US20100212816A1 - Method for producing a hollow structural part made of fiber-reinforced plastic - Google Patents
Method for producing a hollow structural part made of fiber-reinforced plastic Download PDFInfo
- Publication number
- US20100212816A1 US20100212816A1 US12/451,868 US45186808A US2010212816A1 US 20100212816 A1 US20100212816 A1 US 20100212816A1 US 45186808 A US45186808 A US 45186808A US 2010212816 A1 US2010212816 A1 US 2010212816A1
- Authority
- US
- United States
- Prior art keywords
- binding agent
- partly
- water
- filler
- plastic
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 13
- 229920002430 Fibre-reinforced plastic Polymers 0.000 title claims description 6
- 239000011151 fibre-reinforced plastic Substances 0.000 title claims description 6
- 238000000034 method Methods 0.000 claims description 26
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 19
- 239000000945 filler Substances 0.000 claims description 17
- 239000011230 binding agent Substances 0.000 claims description 16
- 239000004033 plastic Substances 0.000 claims description 15
- 229920003023 plastic Polymers 0.000 claims description 15
- 239000002245 particle Substances 0.000 claims description 14
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 9
- 235000019353 potassium silicate Nutrition 0.000 claims description 8
- 239000012783 reinforcing fiber Substances 0.000 claims description 7
- 239000004576 sand Substances 0.000 claims description 7
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 7
- 239000000919 ceramic Substances 0.000 claims description 6
- 229910052681 coesite Inorganic materials 0.000 claims description 6
- 229910052906 cristobalite Inorganic materials 0.000 claims description 6
- 239000000377 silicon dioxide Substances 0.000 claims description 6
- 229910052682 stishovite Inorganic materials 0.000 claims description 6
- 229910052905 tridymite Inorganic materials 0.000 claims description 6
- 239000007787 solid Substances 0.000 claims description 5
- QXJJQWWVWRCVQT-UHFFFAOYSA-K calcium;sodium;phosphate Chemical compound [Na+].[Ca+2].[O-]P([O-])([O-])=O QXJJQWWVWRCVQT-UHFFFAOYSA-K 0.000 claims description 4
- 239000000835 fiber Substances 0.000 claims description 4
- 238000002347 injection Methods 0.000 claims description 4
- 239000007924 injection Substances 0.000 claims description 4
- 229920005989 resin Polymers 0.000 claims description 4
- 239000011347 resin Substances 0.000 claims description 4
- 239000003232 water-soluble binding agent Substances 0.000 claims description 4
- HBBGRARXTFLTSG-UHFFFAOYSA-N Lithium ion Chemical compound [Li+] HBBGRARXTFLTSG-UHFFFAOYSA-N 0.000 claims description 3
- 150000001339 alkali metal compounds Chemical class 0.000 claims description 3
- 229910001416 lithium ion Inorganic materials 0.000 claims description 3
- 229910001414 potassium ion Inorganic materials 0.000 claims description 3
- 229910001415 sodium ion Inorganic materials 0.000 claims description 3
- 238000001721 transfer moulding Methods 0.000 claims description 3
- 239000004111 Potassium silicate Substances 0.000 claims description 2
- 239000004115 Sodium Silicate Substances 0.000 claims description 2
- PAZHGORSDKKUPI-UHFFFAOYSA-N lithium metasilicate Chemical compound [Li+].[Li+].[O-][Si]([O-])=O PAZHGORSDKKUPI-UHFFFAOYSA-N 0.000 claims description 2
- 229910052912 lithium silicate Inorganic materials 0.000 claims description 2
- 229910052913 potassium silicate Inorganic materials 0.000 claims description 2
- NNHHDJVEYQHLHG-UHFFFAOYSA-N potassium silicate Chemical compound [K+].[K+].[O-][Si]([O-])=O NNHHDJVEYQHLHG-UHFFFAOYSA-N 0.000 claims description 2
- 229910052911 sodium silicate Inorganic materials 0.000 claims description 2
- 150000003112 potassium compounds Chemical class 0.000 claims 1
- 150000003388 sodium compounds Chemical class 0.000 claims 1
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 description 6
- 238000009954 braiding Methods 0.000 description 5
- 239000000203 mixture Substances 0.000 description 4
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 239000012778 molding material Substances 0.000 description 3
- 238000000465 moulding Methods 0.000 description 3
