Processing arrangement and a method for producing a fiber-reinforced plastic component

Patent metadata

Field	Value
Publication number	US-10543648-B2
Application number	US-201615552939-A
Country	US
Kind code	B2
Filing date	Feb 15, 2016
Priority date	Feb 23, 2015
Publication date	Jan 28, 2020
Grant date	Jan 28, 2020

Abstract

A process arrangement and a process for the production of a fiber-reinforced plastics component made of at least one continuous-fiber-reinforced semifinished textile fiber product with reactive thermoplastic matrix material, where during the manufacture of the semifinished fiber product trimming residues arise, composed of a composite made of fibers and of the reactive thermoplastic matrix material. The trimming residues obtained during the manufacture of the semifinished fiber product are supplied to a recycling unit for the provision of a recyclate as reactive, as yet unpolymerized starting material for the production of a further component.

First claim

The invention claimed is:

1. A process arrangement for the production of a fiber-reinforced plastics component, comprising:
a manufacture and assembly unit for the provision of at least one continuous-fiber-reinforced semifinished textile fiber product with reactive thermoplastic matrix material, with formation of trimming residues made of a composite of fibers and of the reactive thermoplastic matrix material,
a cutting unit, wherein the manufacture and assembly unit and cutting unit comprise a continuous transport belt on which:
the manufacture and assembly unit preimpregnates at least one continuous web made of a texture structure with a liquid starting component of the reactive thermoplastic matrix material in the manufacturing unit in a continuous process, and
after impregnation, the cutting unit performs edge-trimming in which the preimpregnated continuous structure is cut to size to give the continuous-fiber-reinforced semifinished textile fiber product with reactive thermoplastic matrix material, with formation of an edge-trimming residue, composed of the composite of fibers and of reactive thermoplastic matrix material,

wherein the manufacture and assembly unit comprises a cooling unit upstream from the cutting unit,
a press unit and/or thermoforming unit in which the continuous-fiber-reinforced semifinished textile fiber product with reactive thermoplastic matrix material is heated to a temperature above the polymerization temperature and at the same time can be pressed and/or thermoformed into the shape of the required plastics component, and
a recycling unit into which the trimming residues made of the composite of fibers and of reactive thermoplastic matrix material can be supplied for the provision of a recyclate as reactive, as yet unpolymerized starting material for the production of a further component or for the functionalization of the component.

2. The process arrangement according to claim 1 , further comprising a shaping unit in which the component is produced with polymerization of the recyclate as a result of introduction of heat.

3. The process arrangement according to claim 2 , wherein the shaping unit comprises an extruder or a metering facility in which the recyclate can be melted to above its melting temperature but below its reaction temperature, and the melted recyclate can be introduced by means of the extruder or the metering facility into a shaping mold which is heated to a temperature above the reaction temperature.

4. The process arrangement according to claim 2 , wherein the recyclate, without prior heating to above its melting temperature, can be introduced in the solid aggregate state into a mold cavity of the shaping mold of the shaping unit, and the recyclate is melted, distributed in the mold cavity, and polymerized therein only when the mold cavity of the shaping mold is closed.

5. The process arrangement according to claim 1 , wherein the recycling unit comprises a comminuting assembly, in which the supplied trimming residues can be comminuted to specified fiber lengths.

6. The process arrangement according to claim 3 , wherein a reactive matrix material and/or optionally additives can be added to the trimming residues passed into the recycling unit.

7. The process arrangement according to claim 1 , wherein, in the assembly unit, the continuous-fiber-reinforced semifinished textile fiber products can be mutually superposed in layers to give a layer package in a lay-up procedure, or assembly trimming takes place in which the semifinished fiber product can be trimmed to size in accordance with a final shape of the fiber-reinforced plastics component, with formation of an assembly-trimming residue composed of the composite made of fibers and of reactive thermoplastic matrix material.

Assignees

• Volkswagen Ag
• Basf Se

Inventors

• Mertens Thomas
• Ehleben Max
• Kunze Christine
• Täger Olaf
• Bitterlich Maurice
• Zeuner Katja
• Desbois Philippe
• Wollny Andreas

Classifications

• B29C70/50

  for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] · CPC title

• B29C70/46 Primary

  using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs · CPC title

• B29C70/465 Primary

  and impregnating by melting a solid material, e.g. sheets, powders of fibres · CPC title

• B29B2017/001

  Pretreating the materials before recovery · CPC title

• B29B17/0005 Primary

  Direct recuperation and re-use of scrap material during moulding operation, i.e. feed-back of used material · CPC title