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CN106182947B - 夹层构件 - Google Patents

夹层构件 Download PDF

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CN106182947B
CN106182947B CN201510415284.5A CN201510415284A CN106182947B CN 106182947 B CN106182947 B CN 106182947B CN 201510415284 A CN201510415284 A CN 201510415284A CN 106182947 B CN106182947 B CN 106182947B
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layers
sandwich element
layer
fibre
matrix material
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CN106182947A (zh
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G.沃尔夫斯伯格
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Magna Steyr Automotive Technologies
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Steyr Daimler Puch Fahrzeugtechnik AG and Co KG
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    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered 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
    • B32B5/22Layered 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
    • B32B5/24Layered 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
    • B32B5/26Layered 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 also being fibrous or filamentary
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/12Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/04Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/40Layered products comprising a layer of synthetic resin comprising polyurethanes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered 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
    • B32B5/18Layered 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered 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
    • B32B5/22Layered 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
    • B32B5/32Layered 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 at least two layers being foamed and next to each other
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00Layers arrangement
    • B32B2250/40Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02Composition of the impregnated, bonded or embedded layer
    • B32B2260/021Fibrous or filamentary layer
    • B32B2260/023Two or more layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04Impregnation, embedding, or binder material
    • B32B2260/046Synthetic resin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00Condition, form or state of the layers or laminate
    • B32B2305/02Cellular or porous
    • B32B2305/024Honeycomb
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00Vehicles
    • B32B2605/08Cars
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure

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Abstract

本发明公开了一种夹层构件。该夹层构件(1)包括至少一个芯层(2)和至少两个纤维层(3),其中,至少一个基体材料(4)施加到所述纤维层(3)中至少之一的上面和/或下面,其中,基体材料(4)以不同的方式施加到所述纤维层(3)中的至少两个上和/或基体材料(4)以不同的方式沿着纤维层(3)的上面和/或下面施加到所述纤维层(3)中至少之一上。