- 238000009745 resin transfer moulding Methods 0.000 description 3
- CSNNHWWHGAXBCP-UHFFFAOYSA-L Magnesium sulfate Chemical compound [Mg+2].[O-][S+2]([O-])([O-])[O-] CSNNHWWHGAXBCP-UHFFFAOYSA-L 0.000 description 2
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 2
- 239000003822 epoxy resin Substances 0.000 description 2
- 239000010881 fly ash Substances 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 238000012856 packing Methods 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- 235000011118 potassium hydroxide Nutrition 0.000 description 2
- 229910001152 Bi alloy Inorganic materials 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- 229920000426 Microplastic Polymers 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 229910052797 bismuth Inorganic materials 0.000 description 1
- JCXGWMGPZLAOME-UHFFFAOYSA-N bismuth atom Chemical compound [Bi] JCXGWMGPZLAOME-UHFFFAOYSA-N 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 239000003518 caustics Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 239000004922 lacquer Substances 0.000 description 1
- 229910052943 magnesium sulfate Inorganic materials 0.000 description 1
- 235000019341 magnesium sulphate Nutrition 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000011236 particulate material Substances 0.000 description 1
- 239000013502 plastic waste Substances 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
- B29C33/52—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles soluble or fusible
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
- B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
- B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
Definitions
- This invention relates to a method for producing a hollow structural part made of fiber-reinforced plastic according to the preamble of claim 1 .
- RTM resin transfer molding
- At least one layer of the e.g. uni- or bidirectionally oriented reinforcing fibers is placed between the upper and lower tools of a heated press and the fiber layer impregnated with a heat-curable plastic, for example an epoxy resin with curing agent, which is injected under pressure into the cavity with the fiber layer between upper and lower tools.
- a heat-curable plastic for example an epoxy resin with curing agent
- hollow structural parts for example the support pillars, door sills, bumpers and the like.
- Such hollow parts are usually bonded.
- the bonding point can lead to failure.
- the dimensional accuracy of bonded hollow parts leaves much to be desired.
- support cores made of high-density foamed material which remain within the part and thus lead to a corresponding weight increase.
- the object of the invention is hence to provide, for an RTM process for production of hollow structural parts made of fiber-reinforced plastic, a water-dispersible support core that safely withstands the high pull-off forces upon wrapping with the reinforcing fibers.
- the support core employed according to the invention is characterized by the fact that the water-soluble binding agent contains at least partly a silicate.
- the binding agent preferably employed is a water glass.
- the binding agent is characterized in that the SiO 2 /M 2 O weight ratio is preferably in the range of from 1.6 to 4.0, in particular from 1.8 to 3.5, where M signifies sodium ions and/or potassium ions and/or lithium ions.
- the binding agent preferably has a solids content of SiO 2 and M 2 O in the range of from 30 to 60 wt %.
- the support core has a relatively small content of binding agent of preferably from 0.5 to 8 wt %, in particular from 1 to 5 wt %, and thus an accordingly high filler content. This achieves high strength, so that it withstands the high pull-off forces upon packing, i.e. wrapping, in particular braiding, with the reinforcing fibers.
- the reinforcing fibers used are preferably carbon fibers. However, it is also possible to employ other reinforcing fibers, for example glass fibers.
- the packing is preferably carried out with a braiding machine as employed for braiding cables and ropes, whereby the support core occupies the place of the cable core or rope core in the eye of the machine.
