WO2013139451A2 - Method and device for producing a near net-shaped fabric - Google Patents

Description

 Rheinisch-Westfälische Technische Hochschule Aachen

Templar trench 55

52062 Aachen

Method and device for producing a near-net shape gel

The invention relates to a method for producing a multilayer,

in particular multiaxial Geleges in a machine, especially in a tricot machine with a given constant transport width. The invention further relates to a device for producing a multilayer,

in particular multiaxial Geleges comprising a machine, in particular automatic tricot machines with a predetermined constant transport width, in particular for carrying out the method.

In the prior art it is known scrims, especially so-called multiaxial scrim from several layers of gel with different thread or

Fiber bundle orientation to be used as reinforcing textiles in components made of fiber reinforced plastics.

For this purpose, according to the prior art in designated

Automata having a predetermined constant transport width, e.g. in

Catenary machines, scrim made of several layers of gel, all gel layers and thus the scrim altogether one of the transport width

have corresponding width. Such scrims are impregnated after production and thus form a component made of a fiber composite plastic.

The fact of a constant production width is essentially due to the fact that the transport system of such a machine has a constant width, which is given by the distance between the transport elements, which is limited to two

CONFIRMATION COPY Pages of the machine are moved in the transport direction and are in engagement with the gel levels.

The intervention is carried out by the fact that the threads or bundles of filaments in such a machine are guided back and forth between the two sides of such a machine by means of a weft inserter and are thereby brought into the transport elements, e.g. Needles or hooks are inserted. According to the prior art, therefore, the threads or bundles of threads of all gel layers are inserted into the transport system, so that all gel layers are transported simultaneously and without distortion in the machine, e.g. to a connection unit in which the gel layers are connected.

In a warp knitting machine, this is done e.g. in a knitting unit, in which knitting threads are guided by needles through the gel layers and placed in stitches.

Typically, components that are to be reinforced with or made from such layers have widths or generally outer contours that are smaller than the width (and, if applicable, length) of a backing produced in this manner and adapted to the transport width of the machine. In the production of such components, therefore, a high waste due to the gel shares, which must be cut to achieve the desired later final contour of the component to be manufactured from the scrim, in particular cut off. When cutting the clutches, a waste of the order of about 50% can be produced. A recycling of the waste is so far little established or associated with quality disadvantages, so that usually causes the blending high costs.

It is therefore the object of the invention to provide a method with which the waste can be significantly reduced, but in particular, however, where conventional well-known machines with a constant transport width, in particular

Catenary machines can be used. This object is achieved in that in the machine with the constant transport width a lower layer of gel thread or

Filament bundles is placed in the transport elements of the transport system of the machine and continues to this lower gel layer at least one more gel layer of threads or filament bundles or at least one semi-finished, the width of the gel layer is smaller than the predetermined constant transport width, in particular at least partially related close to final contour is placed on a component to be produced from the clutch and the at least one further gel layer is pulled together with the lower gel layer by the attacking at this lower gel level transport system by a connection unit of the machine.

The object is also achieved by a device adapted to carry out the method, e.g. comprises a control in which a contour is stored, which corresponds to the final contour of a component to be produced or comes close, i. within a tolerance or safety measure corresponds to, by means of the controller a storage device of the

Device according to the invention is driven to lay threads, filament bundles or whole semi-finished products according to the stored contour in at least one other gel level on the lower gel level.

In the connection unit, the at least one further gel layer can be connected to the lower gel layer, i. it can e.g. all gel layers are connected to each other or only on the lower gel layer other Gelgelagen lying.

Regardless of whether the lower gel level only for transport purposes

Use is or part of the later entire Geleges this lower layer of gel can be made of the same material, as the at least one more gel layer or from another material. It can be used especially then another material, if the lower Gelegelage serves only for transport purposes. For example, then a lower material quality of the threads / filament bundles can be used.

It can also be provided that in the case of more than one further gel layer only the further, then at least two further gel layers are connected to one another, but not the further gel layers with the lower gel layer. Thus, it may therefore be provided in an embodiment that the lower

Gelegelage is a part of the entire fabric produced or in another embodiment exclusively for transport purposes, but does not become part of the finished Geleges.

