DE102010051260A1 - Method for producing three-dimensionally drapable thermoplastic semi-finished functional element for integration into fiber thermoplastic composite, involves enabling contact melting of films, and consolidating functional element network - Google Patents

Method for producing three-dimensionally drapable thermoplastic semi-finished functional element for integration into fiber thermoplastic composite, involves enabling contact melting of films, and consolidating functional element network Download PDF

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DE102010051260A1
DE102010051260A1 DE102010051260A DE102010051260A DE102010051260A1 DE 102010051260 A1 DE102010051260 A1 DE 102010051260A1 DE 102010051260 A DE102010051260 A DE 102010051260A DE 102010051260 A DE102010051260 A DE 102010051260A DE 102010051260 A1 DE102010051260 A1 DE 102010051260A1
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thermoplastic
functional element
functional
films
fiber
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DE102010051260B4 (en
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Werner A. Hufenbach
Maik Gude
Thomas Heber
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Technische Universitaet Dresden
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Technische Universitaet Dresden
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—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
    • B29C70/72—Encapsulating inserts having non-encapsulated projections, e.g. extremities or terminal portions of electrical components
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint 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
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General 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
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/433—Casing-in, i.e. enclosing an element between two sheets by an outlined seam
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General 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
    • B29C66/72—General 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
    • B29C66/721—Fibre-reinforced materials
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General 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
    • B29C66/72—General 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
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
    • B29C66/72141—Fibres of continuous length
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General 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
    • B29C66/73—General 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
    • B29C66/739—General 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
    • B29C66/7392—General 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
    • B29C66/73921—General 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
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • 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
    • B29C70/685—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 by laminating inserts between two plastic films or plates
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10N—ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10N30/00—Piezoelectric or electrostrictive devices
    • H10N30/01—Manufacture or treatment
    • H10N30/09—Forming piezoelectric or electrostrictive materials
    • H10N30/098—Forming organic materials
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/006—Preventing damaging, e.g. of the parts to be joined
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/304—Joining through openings in an intermediate part of the article
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General 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
    • B29C66/71—General 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
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8122—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the composition of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81457—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a block or layer of deformable material, e.g. sponge, foam, rubber
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83411—Roller, cylinder or drum types
    • B29C66/83413—Roller, cylinder or drum types cooperating rollers, cylinders or drums
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83421—Roller, cylinder or drum types; Band or belt types; Ball types band or belt types
    • B29C66/83423—Roller, cylinder or drum types; Band or belt types; Ball types band or belt types cooperating bands or belts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/12—Thermoplastic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2701/00—Use of unspecified macromolecular compounds for preformed parts, e.g. for inserts
    • B29K2701/12—Thermoplastic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
    • B29L2031/3481—Housings or casings incorporating or embedding electric or electronic elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
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    • B29L2031/3493—Moulded interconnect devices, i.e. moulded articles provided with integrated circuit traces

Abstract

The method involves providing a lower multi-functional thermoplastic carrier film (22), and presenting and positioning a functional element network (23) formed of flexible conductor tracks connected to planar functional elements e.g. sensor, on the multi-functional thermoplastic carrier film. An upper multi-functional thermoplastic carrier film is provided (24) on the functional element network. Contact melting of the carrier films is enabled (25), and the functional element network is consolidated during hot-pressing process under pressure and increased temperature. An independent claim is also included for a three-dimensionally drapable thermoplastic semi-finished functional element.

Description

Die Erfindung betrifft ein Verfahren zur Erzeugung von dreidimensional drapierfähigen Thermoplast-Funktionselement-Halbzeugen zur Integration in Faser-Thermoplast-Verbunde.The invention relates to a method for the production of three-dimensional drapierfähigen thermoplastic functional element semi-finished products for integration in fiber-thermoplastic composites.

Adaptive Bauteilstrukturen bestehen in der Regel aus passiven Werkstoffen, wie etwa faserverstärkten Kunststoffen oder Leichtmetallen und zusätzlichen aktorischen oder sensorischen Funktionselementen. Derartige Bauteilstrukturen erlauben die zustandsabhängige Anpassung des Strukturverhaltens an betriebsbedingte Belastungen. Die Applikation oder Integration der in separierten Fertigungsteilschritten hergestellten Funktionselemente auf oder in den passiven Werkstoffverbund ist bisher durch einen hohen Montageaufwand sowie durch eine fehlende werkstoffliche Abstimmung zwischen Funktionselementwerkstoff und Verbundwerkstoff gekennzeichnet. Weiterhin besteht die Problematik einer erhöhten Instabilität und unzureichenden Positionier- und Fixierbarkeit der filigranen Funktionselemente in der Bauteilherstellung, d. h. verarbeitungsinduzierte Belastungen wie etwa Verarbeitungsdrücke oder Fließbewegungen von Kunststoffschmelzen führen oft zur Schädigung von einzelnen Funktionselementen oder zur Verwerfung der Faser-Thermoplast-Verbunde. Existierende robuste Funktionselemente sind sowohl durch eine unzureichende werkstoffliche als auch durch eine zu niedrige geometrische Anpassungsfähigkeit an die Faserverbundstruktur gekennzeichnet.Adaptive component structures are usually made of passive materials, such as fiber-reinforced plastics or light metals and additional actuator or sensory functional elements. Such component structures allow the state-dependent adaptation of the structural behavior to operational loads. The application or integration of the functional elements produced in separate production sub-steps on or in the passive material composite has hitherto been characterized by a high assembly cost and by a lack of material coordination between functional element material and composite material. Furthermore, there is the problem of increased instability and insufficient positioning and fixability of the filigree functional elements in the component production, d. H. Processing-induced stresses such as processing pressures or plastic melt flow motions often lead to damage to individual functional elements or to the rejection of the fiber-thermoplastic composites. Existing robust functional elements are characterized by an insufficient mechanical as well as by a too low geometric adaptability to the fiber composite structure.

Bei der Fertigung adaptiver Bauteilstrukturen aus Verbundwerkstoffen werden derzeit die Funktionselemente (Aktoren oder Sensoren) überwiegend erst nach der Verbundherstellung in einem zusätzlichen Montageschritt klebtechnisch auf die Bauteiloberfläche appliziert. Die zur Verbundanbindung zur Verfügung stehende Moduloberfläche besteht dabei meist aus einer Polyimidträgerfolie, wie in den Druckschriften US 6,629,341 B2 , EP 1 983 584 A2 , DE 10 2008 040 316 A1 und US 4,6849,668 beschrieben, die werkstofflich inkompatibel zu mehreren in der Faserverbundtechnik gebräuchlichen Matrixwerkstoffen, insbesondere Thermoplasten, ist.In the manufacture of adaptive component structures made of composite materials, at present the functional elements (actuators or sensors) are predominantly adhesively applied to the component surface only after composite production in an additional assembly step. The module surface available for the composite connection usually consists of a Polyimidträgerfolie, as in the publications US 6,629,341 B2 . EP 1 983 584 A2 . DE 10 2008 040 316 A1 and US 4,6849,668 described, the material incompatible with several common in fiber composite matrix materials, especially thermoplastics, is.

