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DE102013203207B4 - Assembly of two fiber composite components and method for their manufacture as well as repair method for damaged fiber composite components - Google Patents

Assembly of two fiber composite components and method for their manufacture as well as repair method for damaged fiber composite components Download PDF

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Publication number
DE102013203207B4
DE102013203207B4 DE102013203207.2A DE102013203207A DE102013203207B4 DE 102013203207 B4 DE102013203207 B4 DE 102013203207B4 DE 102013203207 A DE102013203207 A DE 102013203207A DE 102013203207 B4 DE102013203207 B4 DE 102013203207B4
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Prior art keywords
fiber composite
composite components
fiber
components
carbon fibers
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DE102013203207A1 (en
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Clemens Stefanziosa
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Bayerische Motoren Werke AG
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Bayerische Motoren Werke AG
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5007Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like
    • B29C65/5014Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like being fibre-reinforced
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/40Applying molten plastics, e.g. hot melt
    • B29C65/42Applying molten plastics, e.g. hot melt between pre-assembled parts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/481Non-reactive adhesives, e.g. physically hardening adhesives
    • B29C65/4815Hot melt adhesives, e.g. thermoplastic adhesives
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4865Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding containing additives
    • B29C65/487Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding containing additives characterised by their shape, e.g. being fibres or being spherical
    • B29C65/488Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding containing additives characterised by their shape, e.g. being fibres or being spherical being longitudinal, e.g. fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5042Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like covering both elements to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/03After-treatments in the joint area
    • B29C66/038Covering the joint by a coating material
    • B29C66/0384Covering the joint by a coating material the coating material being in tape, strip or band form
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114Single butt joints
    • B29C66/1142Single butt to butt joints
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43Joining a relatively small portion of the surface of said articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General 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
    • B29C66/72General 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 characterised by the structure of the material of the parts to be joined
    • B29C66/721Fibre-reinforced materials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General 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
    • B29C66/73General 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 characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739General 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 characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392General 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 characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921General 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 characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/04Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/24Apparatus or accessories not otherwise provided for
    • B29C73/26Apparatus or accessories not otherwise provided for for mechanical pretreatment
    • B29C2073/264Apparatus or accessories not otherwise provided for for mechanical pretreatment for cutting out or grooving the area to be repaired
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/122Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
    • B29C66/1224Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a butt joint-segment
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/122Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
    • B29C66/1226Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least one bevelled joint-segment
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General 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
    • B29C66/71General 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 characterised by the composition of the plastics material of the parts to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/24Apparatus or accessories not otherwise provided for
    • B29C73/26Apparatus or accessories not otherwise provided for for mechanical pretreatment
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING 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
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Reinforced Plastic Materials (AREA)

Abstract

Baugruppe (10) aus zwei Faserbundbauteilen (11, 12), wobei jedes Faserverbundbauteil (11, 12) Verstärkungsfasern aufweist, die in einer Matrix aus thermoplastischem Material eingebettet sind, und die Faserverbundbauteile (11, 12) so zueinander positioniert sind, dass ein stirnseitiger Endbereich eines Faserverbundbauteils (11, 12) einem stirnseitigen Endbereichen eines anderen Faserverbundbauteils (11, 12) gegenübersteht, wobei die Faserverbundbauteile (11, 12) an diesen stirnseitigen Endbereichen miteinander verschweißt sind, wobei in dem Verbindungsbereich der Faserverbundbauteile (11, 12) mindestens eine Verstärkung vorgesehen ist, dadurch gekennzeichnet, dass die Verstärkung als eine Stoßschweißnaht (14) ausgebildet ist, mit einem kurzfaserverstärktem Granulat als Schweißzusatz, wobei das Granulat aus einem thermoplastischen Material, insbesondere aus Polyamid-6 (PA6), Polyamid-66 (PA66), Polyetherimid (PEI), Polyetherketon (PEEK) und/oder Polyphenylensulfid (PPS) mit 10 bis 50 Gew.-% Kohlenstofffasern, bevorzugt 20 bis 40 Gew.-% Kohlenstofffasern und besonders bevorzugt 30 Gew.-% Kohlenstofffasern ausgebildet ist.

