WO2007054079A2 - Moulded component with a sandwich structure, comprising a ceramic core and multidirectional covering layers - Google Patents

Moulded component with a sandwich structure, comprising a ceramic core and multidirectional covering layers Download PDF

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Publication number
WO2007054079A2
WO2007054079A2 PCT/DE2006/001962 DE2006001962W WO2007054079A2 WO 2007054079 A2 WO2007054079 A2 WO 2007054079A2 DE 2006001962 W DE2006001962 W DE 2006001962W WO 2007054079 A2 WO2007054079 A2 WO 2007054079A2
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WO
WIPO (PCT)
Prior art keywords
layers
component according
fibers
resin
mold component
Prior art date
Application number
PCT/DE2006/001962
Other languages
German (de)
French (fr)
Other versions
WO2007054079A3 (en
Inventor
Richard Pott
Original Assignee
Md Fibertech Corporation
Pott, Frank-Armin
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Filing date
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Application filed by Md Fibertech Corporation, Pott, Frank-Armin filed Critical Md Fibertech Corporation
Publication of WO2007054079A2 publication Critical patent/WO2007054079A2/en
Publication of WO2007054079A3 publication Critical patent/WO2007054079A3/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/005—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/047—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material made of fibres or filaments
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0246—Acrylic resin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/105—Ceramic fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/08—Reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/514—Oriented
    • B32B2307/52—Oriented multi-axially

Definitions

  • the invention relates to a molded component in sandwich construction with a core of resin-bonded ceramic substance with multidirectionally oriented cover layer fiber reinforcement.
  • Sandwich components in civil engineering are also known as multi-walled tubular body in z. B. drainage areas or for district heating. Similarly, there are already bridge structures in the form of glass fiber reinforced plastics (GRP), but with large component weights.
  • GRP glass fiber reinforced plastics
  • the sandwich construction used for this purpose has proven itself in many years of practice in many areas, preferably in construction, outstanding.
  • sandwich construction z. B. ceiling structures as lightweight, roof trusses and wall panels created. In all cases, the aim is to achieve the lowest possible support loads while at the same time providing maximum static and dynamic load capacity and high fire safety.
  • the invention is therefore based on the object to show a sandwich component with low weight and high bending tensile strength.
  • a support core of ceramic material is covered on at least one side by a cover layer, which consists of at least two synthetic resin impregnated Fasereinzellagen, the fibers are in the single layer parallel to each other and are in relation to each next single layer in a crossing angle.
  • a high bending tensile strength is achieved for the production of a molded component in sandwich construction, at the same time significantly reduces the total weight becomes.
  • the Fasereinzellagen are arranged for this purpose in at least two different directions, preferably ⁇ 45 °, but any angular positions are conceivable, which may be further enhanced by a mean zero degree position.
  • the previously used fiber reinforcement material for the reinforcement of the cover layers consists of fabrics of all possible fiber types. Due to its construction and production, this fabric has a multiple high application weight with a strength which corresponds to only a fraction of the sandwich component reinforcement according to the invention by fiber unicellulars.
  • the invention takes advantage of the great advantage afforded by stretched, non-directionally oriented reinforcing fibers in the form of lay-ups rather than weaves.
  • all individual filaments of the fiber strands are biased strictly linearly parallel and as fiber strands adjacent to one another.
  • zeillagen fixed and embedded in laminating resin or impregnated therewith.
  • the prefabricated Gelege- single layers are arranged in crossing angles of preferably ⁇ 45 °, whereby a quasi-isotope is achieved, ie, an equal load in all directions.
  • the cover layers together with the ceramic support core form the component in sandwich construction, while the middle support layers are used in the same or different fiber orientation depending on the application at greater load for additional reinforcement of the ceramic support core.
  • the fiber strands can also be arranged, for example, only in the component transverse direction in order to purposefully reinforce the component as a whole in this direction.
