DE102010062057A1 - Process for the production of composite materials - Google Patents

Process for the production of composite materials Download PDF

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Publication number
DE102010062057A1
DE102010062057A1 DE102010062057A DE102010062057A DE102010062057A1 DE 102010062057 A1 DE102010062057 A1 DE 102010062057A1 DE 102010062057 A DE102010062057 A DE 102010062057A DE 102010062057 A DE102010062057 A DE 102010062057A DE 102010062057 A1 DE102010062057 A1 DE 102010062057A1
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composite materials
materials according
resin
tool
producing composite
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wird später genannt werden Erfinder
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BASF SE
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BASF SE
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Priority to PCT/EP2011/070775 priority patent/WO2012069524A1/en
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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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/467—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements during mould closing
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/088—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of non-plastics material or non-specified material, e.g. supports
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/003—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor characterised by the choice of material
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/20—Making multilayered or multicoloured articles
    • B29C43/203—Making multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2307/00—Use of elements other than metals as reinforcement
    • B29K2307/04—Carbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2309/00—Use of inorganic materials not provided for in groups B29K2303/00 - B29K2307/00, as reinforcement
    • B29K2309/08—Glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0285—Condensation resins of aldehydes, e.g. with phenols, ureas, melamines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/06—Open cell foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/08—Impregnating

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Reinforced Plastic Materials (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

Die vorliegende Erfindung betrifft ein Verfahren zur Herstellung von faserverstärkten Verbundwerkstoffen.The present invention relates to a process for the production of fiber reinforced composites.

Description

Die vorliegende Erfindung betrifft ein Verfahren zur Herstellung von faserverstärkten Verbundwerkstoffen.The present invention relates to a process for the production of fiber reinforced composites.

Gewebeverstärkte Faserverbundwerkstoffe werden häufig nach dem RTM-Verfahren (resin-transfer-moulding) oder dem RIM-Verfahren (reaction-injection-moulding) hergestellt. Dabei werden Gewebe oder textile Strukturen dicht in ein Werkzeug gepackt und fixiert. In das mit einer Presse fixierte, geschlossene Werkzeug wird dann ein Harz-Härter-Gemisch (Harzsystem) injiziert.Fabric-reinforced fiber composites are often produced by the RTM process (resin-transfer-molding) or the RIM process (reaction-injection-molding). In this case, tissue or textile structures are tightly packed in a tool and fixed. In the fixed with a press, closed tool then a resin-hardener mixture (resin system) is injected.

Verfahren dieser Art sind bekannt und werden beispielsweise im Handbuch „Faserverbundwerkstoffe” von Gottfried Ehrenstein, Hanser Verlag, auf den Seiten 165 und 166 beschrieben.Methods of this kind are known and are described, for example, in the handbook "Faserverbundwerkstoffe" by Gottfried Ehrenstein, Hanser Verlag, on pages 165 and 166 described.

WO 2009/077616 offenbart ein Verfahren zur Herstellung eines Formteils durch Tränken eines Trägermaterials mit schäumfähigen Reaktivharzen (PU-, Epoxy- oder UP-Harz) und anschließenden Aufschäumen und Aushärten des Harzes. Man kann auf diese Weise Hybridschäume herstellen. WO 2009/077616 discloses a method for producing a molded article by impregnating a carrier material with foamable reactive resins (PU, epoxy or UP resin) and then foaming and curing the resin. One can produce hybrid foams in this way.

Bei dem RTM-Verfahren treten verschiedene Probleme auf. Ein grundlegendes Problem ist, dass dabei ein Reaktionsharz dicht gepackte Faserstrukturen durchdringen muss. Das gelingt oft nur mit großem Aufwand, beispielsweise durch sehr hohe Drücke, Anlegen von Vakuum, spezielle niedrigviskose Formulierungen oder durch kurzzeitiges Öffnen und Wiederschließen des Werkzeugs.There are several problems with the RTM method. A fundamental problem is that a reaction resin has to penetrate tightly packed fiber structures. This often succeeds only with great effort, for example by very high pressures, application of vacuum, special low-viscosity formulations or by short-term opening and re-closing of the tool.

