Component made of a fiber composite material containing wound layers and method of fabricating the component

Patent metadata

Field	Value
Publication number	US-10088235-B2
Application number	US-201414173213-A
Country	US
Kind code	B2
Filing date	Feb 5, 2014
Priority date	Aug 5, 2011
Publication date	Oct 2, 2018
Grant date	Oct 2, 2018

Abstract

A component made of a fiber composite material contains at least three wound layers made of a fiber material that are arranged one over the other. Each of the wound layers contains one or more windings. For each wound layer containing more than one winding, all windings of the wound layer have the same winding angle and are separated from each other in some sections, whereby intermediate spaces are formed between the windings. All windings of at least two of the wound layers have the same first winding angle. All of the windings of one wound layer, which is arranged between the two wound layers having the windings with a same first winding angle, have a second winding angle. The magnitudes of the first and second winding angles differ, and the windings having the second winding angle intersect with the windings having the first winding angle.

First claim

The invention claimed is:

1. A component made of a fiber composite material, comprising:
at least three wound layers made of a fiber material being disposed one over the other, each of said wound layers having at least one winding, wherein for each of said wound layers having windings all of said windings of said wound layer having a same winding angle and are at a distance from each other at least in some sections to form intermediate spaces between said windings wherein there are interleaved windings of other wound layers, all of said windings of at least two of said wound layers have a same first winding angle and all of said windings of at least one of said wound layers, disposed between said at least two wound layers having said windings with said same first winding angle, have a second winding angle, wherein a magnitude of said second winding angle is different from a magnitude of said first winding angle, and wherein at least one of said windings having said second winding angle intersects with at least one of said windings having said first winding angle, wherein at least one of said windings of at least one of said wound layers at least in some said sections engages in at least one said intermediate space of said wound layer disposed below and/or above said one wound layer; and wherein in each of said wound layers containing said windings, a ratio of a sum of areas of said intermediate spaces between said windings in said wound layer to a total area of said wound layer is 0.05000 to 0.99999.

2. The component according to claim 1 , wherein the fiber composite material formed from all said wound layers disposed one above the other does not have holes.

3. The component according to claim 1 , wherein said magnitude of said second winding angle differs from said magnitude of said first winding angle by at least 1°.

4. The component according to claim 1 , wherein all of said windings of at least one of said wound layers having said windings with said first winding angle engage in said intermediate spaces of said at least one said wound layers having said windings with said second winding angle and/or in said intermediate spaces of a further one of said wound layers having said windings with said first winding angle.

5. The component according to claim 1 , wherein each of said wound layers contains 1 to 2,000 windings.

6. The component according to claim 1 , wherein the component has at least 10 said wound layers disposed one above the other.

7. The component according to claim 1 , wherein in each case one said wound layer having said windings with said first winding angle and one said wound layer having said windings with said second winding angle are disposed directly above one another in an alternating sequence.

8. The component according to claim 7 , wherein at least one additional one of said wound layers is disposed between said at least two wound layers having said windings with said first winding angle apart from said wound layer having said windings with said second winding angle.

9. The component according to claim 8 , wherein in said at least one additional wound layer containing said windings, all of said windings of said additional wound layer has a third winding angle whose magnitude differs from said magnitude of said first winding angle and from said magnitude of said second winding angle.

10. The component according to claim 1 , wherein all of said windings having said second winding angle intersect with at least one said winding having said first winding angle.

11. The component according to claim 1 , wherein said fiber material contains fibers selected from the group consisting of carbon fibers, ceramic fibers, glass fibers, polymer fibers and a mixture of at least two of the aforesaid materials.

12. The component according to claim 1 , wherein the fiber composite material is selected from the group consisting of a carbon-fiber-reinforced carbon (CFC), a carbon-fiber-reinforced plastic (CFP), a carbon-fiber-reinforced ceramic and a ceramic-fiber-reinforced ceramic (CMC).

13. The component according to claim 1 , wherein said wound layers disposed one above the other form an unsupported winding.

14. The component according to claim 1 , wherein the component is configured as a crucible for melting and crystallization of a metal and/or semi-metal.

15. A method for fabricating the component of claim 1 , the method comprising the steps of:
winding at least three wound layers of a fiber material one over the other on a winding core, for each of the wound layers at least one winding is wound, and all windings of one wound layer having the windings are wound with a same winding angle and are wound at a distance from each other onto the winding core at least in some sections to form intermediate spaces between the windings, wherein there are interleaved windings of other wound the windings of at least two of the wound layers having a same first winding angle are wound on the winding core and all of the windings of at least one of the wound layers having a second winding angle, whose magnitude differs from a magnitude of the first winding angle are wound on the winding core in such a manner that the one wound layer is disposed between the at least two wound layers having the windings having the first winding angle, and at least one of the windings having the second winding angle intersects with at least one of the windings having the first winding angle least one of the windings of at least one of the wound layers at least in some sections engages in at least one intermediate space of the wound layer disposed below and/or above the one wound layer; and for each of the wound layers, winding at least two of the windings of the fiber material on the winding core at a distance from one another at least in some of the sections to form intermediate spaces between the windings so that a ratio of a sum of areas of the intermediate spaces between the windings in the wound layer to a total area of the wound layer is 0.05000 to 0.99999.

16. The method according to claim 15 , which further comprises winding the windings of the at least three wound layers on the winding core in such a manner that the windings completely cover at least a section of the winding core.

17. The method according to claim 15 , which further comprises:
impregnating the fiber material before, during or after the winding with a binder; and
curing the binder after the impregnating and after the winding of the fiber material.

18. The method according to claim 17 , which further comprises performing the curing via thermally and/or chemically.

19. The method according to claim 15 , wherein for the winding, endless fiber strands containing carbon fibers are laid on the winding core.

20. The method according to claim 15 , which further comprises creating and/or configuring a program containing control instructions relating to the winding for an automatic winding machine before the winding of the wound layers on the winding core, wherein the winding of the windings is accomplished by executing the control instructions.

Assignees

• Sgl Carbon Se

Inventors

• Schroeder Markus
• Frommelt Sebastian
• Hingst Karl

Classifications

• F27B14/10 Primary

  Crucibles · CPC title

• Y10T428/13

  Hollow or container type article [e.g., tube, vase, etc.] · CPC title

• B29C53/602

  for tubular articles having closed or nearly closed ends, e.g. vessels, tanks, containers · CPC title

• B29C53/60 Primary

  using internal forming surfaces, e.g. mandrels · CPC title

• B29C70/16

  using fibres of substantial or continuous length {(non-woven fabrics per se D04H3/00)} · CPC title