Figure DE102013203207B4_0000
Assembly (10) made of two fiber composite components (11, 12), each fiber composite component (11, 12) having reinforcing fibers embedded in a matrix of thermoplastic material, and the fiber composite components (11, 12) being positioned relative to one another in such a way that a front end region of a fiber composite component (11, 12) faces a front end region of another fiber composite component (11, 12), the fiber composite components (11, 12) being welded to one another at these front end regions, at least one reinforcement being provided in the connecting region of the fiber composite components (11, 12), characterized in that the reinforcement is designed as a butt weld seam (14), with a short fiber reinforced granulate as a welding additive, the granulate being made of a thermoplastic material, in particular of polyamide-6 (PA6), polyamide-66 (PA66), polyetherimide (PEI), polyether ketone (PEEK) and/or polyphenylene sulfide (PPS) with 10 to 50 wt.% carbon fibers, preferably 20 to 40 wt.% carbon fibers and particularly preferably 30 wt.% carbon fibers.
Figure DE102013203207B4_0000

Description

Die vorliegende Erfindung betrifft eine Baugruppe aus zwei Faserverbundbauteilen, wobei jedes der Faserverbundbauteile Verstärkungsfasern aufweist, die in einer Matrix eingebettet sind. Darüber hinaus betrifft die Erfindung ein Verfahren zur Herstellung einer solchen Baugruppe sowie ein Reparaturverfahren zur Instandsetzung beschädigter Faserverbundbauteile.The present invention relates to an assembly of two fiber composite components, each of the fiber composite components having reinforcing fibers embedded in a matrix. Furthermore, the invention relates to a method for producing such an assembly and a repair method for repairing damaged fiber composite components.

Zur Schaffung eines nachhaltigen Umgangs mit Energieressourcen ist man im heutigen Fahrzeugbau bestrebt, Leichtbaustrukturen zu verwenden. Hierzu eignen sich kunstfaserverstärkte Kunststoffe, da sie besonders hohe mechanische Eigenschaften aufweisen bei gleichzeitig niedrigem Gewicht. Somit kann der Fahrzeugverbrauch reduziert werden. Im Gegensatz zu bekannten Strukturbauteilen aus Metall, bei denen eine Vielzahl unterschiedlicher Fügeverfahren bekannt sind, kommt zum Fügen von Kunststoffbauteilen bzw. faserverstärkten Kunststoffbauteilen im Allgemeinen nur die Klebetechnik zur Anwendung. Insbesondere wenn faserverstärkte Strukturbauteile beschädigt werden und ersetzt oder repariert werden müssen, sind komplizierte Reparaturverfahren notwendig, die mit hohem Aufwand verbunden sind. Bislang werden die schadhaften Abschnitte herausgetrennt und durch neue Strukturelemente ersetzt. Die neuen Bauteile werden an die bestehende faserverstärkte Struktur über Kupplungselemente angebunden und so überlappend miteinander verklebt. Zur Positionierung des Ersatzbauteils sowie zur Justierung des Klebespalts werden Spannelemente verwendet.In order to ensure sustainable use of energy resources, today's vehicle construction is striving to use lightweight structures. Synthetic fiber-reinforced plastics are suitable for this because they have particularly high mechanical properties and are lightweight at the same time. This can reduce vehicle consumption. In contrast to known structural components made of metal, for which a large number of different joining methods are known, only adhesive technology is generally used to join plastic components or fiber-reinforced plastic components. In particular, when fiber-reinforced structural components are damaged and need to be replaced or repaired, complicated repair processes are necessary that involve a lot of effort. Up to now, the damaged sections have been cut out and replaced with new structural elements. The new components are connected to the existing fiber-reinforced structure using coupling elements and thus glued together in an overlapping manner. Clamping elements are used to position the replacement component and to adjust the adhesive gap.

Solche Überlappverbindungen benötigen je nach Ausführung zusätzlichen Bauraum, der zu Package-Problemen führen kann. Insbesondere bei der Verwendung dünnwandiger Bauteile, die eine Faserverstärkung besitzen, tritt das Problem auf, dass die Faserverstärkung an der Trennstelle unterbrochen ist und dadurch das gesamte Bauteil geringere mechanische Eigenschaften aufweist.Depending on the design, such overlap joints require additional installation space, which can lead to packaging problems. Particularly when using thin-walled components that have fiber reinforcement, the problem arises that the fiber reinforcement is interrupted at the separation point and the entire component therefore has lower mechanical properties.