The advantage of the invention is particularly great in that the at least one further layer of gel at least partially, i. at least in the region of a partial circumference of the gel layer is deposited according to a desired component contour of a manufactured from the fabric component on the lower gel layer, wherein the desired component contour is at least in width smaller than the transport width of the machine, and in particular may be shorter in length than that Total length of the lower layer of gel required for the manufacture of the component for transport.

Thus, a significant amount of waste can be saved, especially when flat later components, if the at least one more gel layer exactly according to the later component contour or for safety reasons by a

Safety dimension greater than the later component contour is executed.

Particularly preferably, the at least one further layer of gel in the region of its overall circumference is laid close to its final contour relative to a component to be manufactured later.

For example, it can be provided that the at least one layer of gel above the lower layer of gel, preferably the several further layers of gel above the lower layer of gel, by a defined tolerance measure or safety measure, For example, 1 to 20% larger, preferably only 1 to 10% is set larger than the contour dimension of the component to be produced. For this purpose, the contour to be applied to the at least one further gel layer in the aforementioned control can be stored as a contour of the component to be produced plus the safety measure or tolerance measure.

It can be provided that all other layers of gel are laid out with the same contour or else that the contours to be defined differ from the other layers of gel. Thus, in the controller, e.g. a contour for all other gel layers be stored or for each or some of the gel layers different contours.

This embodiment of the depositing takes place according to the invention at least in such a way that the near-net shape execution is given at least in the region of a partial circumference of the entire gel layer, preferably in the region of the entire outer circumference, that is to say the entire outer contour. Accordingly, a contour can then be stored analogously to the partial circumference or to the entire circumference in the controller.

A clutch is therefore in the sense of the invention near net shape related to a component to be produced, if at least in a partial extent of the Geleges the contour of the contour of the contour of the component to be produced or greater by said fixed dimension. Here, it can be provided that, at least within this safety measure, the contour of the jaw follows the actual later contour of the component and is thus identical in shape.

The abovementioned contour dimension of the component to be produced can be, for example, the dimension based on a dimensional origin of the component or else a length dimension between two mutually opposite contour edges of the later component. Thus, although in this embodiment, a blend in all layers of gel caused, but this is much smaller than in the previous

Versions in which all gel layers had the same transport width. Instead of a relative determination of the security measure, this can also be determined absolutely, e.g. based on usual cutting widths. This safety measure can be understood in a gel situation as a kind of safety allowance.

It is essential to emphasize here that according to the invention not only local reinforcements are deposited on a lower layer of gel, but a predetermined number of several, in particular at least two later forming a gelatin layers are made of which at least one, preferably all layers of gel above the lower Gelegelage in the above sense of the invention based on the component to be produced at least partially final contour close is placed.

 The at least one further gel layer, in particular all other gel layers, are preferably selected in terms of fiber quantity, fiber orientation and orientation and fiber type according to the component to be produced.

In a preferred embodiment, for the production of later components. 4

Gel layers are used, e.g. a lower layer of gel as a transport layer with a constant width, which enters the scrim and three stored on it

Near-net-close gel layers or alternatively a lower layer of gel as

Transport position with constant width, which does not enter the clutch and four deposited near net shape gelgelagen.

An adaptation to the later component contour can also be achieved in addition by the number of other laid gel layers, which may be different locally on the lower gel level.

If only one more Gelegelage is provided on the lower gel level and this lower gel layer part of the later entire Geleges can be already saved a cut of 50% compared to the state of Technology, because the blending thus takes place essentially only in the lower gel layer. With more additional gel layers, the savings increase

corresponding.

It is a particular distribution of the invention that the conventional transport system of a machine for the production of opportunities, e.g. a tricot machine can be used, since the lower layer of gel with this in a known manner is engaged and thus the lower layer of gel is transported in a known manner.

In one embodiment, it may then be provided that the at least one further layer of gel at least on one side of the machine, preferably on both sides of the machine is free from interference to the transport system of the machine.