Erste Verfahren zur Herstellung werkstoffkompatibler Funktionselemente sind in den Druckschriften DE 10 2006 047 411 A1 und DE 10 2007 037 342 A1 beschrieben, wobei hier die thermoplastbasierten Faserverbundwerkstoffe betrachtet werden.First methods for producing material-compatible functional elements are in the documents DE 10 2006 047 411 A1 and DE 10 2007 037 342 A1 described, wherein the thermoplastic-based fiber composites are considered here.

Nationale und internationale Forschungsansätze zur Integration von Funktionsmodulen in Verbundwerkstoffe zielen insbesondere auf Faserverbundwerkstoffe mit duroplastischen Matrices ab, wobei hier der Fokus auf Einzelfertigungen für Luftfahrtanwendungen liegt und Serienfertigungspakete im Hintergrund stehen. Bei diesem Fertigungsverfahren werden die Funktionselemente weitestgehend einzeln und mit hohem manuellem Aufwand erst während der Fertigung der adaptiven Verbundstruktur derselben zugeführt. Zudem erfolgt keine Anpassung der Funktionselemente auf den Matrixwerkstoff der Verbundstruktur, wie in den Druckschriften US 4,849,668 , DE 101 43 226 A1 , EP 1 168 463 A1 und DE 100 58 096 A1 beschrieben ist.National and international research approaches to the integration of functional modules in composites are aimed in particular at fiber composites with thermoset matrices, with a focus on pilot manufacturing for aerospace applications and mass production packages in the background. In this manufacturing method, the functional elements are largely supplied individually and with high manual effort only during the manufacture of the adaptive composite structure of the same. In addition, there is no adaptation of the functional elements to the matrix material of the composite structure, as in the documents US 4,849,668 . DE 101 43 226 A1 . EP 1 168 463 A1 and DE 100 58 096 A1 is described.

Die Nachteile bestehen in

  • – einer werkstofflichen Inkompatibilität zwischen Funktionselement und Verbundwerkstoff, die zu mangelhafter Anbindung und somit verminderter Leistungsfähigkeit der Funktionselemente führt,
  • – einem hohen manuellen Strukturfertigungsaufwand durch Aufbau eines Funktionselement-Halbzeuges aus einzelnen Funktionselementen erst während der Bauteilherstellung,
  • – einer erhöhten Empfindlichkeit der sensitiven Funktionselemente gegenüber fertigungsprozessinduzierten Belastungen,
  • – einer begrenzten geometrischen Anpassungsfähigkeit existierender adaptronischer Systeme an die Faserverbundstruktur,
  • – einer schwierigen Positionier- und Fixierbarkeit der Funktionselemente im Verarbeitungsprozess.
The disadvantages are in
  • A material incompatibility between functional element and composite material which leads to poor connection and thus reduced performance of the functional elements,
  • A high level of manual structure production expenditure by constructing a functional element semifinished product from individual functional elements only during component production,
  • An increased sensitivity of the sensitive functional elements to production-process-induced stresses,
  • A limited geometric adaptability of existing adaptronic systems to the fiber composite structure,
  • - a difficult positioning and fixability of the functional elements in the processing process.

Der Erfindung liegt deshalb die Aufgabe zugrunde, ein Verfahren zur Erzeugung von dreidimensional drapierfähigen Thermoplast-Funktionselement-Halbzeugen zur Integration in Faser-Thermoplast-Verbunde anzugeben. Das Verfahren beinhaltet den Aufbau und die Positionierung vorkonsolidierter dreidimensional drapierfähiger Thermoplast-Funktionselement-Halbzeuge zur nachfolgenden Integration in Faser-Thermoplast-Verbunde als Teil einer Prozesskette zur seriengerechten Fertigung adaptiver Strukturverbunde, die neben strukturellen auch sensorische und aktorische Funktionen besitzen. Es soll dabei ein an den Matrixwerkstoff der passiven Tragstruktur angepasster Aufbau des Funktionselement-Halbzeuges bereitgestellt werden, der direkt, d. h. ohne zusätzlichen Montageaufwand, zur robusten, automatisierten Fertigung adaptiver Faser-Thermoplast-Verbunde verwendet werden kann und parallel den Schutz des Halbzeuges und der einzelnen Funktionselemente vor fertigungsprozessinduzierten Beanspruchungen garantiert. Gleichzeitig soll ein Höchstmaß an Drapierfähigkeit zur Verarbeitung in einfach und mehrfach gekrümmten Verbunden erreicht werden. Zusätzlich soll eine verbesserte Anbindung von Funktionselementen in/an die Faser-Thermoplast-Verbundstruktur sowie eine Erhöhung des elektrischen Isolationsschutzes erreicht werden.The invention is therefore based on the object of specifying a method for producing three-dimensional drapible thermoplastic functional element semifinished products for integration into fiber-thermoplastic composites. The process involves the construction and positioning of preconsolidated three-dimensional drapeable thermoplastic functional element semifinished products for subsequent integration into fiber-thermoplastic composites as part of a process chain for series production of adaptive structural composites, which have structural as well as sensory and actuator functions. It is intended to provide a structure of the functional element semifinished product which is adapted to the matrix material of the passive support structure and which directly, i. H. can be used without additional assembly effort, for the robust, automated production of adaptive fiber-thermoplastic composites and at the same time guarantees the protection of the semifinished product and of the individual functional elements against production process-induced stresses. At the same time, the highest degree of drapability is to be achieved for processing in single and multiple curved composites. In addition, an improved connection of functional elements in / on the fiber-thermoplastic composite structure and an increase in the electrical insulation protection is to be achieved.

Die Aufgaben werden durch die Merkmale des Patentanspruchs 1 gelöst.The objects are achieved by the features of patent claim 1.

In dem Verfahren zur Erzeugung von dreidimensional drapierfähigen Thermoplast-Funktionselement-Halbzeugen zur Integration in Faser-Thermoplast-Verbunde werden
gemäß dem Kennzeichenteil des Patentanspruchs 1 zumindest folgende Schritte durchgeführt:

  • – Bereitstellen einer ersten multifunktionalen thermoplastischen Trägerfolie (Schutz, Stabilisierung, Anbindung, Isolation),
  • – Auflegen und Positionieren eines Funktionselement-Netzwerkes aus mit flexiblen Leiterbahnen verbundenen flächigen Funktionselementen auf die erste thermoplastische Trägerfolie,
  • – Auflegen einer zweiten multifunktionalen thermoplastischen Trägerfolie auf das Funktionselement-Netzwerkes,
  • – Kontaktschmelzen und Konsolidieren der beiden sich gegenüberliegenden thermoplastischen Trägerfolien mit dem darin befindlichen Funktionselement-Netzwerke in einem Heißpressprozess unter Druck und erhöhter Temperatur.
In the process of producing three-dimensional drapeable thermoplastic functional element semifinished products for integration into fiber-thermoplastic composites
according to the characterizing part of patent claim 1, at least the following steps are carried out:
  • Providing a first multifunctional thermoplastic carrier film (protection, stabilization, connection, insulation),
  • Placing and positioning of a functional element network of planar functional elements connected to flexible conductor tracks onto the first thermoplastic carrier foil,
  • Placing a second multifunctional thermoplastic carrier film on the functional element network,
  • Contact melting and consolidation of the two opposite thermoplastic carrier films with the functional element networks contained therein in a hot press process under pressure and elevated temperature.