Aus der WO 2010/130438A1 ist ein Verfahren zum Fügen von Bauteilen bekannt, die wenigstens teilweise aus thermoplastischem Material bestehen und von denen wenigstens eines langfaserverstärkt ist, wobei die Bauteile in einer Fügezone miteinander verschweißt werden.From the WO 2010/130438A1 A method is known for joining components which consist at least partially of thermoplastic material and at least one of which is long fiber reinforced, wherein the components are welded together in a joining zone.

Die DE 10 2010 025 618 A1 zeigt eine Verbindungsanordnung eines faserverstärkten Verbundbauteils mit einem weiteren, zumindest teilweise metallischen Bauteil, bei welcher das Verbundbauteil wenigstens eine metallische, in eine Kunststoffmatrix eingebettete Verstärkungsfaser aufweist, welche über einen Endbereich des Verbundbauteils hinausragt, wobei die wenigstens eine metallische Verstärkungsfaser stoffschlüssig mit dem weiteren Bauteil verbun-den, insbesondere verschweißt oder verlötet ist.The DE 10 2010 025 618 A1 shows a connection arrangement of a fiber-reinforced composite component with a further, at least partially metallic component, in which the composite component has at least one metallic reinforcing fiber embedded in a plastic matrix, which protrudes beyond an end region of the composite component, wherein the at least one metallic reinforcing fiber is integrally connected to the further component, in particular welded or soldered.

Ausgehend von diesem Stand der Technik macht es sich die vorliegende Erfindung zur Aufgabe, eine Baugruppe und ein Verfahren anzugeben, mit dem die Nachteile des Standes der Technik überwunden werden. Ferner ist es Aufgabe der Erfindung, ein Reparaturverfahren für faserverstärkte Kunststoffbauteile anzugeben, mit dem Baugruppen realisierbar sind, die an der Reparaturstelle hohe mechanische Eigenschaften aufweisen.Based on this prior art, the present invention aims to provide an assembly and a method with which the disadvantages of the prior art are overcome. Furthermore, the invention aims to provide a repair method for fiber-reinforced plastic components with which assemblies can be produced that have high mechanical properties at the repair site.

Diese Aufgabe wird durch eine Baugruppe und ein Verfahren mit den Merkmalen der unabhängigen Ansprüche gelöst. Die abhängigen Ansprüche stellen vorteilhafte Ausführungsformen der Erfindung dar.This object is achieved by an assembly and a method having the features of the independent claims. The dependent claims represent advantageous embodiments of the invention.

Zur Lösung dieser Aufgabe schlägt die Erfindung eine Baugruppe aus zwei Faserverbundbauteilen vor, wobei jedes Faserverbundbauteil Verstärkungsfasern aufweist, die in einer Matrix aus thermoplastischem Material eingebettet sind und wobei die Faserverbundbauteile so zueinander positioniert sind, dass ein stirnseitiger Endbereich eines Faserverbundbauteils einem stirnseitigen Endbereich eines anderen Faserverbundbauteils gegenübersteht. Die Faserverbundbauteile sind somit auf Stoß zueinander ausgerichtet und werden an diesen stirnseitigen Endbereichen miteinander verschweißt. Zudem kann in dem Verbindungsbereich, d.h. an der Stoßstelle der zwei Faserverbundbauteile, mindestens eine Verstärkung vorgesehen sein. Dies bietet den Vorteil, dass die lokale Schwächung der Baugruppe in diesem Bereich ausgeglichen wird.To solve this problem, the invention proposes an assembly of two fiber composite components, each fiber composite component having reinforcing fibers embedded in a matrix of thermoplastic material and the fiber composite components being positioned relative to one another such that a front end region of one fiber composite component faces a front end region of another fiber composite component. The fiber composite components are thus aligned abutting against one another and are welded together at these front end regions. In addition, at least one reinforcement can be provided in the connection region, i.e. at the joint between the two fiber composite components. This offers the advantage that the local weakening of the assembly in this region is compensated.