  • an adhesive thread grid which is embedded between the individual fiber planes and fixes them, is advantageously used.
  • the Fasereinzellagen be immovably interconnected by means of a device applied adhesive traces based on permanent or hot melt adhesive.
  • the Fasereinzellagen be immovably interconnected by applied by means of a device full-surface coating of synthetic resin.
  • the fibrous cell layers or the fibers may consist of textile glass, carbonate, aramid, polyester, acrylic or ceramic, wherein the covering layer consisting of fibers with multidirectional orientation with synthetic resin as a matrix based on polyester, epoxy, melamine, urea, phenol or the like can be impregnated.
  • the support core is preferably made of ceramic material, a resin-bonded or cement-bound granules based on pumice, perlite, mica, hollow glass, foam, expanded clay or split of any kind.
  • the molding component has a plurality of outer layers both as outer base layers, as well as medium reinforcing layers for receiving the bending, tensile, compressive, torsional and shear forces. The recording of the various forces can here be optimized and appropriately counteracted by the orientation of the individual fibers in each cover layer in an advantageous manner.
  • the molded component according to the invention is not exclusively a plate component, but results in a wealth of demanding applications, for example in building construction, especially in refractory areas, because it meets the requirements of fire classification A2, in bridge construction and the construction of sandwich tubular bodies for district heating , Wastewater etc.
  • duct covers covers for cable ducts, base material for curtain-type, refractory facades, tunnel linings, double floors, outer walls for liquid containers, traffic control systems, superstructures for insulated vehicles, rapid assembly bridges in road construction, pontoon bridges in military technology, camping vehicles and attaching
  • the application examples described above are not exhaustive.
  • Fig. 2 shows a finished mold component according to a variant as shown by Fig. 1.
  • 1 shows a molded component 1, consisting of an upper cover layer and a lower cover layer, which each consist of synthetic resin-impregnated fiber cell layers 2, 3 based on reinforcing fiber bundles.
  • the respective fiber cell layers 2, 3 are connected to one another, for example, by adhesive thread meshes 4, which fix the fiber cell layers 2, 3 in a specific position, wherein preferably the fiber cell layers 2, 3 are arranged at an angle of preferably ⁇ 45 °.
  • further Fasereinzellenagen 7 may be provided in a zero degree position or at different angles, which lie between the two outer Fasereinzellagen 2, 3.
  • the middle Fasereinzellage 7 may have a similar structure as the Fasereinzellagen 2, 3, wherein preferably an identical or different fiber orientations is selected.
  • the alignment of the fiber cell 7 is aligned in the direction of the transverse tensile forces, so that the central Fasereinzellage 7 is provided for exclusively absorbing the tensile forces transverse to the component longitudinal axis, whereas the upper and lower Fasereinzellage 2, 3 for receiving tensile forces in the direction the component longitudinal axis are provided.
  • FIG. 2 shows, for example, a finished molded component 10, which represents a curved segment and likewise consists of an upper fiber cell 2 and a lower fiber single layer 3, between which two support core layers 5, 6 are arranged, and in which case a central fiber insert 7 is provided the forces occurring, in particular the tensile forces in the direction transverse to the component longitudinal axis can be optimally absorbed.
  • the molding component 10 shown represents only one of many possible patterns and illustrates only the not only flat, but also curved mold components 10 are readily produced. LIST OF REFERENCE NUMBERS

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  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Architecture (AREA)
  • Chemical & Material Sciences (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)
  • Aiming, Guidance, Guns With A Light Source, Armor, Camouflage, And Targets (AREA)
  • Insulators (AREA)

Abstract

The invention relates to a moulded component (10) with a sandwich structure, consisting of at least one covering layer (2, 3) and a supporting core (5, 6) consisting of at least one core layer. Both the covering layers (2, 3) and the core layers (5, 6) are coated or impregnated with hardenable resin. As the covering layers must absorb the main stresses in a sandwich-type moulded component (10), particular importance is attributed thereto in terms of the absorption of the tractive, compression, shear, torsion and flexural forces. The inventive moulded component (10) presents the fibre orientation thereof in a crossing angle of preferably ± 45° in such a way as to achieve maximum efficiency using a minimum amount of material.