In the case of an intervention of the transport system on one side of the at least one gel layer, it is already possible to save waste on the other side, since the at least one further layer of gel, or the threads or semi-finished products that form it, is near-net-shape on this side which is not engaged. can be placed according to or near the desired later contour. However, such a further layer of gel is advantageously still moved by the machine with the transport system, so that a risk of the

Slipping of the gel layers is reduced to each other.

To maximize the Verschnittreduktion it can be provided that the at least one further gel layer, preferably any further gel layer on both sides without interference to the transport system, so the outer contour of such a gel layer has a distance to the transport elements of the transport system, in particular thus thus threads or bundles of filaments such a further gel layer not be inserted into the transport elements, in particular needles or hooks of a transport chain. In this case, the transport of the entire Geleges takes place only in that the transport system attacks only on the lower gel level and the overlying Layers are transported by means of the lower layer of gel. At this

Accordingly, each additional gel layer lying on the lower gel layer can be made to have a near-net shape in the region of the entire circumference.

In order to avoid slippage of the gel layers with each other and / or relative to the lower gel layer, it may in a further development of the invention

be provided that the gel layers in the transport direction before the

Connection unit of the machine are stabilized with each other, at least temporarily for the purpose of transport.

Such positional stabilization may e.g. be effected by spraying a binder before or after depositing a gel layer. Likewise, adhesive elements, in particular threads of the nonwovens, can be placed between layers of gel. Adhesive threads can also form part of the threads of a gel layer. Likewise, thermoplastic elements, in particular threads or powder can be placed between layers of gel or, in the case of threads, also form part of a gel layer. Such thermoplastic elements can be thermally activated, i. are heated, in particular by radiation or by a heated stamp, which is brought into contact with the thermoplastic element or an above / before lying gel level.

The attitude stabilization can provide a compound of the gel layers with each other, which is sufficient to the overall through the

Connecting unit of the machine to lead, where the actual and final, permanent connection is made, either from all layers of gel or only on the lower layers of gel.

If the lower layer of gel only serves for transport purposes and should not become part of the total layer, it can be provided to separate this lower layer of gel after the transport of all layers of gel through the connection unit from the remaining layers of gel, in particular for what in the connection unit only the other layers of gel above the lower layer of gel are joined together. This compound can be done, for example, thermoplastic.

The lower layer of gel, the threads of which e.g. provided with a size that reduces or prevents adhesion of thermoplastics can then be peeled off the other layers of gel after the compound unit.

In one embodiment, it may also be provided that the threads or

Filament bundles of the lower gel layer are formed of a material which is soluble in a solvent and the lower gel layer after the

Compound of the gel layers is dissolved in the solvent. In this embodiment, the lower layer of gel can be previously bonded to the other layers of gel, e.g. in a warp knitting machine by knitting threads. Due to the dissolution process this is not a problem.

If the lower layer of gel remains in the total layer and e.g. is combined with knitting threads in a knitting unit of a tricot machine with the other layers, however, it forms the largest proportion of waste in a

Final contour formation of the total laminate.

In general, the connection of the gel layers in the connection unit can take place in that the machine is designed as a warp knitting machine and the connection takes place in its active unit by knitting threads which are guided with needles through the gel layers or thermoplastic threads or

Filament bundles are melted, in particular melted in a calender, wherein the thermoplastic threads / filament bundles are arranged between two or at least one of the gel layers, in particular in the lower gel layer are arranged or the lower

Complete gel level. In the last embodiment can therefore be used in the formation of the lower layer of gel in the machine thermoplastic threads or filament bundles, in particular the later

Provide all or part of the impregnation material. Although it may be provided according to the invention, the lower layer of gel always in situ in the machine made of threads or bundles of fibers by laying operation of the threads or the bundle of threads in the transport elements of the transport system to produce the at least one more gel layer both by the laying of threads or bundles of filaments as well as by the deposition of at least one finished sheet semi-finished, so for example of textile fabrics, such as pre-assembled or unwound from a roll and cut strips or strips / tapes.

