Method and apparatus for impregnating a fibre bundle and method and facility for producing a three-dimensional structure

Patent metadata

Field	Value
Publication number	US-12233576-B2
Application number	US-202017438111-A
Country	US
Kind code	B2
Filing date	Feb 13, 2020
Priority date	Mar 13, 2019
Publication date	Feb 25, 2025
Grant date	Feb 25, 2025

Abstract

The invention relates to a method for impregnating at least one fibre bundle ( 11 ) with a high-viscosity plastics material ( 13 ), said method comprising the following steps: •—providing at least one fibre bundle ( 11 ) for impregnation, formed of a multiplicity of continuous fibres, and providing a plastics material ( 13 ), melted at a mandated operating temperature and of high viscosity, and •—impregnating the fibre bundle ( 11 ) with the plastics material ( 13 ), by guiding the fibre bundle for impregnation continuously through an impregnation cavity ( 12 ), filled with the melted plastics material ( 13 ), •—where during impregnation of the fibre bundle, the melted plastics material within the impregnation cavity is contacted with a surface ( 15 ) of at least one oscillation generator ( 14 ) in such a way that sonic energy is introduced by said oscillation generator into the melted high-viscosity plastics material in the impregnation cavity.

First claim

The invention claimed is:

1. A method for impregnating at least one fiber bundle with a highly viscous plastics, comprising:
providing at least one fiber bundle to be impregnated, wherein the at least one fiber bundle is formed from a multiplicity of endless fibers, and providing a plastics material that attains a molten, highly viscous state at a predefined process temperature, and
impregnating the at least one fiber bundle with the plastics material by continuously guiding the at least one fiber bundle to be impregnated through an impregnation cavity which is filled with the plastics material in the molten, and highly viscous state at the predefined process temperature,
wherein, during the impregnation of the at least one fiber bundle, the plastics material located in the impregnation cavity is in contact with a surface of at least one vibration generator such that sound energy is introduced into the plastics material while the plastics material is in the molten, highly viscous state,
wherein a surface of the impregnation cavity is a surface of a structure having a natural vibration characteristic having real and/or complex eigenmodes, and
wherein the vibration generator is configured to induce the real and/or complex eigenmodes of the structure during the impregnation of the at least one fiber bundle, while the plastics material located in the impregnation cavity is in contact with the surface of the structure having the natural vibration characteristic having real and/or complex eigenmodes.

2. The method as claimed in claim 1 , wherein the plastics material is a thermoplastic material.

3. The method as claimed in claim 1 wherein the vibration generator generates a vibration amplitude of between 1 μm and 150 μm, and/or wherein the vibration generator generates a vibration frequency of between 100 Hz and 100 kHz.

4. The method as claimed in claim 1 wherein the surface of the vibration generator in contact with the plastics material is subjected to a microstructuring, roughening and/or plasma pretreatment or is provided such that adhesion and/or wetting of the surface of the vibration generator with the plastics material is better than if no treatment of the surface is provided.

5. The method as claimed in claim 1 wherein the plastics material is physically modified in a manner that reduces forces of cohesion.

6. The method as claimed in claim 1 ,
wherein the vibration generator includes a vibrator,
wherein the vibrator is configured with a hole or recess having a surface,
at least one fiber bundle in the impregnation cavity is guided through the surface of the vibrator in a manner wherein the surface of the vibrator at least partially encloses the at least one fiber bundle while the surface of the vibration generator is in contact with the plastics material while it is in the molten and highly viscous state.

7. The method as claimed in claim 1 wherein the plastics material is guided or flows through the impregnation cavity together with the at least one fiber bundle.

8. The method as claimed in claim 1 further comprising applying a pressure to the plastics material in the impregnation cavity during the impregnation of the at least one fiber bundle.

9. A method for producing a three-dimensional structure which is formed from two or more different materials by a three-dimensional (3D) printhead of a 3D printing installation, comprising:
feeding a plastics material in a molten and highly viscous state as a first material and a virtually endless fiber bundle of a fiber material as a second material to the 3D printing installation,
wherein the first material and the second material are continuously fed to an impregnation cavity of the 3D printing installation in order to impregnate the virtually endless fiber bundle with the plastics material,
extruding the fiber bundle impregnated with the plastics material from a 3D printhead of the 3D printing installation,
wherein, during the production of the three-dimensional structure, the virtually endless fiber bundle is continuously impregnated with the plastics material by the method as claimed in claim 1 .

Assignees

• Deutsch Zentr Luft & Raumfahrt

Inventors

• Titze Maik

Classifications

• B29K2501/12

  Thermoplastic materials · CPC title

• B29C70/382

  Automated fiber placement [AFP] · CPC title

• B33Y70/10

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title

• B33Y40/10

  Pre-treatment · CPC title

• B29C64/209

  Heads; Nozzles · CPC title