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DE19608127B9 - Method for producing a fiber composite component - Google Patents

Method for producing a fiber composite component Download PDF

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Publication number
DE19608127B9
DE19608127B9 DE19608127A DE19608127A DE19608127B9 DE 19608127 B9 DE19608127 B9 DE 19608127B9 DE 19608127 A DE19608127 A DE 19608127A DE 19608127 A DE19608127 A DE 19608127A DE 19608127 B9 DE19608127 B9 DE 19608127B9
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Prior art keywords
fiber
finished
fiber product
semi
semifinished
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DE19608127A
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German (de)
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DE19608127A1 (en
DE19608127C2 (en
Inventor
Klaus Dr. Drechsler
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Mercedes Benz Group AG
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DaimlerChrysler AG
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D65/00—Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for
    • 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
    • B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
    • B29C70/021—Combinations of fibrous reinforcement and non-fibrous material
    • B29C70/023—Combinations of fibrous reinforcement and non-fibrous material with reinforcing inserts
    • 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
    • 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
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
    • 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
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/302—Details of the edges of fibre composites, e.g. edge finishing or means to avoid delamination
    • 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
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/543—Fixing the position or configuration of fibrous reinforcements before or during moulding
    • 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
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/08—Front or rear portions
    • B62D25/14—Dashboards as superstructure sub-units
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/20—Floors or bottom sub-units
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
    • B62D29/041—Understructures

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Composite Materials (AREA)
  • Transportation (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Textile Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Moulding By Coating Moulds (AREA)
  • Reinforced Plastic Materials (AREA)
  • Body Structure For Vehicles (AREA)

Abstract

Verfahren zum Herstellen eines dreidimensional geformten Kraftfahrzeugbodens aus Faserverbund, bestehend aus einer in den Bereichen erhöhter Belastung örtlich verstärkten Grundstruktur aus übereinander liegenden Langfaserlagen, die zu einem Faserhalbzeug miteinander vernäht und anschließend in einem Preßformwerkzeug unter Druck- und Wärmeeinwirkung zum fertigen Faserverbundbauteil konsolidiert werden, dadurch gekennzeichnet, daß die Langfaserlagen (4) im unvertormten Zustand mit örtlichen Verstärkungsteilen (6.5, 6.6) aus nicht-faserverstärktem Material versehen und gemeinsam mit diesen zu einem planaren, integralen Faserhalbzeug (2) vernäht werden und daß das Faserhalbzeug (2) in den Bereichen starker Verformung durch örtliches Vernadeln (10) mit einer Kurzfaserstruktur versehen wird und daß anschließend das Faserhalbzeug als Ganzes in dem Preßformwerkzeug (12) in die dreidimensionale Bauteilgeometrie umgeformt wird.A method for producing a three-dimensionally shaped motor vehicle floor made of fiber composite, consisting of one in the areas of increased stress locally reinforced base structure of superimposed long fiber layers, which are sewn together to form a semi-finished fiber and then consolidated in a press mold under pressure and heat to the finished fiber composite component, characterized in that the long fiber layers (4) are provided in the non-formed state with local reinforcing parts (6.5, 6.6) of non-fiber reinforced material and sewn together to form a planar, integral semifinished fiber product (2) and in that the semifinished fiber product (2) in the regions Deformation by local needling (10) is provided with a short fiber structure and that then the semifinished fiber product as a whole in the press forming tool (12) is formed into the three-dimensional component geometry.

Figure 00000001
Figure 00000001

Description

Die Erfindung bezieht sich auf ein Verfahren zum Herstellen eines dreidimensional geformten Kraftfahrzeugbodens aus Faserverbund, nach dem Oberbegriff des Patentanspruchs 1.The invention relates to a Method for producing a three-dimensionally shaped motor vehicle floor made of fiber composite, according to the preamble of patent claim 1.

