CN102438812A - 纺织半成品的预成型方法和预成型装置 - Google Patents

纺织半成品的预成型方法和预成型装置 Download PDF

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Publication number
CN102438812A
CN102438812A CN2010800212984A CN201080021298A CN102438812A CN 102438812 A CN102438812 A CN 102438812A CN 2010800212984 A CN2010800212984 A CN 2010800212984A CN 201080021298 A CN201080021298 A CN 201080021298A CN 102438812 A CN102438812 A CN 102438812A
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Prior art keywords
textile
fiber
make
finished product
cut
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CN2010800212984A
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CN102438812B (zh
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J.孔茨
F.施塔德勒
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Airbus Defence and Space GmbH
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IDESD AG
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
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    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
    • B29C65/1658—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined scanning once, e.g. contour laser welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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    • B29C66/8126—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
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Abstract

本发明涉及一种用于纺织半成品（48）的预成型的方法，具有如下步骤：设置纺织品，其中纺织品具有至少部分地上下布置的至少两层（12、16）纤维，和/或具有相互交织的纤维和/或纤维束；使得纺织品的纤维相互固定；然后切割纺织品；其中“固定纺织品纤维”包括步骤“射入激光束（34），从而纺织品的可熔化的粘结剂局部地仅熔化而不蒸发”。根据本发明。根据本发明规定，对纺织品纤维的固定沿着固定线（36）进行，而切割则沿着切割线（46）进行；固定线（36）相距切割线（46）具有小的间距，使得纺织品的散边得到防止或抑制。