Es ist bei den bekannten Verfahren schwierig, die dicht gepackten Fasern (oftmals bei Füllgraden bis zu 70 Vol-% mit Glas- oder Kohlefasern), gleichmäßig und vollständig in kurzer Zeit mit dem Harzsystem zu durchtränken.It is difficult in the known processes to impregnate the densely packed fibers (often at fillages up to 70% by volume with glass or carbon fibers) uniformly and completely in a short time with the resin system.

Beim Befüllen fangen schnell katalysierte Systeme schon an zu reagieren. Das Werkzeug wird nicht mehr vollständig gefüllt. Es müssen daher meist niedrigviskose Harzsysteme verwendet werden, denn in der Regel ist eine langsame Polymerisationsreaktion angestrebt, damit das Harz das Werkzeug möglichst vollständig durchdringen kann.When filling fast catalysed systems already begin to react. The tool is no longer completely filled. It is therefore usually necessary to use low-viscosity resin systems, since as a rule a slow polymerization reaction is desired, so that the resin can penetrate the tool as completely as possible.

Das Harzsystem fließt zudem nicht gleichmäßig durch das fasergefüllte Werkzeug. Es gibt mehr oder weniger ungefüllte Stellen.The resin system also does not flow evenly through the fiber-filled tool. There are more or less unfilled places.

Es gibt oft Lufteinschlüsse, die das Harzsystem nicht verdrängen konnte.There are often trapped air that could not displace the resin system.

Durch die Injektion kann es außerdem zu Verschiebungen der textilen Strukturen kommen, was zu schlechteren mechanischen Eigenschaften des Bauteils führt.The injection can also lead to shifts in the textile structures, which leads to poorer mechanical properties of the component.

Die für die Injektion erforderliche Zeit verlängert die Belegungsdauer des Werkzeuges und reduziert den Durchsatz.The time required for injection prolongs the tool life and reduces throughput.

Nach dem Stand der Technik werden Gießmaschinen mit Niederdruck- oder Hochdruckpumpen für die Förderung der Harz- und Härterkomponenten über eine Mischkammer in das Werkzeug eingesetzt. Je nach Reaktivität und Viskosität der Komponenten müssen sehr kostspielige Verarbeitungsmaschinen mit Hochdruckpumpen verwendet werden.According to the state of the art, casting machines with low-pressure or high-pressure pumps for conveying the resin and hardener components are inserted into the tool via a mixing chamber. Depending on the reactivity and viscosity of the components, very expensive processing machines with high pressure pumps have to be used.

Das aus dem Stand der Technik bekannten RIM- oder RTM-Verfahren hat somit einige Nachteile. Desweiteren handelt es sich im Regelfall um ein Batch-Verfahren mit oftmals langen Füllzeiten der Form. Nach dem Entnehmen des Formteils muss dann meist die Form gereinigt werden, was zeitaufwändig ist.The known from the prior art RIM or RTM method thus has some disadvantages. Furthermore, it is usually a batch process with often long filling times of the mold. After removing the molding then usually the mold must be cleaned, which is time consuming.

Es stellte sich somit die Aufgabe, die erwähnten Probleme zu überwinden. Insbesondere sollte die Durchlaufzeit verringert und die aus dem Stand der Technik bekannten Verfahren beschleunigt werden, wodurch es im Regelfall auch zu einer Wirtschaftlichkeitsverbesserung kommen sollte.It was thus the task to overcome the mentioned problems. In particular, the throughput time should be reduced and the methods known from the prior art should be accelerated, which should usually also lead to an improvement in profitability.

Überraschenderweise konnte Abhilfe durch flächiges Einbringen des Reaktionsharzes mittels eines Trägers erreicht werden. Der Träger kann beispielsweise ein Gewebe (Prepreg), Vlies oder offenzelliger Schaumstoff sein.Surprisingly, remedy could be achieved by two-dimensional introduction of the reaction resin by means of a carrier. The carrier can be, for example, a fabric (prepreg), fleece or open-cell foam.