Es ist bekannt, ausgedehntere tragende Wandstrukturen, etwa Kraftfahrzeugböden oder ähnliche, dreidimensional geformte Fahrzeugteile, aus Gewichtsgründen aus Langfaserverbundwerkstoff mit örtlichen Verstärkungen in den Bereichen erhöhter Belastung herzustellen, Dabei muß bei der Umformung und Konsolidierung des Faserverbundmaterials darauf geachtet werden, daß die Faserstruktur von festigkeitsmindernden Faserdesorientierungen freigehalten und eine innige Bindung der Faserlagen untereinander und zu den Verstärkungsteilen gewährleistet wird. Um dies sicherzustellen, werden die Langfaserlagen jeweils einzeln oder in dünnen Schichten nacheinander an das Formwerkzeug angeformt und an vorgegebenen Stellen des so entstehenden Faeerlagenaufbaues werden die örtlichen Verstärkungen beigefügt, bevor das Faserlaminat dann unter Wärme- und Druckeinwirkung konsolidiert wird. Eine solche Herstellungsweise ist mit einem so großen Fertigungsaufwand verbunden, daß sie in der Praxis nur in beschränktem Umfang für hochwertige Bauteile in relativ geringen Stückzahlen Verwendung findet, für eine kostengünstige Großserienfertigung aber ungeeignet ist.It is known to have more extensive supporting wall structures, about car floors or similar, three-dimensionally shaped vehicle parts, for reasons of weight Long fiber composite with local reinforcements in the areas of increased It must be during the transformation and consolidation be ensured that the fiber structure of strength-reducing Faserdesorientierungen kept and a intimate bonding of the fiber layers to each other and to the reinforcing parts guaranteed becomes. To ensure this, the long fiber layers are each individually or in thin layers successively formed on the mold and at predetermined locations of the resulting structure will be the local reinforcements accompanied before the fiber laminate is then consolidated under heat and pressure. Such a manufacturing method is with such a large production cost connected that she in practice only in limited Scope for high-quality components are used in relatively small numbers, for one inexpensive Mass production but is unsuitable.

Die DE 41 39 523 A1 beschreibt ein Verfahren, mit dem Bauteile aus faserverstärkten Kunststoffen herstellbar sind, die hochintegral sind, d.h. mit individuellen Profilaussteifungen ausgeführt sind. Es wird ein Vorformling erzeugt, dessen Form bereits der des Hauteils entspricht. Zur Erzeugung eines solchen dreidimensionalen Vorformlings werden die verstärkungsstoffe für Versteifungen mit den Verstärkungsstoffen für die flachen Hauteile vor dem Einbringen in das Formstück vernäht. Dieser dreidimensionale Vorformling ist dann in die Preßform einzubringen, um die Verbundstruktur zu erzeugen.The DE 41 39 523 A1 describes a method by which components made of fiber-reinforced plastics can be produced, which are highly integral, ie are designed with individual profile stiffeners. It is produced a preform whose shape already corresponds to that of the Hauteils. To produce such a three-dimensional preform, the reinforcing materials for stiffeners are sewn to the reinforcements for the flat skins prior to insertion into the molding. This three-dimensional preform is then to be introduced into the mold to produce the composite structure.

Einen solchen Vorformling bereits vor Bearbeitung mit der Preßform in eine maßstabsgetreue, dreidimensionale Gestalt zu bringen, ist aufwendig und erfordert beispielsweise bei einer lagenweisen Lagerung oder einem Transport eine erhöhte Sorgfalt, um Verschiebungen in der Struktur des Vorformlings zu vermeiden. Das erweist sich als äußerst nachteilig.Such a preform already before processing with the mold in a true-to-scale, three-dimensional Taking shape is complicated and requires, for example, at layered storage or transport increased care, to avoid shifts in the structure of the preform. This proves to be extremely disadvantageous.

Aufgabe der Erfindung ist es, das Herstellungsverfahren der eingangs genannten Art so zu gestalten, daß der Fertigungsaufwand wesentlich verringert und dadurch eine kostengünstige Großserienfertigung von räumlich geformten, örtlich verstärkten Langfaserverbundbauteilen ermöglicht wird.The object of the invention is that Manufacturing process of the type mentioned above, that the Manufacturing costs significantly reduced and thereby cost-effective mass production from spatially shaped, local reinforced long fiber composite components allows becomes.