Description

纺织半成品的预成型方法和预成型装置
本发明涉及一种用于纺织半成品的预成型的方法，具有：步骤（a）、设置纺织品，其中纺织品（i）具有至少部分地上下布置的至少两层纤维，和/或（ii）在底层上具有相互交织的纤维和/或纤维束；步骤（b）、使得纺织品的纤维相互固定；和步骤（c）、然后切割纺织品，其中固定纺织品纤维包括射入激光束的步骤，从而纺织品的可熔化的粘结剂局部地仅熔化而不蒸发。
根据第二方面，本发明涉及一种根据权利要求7的前序部分的预成型装置。
预成型是由纤维复合材料制得构件的一个步骤。在切割之后，纺织品的切边往往不再固定。这导致纺织品很容易就会散边，把纤维固定住的缝线由于脱针而松脱，致使纺织品在使用半成品制得的构件中不再具有所希望的布置方式。
因此已知使用一种包括可熔化的粘结剂的纺织品。在切割之前，在炉中把纺织品加热，使得纺织品的各个纤维相互粘接。接下来切割纺织品。由于纤维粘接，就不再出现散边的现象。
这里不利的是，得到的半成品比较硬，其在以后浸渍和硬化时很难与相应的构件形状相匹配。
所述类型的方法由DE 199 52 443 A1已知。据其所述方法，把纺织品的不同层缝合在一起，以便实现所需要的防滑性，防滑性对于切割来说是必需的。这里不利的是，纺织品在缝线处倾向于散边。
DE 693 04 042 T2记载了用于制造在结构上增强的型坯的方法和装置。这些型坯在各处通过粘结剂的熔化而相互连接。以此方式将多个层相互缝合，使得它们易于处理。即使采用其中所述的方法也会出现散边现象。
DE 35 41 954 C2披露了一种用于制造复合体的方法，采用该方法能制得具有尖锐边棱的复合体。为此对纺织品中存在的合成树脂进行部分硬化，而各个纤维层则被弹性的薄隔膜彼此分开。事后去掉这些隔膜，并把部分硬化的纤维层压制成最终的复合体。该出版物并未提及在切割情况下产生的散边问题。
US 5,418,035 A公开了一种用于制造纤维复合构件的方法，其中首先在一边把纺织品的各个层相互缝合，以便在以后使得这些层成形。该出版物未谈及散边问题。
DE 10 2007 032 904 B3说明了一种用于纺织平幅结构的结构固定的方法，该方法试图以简单的机构来防止纺织半成品在切割时散开脱落。为此模拟了将来的载荷情况，识别半成品的在由此产生的构件中因载荷而经受很小滑移的区域。在这些部位把纺织品相互连接起来。该方法并非被设计用于防止散边。
本发明的目的在于，避免纺织半成品的边缘散边。
本发明采用根据权利要求1的方法来解决该问题。
本发明有利地与以后的切割线即以后的切割边缘相邻地把纺织品的纤维相互连接起来，从而纺织品的边缘不会散边。此外有利的是，这种固定并不会导致所产生的坯件的强度和硬度过大。所产生的坯件因而保持可打褶，也能匹配于双重弯曲的几何体。还可以制造出小型的设计复杂的坯件。
此外有利的是，无需给边缘加料（Zugabe），而在根据现有技术的方法中就需要这样。这种边缘在强度考虑中并不重要，这会导致制好的构件重量增加。
另外有利的是，所述固定可以借助激光器自动地进行。此点可行的原因特别是因为激光束能无接触地在纺织品上面移动。在这里，在其中有纤维相互连接的区域比较窄，因而所产生的坯件保持不稳固（labil）。例如适当地选择激光束，使得纤维在小于一厘米的宽度上相互连接。
例如与感应式加热相比有利的是，其上放置有纺织品的底垫能随意地选择。而在感应式加热情况下，附近不准有金属物体。如果要使用微波辐射，还必须确保微波不会到达外界，因为可能伤及人员。
另外采用本发明有利的是，利用激光器就能实现均匀的加热。因而可以规定，在辐射纺织品时例如无接触地测量温度。于是可以适当地调整激光器功率、激光器射束直径和/或激光器的前进速度，使得不会超过预先设定的温度，从而不会伤及纺织品。此外可以确保温度不会低于预先设定的温度位值，从而保证纺织品中的纤维可靠地连接。
在本说明书的范围内，纺织品纤维的固定系指，纤维至少局部地相互连接，从而防止在以后切割时散边。在这里，可熔化的粘结剂优选已经是纺织品的一部分。但在理论上也可以在激光射束射到纺织品上之前直接涂覆粘结剂。
所述切割尤其意指非常普遍的分割，其可以但并非必须利用机械工具来进行。
粘结剂尤其是一种可熔化的物质，其布置在纺织品纤维附近，或者本身以纤维的形式存在。粘结剂可以加入到纺织品中，或者位于纺织品上。在熔化情况下，粘结剂把周围的纤维相互连接起来。
根据本发明，对至少两层的固定沿着固定线进行，而切割则沿着切割线进行。固定线相距切割线具有一间距，该间距经过选择，使得纺织品的散边得到防止或抑制。该间距例如在0和5mm之间。由此实现最晚在脱针已从切割线到达固定线时阻止从切割线散边。
为了固定纤维，根据一种优选的实施方式可以规定，用可透过激光器的光的薄膜盖住这些层，激光束穿透薄膜射入。特征“薄膜可透过激光器的光”尤其系指，吸收和反射总共小于20％。适当地选择薄膜，就能达到90％以上的透射率。透射率越高，损耗就越小，为了保护外界免受散射的激光而必须采取的防护措施就越少。
薄膜尤其适当地可透过激光辐射，使得薄膜在照射期间本身并不熔化。优选还至少适当地选择薄膜，使得它具有足够大表面分离特性，从而它在两个层被固定之后又可以从这些层取下。薄膜还经过优选选择，使得激光束在垂直入射时最多以30％的功率被反射。
特征“激光束的入射方式使得纺织品的可熔化的粘结剂局部地仅熔化而不蒸发”特别意指，光束功率和激光器的前进速度经过适当选择，使得在任何位置都不会超过危害温度，危害温度会导致粘结剂或纺织品受到危害。尤其是激光束的功率密度经过适当选择，使得不会出现明显的烧焦，也就是说，尽管有一定量的粘结剂和/或纺织品纤维受热损坏，但这种损坏程度很小，以至于其在计算由纺织半成品制成的部件的强度时不必予以考虑。激光束的功率密度经过特别选择，使得纺织品和/或粘结剂的可能的热致损坏仅造成小于10％的强度损失。
