CN116890467A - 复合构件及其制造方法 - Google Patents
复合构件及其制造方法 Download PDFInfo
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- CN116890467A CN116890467A CN202310352993.8A CN202310352993A CN116890467A CN 116890467 A CN116890467 A CN 116890467A CN 202310352993 A CN202310352993 A CN 202310352993A CN 116890467 A CN116890467 A CN 116890467A
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Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Textile Engineering (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
本发明涉及一种用于制造尤其是用于滑行板、轮滑板或滑板的复合构件(1)的方法,该方法包括将由增强纤维制成的底衬(11)、在该底衬上由塑料制成的扁平芯体(12)以及在该扁平芯体上由增强纤维制成的顶衬(13)引入打开的模具(6)中,闭合模具(6),将未固化的塑料基质(14)引入闭合的模具(6)中,允许塑料基质(14)在闭合的模具(6)中固化,打开模具(6),并且使复合构件(1)脱模,其特征在于,芯体(12)在其下侧(16)和上侧(17)上设置有多个间隔凸块(18),该多个间隔凸块在闭合的模具(6)中使底衬(11)和顶衬(12)保持在距下侧(16)和上侧(16)距离(H1)处。
Description
技术领域
本发明涉及一种用于制造尤其是用于滑行板、轮滑板或滑板的复合构件的方法,所述方法包括将由增强纤维制成的底衬、在该底衬上的由塑料制成的扁平芯体以及在该扁平芯体的由增强纤维制成的顶衬引入打开的模具中,闭合所述模具,将未固化的塑料基质引入闭合的模具中,使所述塑料基质在闭合的模具中固化,打开所述模具,以及使复合构件脱模。本发明还涉及通过该方法制造的复合构件。
背景技术
目前,滑板、代步板、长板、滑雪板、大帮板(bigfoots)和其它滑行板和轮滑板,在此简称为“板”,主要由胶合层压木材制成,通常具有七个不同的层,有时也具有竹和玻璃或碳纤维层。木材层的弹性纤维结构赋予板材内部张力和高线性弹性的动态响应性能(称为“pop”),这对于有抱负和专业的滑板者是不可缺少的。然而,由于木材的个体结构,这种板在大规模制造中具有不均匀的机械性能,并且由于老化、吸湿(“湿润板(soggy board)”)、磨损(“剃刀尾”)和变形而趋于失去张力或pop。由于木材的低拉伸强度,木板也可能容易破裂,这可能导致危险事故。例如,专业领域中的木制滑板的寿命仅为一到两天。木制板的制造也是极其耗时的,因为木材和其它层必须被胶合、压制,然后手工铣削、钻孔、锯开和砂磨。
已经在使用层状结构的纤维增强塑料代替木材来制造板方面做出了一些尝试。例如,US 2006/0097469A1描述了一种包括夹层结构的滑板,该夹层结构由PVC制成的塑料芯体和靠在其上的玻璃纤维衬组成,该夹层结构嵌入由环氧树脂、聚酯树脂或聚氨酯树脂制成的塑料基质中。夹层结构在反应注塑工艺中通过将其引入模具中然后注射尚未固化的树脂来制造,该树脂然后在模具中固化。除了在芯体的上侧和下侧上的一些旨在当注入树脂时促进纤维衬的浸泡的纵向凹槽之外,纤维衬直接抵靠芯体的上侧和下侧放置。