Der Begriff ”offenzellig” bezeichnet eine Schaum-Struktur, die dadurch definiert ist, dass jede Zelle mindestens zwei Poren oder zerstörte Flächen aufweist. Außerdem muss die Mehrheit der Zellrippen zu mindestens drei Zellen gehören. Geschlossenzellige Schäume werden in der Regel auf der Basis von Polyurethan (PU), Polyvinylchlorid (PVC), Polymethacrylimid (PMI) und Polystyrol (PS) hergestellt (siehe Arnim Kraatz, Dissertation 2007, Universität Halle ).The term "open-celled" refers to a foam structure defined by each cell having at least two pores or destroyed surfaces. In addition, the majority of cell fins must belong to at least three cells. Closed-cell foams are usually made on the basis of polyurethane (PU), polyvinyl chloride (PVC), polymethacrylimide (PMI) and polystyrene (PS) (see Arnim Kraatz, Dissertation 2007, University of Halle ).

Der Gegenstand der vorliegenden Erfindung ist somit ein Verfahren zur Herstellung von Verbundwerkstoffen, mit den folgenden Schritten: (i) Tränken eines Trägers (T) mit mindestens einem reaktionsfähigen Harz (H), (ii) Einbringen des mit mindestens einem reaktionsfähigen Harz getränkten Trägers in ein Werkzeug (W), (iii) Einbringen mindestens eines Fasern enthaltenden Körpers (K) in das Werkzeug (W), (iv) Aushärten des mindestens einen reaktionsfähigen Harzes im Werkzeug.The subject of the present invention is thus a process for the production of composites, with the following steps: (i) impregnating a support (T) with at least one reactive resin (H), (ii) introducing the support impregnated with at least one reactive resin into a tool (W), (iii) introducing at least one fiber-containing body (K) into the tool (W), (iv) curing the at least one reactive resin in the tool.

In einer bevorzugten Ausführungsform der erfindungsgemäßen Verfahrens werden die Fasern enthaltende Körper (K) (Gewebe, textile Strukturen) zum Teil vor dem Einbringen des harzgetränkten Trägers in das Werkzeug eingelegt. Nach dem Einbringen des harzgetränkten Trägers werden weitere Fasern enthaltende Körper (K) (textile Strukturen) eingelegt. Der harzgetränkte Träger (T) befindet sich somit zwischen den textilen Strukturen.In a preferred embodiment of the method according to the invention, the fibers Containing body (K) (fabric, textile structures) inserted in part before the introduction of the resin-impregnated carrier in the tool. After introduction of the resin-impregnated carrier, further fibers containing body (K) (textile structures) are inserted. The resin-impregnated carrier (T) is thus located between the textile structures.

Bevorzugt ist der Fasern enthaltende Körper (K) textiler Struktur.The fiber-containing body (K) of textile structure is preferred.

Mit Werkzeug sind zwei- oder mehrgeteilte Formen aus Stahl, Aluminium oder mineralisch verstärktem Kunststoff gemeint. Beim bevorzugten Verfahren sind die Formen zweigeteilt (Ober- und Unterschale) und in eine Presse eingebaut. Die dabei auftretenden Pressdrücke liegen zwischen üblicherweise zwischen 5 und 20 bar. Bevorzugt sind die Werkzeuge für größere, flächige Teile ausgelegt. Die üblichen Verarbeitungstemperaturen der Reaktionsharze liegen zwischen 25°C und 90°C, die Werkzeugtemperaturen liegen normalerweise zwischen 40°C und 120°C.By tool is meant two or more divided shapes of steel, aluminum or mineral reinforced plastic. In the preferred method, the molds are divided into two parts (upper and lower shell) and installed in a press. The occurring compression pressures are usually between 5 and 20 bar. Preferably, the tools are designed for larger, flat parts. The usual processing temperatures of the reaction resins are between 25 ° C and 90 ° C, the mold temperatures are usually between 40 ° C and 120 ° C.