该方法中有关固定和切割的步骤优选自动地进行。还可以规定，对纺织品的至少两层的布置也自动地进行。
根据一种优选的实施方式，把纺织品布置在底垫上，且在激光入射之前就把空气从底垫与薄膜之间的区域中抽出。由此使得纤维彼此相对固定，且相对于底垫固定。减小的压力还导致在加热时的氧化风险有所减小。还可以规定，在激光束入射之前用保护性气体吹洗薄膜与底垫之间的区域。有利的是，剩余压力小于200毫巴，特别是小于100毫巴。
优选纺织品在切割之前就被固定，其中这种切割用机械的切割装置来进行。替代地，利用激光器特别是利用同样用来固定的激光器进行切割。但这里不利的是，在切割时纤维和/或粘结剂会热致损坏，因而必须要忍受制好的构件的可能的强度损失。
步骤设置、切割和固定可以针对多个纺织品层重复地进行，直至制得包括多个纺织品层的半成品。此外可以在将另一纺织品层铺设到已经被切割的预型体期间，分别铺上薄膜、将中间腔抽真空，然后如上所述用激光器把预型体与附加的纺织品层连接起来，之后切割附加的纺织品层。但也可以两者同时进行，或者先切割，然后再固定。
本发明的用于将纺织半成品预成型的预成型装置特别是一种被构造和设计用于制造多个纺织半成品的装置。尤其是把底垫、切割装置和固定装置相互固定。切割装置和固定装置还通常是用电机驱动的自动装置。
底垫是任一种能固定纺织品纤维层的装置。底垫可以是桌子，但也可以具有不透气的输送带。
根据一种优选的实施方式，预成型装置包括控制单元，该控制单元被构造用于使得激光器适当运动，从而纺织品的纤维沿着固定线被固定，且被构造用于使得切割装置适当运动，从而该切割装置总是能沿着切割线切割层，其中固定线相距切割线具有较小的间距，从而避免或抑制纺织品散边。
例如可以规定，切割线相距固定线具有小于10mm的间距。控制单元可以与输入机构连接，利用该输入机构能确定切割线和/或固定线相对于底垫的位置。控制单元例如可以具有接口，从而能读入CAD数据。
优选控制单元被设计用于使得激光器以一定速度移动，该速度参照射束强度经过适当选择，使得在激光束射入时粘结剂局部地仅熔化而不蒸发或烧焦。为此可以规定，控制单元与温度测量装置连接，该温度测量装置激光束刚刚所在的部位的温度。
优选固定装置包括用于铺设薄膜的薄膜铺设装置和用于施加差压的差压施加装置，从而使得薄膜紧贴在面状纺织品上。该薄膜铺设装置例如可以是自动的。
预成型装置优选包括屏蔽装置，该屏蔽装置被适当地带动，使得反射的激光束被吸收。由此避免人员受到危险。
下面借助示范性的实施例详细地阐述本发明。其中：
图1示出用于实施本发明的方法的本发明的装置；和
图2为纺织半成品的示意图，其具有相关的固定线和切割线。
图1示出一种平幅纺织品10，其形式为多轴向织物或增强纤维构成的织造织物。多轴向织物或织造织物可以包括碳纤维或者由其构成。平幅纺织品10也可以称为半成品，它具有由多个纤维束14.1、14.2…构成的第一层12，这些纤维束相互平行地伸展，且优选都包括相同数量的在图1中看不到的碳纤维。
平幅纺织品10还包括由纤维束构成的第二层16，在横剖视图中只能看到其中的纤维束18。纤维束14和18夹成一个未示出的纤维角。平幅纺织品10是一种半成品，其在以后的加工步骤中被渗入基质材料例如合成树脂，从而形成层压制品。通过在模具中的硬化，由此例如制得飞机部件。本发明因此还涉及一种用于制造飞机部件或其它结构组件的方法。
平幅纺织品10位于底垫20上，该底垫由平的尽可能平滑的垫板构成。为了使得第一层12与第二层16连接，在处于上面的层16上铺上薄膜22。该薄膜例如是聚乙烯薄膜，其例如可以具有12微米的厚度。薄膜22通过密封板条24压到底垫20上，或者通过密封带24与底垫粘接，从而产生气密的连接。在底垫20与薄膜22之间形成一个中间腔，在该中间腔中布置着平幅纺织品。
通过抽吸通道28形式的用于施加真空的装置，中间腔26与真空泵30连接，该真空泵连续地从中间腔26抽吸空气，从而在外界压力p外界与中间腔26中的内部压力p内部之间产生大于800毫巴的压力差⊿p。特别地，外界压力是约为1013毫巴的大气压，内部压力低于200毫巴，尤其是低于100毫巴。在当前情况下，内部压力p内部=50毫巴。但也可以盖上压力罩，由此提高外界压力p外界。
对中间腔26施加低压，薄膜22由此就会紧贴在平幅纺织品10上，并沿厚度方向挤压该平幅纺织品，进而使得两个层12、16彼此相对固定。如果达到了前述内部压力p内部，激光器32就会沿预先设定的路径移动，使得激光束34透过薄膜22射到第一层12和第二层16上。浸渍给相应的纤维束14的粘结剂由此熔化，并产生了固定线36（参见图2）。固定线36的走向由与激光器32连接的控制单元38预先设定。激光器32、抽吸通道28、真空泵30和控制单元38都是固定装置40的部件。
图2从上面观察示出平幅纺织品10。可看到，固定线36布置在平幅纺织品10的内部。在本例中，固定线还由两条闭合的连续线即第一连续线42.1和第二连续线42.2构成。
图1还示意性地示出切割装置44，其用于沿着切割线46将平幅纺织品10切开（图2）。切割线46也由两条连续线构成，这两条连续线相距固定线36具有例如一毫米的间隔。
在下一工作步骤中，可以将制好的纺织半成品48取下，其也可以称为坯料。在后续步骤中，用树脂浸渍半成品48，使树脂硬化，由此制得结构上模件（Strukturoberteil）。
附图标记列表
10  平幅纺织品
12  第一层
14  纤维束
16  第二层
18  纤维束
20  底垫
22  薄膜
24  密封板条
26  中间腔
28  抽吸通道
30  真空泵
32  激光器
34  激光束
36  固定线
38  控制单元
40  固定装置
42  连续线
44  切割装置
46  切割线
48  半成品