Diese Aufgabe wird erfindungsgemäß durch die Merkmale des Verfahrensanspruchs 1 gelöst.This object is achieved by the Characteristics of method claim 1 solved.

Erfindungsgemäß werden die Langfaserlagen und die örtlichen Verstärkungen vor der räumlichen Verformung in einem ersten Verfahrensschritt durch automatisiertes Vernähen miteinander zu einer integralen planaren Faserstruktur verbunden, die als Faserhalbzeug gehandhabt werden kann. Anschließend wird das Formverhalten des Faserhalbzeugs verbessert, indem es in Bereichen starker Verformung durch örtliches Vernadeln mit einer Kurzfaserstruktur versehen wird und dann in einem weiteren Verfahrensschritt als Ganzes, ähnlich einfach wie bei der spanlosen Kaltverformung von metallischen Blechteilen, maschinell in einem Preßformwerkzeug in die endgültige räumliche Hauteilgeometrie umgeformt und anschließend konsolidiert wird. Dabei wird durch die gegenseitige textile Bindung der einzelnen Faserlagen und örtlichen Verstärkungsteile sichergestellt, daß das entstehende Faserhalbzeug bei der Umformung und Konsolidierung von störenden Faserverschiebungen oder anderen Desorientierungen im Faserlagenaufbau freigehalten wird. Aufgrund des geringen Herstellungsaufwandes und der weitgehenden Automatisierbarkeit eignet sich das erfindungsgemäße Verfahren in hervorragender Weise für eine kostengünstige Großserienfertigung von qualitativ hochwertiger, räumlich geformten Langfaserverbundbauteilen, etwa Bodengruppen im Kraftfahrzeugbau.According to the invention, the long fiber layers and the local ones reinforcements in front of the spatial Deformation in a first step by automated stitch connected together to form an integral planar fiber structure, which can be handled as semi-finished fiber. Subsequently, will the shape behavior of the semifinished fiber product improved by being in areas strong deformation by local Needling is provided with a short fiber structure and then in a further process step as a whole, similar to the simple as in the non-cutting cold forming of metal sheet metal parts, by machine in a press mold in the final spatial Hauteilgeometrie transformed and then consolidated. there becomes due to the mutual textile binding of the individual fiber layers and local reinforcement parts made sure that resulting semi-finished fiber products in the forming and consolidation of disturbing Fiber shifts or other disorientations in fiber layer construction is kept free. Due to the low production costs and the far-reaching automation is the method of the invention in an excellent way for a cost-effective Mass production of high quality, spatially shaped long-fiber composite components, such as floor groups in the automotive industry.

Wahlweise oder zusätzlich können, wie gemäß Anspruch 2 bevorzugt, als örtliche Verstärkungen metallische, durch Vernähen an den Langfasern fixierte Versteifunge- oder Befestigungselemente vorgesehen werden.Optionally or additionally, like according to claim 2 preferred as local reinforcements metallic, by sewing provided on the long fibers stiffening or fasteners become.

Im Rahmen der Erfindung lassen sich sowohl duromere als auch thermoplastische Matrixsysteme verwenden. Entsprechend einer Ausgestaltung nach Anspruch 3 kann das Faserhalbzeug im trockenen Zustand vernäht werden und durch Naßimprägnieren vor dem Einlegen in das Preßformwerkzeug (12) oder im Wege der Herzinjektion innerhalb des Preßformwerkzeugs matrixdurchtränkt werden.Both thermoset and thermoplastic matrix systems can be used within the scope of the invention. According to an embodiment according to claim 3, the semifinished fiber can be sewn in the dry state and by wet impregnation prior to insertion into the compression mold ( 12 ) or matrix-soaked through heart injection within the mold.