In einer bevorzugten Ausführungsform des erfindungsgemäßen Verfahrens ist der Träger saugfähig. Im Sinne der vorliegenden Offenbarung bedeutet der Begriff „saugfähig”, dass das verwendete Reaktionsharz in den benötigten Mengen, die von den Teilegeometrien und dem Faseranteil abhängen, aufgenommen werden kann, ohne abzutropfen.In a preferred embodiment of the method according to the invention, the carrier is absorbent. For the purposes of the present disclosure, the term "absorbent" means that the reaction resin used in the required amounts, which depend on the part geometries and the fiber content, can be included without dripping.

Beim erfindungsgemäßen Verfahren zur Herstellung von glas- oder kohlefaserverstärkten Verbundwerkstoffen wird also ein Harz in einen Träger, bevorzugt in einen saugfähigen Träger, eingebracht.In the process according to the invention for producing glass or carbon fiber reinforced composite materials, therefore, a resin is introduced into a carrier, preferably into an absorbent carrier.

In einer Ausführungsform des erfindungsgemäßen Verfahrens ist der Träger (T) ausgewählt aus der Gruppe umfassend Gewebe (Prepreg), Vliese, offenzellige Schaumstoffe.In one embodiment of the method according to the invention, the support (T) is selected from the group consisting of fabric (prepreg), nonwovens, open-cell foams.

Besonders bevorzugt wird als Träger erfindungsgemäß ein offenzelliger Schaumstoff verwendet, ganz besonders bevorzugt ein offenzelliger Schaumstoff auf Basis von Melaminharz (z. B. Basotect® der BASF SE) verwendet. Basotect® ist ein offenzelliger Melamin/Formaldehydschaum sehr geringer Dichte und geringer Brennbarkeit und ist sehr saugfähig.According to the invention an open-celled foam used, most preferably an open-cell foam based on a melamine resin (for. Example, Basotect ® from BASF SE) is particularly preferably used as the carrier. Basotect ® is an open cell melamine / formaldehyde foam of very low density and low flammability and is very absorbent.

In einer Ausführungsform des erfindungsgemäßen Verfahrens wird Schritt (ii) vor Schritt (iii) durchgeführt.In one embodiment of the method according to the invention, step (ii) is carried out before step (iii).

In einer weiteren Ausführungsform des erfindungsgemäßen Verfahrens wird Schritt (iii) vor Schritt (ii) durchgeführt.In a further embodiment of the method according to the invention, step (iii) is carried out before step (ii).

In einer weiteren Ausführungsform des erfindungsgemäßen Verfahrens wird Schritt (iii) jeweils vor und nach Schritt (ii) durchgeführt.In a further embodiment of the method according to the invention, step (iii) is carried out in each case before and after step (ii).

In einer weiteren Ausführungsform des erfindungsgemäßen Verfahrens werden die Schritte (ii) und (iii) gleichzeitig durchgeführt.In a further embodiment of the process according to the invention, steps (ii) and (iii) are carried out simultaneously.

In einer Ausführungsform des erfindungsgemäßen Verfahrens ist das reaktionsfähige Harz (H) ausgewählt aus der Gruppe umfassend Polyurethanharze, Polyesterharze, Epoxidharze, Phenolharze, Melaminharze, Harnstoffharze, Furanharze, Siliconharze, Vinylharze und Gußpolyamid (aktiviertes Caprolactam). Geeignete Harze werden im Kunststoffhandbuch Band 10, Duroplaste von Becker und Braun, Hanser Verlag , beschrieben.In one embodiment of the process according to the invention, the reactive resin (H) is selected from the group comprising polyurethane resins, polyester resins, epoxy resins, phenolic resins, melamine resins, urea resins, furan resins, silicone resins, vinyl resins and cast polyamide (activated caprolactam). Suitable resins are in the Kunststoffhandbuch Volume 10, thermosets by Becker and Braun, Hanser Verlag , described.

Bevorzugt ist das reaktionsfähige Harz ausgewählt aus der Gruppe umfassend Polyurethanharze, Polyesterharze, Epoxidharze und aktiviertes Caprolactam.Preferably, the reactive resin is selected from the group consisting of polyurethane resins, polyester resins, epoxy resins and activated caprolactam.

In einer Ausführungsform des erfindungsgemäßen Verfahrens ist der Fasern enthaltenden Körper (K) ausgewählt aus Glasfaser- und Kohlefasermatten.In one embodiment of the method according to the invention, the fiber-containing body (K) is selected from fiberglass and carbon fiber mats.