Die Verstärkung kann als ein Band ausgebildet sein, das mit jedem der Faserverbundbauteile in berührendem Kontakt steht und diese miteinander verbindet.The reinforcement can be designed as a band that is in touching contact with each of the fiber composite components and connects them to one another.

Zusätzlich kann das Band aus faserverstärktem Kunststoff ausgebildet sein mit einer thermoplastischen Matrix. Dabei können die Fasern unidirektional in der thermoplastischen Matrix ausgerichtet sein. Dies bietet den Vorteil, dass durch die thermoplastische Matrix eine besonders gute, stoffschlüssige Verbindung beim Schweißen des Bandes mit den beiden Faserverbundbauteilen eingeht.In addition, the band can be made of fiber-reinforced plastic with a thermoplastic matrix. The fibers can be aligned unidirectionally in the thermoplastic matrix. This offers the advantage that the thermoplastic matrix creates a particularly good, material-tight bond when the band is welded to the two fiber composite components.

In einer weiteren Alternative kann auf jeder Seite der Bauteilgruppe ein Band angeordnet sein. Sofern eine beidseitige Zugänglichkeit an der Schweißnaht gewährleistet ist, kann dadurch auf beiden Seiten der Schweißnaht ein Band aufgebracht werden, um eine besonders feste Bauteilverbindung zu realisieren.In a further alternative, a band can be arranged on each side of the component group. If accessibility to the weld seam is guaranteed from both sides, a band can be applied to both sides of the weld seam in order to achieve a particularly strong component connection.

Zusätzlich oder alternativ dazu kann die Verstärkung als eine Stoßschweißnaht ausgebildet sein mit einem kurzfaserverstärkten Granulat als Schweißzusatz, wobei das Granulat aus einem thermoplastischen Material, insbesondere aus Polyamid-6 (PA6), Polyamid-66 (PA66), Polyetherimid (PEI), Polyetherketon (PEEK) und/oder Polyphenylensulfid (PPS) mit 10 bis 50 Gew.-% Kohlenstofffasern, bevorzugt 20 bis 40 Gew.-% Kohlenstofffasern und besonders bevorzugt 30 Gew.-% Kohlenstofffasern ausgebildet ist. Gegenüber reinem Thermoplast-Schweißdraht bietet kurzfaserverstärktes Granulat den Vorteil, dass die Fügestelle höhere mechanische Eigenschaften liefert.Additionally or alternatively, the reinforcement can be designed as a butt weld seam with a short fiber-reinforced granulate as a welding additive, wherein the granulate is made of a thermoplastic material, in particular polyamide-6 (PA6), polyamide-66 (PA66), polyetherimide (PEI), polyetherketone (PEEK) and/or polyphenylene sulfide (PPS) with 10 to 50 wt.% carbon fibers, preferably 20 to 40 wt.% carbon fibers and particularly preferably 30 wt.% carbon fibers. Compared to pure thermoplastic welding wire, short fiber-reinforced granulate offers the advantage that the joint provides higher mechanical properties.

Darüber hinaus kann die Stoßschweißnaht eine V-förmige Querschnittsform aufweisen und in ihrem oberen Bereich mit einem Edelstahlgewebe verstärkt sein.In addition, the butt weld seam can have a V-shaped cross-section and be reinforced with a stainless steel mesh in its upper area.

In einem weiteren Aspekt betrifft die Erfindung ein Verfahren zum Herstellen einer Baugruppe aus zwei Faserverbundbauteilen, wobei jedes Faserverbundbauteil Verstärkungsfasern aufweist, die in einer Matrix aus thermoplastischem Material eingebettet sind, mit den folgenden Schritten:

  • - Ausrichten der zwei Faserverbundbauteile zueinander, so dass ein stirnseitiger Endbereich eines Faserverbundbauteils einem stirnseitigen Endbereich des anderen Faserverbundbauteils gegenübersteht,
  • - Erzeugen einer Schweißverbindung im Stoßbereich der beiden Faserverbundbauteile, wobei im Stoßbereich eine Verstärkung vorgesehen wird. Dies bietet den Vorteil, dass die Stoßverbindung gegenüber Überlappverbindungen eine geringe Bauraumhöhe benötigt.
In a further aspect, the invention relates to a method for producing an assembly from two fiber composite components, each fiber composite component having reinforcing fibers embedded in a matrix of thermoplastic material, comprising the following steps:
  • - Aligning the two fiber composite components to each other so that a front end region of one fiber composite component is opposite a front end region of the other fiber composite component,
  • - Creating a welded joint in the joint area of the two fiber composite components, with reinforcement being provided in the joint area. This offers the advantage that the joint requires a lower installation space than overlap joints.