Description

夹层构件
技术领域
本发明涉及一种特别是用于汽车工业中的夹层构件。
背景技术
夹层构件通常应当被理解为是指由多层相同的材料或不同的材料制成的构件。在最简单的情况中,夹层构件由两个覆盖层(上覆盖层和下覆盖层)、以及布置在上覆盖层与下覆盖层之间的芯层构成。覆盖层以纤维和/或织物的方式构造,并且可以被类似粘合剂的基体材料渗透。各层之间的最终连接常常通过借助合适的工具例如压机加压来进行。
这种夹层构件用在许多不同的领域中。然而,近年来,它们的重要性,尤其是在轻量汽车建造领域中作为结构构件的重要性,已经大大增加。
现有技术公开了生产结构构件的许多不同的方法。
为了获得上下覆盖层与芯层之间的持久连接,使用了基体,特别是粘合剂类型的树脂,在对覆盖层和芯层加压期间,所述基体被挤压通过覆盖层并以此方式形成覆盖层与芯层之间的连接。基体材料在这里仅从外部施加到最外面的覆盖层上。一般地,这里要施加过量的基体材料,以确保对各层进行加压时基体材料可靠地渗透覆盖层。
在根据上面简要描述的方法制造夹层构件的过程中,有如下缺点:仅一种类型的基体材料(在组成和施加厚度方面)可以施加到最外面的覆盖层上。而且,取决于基体材料的粘度和覆盖层的渗透性,基体材料可能过深地进入到覆盖层中并以未受抑制的方式渗透芯层。为了防止这种情况,根据现有技术,在覆盖层与芯层之间常常设置有基体材料不能渗透的阻挡层。然而,该阻挡层在大多数情况下必须在单独的操作步骤中粘结到芯层。
发明内容
本发明的目的是提出一种改进的夹层构件,该夹层构件,尤其对于满足大多数不同的技术和光学要求的需求而言,被设计为简单且节省成本。
该目的通过一种夹层构件来实现,该夹层构件包括至少一个芯层和至少两个纤维层,其中,至少一个基体材料施加到所述纤维层中至少之一的上面和/或下面,其中,基体材料以不同的方式施加到所述纤维层中的至少两个上和/或基体材料以不同的方式沿着纤维层的上面和/或下面施加到所述纤维层中至少之一上。
本发明的有利改进可以从从属权利要求中导出。
根据本发明的夹层构件包括芯层和至少两个纤维层。根据本发明,所述多个纤维层设置在芯层的上面和/或下面。
根据本发明,至少一个基体材料施加到至少一个纤维层的上面和/或下面,其中,特别是基体材料以不同的方式施加到至少两个纤维层上和/或特别是基体材料沿着上面和/或下面以不同的方式施加到至少一个纤维层上。
术语“以不同的方式”旨在描述基体材料特别优选地以不同量和/或以不同类型的基体材料施加到纤维层上。
由此,有利的是,基体材料均质地和/或非均质地施加到一个或多个材料网上。
这带来了如下优点:相应的基体材料以每种情况下单独适于每种纤维层的方式施加在至少一个相应的纤维层上,从而符合夹层构件的功能要求,例如局部不同的区域刚性和表面质量。基体材料施加到相应的纤维层这里可以是均质地或非均质地进行,由此可以沿着例如夹层构件的表面来构造出具有不同的基体材料构造的区域。
此外,因为基体材料(以各种方式)单独施加到各材料网,并且基体材料的性质(例如,粘度、触变性、量)适合于材料网的相应材料,所以在每种情况下仅需要施加较薄的基体,从而在重量和功能方面实现最优化。
优选地,至少两个纤维层设置在芯层的一面。
纤维层优选由纤维材料制成,并优选设计成与芯层相比较薄。由此所使用的纤维是天然纤维,例如大麻纤维、竹纤维、纤维素纤维等,和/或有机和无机人造纤维,例如聚酰胺纤维、玻璃纤维、碳纤维等。
因此,纤维材料优选由已经被加工为纺织的、非纺织的或针织的纤维、垫、网状物等的纤维构成,其中这些形成物优选已被进一步加工成适于相应要求的基体,以形成熟知的复合材料。
在根据本发明的方法的实施例的一个有利的变型中,(由纤维材料制成的)纤维层被预处理,其中在该情况下,可以考虑本领域技术人员熟悉的所有的预处理方式,例如涂底料、浸透、涂覆等。
所使用的各纤维层可以在它们的(基本)组成成分和设计(形状)方面彼此不同。
优选地,纤维层构造为(纤维材料)网和/或与夹层构件的轮廓对应的预制的单独(纤维材料)层。
有利地,纤维层构造为是基体材料可渗透的。
在实施例的可选变型中,各纤维层构造成是分层的,也就是说,它们由至少两个单独层构造,其中,单独层中的至少一个是纤维材料。
在本文中,由非纤维材料构成的单独层有利地构造为塑料膜。
芯层优选构造为蜂窝的样子。然而,不排除芯层的其它结构和形状,例如波状构造。
芯层优选由轻质材料形成,例如聚合物(泡沫、塑料、橡胶等)、纤维素基材料(纸、木材、卡片等)、复合材料或金属。
在另一可选实施例中,芯层例如由多个单独的芯层以分层的方式构造,所述多个单独的芯层布置成一个在另一个之上。在本文中,所述至少两个单独的芯层可以构造为彼此不同。特别地,具有不同的蜂窝形状、蜂窝大小、蜂窝排列、不同的网几何形状和/或蜂窝材料的蜂窝状的芯和/或各单独芯层可以堆叠并互相连接。这是特别有利的,因为这样的结果是,后来完成的构件可以部分地具有不同的功能特性或构件特性,即,一方面,该构件旨在具有特定的所需的强度和刚性,而另一方面,该构件有意在某些位置包含软的、更容易变形的区域,例如,这在车辆部分中是有利的,用于避免碰撞行人时的伤害。
优选地,沿着夹层构件的表面,构造有具有不同的单独芯层、特别是具有不同的数量和/或形状和/或材料组成的区域。
芯层优选地构造成是基体材料可渗透的,至少是半渗透的。
基体材料优选由热塑性和/或热固性聚合物制成。
基体材料优选是树脂、特别优选是合成树脂(聚氨酯)。
特别优选地,基体材料构造为粘合剂的方式,并具有例如树脂和催化剂、或基本成分(base)和催化剂,作为主要组分。
为了针对各种不同的要求来改变基体材料的性质,例如强度或弹性,附加的组分和/或材料(例如,纤维)有利地与基体材料混合。
这可包括短纤维和/或长纤维与基体材料均质地或非均质地混合,从而将基体材料以不同方式、即均质地和/或非均质地、施加到材料网。由此产生了不同的组成性质,例如材料网的表面区域上的非均质和/或均质的区域刚性。这获得了具有在构件的表面区域上和在层的层结构上的均质和/或非均质层结构的夹层构件。
优选地,基体材料设置在纤维层之间、和/或一个纤维层与芯层之间的中间空间中、和/或最外面的纤维层的外部。
在根据本发明的夹层构件的一个优选实施例中,至少一个非纤维层的材料层设置在纤维层之间、和/或一个纤维层与芯层之间的中间空间中、和/或最外面的纤维层的外部。
优选地,纤维层、基体材料、材料层(如果有的话)、以及芯层被加压以形成夹层构件。
根据本发明的夹层构件可以用作机动车的平面构件,特别是用作前盖、门、顶、后舱、装载平板、覆盖物、车身地板、或抗扭箱。
附图说明
下面参照附图示例性地描述本发明。
图1是根据本发明的夹层构件在加压之前的示意图。
图2是根据本发明的夹层构件在加压之后的示意图。
具体实施方式
图1和图2示出根据本发明的夹层构件1在加压之前(图1)和加压之后(图2)的示意图。
图1中示意性示出的夹层构件1具有芯层2和三个纤维层3。纤维层3设置在芯层2的上面。
基体材料4施加到这三个纤维层3中每个纤维层的上面,其中,基体材料4同样设置在最里面的纤维层6与芯层2之间,该基体材料4被施加到最里面的纤维层6的下面。
在已施加的基体材料4的量方面,例如,与施加到最外面的纤维层5的上面的基体材料4相比,更多的基体材料4已施加到最里面的纤维层6的上面。
由此,基体材料4已经“以不同的方式”(在本示意性示例实施例的情况下是以不同的量)施加到最里面的纤维层6和最外面的纤维层7上。
纤维层3构造为与夹层构件1的轮廓对应的预成形的单独层。
芯层2以蜂窝状且一体的方式实现,其中,蜂窝朝着上面开放,并可接收基体材料4。
图2示出夹层构件1在加压之后的示意图。
借助压机通过湿压法来执行加压。
纤维层3构造成对于基体材料4是可渗透的,其中,借助加压,基体材料4被挤压通过全部的纤维层3。
由于基体材料4施加的目标是纤维层3,因此基体材料4仅略微渗入芯层2,这也确保了纤维层3充分地结合到芯层2。