Zur Funktionselemente schonenden Verpressung und/oder automatischen Erzeugung der Funktionselement-Halbzeuge können weitere folgende Teilschritte vorgesehen werden:

  • – Bereitstellen einer unter der ersten multifunktionalen thermoplastischen Trägerfolie anbringbaren ebenen ersten elastischen Prozesshilfsfolie,
  • – Auflegen der unteren ersten thermoplastischen Trägerfolie auf die elastische Prozesshilfsfolie,
  • – Abdecken der oberen zweiten multifunktionalen thermoplastischen Trägerfolie mit einer oberen ebenen zweiten elastischen Prozesshilfsfolie, so dass der Aufbau aus Funktionselement-Halbzeug und thermoplastischen Trägerfolien, mit dem Ziel einer Funktionselemente schonenden Verpressung, zwischen elastischen Prozesshilfsfolien angeordnet ist.
For functional elements gentle pressing and / or automatic generation of the functional element semi-finished products further sub-steps may be provided:
  • Providing a planar first elastic process auxiliary film which can be applied under the first multifunctional thermoplastic carrier film,
  • Placing the lower first thermoplastic carrier film on the elastic process auxiliary film,
  • - Covering the upper second multifunctional thermoplastic support film with an upper planar second elastic process auxiliary film, so that the structure of functional element semifinished and thermoplastic carrier films, with the aim of a functional elements gentle compression, between elastic process auxiliary films is arranged.

Für die automatische Prozesseinbindung – Integration – der trägerfoliengeschützten Funktionselement-Halbzeuge in einen Faser-Thermoplast-Verbund werden zumindest folgende weitere Schritte durchgeführt:

  • – Entfernen der ebenen Prozesshilfsfolien und
  • – Zuführung des Funktionselement-Halbzeuges als dreidimensional verformbare Funktionslage dem Faserverbundfertigungsprozess zur Integration in den Faser-Thermoplast-Verbund.
For automatic process integration-integration-of the carrier film-protected functional element semi-finished products into a fiber-thermoplastic composite, at least the following further steps are carried out:
  • - removing the flat process slides and
  • - Feeding of the functional element-semifinished product as a three-dimensionally deformable functional position of the fiber composite manufacturing process for integration into the fiber-thermoplastic composite.

Das Funktionselement-Halbzeug kann aufbauseitig mit flächigen Funktionselementen auf der unteren ersten multifunktionalen thermoplastischen Trägerfolie manuell und/oder robotergeführt versehen werden, die mit dem Ziel der Netzbildung über Leiterbahnen kontaktiert werden, wobei danach die obere zweite multifunktionale thermoplastische Trägerfolie manuell oder automatisiert aufgelegt wird und mittels des Heißpressprozesses eine Verbindung der sich gegenüberliegenden angeschmolzenen Thermoplastfolien realisiert.The functional element semifinished product can be manually and / or robotically provided on the construction side with flat functional elements on the lower first multifunctional thermoplastic carrier film, which are contacted with the aim of netting via conductor tracks, after which the upper second multifunctional thermoplastic carrier film is placed manually or automatically and by means of the hot pressing process realized a connection of the opposite molten thermoplastic films.

Das Bereitstellen der Prozesshilfsfolien und thermoplastischen Trägerfolien erfolgt sowohl manuell in einem planaren Formwerkzeug als auch automatisiert, etwa mittels eines Rolle-Rolle-Verfahrens.The process auxiliary films and thermoplastic carrier films are provided both manually in a planar molding tool and also automatically, for example by means of a roll-to-roll method.

Die Prozesshilfsfolien sind gekennzeichnet durch eine hohe Temperaturbeständigkeit und Elastizität und dabei insgesamt dicker als das Thermoplast-Funktionselement-Halbzeug, so dass die Prozesshilfsfolien (z. B. Silikon- oder EPDM-Folien) zum einen den Heißpressprozess schädigungsfrei durchlaufen und somit wieder verwendbar sind und zum anderen infolge von Aufdickungen durch Funktionselemente prozessinduzierte Drucküberhöhungen ausgleichen, was zur schonenden Verpressung der Funktionselemente zwischen den thermoplastischen Trägerfolien führt.The process auxiliary films are characterized by a high temperature resistance and elasticity and thereby thicker overall than the thermoplastic functional element semifinished product, so that the process auxiliary films (eg silicone or EPDM films) on the one hand through the hot pressing process without damage and thus reusable, and on the other hand due to thickening by functional elements process-induced pressure peaks, which leads to the gentle compression of the functional elements between the thermoplastic carrier films.

Das Verpressen in einem Heißpressprozess kann sowohl diskontinuierlich in einer stationären Presse mit beheiztem Formwerkzeug als auch kontinuierlich, etwa in einer Doppelbandpresse, erfolgen, so dass ein bei Raumtemperatur hochflexibles aber dennoch maschinell handhabbares flächiges Funktionselement-Halbzeug erreicht wird.The pressing in a hot pressing process can be carried out both discontinuously in a stationary press with a heated mold and continuously, for example in a double belt press, so that a flat functional element semifinished product that is highly flexible at room temperature but nevertheless can be handled by machine.

Nach der Herstellung des Thermoplast-Funktionselement-Halbzeuges werden die Prozesshilfsfolien unmittelbar entfernt. Dies erfolgt manuell oder automatisiert, etwa in Form umlaufender Prozesshilfsfolien in einer Doppelbandpresse und/oder einem Rolle-Rolle-Prozess.After the production of the thermoplastic functional element semifinished product, the process auxiliary films are removed immediately. This is done manually or automatically, for example in the form of circulating process auxiliary films in a double belt press and / or a roll-to-roll process.

Bei der Fertigung der adaptiven Faserverbundstruktur wird das Funktionselement-Halbzeug als dreidimensional verformbare Funktionslage dem Faserverbundfertigungsprozess zugeführt und zur Erweichung während oder kurz vor dem Integrationsprozess trägerfolienaußenseitig angeschmolzen, so dass nach Abschluss der Formgebung die vollständige Anbindung der thermoplastischen Trägerfolien des Funktionselement-Halbzeuges mit dem identischen thermoplastischen Matrixmaterial der Faserverbundstruktur vollzogen ist.When fabricating the adaptive fiber composite structure, the functional element semifinished product is fed to the fiber composite production process as a three-dimensionally deformable functional layer and melted on the outside during softening during or shortly before the integration process, so that complete completion of the thermoplastic carrier films of the functional element semifinished product with the identical thermoplastic Matrix material of the fiber composite structure is completed.