Weiterhin kann ein Band aus faserverstärktem Kunststoff auf die Faserverbundbauteile aufgebracht werden, so dass es mit beiden Faserverbundbauteilen in berührendem Kontakt steht.Furthermore, a band made of fiber-reinforced plastic can be applied to the fiber composite components so that it is in touching contact with both fiber composite components.

Darüber hinaus kann das Band derart aufgebracht werden, dass es sich über den Stoßbereich hinweg über beide Faserverbundbauteile erstreckt und damit beider Faserverbundbauteile zumindest teilweise überlappt.In addition, the tape can be applied in such a way that it extends across the joint area over both fiber composite components and thus at least partially overlaps both fiber composite components.

In einem weiteren Aspekt betrifft die Erfindung ein Reparaturverfahren für beschädigte Faserverbundbauteile mit den Schritten:

  • - Heraustrennen einer beschädigten Stelle aus dem Faserverbundbauteil,
  • - Einbringen eines zweiten Faserverbundbauteils als Ersatzbauteil an die beschädigte Stelle des ersten Faserverbundbauteils, und
  • - Erzeugen einer Baugruppe durch Verbindung der beiden Faserverbundbauteile mit einem oben beschriebenen Verfahren.
In a further aspect, the invention relates to a repair method for damaged fiber composite components comprising the steps:
  • - Separating a damaged area from the fiber composite component,
  • - Inserting a second fibre composite component as a replacement component at the damaged location of the first fibre composite component, and
  • - Creating an assembly by joining the two fiber composite components using a method described above.

Bei den im Vorhergehenden beschriebenen Faserverbundbauteilen können die Fasern als Kurzfaser mit einer Gesamtläng bis zu 20mm, als Langfaser mit einer Länge von 20mm bis 50mm oder als Endlosfaser mit einer Gesamtlänge größer 50mm ausgebildet sein.In the fiber composite components described above, the fibers can be designed as short fibers with a total length of up to 20 mm, as long fibers with a length of 20 mm to 50 mm or as continuous fibers with a total length greater than 50 mm.

Im Folgenden wird die Erfindung anhand der Figurenbeschreibung näher erläutert. Die Ansprüche, die Figuren und die Beschreibung enthalten eine Vielzahl von Merkmalen, die im Folgenden im Zusammenhang mit beispielhaft beschriebenen Ausführungsformen der vorliegenden Erfindung erläutert werden. Der Fachmann wird diese Merkmale auch einzeln und in anderen Kombinationen betrachten, um weitere Ausführungsformen zu bilden, die an entsprechende Anwendungen der Erfindung angepasst sind.The invention is explained in more detail below with reference to the description of the figures. The claims, the figures and the description contain a large number of features which are explained below in connection with embodiments of the present invention described by way of example. The person skilled in the art will also consider these features individually and in other combinations in order to form further embodiments which are adapted to corresponding applications of the invention.

Es zeigt in schematischer Darstellung

  • 1 eine Seitenansicht auf eine Verbindungsstelle zwischen zwei Faserverbundbauteilen.
It shows in schematic representation
  • 1 a side view of a connection point between two fiber composite components.