然而,通过US 2006/0097469A1的方法制造的塑料板以及其它主要通过层压制造的塑料板(参见例如FR 2772624A1和US 2006/0049596A1)在其动态响应行为(“pop”)方面与木板没有可比性,因此使得它们在专业板方面来说是不能令人满意的。同样在其它应用中,例如在汽车工业中,已知的复合材料构件往往缺乏强度和足够弹性。
发明内容
本发明的目的是克服所述现有技术的缺点,并提供一种由纤维增强塑料制成的特别是用于滑行板、轮滑板或滑板的复合构件,该复合构件特别耐用、具有持久的动态响应行为或pop、重量轻并且能够容易且廉价地制造成复杂的形状。
在本发明的第一方面中,该目的通过开头所述类型的方法来实现,其特征在于,所述芯体在其下侧和上侧上设置有多个间隔凸块,所述多个间隔凸块在所述闭合的模具中使所述底衬和顶衬保持在距所述下侧和所述上侧一距离处。
本发明基于特殊的反应注塑工艺,其中,在由纤维衬、芯体和纤维衬形成的夹层结构中使用配备有凸块的芯体,其中,塑料基质在纤维衬的面向芯体的侧面上流过纤维衬,使得在纤维衬的面向芯体的侧面上形成塑料基质的中间层。因此,最终的夹层结构由塑料基质中的纤维衬、塑料基质中间层、芯体、塑料基质中间层和塑料基质中的纤维衬构成,即夹层结构至少是五层的,其中,凸块的高度决定了芯体和纤维衬之间的塑料基质中间层的厚度。通过改变间隔凸块的高度并因此改变中间层的密度,能够最佳地调节复合构件的强度和弹性,并且因此能够实现例如具有优良且持久的pop的板。
优选地,所述多个间隔凸块具有0.5-2.5mm的高度,特别优选地具有1-2mm的高度。这导致在芯体与底衬和顶衬之间的塑料基质中间层具有相应的厚度。该层厚度导致在构件中良好的力分布,并因此导致良好的整体强度同时具有良好弹性。
如果所述多个间隔凸块具有1-5mm、优选地2-4mm的直径,并且它们的相互间隔大于它们的直径,则是特别有利的。这允许塑料基质在芯体的面积范围的方向上沿着芯体的下侧和上侧在间隔凸块之间不受阻碍地流动,并且因此也能够在大面积上润湿底衬和顶衬。在此,间隔凸块在芯体与底衬和顶衬之间的塑料中间层中仅形成小的“岛”。
在根据本发明的方法的特别优选的实施例中,所述芯体还在其下侧和上侧上设置有若干固定凸块,所述若干固定凸块高于所述多个间隔凸块,并且当所述模具闭合时,所述若干固定凸块部分地刺入所述底衬和所述顶衬中并且将所述底衬和所述顶衬压靠在所述模具上,以便在所述塑料基质的引入和固化期间将由底衬、芯体和顶衬形成的夹层结构固定在所述模具中。
优选地,固定凸块具有1-5mm的高度,特别优选地具有2-4mm的高度。因此,当底衬和顶衬具有例如5-10mm的厚度时,固定凸块仅略微按压或刺入底衬和顶衬,这足以将夹层结构固定在模具中,而不会显著影响最终复合构件的强度和弹性。
原则上,芯体可以由任何塑料制成。然而,如果芯体由发泡材料制成,则是特别有利的,这导致特别轻的构件。优选地,芯体由发泡聚己内酰胺(聚酰胺6)制成,其赋予复合构件高弹性和低重量。
塑料基质原则上可以由任何可以在模具中(“原位”)固化的塑料形成,例如双组分环氧树脂。如果塑料基质是基于己内酰胺,则是特别有利的,使其在固化后聚合成聚己内酰胺(聚酰胺6),并因此可以与发泡芯体,尤其是由发泡聚己内酰胺制成的发泡芯体形成特别紧密的结合。
根据本发明的另一优选特征,纤维衬包含玻璃纤维、碳纤维和/或聚酰胺纤维。如果纤维衬仅由聚酰胺纤维制成,则是特别有利的,聚酰胺纤维提供特别高的强度和良好的pop。这些纤维可以是非织造物、无纬稀松布、织造织物或针织织物的形式作为衬。特别地,这种纤维衬也可以预成型以最佳地配合芯体的上侧和下侧,即,作为所谓的“预成型件”,其包含例如细的、可热塑变形的聚酰胺线。在这种热塑性线的帮助下,纤维衬可以在它们被插入到模具中的芯体的下面和上面之前在加热下预成形。