Description

Formbauteil in Sandwichbauweise mit keramischem Kern und multidirektionalen Decklagen Molded component in sandwich construction with ceramic core and multidirectional cover layers
Die Erfindung betrifft ein Formbauteil in Sandwichbauweise mit einem Kern aus kunstharzgebundener keramischer Substanz mit multidirektional orientierter Decklagen-Faserverstärkung.The invention relates to a molded component in sandwich construction with a core of resin-bonded ceramic substance with multidirectionally oriented cover layer fiber reinforcement.
Sandwichbauteile im Hoch- und Tiefbau sind auch bekannt als mehrwandige Rohrkörper in z. B. Entwässerungsbereichen oder für Fernheizungen. Ebenso gibt es bereits Brückenbauwerke in Formbauweise aus glasfaserverstärkten Kunststoffen (GFK), bei allerdings großen Bauteilgewichten. Die hierzu angewendete Sandwichbauweise hat sich in langjähriger Praxis in vielen Bereichen, vorzugsweise im Bauwesen, hervorragend bewährt. In Sandwichbauweise werden z. B. Deckenkonstruktionen als Leichtbau, Dachbinder und Wandpaneele erstellt. In allen Fällen strebt man geringstmögliche Stützlasten bei zugleich größtmöglicher statischer und dynamischer Belastbarkeit und hoher Brandsicherheit an.Sandwich components in civil engineering are also known as multi-walled tubular body in z. B. drainage areas or for district heating. Similarly, there are already bridge structures in the form of glass fiber reinforced plastics (GRP), but with large component weights. The sandwich construction used for this purpose has proven itself in many years of practice in many areas, preferably in construction, outstanding. In sandwich construction z. B. ceiling structures as lightweight, roof trusses and wall panels created. In all cases, the aim is to achieve the lowest possible support loads while at the same time providing maximum static and dynamic load capacity and high fire safety.
Alle derartigen konzeptionell hervorragenden Konstruktionen haben den von Konstrukteuren wenig geschätzten und bisher kaum abänderbaren Nachteil des zu hohen Gewichtes bzw. zu geringer Biegezugfestigkeit und zu großer Druckbiegung.All such conceptually excellent constructions have the disadvantage of the designer, which has been little appreciated and has hitherto barely changed, of too high a weight or too low bending tensile strength and too great a pressure deflection.
Der Erfindung liegt daher die Aufgabe zugrunde, ein Sandwichbauteil mit geringem Gewicht und hoher Biegezugfestigkeit aufzuzeigen.The invention is therefore based on the object to show a sandwich component with low weight and high bending tensile strength.
Erfindungsgemäß ist vorgesehen, dass ein Stützkern aus keramischem Material auf mindestens einer Seite von einer Decklage abgedeckt ist, welche aus mindestens zwei kunstharzgetränkten Fasereinzellagen besteht, deren Fasern in der Einzellage parallel nebeneinander liegen und sich im Verhältnis zur jeweils nächsten Einzellage in einem Kreuzungswinkel befinden. Weitere vorteilhafte Ausgestaltungen der Erfindung ergeben sich aus den Unteransprüchen.According to the invention, it is provided that a support core of ceramic material is covered on at least one side by a cover layer, which consists of at least two synthetic resin impregnated Fasereinzellagen, the fibers are in the single layer parallel to each other and are in relation to each next single layer in a crossing angle. Further advantageous embodiments of the invention will become apparent from the dependent claims.