Das erfindungsgemäße Verfahren kann kontinuierlich durchgeführt werden.The process according to the invention can be carried out continuously.

Durch Tränken eines Trägers, bevorzugt eines saugfähigen Trägers, besonders bevorzugt eines offenzelligen Schaumstoffs, wie Basotect®, mit einem Harzsystem (z. B. Polyurethan-, Polyester-, Epoxidharz oder aktiviertes Caprolactam (Gußpolyamid)) lassen sich für begrenzte Zeit auch reaktive Harzsysteme lagern und transportieren. Die flüssigen Harzsysteme müssen dann nicht in das mit Gewebe gefüllte Werkzeug injiziert oder vergossen werden, sondern können durch Einlegen des mit dem Harzsystem getränkten Schaumstoffs in das Werkzeug eingebracht werden. Mit Schließen des beheizten Werkszeugs und Verdichten wird die Struktur des offenzelligen Schaums zerstört, das Harzsystem verteilt sich in der Form und tränkt das Fasermaterial.By impregnating a carrier, preferably an absorbent carrier, particularly preferably an open-cell foam, such as Basotect®, with a resin system (eg polyurethane, polyester, epoxy or activated caprolactam (cast nylon)), reactive resin systems can also be obtained for a limited time store and transport. The liquid resin systems then do not need to be injected or potted into the tissue-filled tool, but can be incorporated into the tool by placing the resin impregnated foam into the mold. Closing the heated tool and compacting destroys the structure of the open cell foam, dispersing the resin system in the mold and soaking the fiber material.

Die verbleibenden Schaumstoffteile verstärken in einer bevorzugten Ausführungsform die Struktur des Bauteils und tragen bevorzugt, weil unbrennbar, zum Flammschutz bei.The remaining foam parts reinforce the structure of the component in a preferred embodiment and preferably, because they are non-combustible, contribute to flame retardancy.

Durch das örtliche Trennen von Infusion und Aushärtung erhöht sich die Zykluszeit des Werkzeuges, was einen bedeutenden wirtschaftlichen Vorteil darstellt.The local separation of infusion and curing increases the cycle time of the tool, which represents a significant economic advantage.

Die Tränkung des Trägermaterials kann bei niedrigerer Temperatur als im Werkzeug stattfinden, dadurch erhöht sich die Topfzeit des Harzsystems und es können auch sehr reaktive Systeme eingesetzt werden.The impregnation of the carrier material can take place at a lower temperature than in the tool, thereby increasing the pot life of the resin system and very reactive systems can also be used.

Beim „klassischen” RTM-Prozess können nur niedrigviskose Komponenten zum Einsatz kommen, beim vorgeschlagenen Verfahren können auch höher viskose Harze, Härter oder Additive zum Einsatz kommen, da sich der erforderliche Fließweg des Harzsystems im Bauteil sich auf wenige Millimeter beschränkt.In the "classical" RTM process, only low-viscosity components can be used; in the proposed process, higher-viscosity resins, hardeners or additives can also be used, since the required flow path of the resin system in the component is limited to a few millimeters.

Ein Verschieben der textilen Strukturen ist durch das vorgeschlagene Verfahren ausgeschlossen, weil keine Flüssigharze mit hohem Druck durch die Fasern gedrückt werden.Movement of the textile structures is precluded by the proposed method because no liquid resins are forced through the fibers at high pressure.

Ein weiterer Gegenstand der vorliegenden Erfindung ist auch ein Verbundwerkstoff, herstellbar nach dem erfindungsgemäßen Verfahren; ein weiterer Gegenstand der vorliegenden Erfindung ist zudem die Verwendung eines nach dem erfindungsgemäßen Verfahrens herstellbaren Verbundwerkstoffs zur Herstellung von Verbundbauteilen zur Verwendung im Transportwesen, zum Beispiel im Automobilbau.A further subject of the present invention is also a composite material which can be produced by the process according to the invention; Another object of the present invention is also the use of a producible by the process according to the invention composite material for the production of composite components for use in transportation, for example in the automotive industry.