Die Lagerung des hochflexiblen thermoplastischen Funktionselement-Halbzeuges wird bis zur Verarbeitung in einem adaptiven Faser-Thermoplast-Verbund bei Raumtemperatur durchgeführt.The storage of the highly flexible thermoplastic functional element semifinished product is carried out at room temperature until it is processed in an adaptive fiber-thermoplastic composite.

Im Fall thermoplastisch umhüllter Funktionselement-Halbzeuge und Faser-Thermoplaste-Verbunde erfolgt die Fixierung der beiden sich gegenüberliegenden Thermoplaste durch Anschmelzen.In the case of thermoplastically coated functional element semifinished products and fiber-thermoplastic composites, the fixation of the two opposing thermoplastics takes place by melting.

Das Funktionselement-Halbzeug zur Integration in Faser-Thermoplast-Verbunde, das mittels des vorgenannten Verfahrens hergestellt wird,
besteht zumindest aus

  • – einem flächenbezogenen, zentral befindlichen Funktionselement-Netzwerk aus Funktionselementen und Leiterbahnen mit elektrischen Anschlüssen und
  • – einem das Funktionselement-Netzwerk umgebenden dünnwandigen thermoplastischen Trägerfolienmantel.
The functional element semifinished product for integration in fiber-thermoplastic composites, which is produced by means of the aforementioned method,
at least consists of
  • - A surface-related, centrally located functional element network of functional elements and interconnects with electrical connections and
  • A thin-walled thermoplastic carrier film jacket surrounding the functional element network.

Im Funktionselement-Netzwerk sind als Komponenten zumindest Sensor(en), Aktor(en) und/oder Ansteuerelemente wie Operationsverstärker, Mikrokontroller vorhanden, die mittels zumindest als elektrisch leitfähige Strukturen ausgebildeten Leiterbahnen miteinander in Verbindung stehen.In the functional element network, at least one sensor (s), actuator (s) and / or control elements such as operational amplifiers, microcontrollers are present as components, which are connected to one another by means of interconnects formed as electrically conductive structures.

Weiterbildungen und weitere Ausgestaltungen der Erfindung werden in weiteren Unteransprüchen angegeben.Further developments and further embodiments of the invention are specified in further subclaims.

Die Erfindung wird mittels eines Ausführungsbeispiels anhand mehrerer Zeichnungen näher erläutert. Es zeigt:The invention will be explained in more detail by means of an embodiment with reference to several drawings. It shows:

1 eine schematische Darstellung des erfindungsgemäßen Verfahrens, 1 a schematic representation of the method according to the invention,

2 eine schematische Querschnittsdarstellung eines thermoplastischen Funktionselement-Halbzeuges während der heißpresstechnischen Fertigung und 2 a schematic cross-sectional view of a thermoplastic functional element-semifinished product during hot press manufacturing and

3 eine schematische Darstellung des Faser-Thermoplast-Verbundes mit integriertem Funktionselement-Halbzeug. 3 a schematic representation of the fiber-thermoplastic composite with integrated functional element-semifinished product.

Im Folgenden werden die 1 und 2 gemeinsam betrachtet. In 1 ist das Verfahren zur Erzeugung von dreidimensional drapierfähigen Thermoplast-Funktionselement-Halbzeugen 1 zur Integration in Faser-Thermoplast-Verbunde 7 dargestellt, The following are the 1 and 2 considered together. In 1 is the process for producing three-dimensional drapeable thermoplastic functional element semifinished products 1 for integration into fiber-thermoplastic composites 7 shown,

Erfindungsgemäß werden zumindest folgende Schritte durchgeführt:

  • – Bereitstellen 22 einer ersten multifunktionalen thermoplastischen Trägerfolie 3,
  • – Auflegen und Positionieren 23 eines Funktionselement-Netzwerkes 10 aus mit flexiblen Leiterbahnen 8 verbundenen flächigen Funktionselementen 9 auf die erste thermoplastische Trägerfolie 3,
  • – Auflegen 24 einer zweiten multifunktionalen thermoplastischen Trägerfolie 11 auf das Funktionselement-Netzwerk 10,
  • – Kontaktschmelzen und Konsolidieren 25 der beiden sich gegenüberliegenden thermoplastischen Trägerfolien 3, 11 mit dem darin befindlichen Funktionselement-Netzwerk 10 in einem Heißpressprozess 6 unter Druck 61 und erhöhter Temperatur 62.
According to the invention, at least the following steps are carried out:
  • - Provide 22 a first multifunctional thermoplastic carrier film 3 .
  • - hang up and positioning 23 a functional element network 10 out with flexible tracks 8th connected flat functional elements 9 on the first thermoplastic carrier film 3 .
  • - Hang up 24 a second multifunctional thermoplastic carrier film 11 on the functional element network 10 .
  • - Contact melting and consolidation 25 the two opposite thermoplastic carrier films 3 . 11 with the functional element network located therein 10 in a hot pressing process 6 vacuum 61 and elevated temperature 62 ,

Unter den Umständen der Funktionselemente schonenden Verpressung und/oder automatischen Fertigung der Funktionselement-Halbzeuge 1 können folgende Teilschritte vorgesehen werden:

  • – Bereitstellen 20 einer unter der ersten multifunktionalen thermoplastischen Trägerfolie 3 anbringbaren ebenen ersten Prozesshilfsfolie 5,
  • – Auflegen 21 der unteren ersten multifunktionalen thermoplastischen Trägerfolie 3 auf die ebene Prozesshilfsfolie 5 und nach dem Aufbringen des Funktionselement-Netzwerkes 10 auf die untere erste multifunktionalen thermoplastische Trägerfolie 3,
  • – Abdecken 26 der oberen zweiten multifunktionalen thermoplastischen Trägerfolie 11 mit einer oberen ebenen zweiten Prozesshilfsfolie 12, so dass ein dünnwandiger thermoplastischer Sandwich 13 aus Funktionselement-Halbzeug 1 und thermoplastischen Trägerfolien 3, 11, mit dem Ziel einer Funktionselemente schonenden Verpressung, zwischen elastischen Prozesshilfsfolien angeordnet ist, wobei die thermoplastischen Trägerfolien 3, 11 die einzelnen Funktionselemente 9 und zugehörigen elektrischen Komponenten 8 umgeben.
  • – Entfernen 27 der ebenen Prozesshilfsfolien 5, 12,
Under the circumstances of the functional elements gentle pressing and / or automatic production of functional element semi-finished products 1 the following sub-steps can be provided:
  • - Provide 20 one below the first multifunctional thermoplastic support film 3 attachable planar first process auxiliary film 5 .
  • - Hang up 21 the lower first multifunctional thermoplastic carrier film 3 on the level process auxiliary foil 5 and after application of the functional element network 10 on the lower first multifunctional thermoplastic carrier film 3 .
  • - Cover 26 the upper second multifunctional thermoplastic support film 11 with an upper level second process auxiliary film 12 making a thin-walled thermoplastic sandwich 13 made of functional element semifinished product 1 and thermoplastic carrier films 3 . 11 , with the aim of a functional elements gentle pressing, is arranged between elastic process auxiliary films, wherein the thermoplastic carrier films 3 . 11 the individual functional elements 9 and associated electrical components 8th surround.
  • - Remove 27 the flat process slides 5 . 12 .