Durch die Verwendung zumindest zweier kunstharzgetränkter Fasereinzellagen, deren Fasern in der jeweiligen Einzellage parallel nebeneinander liegen und im Verhältnis zur jeweils nächsten Einzellage in einem Kreuzungswinkel zueinander angeordnet sind, wird für die Herstellung eines Formbauteils in Sandwichbauweise eine hohe Biegezugfestigkeit erreicht, wobei gleichzeitig das Gesamtgewicht erheblich reduziert wird. Zu diesem Zweck wird ein Stützkern aus keramischem Material auf mindestens einer Seite von einer solchen Decklage, bestehend aus Fasereinzellagen, abgedeckt. Die Fasereinzellagen sind zu diesem Zweck in mindestens zwei verschiedene Richtungen, vorzugsweise ±45° angeordnet, wobei jedoch beliebige Winkellagen denkbar sind, die ggf. durch eine mittlere Nullgradlage zusätzlich verstärkt werden.By using at least two synthetic resin-impregnated fiber conjugates whose fibers lie parallel next to one another in the respective individual layer and are arranged in relation to the next single layer at a crossing angle to each other, a high bending tensile strength is achieved for the production of a molded component in sandwich construction, at the same time significantly reduces the total weight becomes. For this purpose, a support core made of ceramic material on at least one side of such a cover layer, consisting of Fasereinzellagen covered. The Fasereinzellagen are arranged for this purpose in at least two different directions, preferably ± 45 °, but any angular positions are conceivable, which may be further enhanced by a mean zero degree position.
Bisher war es nicht möglich, moderne Sandwichbauteile für anspruchsvolle Projekte zu produzieren, weil die bisher praktizierten Bauweisen die Möglichkeiten, die die vorliegende Erfindung bietet, bisher nicht bekannt waren und die somit eine echte Innovation darstellt.So far, it has not been possible to produce modern sandwich components for demanding projects, because the previously practiced construction methods, the possibilities offered by the present invention, were previously unknown and thus represents a real innovation.
Das bisher verwendete Faser-Verstärkungsmaterial für die Armierung der Decklagen besteht aus Geweben aller möglichen Faserarten. Dieses Gewebe hat konstruktions- und fertigungsbedingt ein mehrfach hohes Einsatzgewicht bei einer Festigkeit, die nur einem Bruchteil der erfindungsgemäßen Sandwichbauteil-Armierung durch Fasereinzellagen entspricht.The previously used fiber reinforcement material for the reinforcement of the cover layers consists of fabrics of all possible fiber types. Due to its construction and production, this fabric has a multiple high application weight with a strength which corresponds to only a fraction of the sandwich component reinforcement according to the invention by fiber unicellulars.
Die Erfindung macht sich dabei den großen Vorteil zunutze, den gestreckte, undirektional orientierte Verstärkungsfasern in Form von Gelegen anstatt Ge- weben bieten. Hierbei werden alle Einzelfilamente der Faserstränge streng linear parallel vorgespannt und als Faserstränge nebeneinanderliegend zu Ein- zeillagen fixiert und in Laminierharz eingebettet bzw. damit imprägniert. Um aber die Nutzbarkeit der Zugbelastung auf das gesamte Formbauteil zu gewährleisten, werden die vorgefertigten Gelege- Einzellagen in Kreuzungswinkeln von vorzugsweise ±45° angeordnet, womit ein Quasi-Isotop erreicht wird, d.h., eine gleiche Belastbarkeit in alle Richtungen. Die Decklagen bilden zusammen mit dem keramischen Stützkern das Formbauteil in Sandwich- Bauweise, während die mittleren Tragschichten in gleicher oder abweichender Faserorientierung je nach Einsatzzweck bei größerer Belastung zur zusätzlichen Verstärkung des keramischen Stützkerns eingesetzt werden. Hier können die Faserstränge bei Bedarf insgesamt z.B. auch nur in Bauteil-Querrichtung angeordnet werden, um so gezielt das Bauteil als Ganzes in diese Richtung zu verstärken.The invention takes advantage of the great advantage afforded by stretched, non-directionally oriented reinforcing fibers in the form of lay-ups rather than weaves. Here, all individual filaments of the fiber strands are biased strictly linearly parallel and as fiber strands adjacent to one another. zeillagen fixed and embedded in laminating resin or impregnated therewith. However, in order to ensure the usability of the tensile load on the entire mold component, the prefabricated Gelege- single layers are arranged in crossing angles of preferably ± 45 °, whereby a quasi-isotope is achieved, ie, an equal load in all directions. The cover layers together with the ceramic support core form the component in sandwich construction, while the middle support layers are used in the same or different fiber orientation depending on the application at greater load for additional reinforcement of the ceramic support core. Here, if required, the fiber strands can also be arranged, for example, only in the component transverse direction in order to purposefully reinforce the component as a whole in this direction.