Claims (9)

1. 一种用于纺织半成品（48）的预成型的方法，具有如下步骤：
（a）、设置纺织品，其中纺织品
- 具有至少部分地上下布置的至少两层（12、16）纤维，和/或
- 具有相互交织的纤维和/或纤维束；
（b）、使得纺织品的纤维相互固定；和
（c）、然后切割纺织品；
（d）、其中“固定纺织品纤维”包括步骤
“射入激光束（34），从而纺织品的可熔化的粘结剂局部地仅熔化而不蒸发” ；
其特征在于，
（e）、对纺织品纤维的固定沿着固定线（36）进行，而切割则沿着切割线（46）进行；和
（f）、固定线（36）相距切割线（46）具有小的间距，使得纺织品的散边得到防止或抑制。
2. 如前述权利要求中任一项所述的方法，其特征在于如下步骤：
- 用可透过激光器的光的薄膜（22）盖住所述层（12、16）；和
- 使得激光束（34）穿透薄膜（22）射入。
3. 如权利要求2所述的方法，其特征在于，把纺织品布置在底垫（20）上，且在激光束（34）入射之前就把空气从底垫（20）与薄膜（22）之间的区域中抽出。
4. 如前述权利要求中任一项所述的方法，其特征在于，
- 对纤维的固定在切割之前进行；和
- 对纺织品的切割用机械的切割装置（44）来进行。
5. 如前述权利要求中任一项所述的方法，其特征在于，步骤“设置、切割和固定”针对多个纺织品层重复地进行，直至制得包括多个层的半成品（48）。
6. 如前述权利要求中任一项所述的方法，其特征在于如下步骤：
- 在固定和切割之后对纺织半成品进行浸渍；和
- 使得已浸渍的半成品硬化，从而得到纤维复合构件。
7. 一种用于将纺织半成品预成型的预成型装置，具有：
（a）、用于设置纺织品的底垫；
（b）、用于切割纺织品的切割装置；和
（c）、用于使得纺织品的纤维相互固定的固定装置（40）；
（d）、其中固定装置（40）包括激光器（32），该激光器的射束强度经过适当设计，使得在激光射束（34）入射时纺织品的粘结剂局部地仅熔化而不蒸发” ；
其特征在于
（e）、控制单元（38），该控制单元被构造用于
- 使得激光器（32）适当运动，从而纺织品的纤维沿着固定线（36）被固定；和
- 使得切割装置（44）适当运动，从而该切割装置沿着切割线（46）切割纺织品的纤维，其中固定线（36）相距切割线（46）具有较小的间距，从而避免或抑制纺织品散边。
8. 如权利要求7所述的用于将纺织半成品预成型的预成型装置，其特征在于，控制单元（38）被设计用于使得激光器（32）以一定速度移动，该速度参照射束强度经过适当选择，使得在激光束（34）射入时粘结剂局部地仅熔化而不蒸发。
9. 如权利要求7至8中任一项所述的用于将纺织半成品预成型的预成型装置，其特征在于，固定装置包括
（i）、用于铺设薄膜（22）的薄膜铺设装置（42）；和
（ii）、用于施加差压（⊿p）的差压施加装置，从而使得薄膜（22）紧贴在面状纺织品上。
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