Bei Verwendung eines thermoplastischen Matrixsystems hingegen wird dieses dem Faserhalbzeug gemäß Anspruch 4 vorzugsweise vor dem Vernähen in Form von thermoplastischen Faseranteilen zugemischt.When using a thermoplastic matrix system However, this is the semi-finished fiber according to claim 4 preferably before sewing mixed in the form of thermoplastic fiber components.

Im Hinblick auf eine last- und faserverbundgerechte Ausgestaltung wird das Faserhalbzeug ferner nach Anspruch 5 zweckmäßigerweise mit unterschiedlichen Fasersorten und -orientierungen gefertigt.With regard to a load and fiber composite Embodiment, the semifinished fiber product further according to claim 5 expediently manufactured with different fiber types and orientations.

Die Erfindung wird nunmehr anhand eines Ausführungsbeispieles in Verbindung mit den Zeichnungen näher beschrieben. Es zeigen in stark schematisierter Darstellung:The invention will now be apparent from an embodiment in conjunction with the drawings described in more detail. Show it in a highly schematic representation:

1 ein planares, integrales Faserhalbzeug zur Herstellung eines Kraftfahrzeugbodens mit örtlichen Verstärkunggen und abschnittsweise unterschiedlichen Faser-Hauptorientierungen; 1 a planar, integral semi-finished fiber product for producing a motor vehicle floor with local reinforcement gene and sections different fiber main orientations;

2 einen Schnitt längs der Linie II-II der 1 im Bereich einer Aufdoppelung; 2 a section along the line II-II of 1 in the area of a doubling;

3 einen Schnitt längs der Linie III-III der 1 im Bereich eines metallischen Befestigungselements; 3 a section along the line III-III of 1 in the area of a metallic fastener lements;

4 einen Schnitt längs der Linie IV-IV der 1 im Bereich einer Sandwichzone; 4 a section along the line IV-IV of 1 in the area of a sandwich zone;

5 eine Imprägniervorrichtung für das Faserhalbzeug und ein nachgeschaltetes Preßformwerkzeug zum Umformen und Konsolidieren; und 5 an impregnating device for the semi-finished fiber product and a downstream press-forming tool for forming and consolidating; and

6 die Faserverbund-Bodengruppe im fertiggestellten Zustand. 6 the fiber composite flooring group in the finished state.

1 zeigt ein Faserhalbzeug 2 für eine Kraftfahrzeug-Bodengruppe, welches aus einer Vielzahl von eben übereinandergelegten, textilen Gewebezuschnitten 4 aufgebaut ist und eine multiaxiale Faserorientierung besitzt, wobei die einzelnen, in 1 strichpunktiert berandeten Bereiche des Faserhalbzeugs 2 jeweils unterschiedliche Faser-Vorzugsrichtungen haben. So werden für den mittleren Bereich des Faserhalbzeugs 2, der in der fertigen Bodengruppe den Bodentunnel bildet, vorwiegend Gewebelagen mit einer in Längsrichtung unidirektionalen Faserorientierung 4A gewählt, während die seitlichen Randbereiche, die die Schwel ler ergeben, hauptsächlich aus Gewebelagen mit einer sich kreuzenden, zur Längsrichtung des Faserhalbzeugs 2 unter ± 45° geneigten Faserorientierung 4B und die dazwischenliegenden Abschnitte des Faserhalbzeugs 2, also die pedal-, sitz- und koffenaumseitigen Bodenteile des herzustellenden Bauteils, vornehmlich aus Gewebelagen mit einer in Querrichtung unidirektionalen Faserrichtung 4C aufgebaut sind. 1 shows a semi-finished fiber 2 for a motor vehicle floor group, which consists of a plurality of just superimposed, textile fabric blanks 4 is constructed and has a multi-axial fiber orientation, with the individual, in 1 dash-dotted bordered areas of the semifinished fiber product 2 each have different fiber preferential directions. Thus, for the middle region of the semifinished fiber product 2 , which forms the bottom tunnel in the finished floor panel, mainly fabric layers with a longitudinal unidirectional fiber orientation 4A chosen, while the lateral edge regions, which give the Schwel ler, mainly of fabric layers with a crossing, to the longitudinal direction of the semifinished fiber product 2 at ± 45 ° inclined fiber orientation 4B and the intermediate portions of the semifinished fiber product 2 , So the pedal, seat and koffaumaumseitige bottom parts of the component to be produced, primarily from fabric layers with a unidirectional fiber direction in the transverse direction 4C are constructed.