Damit die Decklagen, bestehend aus Fasereinzellagen nicht gegeneinander verrutschen können, wird in vorteilhafterweise ein Haftfadengitter verwendet, welches zwischen den einzelnen Faserebenen eingebettet ist und diese fixiert. Alternativ besteht die Möglichkeit, dass die Fasereinzellagen durch mittels einer Vorrichtung aufgetragene Klebespuren auf der Basis von Permanent- bzw. Schmelzkleber unverschiebbar miteinander verbunden werden. Des Weiteren ist es denkbar, dass die Fasereinzellagen durch mittels einer Vorrichtung aufgetragenen vollflächigen Beschichtung aus Kunstharz unverschiebbar miteinander verbunden werden.In order that the cover layers, consisting of fiber cell layers, can not slip against each other, an adhesive thread grid, which is embedded between the individual fiber planes and fixes them, is advantageously used. Alternatively, there is the possibility that the Fasereinzellagen be immovably interconnected by means of a device applied adhesive traces based on permanent or hot melt adhesive. Furthermore, it is conceivable that the Fasereinzellagen be immovably interconnected by applied by means of a device full-surface coating of synthetic resin.
Die Fasereinzellagen bzw. die Fasern können hierbei aus Textilglas, Karbonat, Aramid, Polyester, Acryl oder Keramik bestehen, wobei die aus Fasern mit mul- tidirektionaler Orientierung bestehende Decklage mit Kunstharz als Matrix auf der Basis von Polyester, Epoxid, Melamin, Harnstoff, Phenol oder dergleichen imprägniert werden kann. Der Stützkern hingegen wird vorzugsweise aus keramischem Material, ein kunstharz- oder zementgebundenes Granulat auf der Basis von Bims, Perlite, Glimmer, Hohlglas, Schaumstoff, Blähton oder Split jeglicher Art hergestellt. In besonderer Ausführung der Erfindung ist vorgesehen, dass das Formbauteil mehrere Deckschichten sowohl als äußere Tragschichten, wie auch als mittlere Verstärkungsschichten zur Aufnahme der Biege-, Zug-, Druck-, Torsions- und Scherkräfte aufweist. Der Aufnahme der verschiedenen Kräfte kann hierbei optimiert und zweckentsprechend durch die Ausrichtung der Einzelfasern in jeder Deckschicht in vorteilhafter weise gegengewirkt werden.The fibrous cell layers or the fibers may consist of textile glass, carbonate, aramid, polyester, acrylic or ceramic, wherein the covering layer consisting of fibers with multidirectional orientation with synthetic resin as a matrix based on polyester, epoxy, melamine, urea, phenol or the like can be impregnated. The support core, however, is preferably made of ceramic material, a resin-bonded or cement-bound granules based on pumice, perlite, mica, hollow glass, foam, expanded clay or split of any kind. In a particular embodiment of the invention, it is provided that the molding component has a plurality of outer layers both as outer base layers, as well as medium reinforcing layers for receiving the bending, tensile, compressive, torsional and shear forces. The recording of the various forces can here be optimized and appropriately counteracted by the orientation of the individual fibers in each cover layer in an advantageous manner.