BeispieleExamples

Nachfolgend werden einige Beispiele angeführt, die einige Aspekte der Erfindung verdeutlichen sollen. Keinesfalls soll dadurch die Erfindung in ihrem Umfang eingeschränkt werden.The following are some examples that are intended to illustrate some aspects of the invention. In no way should the invention be limited in scope.

Vergleich:Comparison:

In eine Stahlform der Größe: 200 × 50 × 2 mm3 wurden 5 Glasfasermatten (Fa. Interglas Style 92146 (90/10) FK800) eingelegt. Bei einer Formtemperatur von etwa 100°C wurde dann gravimetrisch und unter Zuhilfenahme eines leichten Vakuums ein Epoxidharzsystem der BASF (Baxxores® 2200, Baxxodur® ECX 2110) eingeführt.In a steel mold of the size: 200 × 50 × 2 mm 3 , 5 glass fiber mats (Fa. Interglas Style 92146 (90/10) FK800) were inserted. At a mold temperature of about 100 ° C an epoxy resin of BASF (Baxxores ® 2200 Baxxodur ® ECX 2110) was then introduced gravimetrically and with the aid of a slight vacuum.

Der Versuch wurde mehrmals wiederholt. Es gelang nicht, mit den vorhandenen Mitteln die Glasfasermatten vollständig zu durchdringen.The experiment was repeated several times. It was not possible to completely penetrate the glass fiber mats with the means available.

Erfindungsgemäßes Beispiel:Inventive example:

Eine 4 mm dicke Schaumstoffmatte aus Basotect® wurde mittels einer Rakel mit Epoxidharz gleichmäßig durchtränkt. Dabei lag die Harzaufnahme bei etwa 2 kg/m2 Schaumstoffmatte.A 4 mm thick foam mat made of Basotect ® was evenly impregnated with epoxy resin using a squeegee. The resin absorption was about 2 kg / m 2 foam mat.

Ein entsprechend großes Stück der getränkten Basotect®-Platte (200 × 50 × 2 mm3) wurde zusammen mit den 5 Glasfasermatten in das offene Werkzeug eingelegt, das Werkzeug geschlossen und evakuiert. Dabei war es von Vorteil, den Basotect®-Schaum zwischen die Matten zu legen und nicht auf die Außenseiten. Es gelang, gute Teile zu fertigen.An appropriately sized piece of the soaked Basotect ® panel (200 × 50 × 2 mm 3) was placed together with the glass fiber mats 5 in the open mold, the mold is closed and evacuated. It was an advantage to place the Basotect ® foam between the mats and not on the outsides. It succeeded in producing good parts.

ZITATE ENTHALTEN IN DER BESCHREIBUNG QUOTES INCLUDE IN THE DESCRIPTION

Diese Liste der vom Anmelder aufgeführten Dokumente wurde automatisiert erzeugt und ist ausschließlich zur besseren Information des Lesers aufgenommen. Die Liste ist nicht Bestandteil der deutschen Patent- bzw. Gebrauchsmusteranmeldung. Das DPMA übernimmt keinerlei Haftung für etwaige Fehler oder Auslassungen.This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Zitierte PatentliteraturCited patent literature

  • WO 2009/077616 [0004] WO 2009/077616 [0004]

Zitierte Nicht-PatentliteraturCited non-patent literature

  • „Faserverbundwerkstoffe” von Gottfried Ehrenstein, Hanser Verlag, auf den Seiten 165 und 166 [0003] "Fiber Composites" by Gottfried Ehrenstein, Hanser Verlag, on pages 165 and 166 [0003]
  • Arnim Kraatz, Dissertation 2007, Universität Halle [0016] Arnim Kraatz, Dissertation 2007, University of Halle [0016]
  • Band 10, Duroplaste von Becker und Braun, Hanser Verlag [0029] Volume 10, thermosets by Becker and Braun, Hanser Verlag [0029]

Claims (12)