Such finished semi-finished products either themselves at least partially have a peripheral region which in the abovementioned sense is near-net shape to a component to be produced or the semi-finished products are placed / deposited in such a way that at least one partial peripheral region is close to the final contour of the

comes to lie to be manufactured component. A gel layer can also be laid out of several semi-finished products that lie next to each other or that are partially overlapped. A gel layer then results from the sum of all semi-finished products lying in the plane of this gel layer. The semi-finished products are preferably laid so that the outer contour of this gel layer produced in this way is at least in a region of the circumference, in particular completely close to the final contour.

In both cases, it may be provided that the threads or bundles of threads or semi-finished products are deposited on the lower layer of gel by a depositing device which can be positioned and guided parallel to the lower layer of gel in the machine, in particular at variable angles and lengths.

For this, the depositing device may be e.g. in a gantry or on one

Robot arm are guided, whereby you at least in the aforementioned level in two dimensions (XY direction) is movable, if necessary. Even three-dimensional positionable. With the filing device, either filaments or bundles of filaments or else semifinished products can be laid, for example, in each case unwound from a stationary supply roll or a supply roll entrained with the filing device and optionally cut to length by a cutting device.

For depositing threads or bundles of fibers, it may also be provided that these are deposited by a Schußlegersystem on the lower gel level, the Schußlegersystem only partially vertical or transverse to

Transport direction of the machine is performed, so the threads or bundles of fibers so does not insert into the transport elements of the transport system.

It can for this purpose the Schußlegersystem a conventional

Catenary machines are used, in particular that with which the lower layer of gel is made, the control of the

Schußlegersystems is modified such that the Schußlegersystem for producing the other gel layer does not cover the full width perpendicular or at least across the width of the transport system, but the

Reversal points of the Schußlegersystems before the transport elements of the

Transport system, in particular within a programmed stored in the control contour, in particular corresponds to the final contour of the component to be produced or this comes close in the above sense,

especially within a security measure.

Accordingly, then deposited in this way threads or filament bundles are also within such a stored contour. If necessary. are only the reverse loops of threads / bundles of fibers outside the stored contour or within. Threads or filament bundles can be laid as cut pieces or endless. For cut pieces, preferably no reverse loops occur. In this case, then the two-sided ends of the threads or bundles of fibers may lie within said stored contour or around it by a certain amount, preferably outside. Within a gel layer, the threads or bundles of fibers, possibly all but the reverse loops, can have the same orientation. However, the threads or bundles of filaments can also be laid spirally against each other starting from the inside outwards to the outside contour or from the outside on the outside contour.

To produce a close to net shape, in particular multiaxial Geleges a desired final contour according to or near the final contour of the component to be manufactured in the control of a Schußlegersystems a

Warp knitting machine are programmed, then the controller controls the Schußlegersystem so that it over the entire width of the

Transport systems threads or bundles of fibers in the transport elements of

Inserting transport system and so first produces the lower layer of gel and further deposits at least one more layer of gel on it, in particular wherein the reverse loops of the threads or bundles of filaments between the

Transport elements lie.

To place the reversing loops, it may be provided to use at least one mobile needle which is movable and positionable below the lower layer of gel at the location of a desired reversal loop and pierces the lower layer of gel at this location from bottom to top, so that the

Schußlegersystem a thread or a thread bundle around this needle

can lead around.

Preferably, at least two mobile needles or two groups of mobile needles are used, which are each assigned to one side of the transport system, with which therefore reversal loops of the same direction reversal are always placed. It can then be provided a needle after laying a

Leave reversing loop inserted so long through the lower layer of gel until at least a next subsequent reversing loop is wrapped around another needle and then the at least one other needle takes over the tensile forces occurring in the thread or bundle of fibers. Only then the needle mentioned above emerges and becomes the next loop repositioned and stung by the lower layer of gel. From a group of needles so preferably always only one of the needles can be moved and

repositioned while the others stabilize the threadline.