1 zeigt eine Baugruppe 10, bei der zwei Faserverbundbauteile 11 und 12 miteinander gefügt sind, um die Baugruppe 10 zu bilden. Jedes Bauteil 11, 12 weist einen stirnseitigen Endbereich auf. Dieser Endbereich ist in Längsrichtung am Ende des Bauteils angeordnet und weist eine im Wesentlichen senkrecht zur Längsachse des Bauteils ausgerichtete Oberfläche auf. Die Bauteile 11, 12 sind zum Fügen so zueinander ausgerichtet, dass diese Endbereiche einander gegenüber liegen. Dadurch kann ein Fügen der Bauteile 11, 12 auf Stoß erfolgen. In dem Stoßbereich 13 werden die Bauteile mit Hilfe einer Stoßschweißnaht miteinander verschweißt. 1 shows an assembly 10 in which two fiber composite components 11 and 12 are joined together to form the assembly 10. Each component 11, 12 has a front end region. This end region is arranged in the longitudinal direction at the end of the component and has a surface aligned essentially perpendicular to the longitudinal axis of the component. The components 11, 12 are aligned with each other for joining so that these end regions lie opposite each other. This allows the components 11, 12 to be joined butt-jointed. In the butt region 13, the components are welded together using a butt weld seam.

Um den Stoßbereich 13, d.h. die Verbindungsstelle, zu verstärken und dadurch hohe mechanische Eigenschaften zu erzielen, wird ein Band 15 auf den Stoßbereich 13 aufgebracht. Hierbei finden insbesondere Tapes aus thermoplastischem Matrixmaterial mit unidirektional darin ausgerichteten Fasern Anwendung. Als Schweißzusatz zum Erzeugen der Stoßschweißnaht 14 wird ein Granulat aus thermoplastischen Material, insbesondere aus Polyamid-6 (PA6), Polyamid-66 (PA66), Polyetherimid (PEI), Polyetherketon (PEEK) und/oder Polyphenylensulfid (PPS)verwendet, das mit Carbonfasern verstärkt sind. Die Kohlenstofffasern liegen als Kurzfasern vor Das Granulat weißt somit 10 bis 50 Gew.-% Kohlenstofffasern, bevorzugt 20 bis 40 Gew.% Kohlenstofffasern und besonders bevorzugt 30 Gew.-% Kohlenstofffasern auf.In order to reinforce the joint area 13, i.e. the connection point, and thereby achieve high mechanical properties, a tape 15 is applied to the joint area 13. In particular, tapes made of thermoplastic matrix material with unidirectionally aligned fibers are used here. A granulate made of thermoplastic material, in particular polyamide-6 (PA6), polyamide-66 (PA66), polyetherimide (PEI), polyetherketone (PEEK) and/or polyphenylene sulfide (PPS), which is reinforced with carbon fibers, is used as a welding additive for producing the joint weld seam 14. The carbon fibers are in the form of short fibers. The granulate therefore has 10 to 50% by weight carbon fibers, preferably 20 to 40% by weight carbon fibers and particularly preferably 30% by weight carbon fibers.

Zusätzlich oder alternativ kann in der Kehlnaht 14 zur Verstärkung ein Edelstahlgewebe angeordnet sein. Dieses Edelstahlgewebe ist dann in 1 oberen Bereich der V-Naht 14 vorzusehen, um eine besonders gute Verstärkung der Schweißnaht zu realisieren.Additionally or alternatively, a stainless steel mesh can be arranged in the fillet weld 14 for reinforcement. This stainless steel mesh is then 1 upper area of the V-seam 14 in order to achieve a particularly good reinforcement of the weld seam.

Im Folgenden soll ein Reparaturverfahren zum Reparieren beschädigter Faserverbundbauteile erläutert werden unter Bezugnahme auf 1. Abweichend von der Darstellung in 1 ist das Faserverbundbauteil 11 nicht einseitig, sondern beidseitig von dem zweiten Faserverbundteil 12 ausgerichtet. Mit anderen Worten, bei dem Faserverbundteil 11 handelt es sich um ein durchgängiges Bauteil, das eine schadhafte Stelle aufweist, an der Stelle, an der das zweite Bauteil 12 eingebracht wird. Diese schadhafte Stelle wird herausgetrennt beispielsweise durch Heraussägen oder -flexen. Nach dem Entfernen der schadhaften Stelle wird ein zweites Verbundbauteil 12 so zurecht geschnitten, dass es geometrisch in die herausgetrennte Stelle zwischen die zwei Teile des ersten Faserverbundteils 11 hineinpasst. Beim Einbringen des zweiten Faserverbundteils 12 an die beschädigte Stelle des ersten Faserverbundteils 11 werden stirnseitige Endbereiche des Faserverbundteils 11 und das Ersatzbauteils 12 einander gegenüberliegend ausgerichtet. Anschließend wird in den Stoßbereichen der beiden Faserverbundteile 11, 12 eine Schweißnaht 14 erzeugt. Diese Schweißnaht kann wie oben beschrieben mit Bezug zu 1 entsprechende Verstärkungen aufweisen.In the following, a repair procedure for repairing damaged fiber composite components will be explained with reference to 1 . Deviating from the representation in 1 the fiber composite component 11 is not aligned on one side, but on both sides of the second fiber composite part 12. In other words, the fiber composite part 11 is a continuous component that has a damaged area at the point where the second component 12 is inserted. This damaged area is cut out, for example by sawing or grinding. After the damaged area has been removed, a second composite component 12 is cut to size so that it fits geometrically into the cut-out area between the two parts of the first fiber composite part 11. When the second fiber composite part 12 is inserted into the damaged area of the first fiber composite part 11, the front end areas of the fiber composite part 11 and the replacement component 12 are aligned opposite one another. A weld seam 14 is then created in the joint areas of the two fiber composite parts 11, 12. This weld seam can be made as described above with reference to 1 have appropriate reinforcements.