Das erfindungsgemäße Formbauteil stellt nicht ausschließlich ein Plattenbauteil dar, sondern es ergibt sich eine Fülle von anspruchsvollen Anwendungen, beispielsweise im Hochbau, hier besonders in Feuerfestbereichen, denn es werden die Anforderungen der Brandschutzklasse A2 erfüllt, im Brückenbau und beim Bau von Sandwich-Rohrkörpern für Fernwärme, Abwässer etc..The molded component according to the invention is not exclusively a plate component, but results in a wealth of demanding applications, for example in building construction, especially in refractory areas, because it meets the requirements of fire classification A2, in bridge construction and the construction of sandwich tubular bodies for district heating , Wastewater etc.
Einige weitere Einsatzbeispiele sind beispielsweise Kanalabdeckungen, Abdeckhauben für Kabelschächte, Basismaterial für vorgehängte, feuerfeste Fassaden, Tunnelauskleidungen, Doppel-Fußböden, Außenwände für Flüssigkeitsbehälter, Verkehrsleitsysteme, Aufbauten für Isolierfahrzeuge, Schnell- Montagebrücken im Straßenbau, Pontonbrücken in der Wehrtechnik, Camping- fahrzeuge und -anhängen Die zuvor beschriebenen Einsatzbeispiele erheben keinen Anspruch auf Vollständigkeit.Some other examples of application are, for example, duct covers, covers for cable ducts, base material for curtain-type, refractory facades, tunnel linings, double floors, outer walls for liquid containers, traffic control systems, superstructures for insulated vehicles, rapid assembly bridges in road construction, pontoon bridges in military technology, camping vehicles and attaching The application examples described above are not exhaustive.
Die Erfindung wird anhand der folgenden Figuren näher erläutert:The invention will be explained in more detail with reference to the following figures:
Es zeigt:It shows:
Fig. 1 in einer Explosionsdarstellung den Schichtenaufbau eines erfindungsgemäßen Formbauteils undFig. 1 in an exploded view of the layer structure of a mold component according to the invention and
Fig. 2 ein fertiges Formbauteil gemäß einer Ausführungsvariante wie sie durch Fig. 1 dargestellt ist. Fig. 1 zeigt ein Formbauteil 1, bestehend aus einer oberen Decklage und einer unteren Decklage, welche jeweils aus kunstharzimprägnierten Fasereinzellagen 2, 3 auf der Basis von Verstärkungsfaserbündeln bestehen. Die jeweiligen Fa- sereinzellagen 2, 3 werden beispielsweise durch Haftfadengitter 4 miteinander verbunden, welche die Fasereinzellagen 2, 3 in einer bestimmten Position fixieren, wobei vorzugsweise die Fasereinzellagen 2, 3 unter einem Winkel von vorzugsweise ± 45° angeordnet sind. Vorzugsweise können weitere Fasereinzellagen 7 in einer Nullgradlage oder unter anderen Winkeln vorgesehen sein, die zwischen den beiden äußeren Fasereinzellagen 2, 3 liegen. Ein weiterer Bestandteil des Formbauteils 1 besteht aus einer oberen Stützkernschicht 5 und einer unteren Stützkernschicht 6, welche durch die mittlere Fasereinzellage 7 voneinander getrennt sind. Die mittlere Fasereinzellage 7 kann hierbei einen ähnlichen Aufbau wie die Fasereinzellagen 2, 3 aufweisen, wobei vorzugsweise eine identische oder andere Faserausrichtungen gewählt wird. Im gezeigten Ausführungsbeispiel ist die Ausrichtung der Fasereinzellage 7 in Richtung der quer auftretenden Zugkräfte ausgerichtet, so dass die mittlere Fasereinzellage 7 zur ausschließlichen Aufnahme der Zugkräfte quer zur Bauteillängsachse vorgesehen ist, während demgegenüber die obere und untere Fasereinzellage 2, 3 zur Aufnahme von Zugkräften in Richtung der Bauteillängsachse vorgesehen sind.Fig. 2 shows a finished mold component according to a variant as shown by Fig. 1. 