In one development, it may also be provided, the threads or

To support bundles of threads of the lowest layer of gel in the said machine from below with a proppant, e.g. with a plate, conveyor belt, rollers or the like, to avoid sagging when this lower

Gelgelage carries all above gel levels and is inserted here only in the side areas in the transport system of the machine. Preferably, the connection between the transport system and the lower layer of gel can also be relieved of force. It can be provided to transport the support means in the transport direction of the lower layer of gel in the machine.

Claims

1 claims Method for producing a multilayer, in particular multi-axial, fabric in an automatic machine, in particular automatic warp knitting machines with a predetermined constant transport width, characterized in that a. in the machine a lower layer of gel of threads or  Filament bundles is placed in the transport elements of the transport system of the machine with the predetermined constant transport width b. at least one further layer of gel at least partially close to final contour near a component of threads or bundles of filaments or at least one semifinished product to be produced from the fabric, the width of the gel layer being smaller than the predetermined constant transport width c. the at least one further gel layer is pulled together with the lower gel layer by the transport system acting on this lower gel layer by a connecting unit of the machine. A method according to claim 1, characterized in that the at least one more gel layer at least on one side of the Automaten, preferably on both sides of the machine without intervention is the transport system of the machine. Method according to one of the preceding claims, characterized in that the at least one further gel layer, in particular in the region of the entire circumference, is in accordance with a desired component contour of a produce from the context 2 Is placed on the lower layer of gel component, wherein the desired component contour in the width is smaller than the transport width of the  Machines. 4. The method according to any one of the preceding claims, characterized  in that the gel layers are stabilized in position in the transport direction in front of the connection unit of the machine. 5. The method according to claim 4, characterized in that the  Position stabilization is carried out by a. Binders before or after depositing a gel layer  be sprayed or b. adhesive elements, in particular threads which are placed between layers of gel or which are part of the threads of a gel layer or c. thermoplastic elements, in particular threads or powders, which are placed between layers of gel or which are part of a gel layer and are heated after depositing a gel layer, in particular by radiation or a contacting heated stamp. 6. The method according to any one of the preceding claims, characterized  in that after the transport of all gel layers the lower gel layer is separated from the remaining gel layers by the connection unit, in particular for which only further gel layers lying above the lower gel layer are connected to one another in the connection unit, in particular thermoplastic. 7. The method according to any one of the preceding claims, characterized  characterized in that the threads or bundles of threads of the lower Gelegelage be formed from a material that in one 3 Solvent is dissolvable and the lower gel layer is dissolved after the compound of the gel layers in the solvent. 8. The method according to any one of the preceding claims, characterized  characterized in that the compound of the gel levels in the  Connection unit is done by a. The machine is designed as a warp knitting machine and the  Connection is made in its active unit by knitting threads, which are guided with needles through the gel layers or b. thermoplastic threads or bundles of filaments are melted, in particular melted in a calender, which are arranged between two or in at least one of the gel layers, in particular those which are arranged in the lower gel layer or completely form the lower layer of gel. 9. The method according to any one of the preceding claims, characterized  in that the threads or filament bundles or semi-finished products are deposited on the lower gel layer by a depositing device which can be positioned in a plane parallel to the lower gel layer, in particular wherein the depositing device is guided in a gantry system or on a robot arm. 10. The method according to any one of the preceding claims, characterized  characterized in that the threads or thread bundles by a  Schußlegersystem be placed on the lower gel level, the Schußlegersystem only partially vertical or transverse to  Transport direction of the machine is performed. 1 1 .Vorrichtung for producing a multilayer, in particular multi-axial Geleges comprising a machine, in particular automatic warewashing machines with a predetermined constant transport width, in particular for Carrying out a method according to one of the preceding Anasprüche, characterized in that the machine is set up to insert a lower layer of gel thread or bundles of fibers in the transport elements of the transport system of the machine with the predetermined constant transport width and is set to this lower Gelegelage at least one more gel layer at least partially near net shape related to a produced from the fabric component of threads or filament bundles or at least a semi-finished, the width of the gel layer is smaller than the predetermined constant transport width and is set, the at least one more Gelegelage together with the lower gel layer by the attacking at this lower gel level transport system by a Connection unit of the machine to pull.