Claims (8)

Baugruppe (10) aus zwei Faserbundbauteilen (11, 12), wobei jedes Faserverbundbauteil (11, 12) Verstärkungsfasern aufweist, die in einer Matrix aus thermoplastischem Material eingebettet sind, und die Faserverbundbauteile (11, 12) so zueinander positioniert sind, dass ein stirnseitiger Endbereich eines Faserverbundbauteils (11, 12) einem stirnseitigen Endbereichen eines anderen Faserverbundbauteils (11, 12) gegenübersteht, wobei die Faserverbundbauteile (11, 12) an diesen stirnseitigen Endbereichen miteinander verschweißt sind, wobei in dem Verbindungsbereich der Faserverbundbauteile (11, 12) mindestens eine Verstärkung vorgesehen ist, dadurch gekennzeichnet, dass die Verstärkung als eine Stoßschweißnaht (14) ausgebildet ist, mit einem kurzfaserverstärktem Granulat als Schweißzusatz, wobei das Granulat aus einem thermoplastischen Material, insbesondere aus Polyamid-6 (PA6), Polyamid-66 (PA66), Polyetherimid (PEI), Polyetherketon (PEEK) und/oder Polyphenylensulfid (PPS) mit 10 bis 50 Gew.-% Kohlenstofffasern, bevorzugt 20 bis 40 Gew.-% Kohlenstofffasern und besonders bevorzugt 30 Gew.-% Kohlenstofffasern ausgebildet ist.Assembly (10) made of two fiber composite components (11, 12), each fiber composite component (11, 12) having reinforcing fibers embedded in a matrix of thermoplastic material, and the fiber composite components (11, 12) being positioned relative to one another in such a way that a front end region of a fiber composite component (11, 12) faces a front end region of another fiber composite component (11, 12), the fiber composite components (11, 12) being welded to one another at these front end regions, at least one reinforcement being provided in the connecting region of the fiber composite components (11, 12), characterized in that the reinforcement is designed as a butt weld seam (14), with a short fiber reinforced granulate as a welding additive, the granulate being made of a thermoplastic material, in particular of polyamide-6 (PA6), polyamide-66 (PA66), Polyetherimide (PEI), polyetherketone (PEEK) and/or polyphenylene sulfide (PPS) with 10 to 50 wt.% carbon fibers, preferably 20 to 40 wt.% carbon fibers and particularly preferably 30 wt.% carbon fibers. Baugruppe nach Anspruch 1, dadurch gekennzeichnet, dass die Stoßschweißnaht einen v-förmigen Querschnitt aufweist und in ihrem oberen Bereich mit einem Edelstahlgewebe verstärkt ist.assembly according to claim 1 , characterized in that the butt weld has a V-shaped cross-section and is reinforced in its upper region with a stainless steel mesh. Baugruppe nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die Verstärkung als ein Band (15) ausgebildet ist, das mit jedem der Faserverbundbauteile (11, 12) in berührendem Kontakt steht und diese miteinander verbindet.Assembly according to one of the preceding claims, characterized in that the reinforcement is designed as a band (15) which is in contact with each of the fiber composite components (11, 12) and connects them to one another. Baugruppe nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass das Band aus faserverstärktem Kunststoff mit einer thermoplastischen Matrix ausgebildet ist.Assembly according to one of the preceding claims, characterized in that the band is made of fiber-reinforced plastic with a thermoplastic matrix. Verfahren zur Herstellung einer Baugruppe aus zwei Faserverbundbauteilen (11, 12), wobei jedes Faserverbundbauteil (11, 12) Verstärkungsfasern aufweist, die in einer Matrix aus thermoplastischem Material eingebettet sind, mit