在第二方面,本发明还提供了一种尤其是用于滑行板、轮滑板或滑板的复合构件,其包括由增强纤维制成的底衬、在该底衬上方的由塑料制成的扁平芯体以及在该扁平芯体上方的由增强纤维制成的顶衬形成的夹层结构,该夹层结构嵌入通过反应注塑形成的塑料基质中,其中根据本发明,该复合构件的特征在于,芯体在其下侧和上侧上设置有多个间隔凸块,该间隔凸块将底衬和顶衬保持在距下侧和上侧一距离处,该距离由塑料基质填充。
关于其优点和根据本发明的复合构件的进一步优选的实施例,参考根据本发明的方法的上述解释。
附图说明
下面将参考附图中所示的示例性实施例更详细地说明本发明。在附图中:
图1以从下方观察的透视图示出了本发明的复合构件(这里:滑板板面);
图2以截面图示出了根据本发明的复合构件及其制造方法的一部分,该截面图穿过制造期间的填充且闭合的反应注射模具;
图3以斜上方的透视图示出了图1和2的复合构件的芯体;以及
图4放大地示出了图3的细节IV。
具体实施方式
图1示出了示例性的复合构件1,其使用参照图2-4说明的方法制造。复合构件1可以是任何扁平构件,即具有显著的面积范围(这里:在x/y平面中)的构件。应理解,构件1不必是平面的;它也可以具有弯曲表面,并且特别地也具有垂直于其面积范围(这里:在z方向上)的变化的厚度。
例如,复合构件1是汽车或航空工业中的主体构件、建筑工业中的建筑面板等。在所示的示例中,复合构件1是滑行板或轮滑板(“板”),特别是在其底面上具有用于锚定轮组(未示出)的孔2的滑板或滑板面板。它还可以是任何其它类型的板,例如代步板、长板、滑雪板、单板滑雪板、大帮板等。
在复合构件1的下侧上,此处:可以形成板、滑轨3,或者可以模制平坦的支承表面4,用于板、唇缘、鼻部或尾部滑动件。端部5可以铲状方式向上弯曲,以便能够通过踩在铲面上而跳跃(“带板跳(ollie)”)。板的上侧可以具有用于牢固握持的凹入区域。
根据图2,复合构件1(在此仅以截面示出其一部分)以特殊的注射成型工艺制造。为此,使用由两个半模7(阴)和8(阳)组成的模具6,其可以打开和闭合,并且具有浇道9和可选地加热装置10,如本领域已知的。
首先,将由底衬11、芯体12和顶衬13形成的叠层或夹层结构引入打开的模具6中。然后,闭合模具6,并将尚未固化的塑料基质14经由浇道9引入闭合的模具6中。在此可以在压力下或在无压力下(分别通过“强制填充”或“允许其缓慢注入”的方式)引入基质,这两种方法在此也被称为术语“注射”。其尚未固化的塑料基质14润湿并浸透底衬11和顶衬13,并填充模具6中剩余的所有间隙,包括芯体12中的任何孔15。如果需要,然后借助于加热装置10利用模具6的适当温度控制来允许塑料基质14在模具6中固化。
当塑料基质14固化时,它聚合以形成硬质塑料聚合物。在允许塑料基质14在模具6中固化之后,通过分开半模7、8来打开模具,并且将完成的复合构件1从模具6脱模。
通过“原位”固化塑料基质14在模具6中制造诸如复合材料构件1之类的注塑制品,也称为反应注塑(RIM)或树脂转换模塑(RTM)。本领域已知的所有RIM和RTM工艺参数和选项都可以用于在模具6中进行塑料基质14的反应注塑。
芯体12可由任何塑料制成,例如由聚氨酯、聚碳酸酯或聚酰胺(PA)制成的热固性或热塑性塑料,特别是PA6、PA11或PA12。芯体12可以是实心芯体或中空芯体,并且可选地设置有特别是在z方向上的多个孔15,如图3所示。
对于特别轻的芯体12,其可由发泡塑料(“发泡材料”)制成,例如发泡聚己内酰胺(聚酰胺6,PA6)。芯体12也可以由多于一种的塑料制成,例如由用于机械稳定性的树脂塑料制成,填充有发泡塑料,可选地设置有孔15。
底衬11和顶衬13各自是由能够被塑料基质14润湿和浸透的增强纤维制成的单层或多层非织造物、无纬稀松布、织造物或针织物,例如由玻璃纤维、碳纤维、芳族聚酰胺纤维、玄武岩纤维、亚麻纤维、聚酰胺纤维或其组合制成。在一个可选实施例中,底衬11和顶衬13仅由聚酰胺纤维制成。