Für die automatische Prozesseinbindung – Integration – der trägerfoliengeschützten Funktionselement-Halbzeuge 1 in einen Faser-Thermoplast-Verbund 7 können zumindest folgende weitere Schritte durchgeführt werden:

  • – Zuführung 28 des Funktionselement-Halbzeuges 1 als dreidimensional verformbare hochflexible Funktionslage mit thermoplastischen Trägerfolien 3, 11 dem Faserverbundfertigungsprozess zur Integration in den Faser-Thermoplast-Verbund 7,
  • – Auf- bzw. Anschmelzen und werkstoffhomogene Verbindung/Konsolidierung 29 der thermoplastischen Trägerfolien 3, 11 des Funktionselement-Halbzeuges 1 und der den Trägerfolien 3, 11 identischen thermoplastischen Matrix 71, 72 des Thermoplast-Verbundes 7.
For automatic process integration - integration - of the carrier film-protected functional element semi-finished products 1 in a fiber-thermoplastic composite 7 At least the following additional steps can be carried out:
  • - Feeder 28 of the functional element semifinished product 1 as a three-dimensional deformable highly flexible functional layer with thermoplastic carrier foils 3 . 11 the fiber composite manufacturing process for integration into the fiber-thermoplastic composite 7 .
  • - Smoothing and melting and material homogenous connection / consolidation 29 the thermoplastic carrier films 3 . 11 of the functional element semifinished product 1 and the carrier foils 3 . 11 identical thermoplastic matrix 71 . 72 of the thermoplastic composite 7 ,

Es wird zur Ausbildung eines Funktionselement-Halbzeuges 1 aufbauseitig vorgeschlagen, dass die flächigen Funktionselemente 9 (Sensor(en), Aktor(en) und Ansteuerelemente wie Operationsverstärker, Mikrokontroller usw.) auf der unteren ersten multifunktionalen thermoplastischen Trägerfolie 3 manuell und/oder robotergeführt angeordnet werden, wobei danach die obere zweite multifunktionale thermoplastische Trägerfolie 11 manuell oder automatisiert aufgelegt wird und mittels des Heißpressprozesses 6 eine Verbindung der sich gegenüberliegenden angeschmolzenen Thermoplastfolien 3, 11 realisiert wird. Das Kontaktschmelzen 25 kann auch durchgeführt werden, wenn die Prozesshilfsfolien 5, 12 beidseitig an dem Funktionselement-Halbzeug 1 anliegen.It is for the formation of a functional element semi-finished product 1 body side proposed that the flat functional elements 9 (Sensor (s), Actuator (s) and Actuators such as operational amplifiers, microcontroller, etc.) on the lower first multifunctional thermoplastic support film 3 be arranged manually and / or guided by a robot, wherein thereafter the upper second multifunctional thermoplastic support film 11 manually or is automatically hung up and by means of the hot pressing process 6 a compound of the opposing fused thermoplastic films 3 . 11 is realized. The contact melting 25 can also be done when the process slides 5 . 12 on both sides of the functional element semi-finished product 1 issue.

Auf Zusatzkomponenten an Sensoren und Aktoren, wie etwa Schutzfolien und elektrisch isolierende Bestandteile, kann hierbei ausdrücklich verzichtet werden, da diese die direkte funktionale Anbindung an den Faserverbundwerkstoff beeinträchtigen.On additional components of sensors and actuators, such as protective films and electrically insulating components, this can be explicitly omitted, as they affect the direct functional connection to the fiber composite material.

Der thermoplastische Trägerfolienverbund im Funktionselement-Halbzeug 1 umgibt die einzelnen Komponenten und stellt somit einen mechanischen Schutz und eine elektrische Isolation dieser sicher.The thermoplastic carrier film composite in the functional element semifinished product 1 surrounds the individual components and thus ensures mechanical protection and electrical insulation of these.

Das Bereitstellen 20, 22, 24, 26 der Prozesshilfsfolien 5, 12 und thermoplastischen Trägerfolien 3, 11 kann sowohl manuell in einem planaren Formwerkzeug als auch automatisiert, etwa mittels Rolle-Rolle-Verfahren, erfolgen.Deploying 20 . 22 . 24 . 26 the process help slides 5 . 12 and thermoplastic carrier films 3 . 11 can be done both manually in a planar mold as well as automated, such as by roll-roll method.

Das Kontaktschmelzen 25 in einem Heißpressprozess 6 kann sowohl diskontinuierlich in einer stationären Presse mit beheiztem Formwerkzeug als auch kontinuierlich, etwa in einer Doppelbandpresse, erfolgen, so dass ein bei Raumtemperatur hochflexibles aber dennoch maschinell handhabbares flächiges Funktionselement-Halbzeug 1 erreicht wird.The contact melting 25 in a hot pressing process 6 can both discontinuously in a stationary press with heated mold and continuously, such as in a double belt press, done so that a highly flexible at room temperature, but still manageable machined flat functional element semifinished 1 is reached.

Nach der Herstellung des Thermoplast-Funktionselement-Halbzeuges 1 werden die Prozesshilfsfolien 5, 12 unmittelbar entfernt. Dies erfolgt manuell oder automatisiert, etwa in Form umlaufender Prozesshilfsfolien 5, 12 in einer Doppelbandpresse und/oder einem Rolle-Rolle-Prozess, so dass die Prozesshilfsfolien 5, 12 dem Prozess und nicht dem Thermoplast-Funktionselement-Halbzeug 1 zugeordnet sind.After the production of the thermoplastic functional element semifinished product 1 become the process help slides 5 . 12 immediately removed. This is done manually or automatically, for example in the form of circulating process auxiliary films 5 . 12 in a double belt press and / or a roll-to-roll process, so that the process auxiliary films 5 . 12 the process and not the thermoplastic functional element semifinished product 1 assigned.

Bei der Fertigung der adaptiven Faserverbundstruktur wird das Funktionselement-Halbzeug 1 zur Erweichung trägerfolienaußenseitig angeschmolzen und als dreidimensional verformbare Funktionslage dem Faserverbundfertigungsprozess zugeführt, in dem nach Abschluss der Formgebung die vollständige Anbindung der angeschmolzenen erweichten thermoplastischen Trägerfolien 3, 11 gemeinsam mit der vernetzenden Anbindung des identischen angeschmolzenen erweichten faserverstärkten thermoplastischen Matrixmaterials 71, 72, wie in 3 gezeigt ist, erfolgt, was eine werkstoffhomogene Anbindung von Funktionselementen 9 und Faserverbundstruktur garantiert.In the manufacture of the adaptive fiber composite structure, the functional element semifinished product 1 for softening carrier film outside melted and fed as a three-dimensionally deformable functional position of the fiber composite manufacturing process, in which after completion of the molding the complete connection of the melted softened thermoplastic carrier films 3 . 11 together with the cross-linking of the identical fused softened fiber reinforced thermoplastic matrix material 71 . 72 , as in 3 is shown, which is a material-homogeneous connection of functional elements 9 and fiber composite structure guaranteed.