Aus Festigkeits- und Gewichtsgründen sind die Gewebelagen 4 aus Carbonfasern hergestellt, denen in bestimmten Bereichen, wo ein örtlich erhöhtes Elastizitäts- oder Stoßabsorptionsverhalten gefordert wird, Glas- bzw. Aramidfaseranteile zugemischt sind. Bei Verwendung eines thermoplastischen Matrixsystems enthalten die Gewebe 4 ferner thermoplastische Faseranteile in gleichförmiger Verteilung. Kommt hingegen – wie bei dem nachfolgend beschriebenen Ausführungsbeispiel – ein duromeres Matrixsystem zur Anwendung, so wird das Faserhalbzeug 2 aus trockenen Gewebelagen 4 aufgebaut. Statt dessen können gewünschtenfalls aber auch vorimprägnierte Gewebezuschnitte, sog. Prepregs, verwendet werden.For strength and weight reasons, the fabric layers 4 made of carbon fibers mixed with glass or aramid fiber in certain areas where locally increased elasticity or impact absorption is required. When using a thermoplastic matrix system, the tissues contain 4 furthermore, thermoplastic fiber components in a uniform distribution. If, on the other hand, a thermoset matrix system is used, as in the exemplary embodiment described below, then the semifinished fiber product is produced 2 from dry tissue layers 4 built up. Instead, if desired, it is also possible to use preimpregnated fabric blanks, so-called prepregs.

Komplettiert wird das Faserhalbzeug 2 durch örtliche, lastspezifisch gestaltete Verstärkungsteile 6, die an den Stellen erhöhter mechanischer Beanspruchung der Bodengruppe zwischen oder auf den Gewebelagen des Faserhalbzeugs 2 angeordnet werden. So wird das Faserhalbzeug 2 z. B. im Bereich des Sitzbodenteils mit in Längsrichtung rippenförmig verlaufenden Fasergestricken 6.1 zur Erhöhung der lokalen Biegesteifigkeit und am koffenaumseitigen Ende mit textilen Vorformlingen 6.2 zur örtlichen Krafteinleitung belegt, und im Bereich des Pedalbodenteils sind den Gewebelagen Aramidstreifen 6.3 zur Verbesserung des Stoßabsorptions- und Zähigkeitsverhaltens beigefügt, Weiterhin wird die Mittelzone des Faserlagenaufbaues 4 durch eine Aufdoppelung 6.4 aus Faserlagen, die eine quasi-isotrope, in Längsrichtung und unter ± 45° verlaufende Faserorientierung 4D besitzen, örtlich verstärkt (2), und im Bereich des Sitzbodenteils werden im Faserlagenaufbau 4 metallische Anschlußelemente 6.5 für spätere Schraubverbindungen eingebettet (3). Wie für den koffenaumseitigen Abschnitt des Faserhalbzeugs 2 und im einzelnen in 4 dargestellt, können ferner zwischen die Gewebelagen 4 Schaumstoffeinlagen oder Abstandsgewebe 6.6 eingefügt werden, um der fertigen Bodengruppe eine örtliche Sandwichstruktur zu verleihen.The semi-finished fiber product is completed 2 by local, load-specific designed reinforcing parts 6 at the points of increased mechanical stress on the floor group between or on the fabric layers of the semifinished fiber product 2 to be ordered. This is how the semi-finished fiber is made 2 z. B. in the region of the seat bottom part with ribs extending in the longitudinal direction fiber knit 6.1 to increase the local bending stiffness and at the koffaumseitige end with textile preforms 6.2 for the local application of force, and in the area of the pedal floor part the fabric layers are aramid stripes 6.3 attached to improve the impact absorption and toughness behavior, Furthermore, the center zone of the fiber layer structure 4 by a doubling 6.4 fiber layers having a quasi-isotropic, longitudinal and ± 45 ° fiber orientation 4D own, locally strengthened ( 2 ), and in the area of the seat bottom part are in fiber layer structure 4 metallic connection elements 6.5 embedded for future screw connections ( 3 ). As for the koffeaumseitigen section of the semifinished fiber product 2 and in detail in 4 can also be shown between the fabric layers 4 Foam inserts or spacer fabric 6.6 be inserted to give the finished floor assembly a local sandwich structure.