Claims (17)

1.夹层构件(1),包括至少一个芯层(2)和至少两个纤维层(3),以及施加到所述纤维层(3)上的基体材料(4)的多层,并且纤维层(3)、基体材料(4)、以及芯层(2)被加压以形成夹层构件(1),其中:
-所述基体材料(4)的多层的第一层设置在所述纤维层(3)中的最内一层上且包含第一量的所述基体材料(4),
-所述基体材料(4)的多层的第二层设置为在所述纤维层(3)的最外一层上,
-所述基体材料(4)的多层的第二层包含第二量的所述基体材料(4),所述第二量的所述基体材料(4)小于所述第一量的所述基体材料(4),
-所述至少一个芯层(2)构造为对于基体材料(4)是半渗透的,
-纤维层(3)构造成是基体材料(4)可渗透的,并且
-所述基体材料(4)通过所述加压被挤压通过全部所述纤维层(3),并且仅略微浸入所述芯层(2)。
2.根据权利要求1的夹层构件(1),其特征在于,
所述基体材料(4)的所述层为彼此不同类型的基体材料(4)。
3.根据权利要求1的夹层构件(1),其特征在于,
所述至少两个纤维层(3)设置于所述至少一个芯层(2)的一面上。
4.根据权利要求1的夹层构件(1),其特征在于,
基体材料(4)包括纤维。
5.根据权利要求1的夹层构件(1),其特征在于,
基体材料(4)包括树脂。
6.根据权利要求5的夹层构件(1),其特征在于,
所述树脂是聚氨酯。
7.根据权利要求1的夹层构件(1),
其中所述基体材料(4)的所述多层包含:设置在所述纤维层(3)中的一层与所述芯层(2)之间的中间空间中的层。
8.根据权利要求1的夹层构件(1),其特征在于,
所述至少一个芯层(2)基本上形成为蜂窝的方式。
9.根据权利要求1的夹层构件(1),其特征在于,
所述至少一个芯层(2)由至少两个单独的芯层以分层的方式构造,所述至少两个单独的芯层的一个堆叠在另一个之上。
10.根据权利要求9的夹层构件(1),其特征在于,
所述单独的芯层在它们的形状和材料组成方面构造成彼此不同。
11.根据权利要求9的夹层构件(1),其特征在于,
沿着夹层构件的表面,构造有具有不同的所述单独的芯层的区域。
12.根据权利要求11的夹层结构(1),其特征在于,
所述具有不同的所述单独的芯层的区域是具有不同的数量和/或形状和/或材料组成的区域。
13.根据权利要求1的夹层构件(1),其特征在于,
所述至少一个芯层由轻质材料来构造。
14.根据权利要求13的夹层构件(1),其特征在于,
所述轻质材料是聚合物轻质材料。
15.根据权利要求1的夹层构件(1),还包含
至少一个非纤维层(3)的材料层,所述材料层在纤维层(3)之间、和/或一个纤维层(3)与芯层(2)之间的中间空间中、和/或所述纤维层(3)中的最外一层的外部。
16.根据权利要求1的夹层构件(1),其特征在于,
纤维层(3)构造为网或与夹层构件的轮廓对应的预制的单独层。
17.根据权利要求1的夹层构件(1),其特征在于,
纤维层(3)通过预处理过程进行预处理。
CN201510415284.5A 2014-12-22 2015-07-15 夹层构件 Active CN106182947B (zh)

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