Zusammenfassend wird das Integrationsverfahren nochmals kurz erläutert:
Es wird zunächst auf eine untere Trägerfolie 3 analog das Funktionselement-Netzwerk 10 aufgebaut. Nach Auflegen einer oberen Trägerfolie 11 erfolgt das Aufschmelzen 25 und Konsolidieren des Gesamtaufbaus in einem Heißpressprozess 6 unter Druck 61 und erhöhter Temperatur 62, wobei der Aufbau zur Gewährleistung einer quasistatischen Druckverteilung und somit zum Schutz der Funktionselemente 9 vor lokaler Überbeanspruchung wahlweise zwischen dickeren elastischen Folien (z. B. Silikon- oder EPDM-Folien) als Prozesshilfsmittel 5, 12 angeordnet ist. Die Lagerung des hochflexiblen Thermoplast-Funktionselement-Halbzeuges 1 bis zur Verarbeitung in einem adaptiven Thermoplastverbund erfolgt bei Raumtemperatur.In summary, the integration procedure is briefly explained again:
It is first applied to a lower carrier film 3 analogous to the functional element network 10 built up. After placing an upper carrier foil 11 the melting takes place 25 and consolidating the overall design in a hot pressing process 6 vacuum 61 and elevated temperature 62 , Wherein the construction to ensure a quasi-static pressure distribution and thus to protect the functional elements 9 against local overstress optionally between thicker elastic foils (eg silicone or EPDM foils) as process auxiliaries 5 . 12 is arranged. The storage of the highly flexible thermoplastic functional element semi-finished product 1 until processing in an adaptive thermoplastic composite takes place at room temperature.

Der Kern der Erfindung liegt in der Verwendung von multifunktionalen thermisch erweichbaren thermoplastischen Trägerfolien 3, 11 für den Aufbau eines Thermoplast-Funktionselement-Halbzeuges 1, um somit eine plastische Verformbarkeit entsprechend der zumindest ebenfalls oberflächig erweichten Verbundstruktur bei gleichzeitiger Isolation und bestmöglichem Schutz der Funktionselemente 9 zu gewährleisten.The core of the invention lies in the use of multifunctional thermally softenable thermoplastic carrier films 3 . 11 for the construction of a thermoplastic functional element semi-finished product 1 Thus, a plastic deformability according to the at least also surface-softened composite structure with simultaneous isolation and the best possible protection of the functional elements 9 to ensure.

Im Fall thermoplastisch umhüllter Funktionselement-Halbzeuge 1 und Faser-Thermoplaste-Verbunde 7 kann die Fixierung der beiden sich gegenüberliegenden Thermoplastflächen durch das kontaktflächenseitige Auf- oder Anschmelzen und Konsolidieren 29 erfolgen.In the case of thermoplastically coated functional element semifinished products 1 and fiber-thermoplastics composites 7 For example, the fixation of the two opposite thermoplastic surfaces by the contact surface side melting or melting and consolidation 29 respectively.

Der Kern liegt weiterhin in der Realisierung einer maximal möglichen Werkstoffkompatibilität durch verbundmatrixgerechte Anpassung des thermoplastischen Funktionselementträgerwerkstoffes.The core continues to be the realization of a maximum possible material compatibility by composite matrix-compatible adaptation of the thermoplastic functional element carrier material.

Im Zusammenhang mit Thermoplast-Funktionselement-Halbzeugen 1 liegt der Kern zusätzlich in der funktionselementschonenden heißpresstechnischen Fertigungstechnologie.In connection with thermoplastic functional element semi-finished products 1 In addition, the core lies in the functional element-protecting hot press technology manufacturing technology.

Die Vorteile der Erfindung sind folgende:

  • – Robuste und automatisierte Handhabbarkeit eines komplett aufgebauten Funktionselement-Halbzeuges 1 während der Fertigung adaptiver Bauteilstrukturen,
  • – Entfall zeitaufwändiger manueller Montageschritte während der Bauteilfertigung,
  • – Plastische Verformbarkeit oder hochflexible Anpassbarkeit und somit Möglichkeit der dreidimensionalen geometrischen Konturanpassung des Funktionselemente-Halbzeuges 1 an die Verbundstruktur,
  • – Mechanischer Schutz und elektrische Isolation des Funktionselement-Halbzeuges 1 durch vollständige Matrixeinbettung,
  • – Werkstoffhomogene Anbindung der Funktionselemente 9 an die Verbundstruktur zur Gewährleistung maximaler Funktionalität.
The advantages of the invention are as follows:
  • Robust and automated handling of a completely assembled functional element semifinished product 1 during the manufacturing of adaptive component structures,
  • - elimination of time-consuming manual assembly steps during component production,
  • - Plastic deformability or highly flexible adaptability and thus possibility of the three-dimensional geometric contour adjustment of the functional semifinished product 1 to the composite structure,
  • - Mechanical protection and electrical insulation of the functional element-semifinished product 1 by complete matrix embedding,
  • - Material-homogeneous connection of the functional elements 9 to the composite structure to ensure maximum functionality.

BezugszeichenlisteLIST OF REFERENCE NUMBERS

11
Thermoplast-Funktionselement-HalbzeugThermoplastic functional element semifinished
22
Elektrische AnschlüsseElectrical connections
33
erste multifunktionale thermoplastische Trägerfoliefirst multifunctional thermoplastic carrier film
55
erste Prozesshilfsfoliefirst process auxiliary film
66
HeißpressprozessHot-pressing process
6161
Druckrichtungprint direction
6262
Temperaturrichtungtemperature direction
77
adaptiver Faser-Thermoplast-Verbundadaptive fiber-thermoplastic composite
7171
erstes faserverstärktes thermoplastisches Matrixmaterialfirst fiber-reinforced thermoplastic matrix material
7272
zweites faserverstärktes thermoplastisches Matrixmaterialsecond fiber reinforced thermoplastic matrix material
88th
Leiterbahnenconductor tracks
99
Funktionselementefunctional elements
1010
Funktionselement-NetzwerkFunctional element network
1111
zweite multifunktionale thermoplastische Trägerfoliesecond multifunctional thermoplastic carrier film
1212
zweite Prozesshilfsfoliesecond process auxiliary foil
1313
thermoplastischer Sandwichthermoplastic sandwich
2020
BereitstellenProvide
2121
Auflegenhang up
2222
BereitstellenProvide
2323
Auflegen und PositionierenHang up and positioning
2424
Auflegenhang up
2525
KontaktschmelzenContact melting
2626
AbdeckenCover
2727
EntfernenRemove
2828
Zuführungfeed
2929
Anschmelzen und KonsolidierenMelt and consolidate