纤维可以单向、双向或多向地铺置在底衬11和顶衬13中,也可以以不同方向铺置在不同的层中。底衬11和顶衬13可以可选地由彼此相邻铺置的若干部分(“补片”)组成,如果需要的话,还具有相互间隔,其中在多层底衬11或顶衬13中,也可以仅由这样的补片形成单独的层。
底衬11或顶衬13可以另外包含一些细热塑性线,例如聚酰胺线,其允许通过再次加热、变形和冷却而使底衬11和顶衬13热预变形,以便预先使它们已经预先适配芯体12的可能的表面弯曲。
塑料基质14可以由任何适于反应注塑的热固性或热塑性塑料制成,例如由在引入模具6中之后在其中固化的双组分低粘度塑料树脂制成。例如,塑料基质14基于聚氨酯或环氧树脂。特别适合用于塑料基质14的碱是己内酰胺(聚酰胺6),其通过适当的活化来交联以形成聚己内酰胺,例如通过加入水的开环聚合(“水解开环”)。
基于己内酰胺的塑料基质14特别适合与由发泡聚己内酰胺制成的芯体12一起使用,因为芯体12和塑料基质14的材料同一性导致复合构件1的特别紧密的结合。
如图2至4所示,芯体12在其下侧面16或上侧面17上,特别是在下侧面16和上侧面17两者上设置有多个间隔凸块18。当形成夹层结构11-13时,间隔凸块18将底衬11或顶衬13分别保持在距芯体12的下侧面16和上侧面17距离H1处。当未固化的塑料基质14被引入模具6中时,该距离H1也完全被塑料基质14填充,因此在完成的复合构件1中产生一个在底衬11和芯体12之间、一个在芯体12和顶衬13之间的中间层19和中间层20。因此复合构件1变成由至少五层(11、19、12、20、13)形成的复合构件。
如图2所示,模具6还可以具有位于底衬11下方和顶衬13上方的模腔或凹入区域,这导致在底衬11和顶衬13下方和上方分别形成附加的塑料基质层21、22,以使得复合构件1还可以具有六层或七层。层21、22例如可以用于滑轨3的整体模制。
距离H1和因此塑料基质层19、20的厚度等于间隔凸块18的高度,即它们从芯体12的相应下侧16或上侧17突出的程度。因此,可通过选择间隔凸块18的高度H1和因此层19、20的厚度而改变复合构件1的强度和弹性性能。对于长度例如为60-80cm的滑板的制造,例如具有0.5-2.5mm的高度H1的间隔凸块18是合适的,优选为1-2mm,特别优选为约1mm。
选择间隔凸块18的直径D1和它们在下侧16和上侧17上的相互(最小)间隔A,以确保当未固化的塑料基质14被引入到芯体12与底衬11和顶衬13之间的间隙中时,其无阻碍地通过。根据间隔凸块18的芯体料与中间层19、20的塑料基质材料的期望比例,进一步选择高度H1、直径D1和间隔凸块18的最小间隔A,以便实现完成的复合构件1的期望强度和弹性特性。例如,对于长度为60-80cm的滑板,例如,间隔凸块18的直径D1为1-5mm,优选2-4mm,尤其优选约2mm,并且它们的相互最小间距A大于其直径D1,例如至少是其直径D1的1-2倍。
应理解,间隔凸块18在平面图中可具有任何横截面形状,无论是圆形(如图所示)、椭圆形、矩形、正方形、五边形、六边形、任何多边形形状等。它们在侧视图中也可以具有任何横截面形状,例如圆弧形(如图所示)、三角形、梯形、矩形、正方形等。更一般地,它们可以是圆顶形(如图所示)、金字塔形、截头金字塔形、圆锥形、截头圆锥形、圆柱形、棱柱形等。如图3所示,间隔凸块18也可以不均匀地分布在相应的下侧16或上侧17上,例如在复合构件1的边缘或向外凸出的区域中更密集,而在复合构件1的中心或凹陷区域中更稀疏。