1 shows a molded component 1, consisting of an upper cover layer and a lower cover layer, which each consist of synthetic resin-impregnated fiber cell layers 2, 3 based on reinforcing fiber bundles. The respective fiber cell layers 2, 3 are connected to one another, for example, by adhesive thread meshes 4, which fix the fiber cell layers 2, 3 in a specific position, wherein preferably the fiber cell layers 2, 3 are arranged at an angle of preferably ± 45 °. Preferably, further Fasereinzellenagen 7 may be provided in a zero degree position or at different angles, which lie between the two outer Fasereinzellagen 2, 3. Another component of the mold component 1 consists of an upper support core layer 5 and a lower support core layer 6, which are separated from each other by the middle Fasereinzellage 7. The middle Fasereinzellage 7 here may have a similar structure as the Fasereinzellagen 2, 3, wherein preferably an identical or different fiber orientations is selected. In the exemplary embodiment shown, the alignment of the fiber cell 7 is aligned in the direction of the transverse tensile forces, so that the central Fasereinzellage 7 is provided for exclusively absorbing the tensile forces transverse to the component longitudinal axis, whereas the upper and lower Fasereinzellage 2, 3 for receiving tensile forces in the direction the component longitudinal axis are provided.
Fig. 2 zeigt beispielsweise ein fertiges Formbauteil 10, welches ein Bogenseg- ment darstellt und ebenfalls aus einer oben Fasereinzellage 2 und einer unteren Fasereinzeliage 3 besteht, zwischen denen zwei Stützkernschichten 5, 6 angeordnet sind und wobei zusätzlich eine mittlere Fasereinzeliage 7 vorgesehen ist, damit die auftretenden Kräfte, insbesondere die Zugkräfte in Richtung quer zur Bauteillängsachse optimal aufgenommen werden können. Das gezeigte Formbauteil 10 stellt nur eins von vielen möglichen Mustern dar und verdeutlicht lediglich das nicht nur ebene, sondern auch gekrümmte Formbauteile 10 ohne weiteres herstellbar sind. BezugszeichenlisteFIG. 2 shows, for example, a finished molded component 10, which represents a curved segment and likewise consists of an upper fiber cell 2 and a lower fiber single layer 3, between which two support core layers 5, 6 are arranged, and in which case a central fiber insert 7 is provided the forces occurring, in particular the tensile forces in the direction transverse to the component longitudinal axis can be optimally absorbed. The molding component 10 shown represents only one of many possible patterns and illustrates only the not only flat, but also curved mold components 10 are readily produced. LIST OF REFERENCE NUMBERS
1 Formbauteil1 molded component
2 Fasereinzellage2 fiber single cell site
3 Fasereinzellage3 Fasereinzellage
4 Haftfadengitter 5 Stützkernschicht4 adhesive thread grid 5 supporting core layer
6 Stützkernschicht6 supporting core layer
7 Fasereinzellage7 Fasereinzellage
10 Formbauteil 10 molded component

Claims

Patentansprüche claims
1. Formbauteil (1 ,10) in Sandwichbauweise mit einem Kern aus kunstharzgebundener keramischer Substanz mit multidirektional orientierter Decklagen-Faserverstärkung,1. mold component (1, 10) in sandwich construction with a core made of resin-bonded ceramic substance with multidirectionally oriented cover layer fiber reinforcement,
dadurch gekennzeichnet,characterized,
dass ein Stützkern (5, 6) aus keramischem Material auf mindestens einer Seite von einer Decklage abgedeckt ist, welche aus mindestens zwei kunstharzgetränkten Fasereinzellagen (2, 3) besteht, deren Fasern in der Einzellage parallel nebeneinander liegen und sich im Verhältnis zur jeweils nächsten Einzellage in einem Kreuzungswinkel befinden.in that a support core (5, 6) of ceramic material is covered on at least one side by a cover layer which consists of at least two resin-impregnated fiber cell layers (2, 3) whose fibers lie parallel next to each other in the single layer and in relation to the next single layer located at a crossing angle.