ZITATE ENTHALTEN IN DER BESCHREIBUNG QUOTES INCLUDE IN THE DESCRIPTION

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

Zitierte PatentliteraturCited patent literature

  • US 6629341 B2 [0003] US 6629341 B2 [0003]
  • EP 1983584 A2 [0003] EP 1983584 A2 [0003]
  • DE 102008040316 A1 [0003] DE 102008040316 A1 [0003]
  • US 46849668 [0003] US 46849668 [0003]
  • DE 102006047411 A1 [0004] DE 102006047411 A1 [0004]
  • DE 102007037342 A1 [0004] DE 102007037342 A1 [0004]
  • US 4849668 [0005] US 4849668 [0005]
  • DE 10143226 A1 [0005] DE 10143226 A1 [0005]
  • EP 1168463 A1 [0005] EP 1168463 A1 [0005]
  • DE 10058096 A1 [0005] DE 10058096 A1 [0005]

Claims (12)

Verfahren zur Erzeugung von dreidimensional drapierfähigen Thermoplast-Funktionselement-Halbzeugen (1) zur Integration in Faser-Thermoplast-Verbunde (7), gekennzeichnet durch zumindest folgende Schritte: – Bereitstellen (22) einer ersten multifunktionalen thermoplastischen Trägerfolie (3), – Auflegen und Positionieren (23) eines Funktionselement-Netzwerkes (10) aus mit flexiblen Leiterbahnen (8) verbundenen flächigen Funktionselementen (9) auf die erste multifunktionale thermoplastische Trägerfolie (3), – Auflegen (24) einer zweiten multifunktionalen thermoplastischen Trägerfolie (11) auf das Funktionselement-Netzwerke (10), – Kontaktschmelzen (25) der beiden sich gegenüberliegenden thermoplastischen Trägerfolien (3, 11) und Konsolidieren des darin befindlichen Funktionselement-Netzwerkes (10) in einem Heißpressprozess (6) unter Druck (61) und erhöhter Temperatur (62).Method for producing three-dimensionally drapeable thermoplastic functional element semi-finished products ( 1 ) for integration into fiber-thermoplastic composites ( 7 ) characterized by at least the following steps: - providing ( 22 ) a first multifunctional thermoplastic carrier film ( 3 ), - hang up and positioning ( 23 ) of a functional element network ( 10 ) made of flexible interconnects ( 8th ) connected planar functional elements ( 9 ) to the first multifunctional thermoplastic carrier film ( 3 ), - Hang up ( 24 ) a second multifunctional thermoplastic carrier film ( 11 ) on the functional element networks ( 10 ), - contact melting ( 25 ) of the two opposing thermoplastic carrier films ( 3 . 11 ) and consolidate the functional element network ( 10 ) in a hot pressing process ( 6 ) vacuum ( 61 ) and elevated temperature ( 62 ). Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass zur automatischen Erzeugung der Thermoplast-Funktionselement-Halbzeuge (1) folgende Teilschritte vorgesehen werden: – Bereitstellen (20) einer unter der ersten multifunktionalen thermoplastischen Trägerfolie (3) anbringbaren ebenen ersten Prozesshilfsfolie (5), – Auflegen (21) der unteren ersten multifunktionalen thermoplastischen Trägerfolie (3) auf die ebene Prozesshilfsfolie (5) und nach dem Aufbringen des Funktionselement-Netzwerkes (10) auf die untere erste thermoplastische Trägerfolie (3), – Abdecken (26) der oberen zweiten multifunktionalen thermoplastischen Trägerfolie (11) mit einer oberen ebenen zweiten Prozesshilfsfolie (12), so dass ein dünnwandiger thermoplastischer Sandwich (13) aus Funktionselement-Halbzeug (1) und thermoplastischen Trägerfolien (3, 11), mit dem Ziel einer Funktionselemente schonenden Verpressung, zwischen elastischen Prozesshilfsfolien angeordnet ist, wobei die thermoplastischen Trägerfolien (3, 11) die einzelnen Funktionselemente (9) und zugehörigen elektrischen Komponenten (8) umgeben, – Entfernen (27) der ebenen Prozesshilfsfolien (5, 12).Method according to claim 1, characterized in that for the automatic production of the thermoplastic functional element semi-finished products ( 1 ) the following sub-steps are envisaged: - providing ( 20 ) one of the first multifunctional thermoplastic carrier film ( 3 ) attachable planar first process auxiliary film ( 5 ), - Hang up ( 21 ) of the lower first multifunctional thermoplastic carrier film ( 3 ) on the flat process auxiliary foil ( 5 ) and after applying the functional element network ( 10 ) on the lower first thermoplastic carrier film ( 3 ), - Covering ( 26 ) of the upper second multifunctional thermoplastic carrier film ( 11 ) with an upper level second process auxiliary film ( 12 ), so that a thin-walled thermoplastic sandwich ( 13 ) made of functional element semifinished product ( 1 ) and thermoplastic carrier films ( 3 . 11 ), with the aim of a functional elements gentle pressing, between elastic process auxiliary films is arranged, wherein the thermoplastic carrier films ( 3 . 11 ) the individual functional elements ( 9 ) and associated electrical components ( 8th ), - Remove ( 27 ) of the flat process auxiliary slides ( 5 . 12 ). Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass für die automatische Prozesseinbindung der trägerfoliengeschützten Thermoplast-Funktionselement-Halbzeuge (1) in einen Faser-Thermoplast-Verbund (7) zumindest folgende weitere Schritte durchgeführt werden: – Zuführung (28) des Funktionselement-Halbzeuges (1) als dreidimensional verformbare hochflexible Funktionslage mit thermoplastischen Trägerfolien (3, 11) dem Faserverbundfertigungsprozess zur Integration in den Faser-Thermoplast-Verbund (7), – Auf- bzw. Anschmelzen und werkstoffhomogene Verbindung/Konsolidierung (29) der thermoplastischen Trägerfolien (3, 11) des Funktionselement-Halbzeuges (1) und der den Trägerfolien (3, 11) identischen thermoplastischen Matrix (71, 72) des Thermoplast-Verbundes (7).A method according to claim 1, characterized in that for the automatic process integration of the carrier film-protected thermoplastic functional element semi-finished products ( 1 ) into a fiber-thermoplastic composite ( 7 ) at least the following additional steps are carried out: 28 ) of the functional element semifinished product ( 1 ) as a three-dimensionally deformable highly flexible functional layer with thermoplastic carrier films ( 3 . 11 ) the fiber composite manufacturing process for integration into the fiber-thermoplastic composite ( 7 ), - melting or melting and material homogenous connection / consolidation ( 29 ) of the thermoplastic carrier films ( 3 . 11 ) of the functional element semifinished product ( 1 ) and the carrier foils ( 3 . 11 ) identical thermoplastic matrix ( 71 . 72 ) of the thermoplastic composite ( 7 ). Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass das Thermoplast-Funktionselement-Halbzeug (1) aufbauseitig mit flächigen Funktionselementen (9) auf der unteren ersten multifunktionalen thermoplastischen Trägerfolie (3) manuell und/oder robotergeführt versehen wird, wobei danach die obere zweite multifunktionale thermoplastische Trägerfolie (11) manuell oder automatisiert aufgelegt wird und mittels des Heißpressprozesses (6) eine Verbindung der sich gegenüberliegenden angeschmolzenen Thermoplastfolien (3, 11) realisiert wird.Method according to claim 1, characterized in that the thermoplastic functional element semifinished product ( 1 ) on the body side with flat functional elements ( 9 ) on the lower first multifunctional thermoplastic support film ( 3 ) is provided manually and / or robotically guided, after which the upper second multifunctional thermoplastic carrier film ( 11 ) is applied manually or automatically and by means of the hot pressing process ( 6 ) a compound of the opposing fused thermoplastic films ( 3 . 11 ) is realized. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass bei Fertigung der adaptiven Faserverbundstruktur das Thermoplast-Funktionselement-Halbzeug (1) als hochflexible verformbare Funktionslage dem Faserverbundfertigungsprozess zugeführt wird und zur Erweichung trägerfolienaußenseitig aufgeschmolzen oder angeschmolzen wird, so dass nach Abschluss der Formgebung die vollständige Anbindung der thermoplastischen Trägerfolien (3, 11) gemeinsam mit der vernetzenden Anbindung des erweichten identischen faserverstärkten thermoplastischen Matrixmaterials (71, 72) erfolgt.A method according to claim 1, characterized in that during manufacture of the adaptive fiber composite structure, the thermoplastic functional element semifinished product ( 1 ) is supplied to the fiber composite production process as a highly flexible, deformable functional layer and is melted or fused onto the outer surface of the carrier film for softening, so that complete completion of the thermoplastic carrier films ( 3 . 11 ) together with the cross-linking of the softened identical fiber-reinforced thermoplastic matrix material ( 71 . 72 ) he follows. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass die Lagerung des hochflexiblen Thermoplast-Funktionselement-Halbzeuges (1) bis zur Verarbeitung in einem adaptiven Faser-Thermoplast-Verbund (7) bei Raumtemperatur durchgeführt wird.A method according to claim 1, characterized in that the storage of the highly flexible thermoplastic functional element semifinished product ( 1 ) to processing in an adaptive fiber-thermoplastic composite ( 7 ) is carried out at room temperature. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass im Fall thermoplastisch umhüllter Funktionselement-Halbzeuge (1) und Faser-Thermoplaste-Verbunde (7) die Fixierung der beiden sich gegenüberliegenden Thermoplaste durch Anschmelzen (25) erfolgt.A method according to claim 1, characterized in that in the case of thermoplastic-coated functional element semi-finished products ( 1 ) and fiber-thermoplastic composites ( 7 ) the fixation of the two opposite thermoplastics by melting ( 25 ) he follows. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass das Bereitstellen (20, 22, 24, 26) der Prozesshilfsfolien (5, 12) und thermoplastischen Trägerfolien (3, 11) manuell in einem Planaren Formwerkzeug oder automatisiert, vorzugsweise mittels Rolle-Rolle-Verfahren, erfolgt.Method according to claim 1, characterized in that the providing ( 20 . 22 . 24 . 26 ) of the process auxiliary slides ( 5 . 12 ) and thermoplastic carrier films ( 3 . 11 ) manually in a planar mold or automated, preferably by means of roll-roll method occurs. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass das Kontaktschmelzen (25) in einem Heißpressprozess (6) diskontinuierlich in einer stationären Presse mit beheiztem Formwerkzeug oder kontinuierlich, etwa in einer Doppelbandpresse, erfolgt, so dass ein bei Raumtemperatur hochflexibles, aber dennoch maschinell handhabbares flächiges Funktionselement-Halbzeug (1) erreicht wird.Method according to claim 1, characterized in that the contact melting ( 25 ) in a hot pressing process ( 6 ) discontinuously in a stationary press with a heated mold or continuously, for example in a double-belt press, so that a highly flexible at room temperature, but nevertheless machine-manageable planar functional element semifinished product ( 1 ) is achieved. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass nach der Herstellung des Thermoplast-Funktionselement-Halbzeuges (1) die Prozesshilfsfolien (5, 12) unmittelbar entfernt werden und dies manuell oder automatisiert erfolgt, etwa in Form umlaufender Prozesshilfsfolien (5, 12) in einer Doppelbandpresse und/oder in einem Rolle-Rolle-Prozess, so dass die Prozesshilfsfolien (5, 12) dem Prozess und nicht dem Thermoplast-Funktionselement-Halbzeug (1) zugeordnet sind.A method according to claim 1, characterized in that after the production of the thermoplastic functional element semifinished product ( 1 ) the process help slides ( 5 . 12 ) are removed directly and this is done manually or automatically, for example in the form of circulating process auxiliary films ( 5 . 12 ) in a double belt press and / or in a roll-to-roll process, so that the process auxiliary films ( 5 . 12 ) the process and not the thermoplastic functional element semifinished product ( 1 ) assigned. Thermoplast-Funktionselement-Halbzeug (1) zur Integration in Faser-Thermoplast-Verbunde (7), hergestellt mittels des Verfahrens nach den Ansprüchen 1 bis 7, dadurch gekennzeichnet, dass es besteht aus – einem flächenbezogenen, zentral befindlichen Funktionselement-Netzwerk (10) aus Funktionselementen (9) und Leiterbahnen (6) mit elektrischen Anschlüssen (2), – einem das Funktionselement-Netzwerk (10) umgebenden dünnwandigen thermoplastischen Trägerfolienmantel (3, 11) undThermoplastic functional element semifinished product ( 1 ) for integration into fiber-thermoplastic composites ( 7 ), produced by means of the method according to claims 1 to 7, characterized in that it consists of - a surface-related, centrally located functional element network ( 10 ) from functional elements ( 9 ) and printed conductors ( 6 ) with electrical connections ( 2 ), - the functional element network ( 10 ) surrounding thin-walled thermoplastic carrier film jacket ( 3 . 11 ) and Thermoplast-Funktionselement-Halbzeug nach Anspruch 11, dadurch gekennzeichnet, dass im Funktionselement-Netzwerk (10) als Komponenten zumindest Sensor/en, Aktor/en und/oder Ansteuerelemente wie Operationsverstärker, Mikrokontroller vorhanden sind, die mittels zumindest als elektrisch leitfähige Strukturen ausgebildeten Leiterbahnen (8) miteinander in Verbindung stehen.Thermoplastic functional element semifinished product according to claim 11, characterized in that in the functional element network ( 10 ) are present as components at least sensor / s, actuator / s and / or control elements such as operational amplifiers, microcontrollers, which are formed by means of at least as electrically conductive structures conductor tracks ( 8th ) communicate with each other.
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