根据图2和图4,芯体12可以可选地在其下侧16和/或上侧17上设置有多个分布的固定凸块23。固定凸块23具有比间隔凸块18的高度H1更大的高度H2。如果将固定凸块23布置在下侧面16、17的模具6没有从底衬11和顶衬13中退出以形成层21、层22的区域的这种位置处,那么当模具6闭合时,固定凸块23部分刺入底衬11和顶衬13,即在那里局部挤压它们;见图2。因此,由底衬11、芯体12和顶衬13形成的夹层结构在那里被压在半模7、8之间,从而被固定以防止在塑料基质14的引入和固化期间在模具6中移位。
与间隔凸块18类似,固定凸块23在平面图和侧视图中也可以具有任何横截面,并且可以是例如圆顶形(如图所示)、金字塔形、截头金字塔形、圆锥形、截头圆锥形、圆柱形、棱柱形等。
对于长度例如为60-80cm的滑板,固定凸块23具有例如1-5mm、优选2-4mm、特别优选约2mm的高度H2。固定凸块23具有相应较大的直径D2,例如1-10mm,优选3-6mm,特别优选约4mm。
应当理解,对于较大的复合构件1,高度H1、H2、直径D1、D2以及间隔凸块18和固定凸块23的间距A可相应地缩放。
本发明不限于所示的实施例,而是包括落入所附权利要求范围内的所有变型、修改及其组合。
Claims (21)
1.一种用于制造复合构件(1)的方法,所述方法包括将由增强纤维制成的底衬(11)、在所述底衬(11)上方的由塑料制成的扁平芯体(12)以及在所述扁平芯体(12)上方的由增强纤维制成的顶衬(13)引入到打开的模具(6)中,闭合所述模具(6),将未固化的塑料基质(14)引入到所述闭合的模具(6)中,允许所述塑料基质(14)在所述闭合的模具(6)中固化,打开所述模具(6),并且使所述复合构件(1)脱模,其特征在于,所述芯体(12)在其下侧(16)和上侧(17)上设置有多个间隔凸块(18),所述多个间隔凸块(18)在所述闭合的模具(6)中使所述底衬(11)和所述顶衬(12)保持在距所述下侧(16)和所述上侧(17)一距离(H1)处。
2.根据权利要求1所述的方法,其特征在于,所述多个间隔凸块(18)具有0.5-2.5mm的高度(H1)。
3.根据权利要求1所述的方法,其特征在于,所述多个间隔凸块(18)具有1-5mm直径(D1),并且它们的相互间隔(A)大于它们的直径(D1)。
4.根据权利要求1所述的方法,其特征在于,所述芯体(12)还在其下侧(16)和上侧(17)上设置有若干固定凸块(23),所述若干固定凸块(23)高于所述多个间隔凸块(18),并且当所述模具(6)闭合时,所述若干固定凸块(23)部分地刺入所述底衬(11)和所述顶衬(12)中并且将所述底衬(11)和所述顶衬(12)压靠在所述模具(6)上,以便在所述塑料基质(14)的引入和固化期间将由所述底衬(11)、所述芯体(12)和所述顶衬(13)形成的夹层结构固定在所述模具(6)中。
5.根据权利要求4所述的方法,其特征在于,所述若干固定凸块(23)具有1-5mm的高度(H2)。
6.根据权利要求1至5中任一项所述的方法,其特征在于,所述芯体(12)由发泡材料制成。
7.根据权利要求1至5中任一项所述的方法,其特征在于,所述芯体(12)由发泡聚己内酰胺制成。
8.根据权利要求7所述的方法,其特征在于,所述塑料基质(14)基于己内酰胺。
9.根据权利要求1至5中任一项所述的方法,其特征在于,所述纤维衬(11、13)包含玻璃纤维、碳纤维和/或聚酰胺纤维。
10.根据权利要求1至5中任一项所述的方法,其特征在于,所述纤维衬(11、13)仅由聚酰胺纤维制成。
11.根据权利要求1至5中任一项所述的方法,其特征在于,所述复合构件(1)为滑行板、轮滑板或滑板。
12.一种复合构件,包括由增强纤维制成的底衬(11)、在所述底衬上方(11)的由塑料制成的扁平芯体(12)以及在所述扁平芯体(12)上方的由增强纤维制成的顶衬(13)形成的夹层结构,所述夹层结构嵌入在通过反应注塑形成的塑料基质(14)中,其特征在于,所述芯体(12)在其下侧(16)和上侧(17)上设有多个间隔凸块(18),所述多个间隔凸块(18)将所述底衬(11)和所述顶衬(12)保持在距所述下侧(16)和所述上侧(17)一距离(H1)处,所述距离由所述塑料基质(14)填充。