2. Formbauteil nach Anspruch 1 ,2. molding component according to claim 1,
dadurch gekennzeichnet,characterized,
dass die Fasern der jeweiligen Einzellage mittels eines Haftfadengitters (4) unverschiebbar verbunden sind.that the fibers of the respective individual layer are immovably connected by means of an adhesive thread grid (4).
3. Formbauteil nach Anspruch 1 ,3. mold component according to claim 1,
dadurch gekennzeichnet,characterized,
dass die Fasern durch mittels einer Vorrichtung aufgetragene Klebespuren auf der Basis von Permanent- bzw. Schmelzkleber unverschiebbar verbunden sind. that the fibers are immovably connected by means of a device applied adhesive traces based on permanent or hot melt adhesive.
4. Formbauteil nach Anspruch 1 ,4. mold component according to claim 1,
dadurch gekennzeichnet,characterized,
dass die Fasern durch mittels einer Vorrichtung aufgetragenen vollflächigen Beschichtung aus Kunstharz unverschiebbar verbunden sind.that the fibers are immovably connected by means of a device applied full-surface coating of synthetic resin.
5. Formbauteil nach Anspruch 1 ,5. molded component according to claim 1,
dadurch gekennzeichnet,characterized,
dass die Fasern der Einzellagen aus Textilglas, Karbon, Aramid, Polyester, Acryl oder Keramik bestehen.that the fibers of the individual layers of textile glass, carbon, aramid, polyester, acrylic or ceramic.
6. Formbauteil nach Anspruch 1 ,6. mold component according to claim 1,
dadurch gekennzeichnet,characterized,
dass die aus Fasern mit multidirektionaler Orientierung bestehende Decklage mit Kunstharz als Matrix auf der Basis von Polyester, Epoxid, MeI- amin, Harnstoff, Phenol oder dergleichen imprägniert ist.the cover layer consisting of fibers with multidirectional orientation is impregnated with synthetic resin as a matrix based on polyester, epoxide, melamine, urea, phenol or the like.
7. Formbauteil nach Anspruch 1 ,7. mold component according to claim 1,
dadurch gekennzeichnet, dass als Stützkern (5, 6) aus keramischem Material, ein kunstharz- oder zementgebundenes Granulat auf der Basis von Bims, Perlite, Glimmer, Hohlglas, Schaumstoff, Blähton oder Split jeglicher Art verwendet wird.characterized, that as a support core (5, 6) made of ceramic material, a resin or cement-bound granules based on pumice, perlite, mica, hollow glass, foam, expanded clay or split of any kind is used.
8. Formbauteil nach Anspruch 1 und einem der nachfolgenden Ansprüche,8. molded component according to claim 1 and one of the subsequent claims,
dadurch gekennzeichnet,characterized,
dass das Formbauteil (1 ,10) mehrere Deckschichten sowohl als äußerein that the molding component (1, 10) has several outer layers as well as outer layers
Tragschichten, wie auch als mittlere Verstärkungsschichten zur Aufnahme der Biege-, Zug-, Druck-, Torsions- und Scherkräfte aufweist. Supporting layers, as well as medium reinforcing layers for receiving the bending, tensile, compressive, torsional and shear forces.
PCT/DE2006/001962 2005-11-10 2006-11-09 Moulded component with a sandwich structure, comprising a ceramic core and multidirectional covering layers WO2007054079A2 (en)

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