Das so aufgebaute textile Gebilde wird anschließend, wie in 1 durch das Bezugszeichen 8 angedeutet, zusammen mit den örtlichen Verstärkungsteilen 6 maschinell unter Beibehalt der planaren Schichtung zu dem integralen Faserhalbzeug 2 vernäht, wodurch sämtliche Verstärkungsteile 6 und Gewebezuschnitte 4 zueinander und in ihrer Faserorientierung sicher fixiert werden, so daß sich das Faserhalbzeug 2 als Ganzes ohne die Gefahr störender Faserverschiebungen oder anderer Fehlorientierungen problemlos transportieren, lagern und schließlich in die endgültige dreidimensionale Bauteilgeometrie umformen und konsolidieren läßt. Einzelne Verstärkungsteile, wie etwa die metallischen Befestigungselemente 6.5 oder die Abstandsgewebe 6.6 werden natürlich nur randseitig mitvernäht.The textile structure thus constructed is then, as in 1 by the reference numeral 8th indicated, together with the local reinforcing parts 6 machining while maintaining the planar lamination to the integral semifinished fiber product 2 sewn, causing all reinforcing parts 6 and tissue blanks 4 be securely fixed to each other and in their fiber orientation, so that the semi-finished fiber 2 as a whole without the risk of disturbing fiber shifts or other misalignments easily transport, store and finally reshape into the final three-dimensional component geometry and consolidate. Individual reinforcement parts, such as the metallic fasteners 6.5 or the spacer fabrics 6.6 Of course, they are only stitched together at the edges.

In einem Zwischenschritt wird das Faserhalbzeug 2 noch an den Stellen stärkerer räumlicher Formänderung vernadelt, so daß die Langfaserlagen örtlich eine Kurzfaserstruktur erhalten, wie dies in 1 durch die Vernadelungszonen 10 angedeutet ist.In an intermediate step, the semi-finished fiber is 2 even at the points of stronger spatial shape change needled, so that the long fiber layers locally get a short fiber structure, as in 1 through the needling zones 10 is indicated.

Das duromere Matrixsystem wird dem Faserhalbzeug 2 entweder im Wege der Harzinjektion innerhalb des Preßformwerkzeugs 12 (5) oder aber an einer diesem vorgeschalteten Imprägnierstation 14 zugegeben, wo das Faserhalbzeug 2 beidseitig mit einer über Preßwalzen 16 angedrückten Harzfolie 18 belegt und/oder mittels einer Sprühvorrichtung 20 mit Flüssigharz imprägniert wird, bevor es als Ganzes in das Preßformwerkzeug 12 eingelegt und beim Schließen desselben in die räumliche Bauteilgeometrie umgeformt und dann unter Druck- und Wärmeeinwirkung konsolidiert wird.The thermosetting matrix system becomes the semifinished fiber product 2 either by way of resin injection within the press mold 12 ( 5 ) or on an impregnating station upstream of this 14 added where the semi-finished fiber 2 on both sides with a press rolls over 16 pressed-on resin film 18 occupied and / or by means of a spray device 20 is impregnated with liquid resin before it as a whole in the press mold 12 is inserted and reshaped when closing it in the spatial component geometry and then consolidated under pressure and heat.