13.根据权利要求12所述的复合构件,其特征在于,所述多个间隔凸块(18)具有0.5-2.5mm的高度(H1)。
14.根据权利要求12所述的复合构件,其特征在于,所述芯体(12)还在其下侧(16)和上侧(17)上设置有若干固定凸块(23),所述若干固定凸块高于所述多个间隔凸块(18)并且部分地穿入所述底衬(11)和所述顶衬(12)中。
15.根据权利要求12至14中任一项所述的复合构件,其特征在于,所述芯体(12)由发泡材料。
16.根据权利要求12至14中任一项所述的复合构件,其特征在于,所述纤维衬(11、13)由发泡聚己内酰胺制成。
17.根据权利要求16所述的复合构件,其特征在于,所述塑料基质(14)基于己内酰胺。
18.根据权利要求12至14中任一项所述的复合构件,其特征在于,所述纤维衬(11、13)包含玻璃纤维、碳纤维和/或聚酰胺纤维。
19.根据权利要求12至14中任一项所述的复合构件,其特征在于,所述纤维衬(11、13)仅由聚酰胺纤维制成。
20.根据权利要求12至14中任一项所述的复合构件,其特征在于,所述芯体(12)具有由所述塑料基质(14)填充的多个孔(15)。
21.根据权利要求12至14任一项所述的复合构件,其特征在于,所述复合构件为滑行板、轮滑板或滑板。
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EP22166947.6A EP4257344A1 (de) | 2022-04-06 | 2022-04-06 | Kompositbauteil und verfahren zu seiner herstellung |
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FR2772624A1 (fr) | 1997-12-24 | 1999-06-25 | Bertrand Alessandra | Surf des neiges, planche a roulettes, ski, monoski composes d'une conception destinee a ameliorer les performances d'une planche de par sa nervosite, son etancheite, sa solidite et sa legerete |
CA2362871A1 (en) * | 1999-02-16 | 2000-08-24 | Yukitane Kimoto | Frp structural material and process for manucfacturing the same |
AUPS289402A0 (en) | 2002-06-11 | 2002-07-04 | Mitchell, Jennifer Joyce | Composite board and process for making the board |
US7347431B2 (en) | 2004-09-09 | 2008-03-25 | Chomp, Inc. | Skateboard deck construction |
GB2491190B (en) * | 2011-05-27 | 2013-07-17 | Gurit Uk Ltd | Foam core for a composite laminated article, and manufacture thereof |
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