long fibres.

5. A machining tool according to claim 4, the mold (2) has two tool halves (3, 4), with the flow channel (10) being formed by both tool halves (3, 4).

6. A machining tool according to claim 4, wherein the at least one flow channel (10) dictates the orientation for continuous fibres (16) or long fibres from the fibre reservoir (14).

7. A machining tool according to claim 4, wherein the mold (2) has a plurality of flow channels (10).

8. A machining tool according to claim 4, wherein a pump is allocated to at least one flow channel (10).

9. A machining tool according to claim 7, wherein the fluid nozzle (12) has a moving unit and is movable from one flow channel (10) to the next flow channel (10).

Description

DETAILED DESCRIPTION OF THE INVENTION

[0042] The invention is explained in further detail below, using examples and figures.

[0043] FIG. 1 schematically shows the lower part of a mold having flow channels.

[0044] FIG. 2 schematically shows the lower part of a mold according to FIG. 1 with an upper part of the mold shown as transparent and the nozzles allocated to the flow channels.

[0045] FIG. 3 shows the mold of FIG. 2 with nozzles and continuous fibres.

[0046] FIG. 4 shows a substrate with continuous fibres that have been deposited.

[0047] FIG. 5 schematically shows the entire structure of a machining tool according to the invention for a plastics processing plant.

[0048] The process according to the invention and the machining tool according to the invention are illustrated by way of the figures. Since the figures and the process steps are related, all figures are described jointly. In FIG. 3, the machining tool is shown. It includes a mold with two tool halves. The two tool halves form the flow channels.

[0049] As an example, a fluid nozzle 12 is allocated to each flow channel 10, the fluid nozzle having a fibre reservoir for continuous fibres.

[0050] For the process according to the invention for manufacturing a fibre-plastic composite with continuous fibres or long fibres, a mold with a tool half comprising at least one flow channel is initially provided. In the example of FIG. 1, three flow channels 10 are shown, which, in addition, are curved in different ways. The second tool half 3 is now positioned on the first tool half 4 and nozzles 12 are applied (FIG. 2). Subsequently, continuous fibres or long fibres are introduced into the flow channels via the nozzles. The continuous fibres are positioned in the flow channel via a pressure gradient (FIG. 3). The upper tool half can, for example, also be a plastic substrate so that the continuous fibres are fixed to the substrate by means of dies in the mold, for example.

[0051] The fibres used in the process are provided by nozzles. The fibre sections that are to be positioned in the tool are located in the nozzles in reservoirs tightly sealed against the environment. The channels are supplied through these nozzles. If the pressure gradient is generated, the nozzle and the tool, apart from inflow and outflow openings, are tightly sealed in order to generate the desired fluid stream in the tool channels. If the fibres are positioned in the tool, the nozzle withdraws from the tool and the rovings are severed between the tool and the nozzle. The separation can occur both mechanically and by removal (e.g., thermally).

[0052] The semi-finished products produced can be further processed by injection moulding. The semi-finished products can be functionalized in an already reshaped form by injection moulding, and any components as desired can be manufactured in this way.

[0053] In FIG. 5, the machining tool 1 according to the invention for performing the process is illustrated. It comprises a mold 2 with two tool halves 3, 4, an upper tool half 3 and a lower tool half 4. A flow channel 10 is inserted into the mold 2. This flow channel is formed in the lower tool half 4. A fluid nozzle 12 is allocated to the flow channel 10, the fluid nozzle 12 having a fibre reservoir 14 for continuous fibres 16 in the form of a roving. At the inlet 18 of the fluid nozzle 12, there is a pressure pi which is higher than the pressure p.sub.2 in the flow channel 10. As a result of the pressure gradient Δp = pi - p.sub.2 thus arising, the continuous fibre 16 is introduced into the flow channel 10.