In 6 ist die auf diese Weise fertiggestellte Kraftfahrzeug-Bodengruppe mit Abgastunnel 22, Schwellern 24, Pedalboden 26, Sitzboden 28 und kofferraumseitiger Abschlußwand 30 einschließlich der örtlichen Verstärkungsteile 6 und der entsprechenden Faser-Vorzugsrichtungen dargestellt.In 6 is the completed in this way motor vehicle floor assembly with exhaust tunnel 22 Swells 24 , Pedal floor 26 , Seat bottom 28 and trunk side end wall 30 including the local reinforcement parts 6 and the corresponding fiber preferred directions.

Claims (5)

Verfahren zum Herstellen eines dreidimensional geformten Kraftfahrzeugbodens aus Faserverbund, bestehend aus einer in den Bereichen erhöhter Belastung örtlich verstärkten Grundstruktur aus übereinander liegenden Langfaserlagen, die zu einem Faserhalbzeug miteinander vernäht und anschließend in einem Preßformwerkzeug unter Druck- und Wärmeeinwirkung zum fertigen Faserverbundbauteil konsolidiert werden, dadurch gekennzeichnet, daß die Langfaserlagen (4) im unvertormten Zustand mit örtlichen Verstärkungsteilen (6.5, 6.6) aus nicht-faserverstärktem Material versehen und gemeinsam mit diesen zu einem planaren, integralen Faserhalbzeug (2) vernäht werden und daß das Faserhalbzeug (2) in den Bereichen starker Verformung durch örtliches Vernadeln (10) mit einer Kurzfaserstruktur versehen wird und daß anschließend das Faserhalbzeug als Ganzes in dem Preßformwerkzeug (12) in die dreidimensionale Bauteilgeometrie umgeformt wird.A method for producing a three-dimensionally shaped motor vehicle floor made of fiber composite, consisting of a locally reinforced in the areas of increased stress basic structure of superimposed long fiber layers sewn together to form a semi-finished fiber product and then ßend be consolidated in a press mold under pressure and heat to the finished fiber composite component, characterized in that the long fiber layers ( 4 ) in the non-deformed state with local reinforcing parts ( 6.5 . 6.6 ) made of non-fiber-reinforced material and together with these to form a planar, integral semifinished fiber product ( 2 ) and that the semifinished fiber product ( 2 ) in the areas of severe deformation by local needling ( 10 ) is provided with a short fiber structure and that subsequently the semifinished fiber product as a whole in the compression molding tool ( 12 ) is converted into the three-dimensional component geometry. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß als örtliche Verstärkungen metallische, durch Vernähen an den Langfaserlagen (4) fixierte Versteifungs- oder Befestigungselemente (6.5) vorgesehen werden.Process according to Claim 1, characterized in that metallic reinforcements, as by local stitching, are applied to the long fiber layers ( 4 ) fixed stiffening or fastening elements ( 6.5 ). Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, daß das Faserhalbzeug (2) im trockenen Zustand vernäht und durch Naßimprägnieren vor dem Einlegen in das Preßformwerkzeug (12) oder im Wege der Harzinjektion innerhalb des Preßformwerkzeugs matrixdurchtränkt wird.Method according to claim 1 or 2, characterized in that the semi-finished fiber product ( 2 ) sewn in the dry state and by wet impregnation prior to insertion into the press mold ( 12 ) or matrix impregnated in the way of the resin injection inside the press-forming tool. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, daß das Faserhalbzeug (2) als Matrix thermoplastische Faseranteile enthält.Method according to claim 1 or 2, characterized in that the semi-finished fiber product ( 2 ) contains as a matrix thermoplastic fiber components. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, daß das Faserhalbzeug (2) mit unterschiedlichen Fasersorten und -orientierungen gefertigt wird.Method according to one of the preceding claims, characterized in that the semi-finished fiber product ( 2 ) is manufactured with different fiber types and orientations.
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