den Schritten: - Ausrichten der zwei Faserverbundbauteile (11, 12) zueinander, so dass ein stirnseitiger Endbereich eines Faserverbundbauteils (11) einem stirnseitigen Endbereich des anderen Faserverbundbauteils (12) gegenüber steht, - Erzeugen einer Schweißverbindung im Stoßbereich (13) der beiden Faserverbundbauteile (11, 12), wobei - im Stoßbereich (13) eine Verstärkung (14, 15) vorgesehen ist, dadurch gekennzeichnet, dass die Verstärkung als eine Stoßschweißnaht (14) ausgebildet ist, mit einem kurzfaserverstärktem Granulat als Schweißzusatz, wobei das Granulat aus einem thermoplastischen Material, insbesondere aus Polyamid-6 (PA6), Polyamid-66 (PA66), Polyetherimid (PEI), Polyetherketon (PEEK) und/oder Polyphenylensulfid (PPS) mit 10 bis 50 Gew.-% Kohlenstofffasern, bevorzugt 20 bis 40 Gew.-% Kohlenstofffasern und besonders bevorzugt 30 Gew.-% Kohlenstofffasern ausgebildet ist.Method for producing an assembly from two fiber composite components (11, 12), each fiber composite component (11, 12) having reinforcing fibers embedded in a matrix of thermoplastic material, comprising the steps of: - aligning the two fiber composite components (11, 12) with one another so that a front end region of one fiber composite component (11) is opposite a front end region of the other fiber composite component (12), - producing a welded connection in the butt region (13) of the two fiber composite components (11, 12), wherein - a reinforcement (14, 15) is provided in the butt region (13), characterized in that the reinforcement is designed as a butt weld seam (14), with a short fiber reinforced granulate as a welding additive, wherein the granulate is made of a thermoplastic material, in particular of polyamide-6 (PA6), polyamide-66 (PA66), polyetherimide (PEI), Polyether ketone (PEEK) and/or polyphenylene sulfide (PPS) with 10 to 50 wt.% carbon fibers, preferably 20 to 40 wt.% carbon fibers and particularly preferably 30 wt.% carbon fibers. Verfahren nach Anspruch 5, dadurch gekennzeichnet, dass - ein Band aus faserverstärktem Kunststoff auf die Faserverbundbauteile (11, 12) aufgebracht wird, so dass es mit beiden Faserverbundbauteilen (11, 12) in berührendem Kontakt steht.procedure according to claim 5 , characterized in that - a band made of fiber-reinforced plastic is applied to the fiber composite components (11, 12) so that it is in touching contact with both fiber composite components (11, 12). Verfahren nach Anspruch 6, dadurch gekennzeichnet, dass das Band über den Stoßbereich hinweg aufgebracht wird.procedure according to claim 6 , characterized in that the tape is applied over the joint area. Reparaturverfahren für beschädigte Faserverbundbauteile, mit den Schritten: - Heraustrennen einer beschädigten Stelle aus dem Faserverbundbauteil (11), - Einbringen eines zweiten Faserverbundbauteil (12) als Ersatzbauteil an die beschädigte Stelle des ersten Faserverbundbauteils, und - Erzeugen einer Baugruppe durch Verbindung der beiden Faserverbundbauteile (11, 12) mit einem Verfahren nach einem der Ansprüchen 5 bis 7.Repair method for damaged fiber composite components, comprising the steps: - removing a damaged area from the fiber composite component (11), - inserting a second fiber composite component (12) as a replacement component into the damaged area of the first ten fiber composite component, and - producing an assembly by connecting the two fiber composite components (11, 12) using a method according to one of the claims 5 until 7 .
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