Verfahren zur Herstellung von Verbundwerkstoffen, mit den folgenden Schritten: (i) Tränken eines Trägers (T) mit mindestens einem reaktionsfähigen Harz (H), (ii) Einbringen des mit mindestens einem reaktionsfähigen Harz getränkten Trägers in ein Werkzeug (W), (iii) Einbringen mindestens eines Fasern enthaltenden Körpers (K) in das Werkzeug (W), (iv) Aushärten des mindestens einen reaktionsfähigen Harzes im Werkzeug.Process for the production of composites, comprising the following steps: (i) impregnating a support (T) with at least one reactive resin (H), (ii) introducing the support impregnated with at least one reactive resin into a tool (W), (iii ) Introducing at least one fiber-containing body (K) into the tool (W), (iv) curing the at least one reactive resin in the tool. Verfahren zur Herstellung von Verbundwerkstoffen gemäß Anspruch 1, wobei Schritt (ii) vor Schritt (iii) durchgeführt wird.A method of producing composite materials according to claim 1, wherein step (ii) is performed prior to step (iii). Verfahren zur Herstellung von Verbundwerkstoffen gemäß Anspruch 1, wobei Schritt (iii) vor Schritt (ii) durchgeführt wird.A method of producing composite materials according to claim 1, wherein step (iii) is performed prior to step (ii). Verfahren zur Herstellung von Verbundwerkstoffen gemäß Anspruch 1, wobei Schritt (iii) jeweils vor und nach Schritt (ii) durchgeführt wird.A method of producing composite materials according to claim 1, wherein step (iii) is carried out before and after step (ii), respectively. Verfahren zur Herstellung von Verbundwerkstoffen gemäß Anspruch 1, wobei die Schritte (ii) und (iii) gleichzeitig durchgeführt werden.A method of producing composite materials according to claim 1, wherein steps (ii) and (iii) are carried out simultaneously. Verfahren zur Herstellung von Verbundwerkstoffen gemäß einem der Ansprüche 1 bis 5, wobei der Träger (T) ausgewählt ist aus der Gruppe umfassend Gewebe (Prepreg), Vliese, offenzellige Schaumstoffe.A process for producing composite materials according to any one of claims 1 to 5, wherein the support (T) is selected from the group consisting of fabric (prepreg), nonwovens, open-cell foams. Verfahren zur Herstellung von Verbundwerkstoffen gemäß einem der Ansprüche 1 bis 6, wobei der Träger (T) ausgewählt ist aus offenzelligen Schaumstoffen.Process for the production of composites according to one of claims 1 to 6, wherein the support (T) is selected from open-cell foams. Verfahren zur Herstellung von Verbundwerkstoffen gemäß einem der Ansprüche 1 bis 7, wobei der Träger (T) ein offenzelliger Schaumstoff auf Basis von Melaminharz ist.A process for producing composite materials according to any one of claims 1 to 7, wherein the support (T) is an open-celled foam based on melamine resin. Verfahren zur Herstellung von Verbundwerkstoffen gemäß einem der Ansprüche 1 bis 8, wobei das reaktionsfähige Harz (H) ausgewählt ist aus der Gruppe umfassend Polyurethanharze, Polyesterharze, Epoxidharze und aktiviertes Caprolactam.A process for producing composite materials according to any one of claims 1 to 8, wherein the reactive resin (H) is selected from the group consisting of polyurethane resins, polyester resins, epoxy resins and activated caprolactam. Verfahren zur Herstellung von Verbundwerkstoffen gemäß einem der Ansprüche 1 bis 9, wobei der Fasern enthaltende Körper (K) ausgewählt ist aus Glasfaser- und Kohlefasermatten.A method for producing composite materials according to any one of claims 1 to 9, wherein the fiber-containing body (K) is selected from glass fiber and carbon fiber mats. Verbundwerkstoff, herstellbar nach dem Verfahren eines der Ansprüche 1 bis 10.Composite material producible according to the method of one of claims 1 to 10. Verwendung eines nach dem Verfahren eines der Ansprüche 1 bis 10 herstellbaren Verbundwerkstoffs zur Herstellung von Verbundbauteilen zur Verwendung im Transportwesen.Use of a composite material producible by the process of any of claims 1 to 10 for the manufacture of composite components for use in transportation.
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