- the production of the fiber-reinforced hollow structural part is then preferably effected by the RTM process. That is, the packed support core is placed between the two tools, for example, the upper and lower tools of a heated press, whereupon the reinforcing fibers on the support core are impregnated with a heat-curable plastic, for example an epoxy resin which is injected into the cavity with the support core between the two tool parts.
- a heat-curable plastic for example an epoxy resin which is injected into the cavity with the support core between the two tool parts.
- RTM resin transfer molding
- demolding is effected and the support core flushed out with water, so that the fiber-reinforced hollow structural part is formed.
- the employed water glass can be for example a sodium silicate. However, it is also possible to employ other water glasses, in particular potassium silicate or also lithium silicate.
- the binding agent can contain further alkali metal compounds which can be added in solid form or as an aqueous solution, for example sodium hydroxide or potassium hydroxide or, in dissolved form, caustic sodium or caustic potash.
- Said additives can be used for example to control the modulus (SiO 2 /M 2 O ratio) and the solids content.
- the filler consists of a water-insoluble particulate material, preferably at least partly of sand.
- the sand preferably has an average grain size of from 100 to 500 ⁇ m.
- the support cores for the inventive method are preferably produced by a core shooting machine as described for example in DE 102 00 927 A1 for the production of cores for foundry purposes.
- a mixture of foundry sand, water-dissolved magnesium sulfate as a binding agent and water is shot into a molding tool. The water is subsequently evaporated to form the foundry core for production of the casting.
- the sand content of the filler is at least 30 wt %.
- the filler preferably contains plastic particles, normally with an average grain size of from 100 ⁇ m to 2 mm.
- the plastic particles are preferably formed from shredded plastic waste.
- the spherical shape accordingly increases the above-mentioned fluidity of the mixture of filler, dissolved binding agent and water.
- the plastic particles in addition increase the elasticity of the support core, i.e. reduce its brittleness.
- the weight of the support cores can be substantially lowered by the use of plastic particles as the filler.
- the content of plastic in the filler is at least 10 wt %. However, it can also be considerably higher, amounting to 50 wt % and more. This makes it possible to obtain substantially lighter and thus accordingly more easily handled cores.
- a weight reduction of the cores is further attainable with ceramic particles or hollow glass spheres.
- the ceramic particles can be formed for example by fly ash. Because the fly ash particles are likewise of rather spherical configuration, they at the same time ensure the fluidity necessary for shooting. This is of course especially true of hollow glass spheres as a filler.
- the average particle size of the ceramic particles and the hollow glass spheres can be for example from 50 to 800 ⁇ m.
- the water content of the molding material i.e. of the mixture of filler, binding agent and water, is preferably from 0.2 to 5 wt % based on the weight of the filler. This ensures the processability of the molding material upon insertion into the molding tool, for example, by shooting or pressing. However, the water content is chosen as low as possible, because the support core must be dried before demolding in order for it to possess the necessary strength.
- a preferred molding material consists for example of from 0.5 to 5 wt %, in particular from 1 to 2 wt %, of silicate-containing water-soluble binding agent, with a SiO 2 /M 2 O ratio preferably in the range of from 1.6 to 4.0, where M signifies sodium ions and/or potassium ions and/or lithium ions, and a solids content of from 30 to 60%; and balance sand.
- any hollow structural parts made of fiber-reinforced plastic In the automobile sector there are to be mentioned in particular the support pillars, i.e. the A-, B- and C-pillars, door sills and bumpers as examples of such fiber-reinforced hollow structural parts.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Reinforced Plastic Materials (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Laminated Bodies (AREA)
Abstract
Description
- This invention relates to a method for producing a hollow structural part made of fiber-reinforced plastic according to the preamble of claim 1.
- For production of hollow fiber-reinforced plastic parts there are employed inter alia the so-called RTM (resin transfer molding) process and the vacuum injection process.
- For this purpose, at least one layer of the e.g. uni- or bidirectionally oriented reinforcing fibers is placed between the upper and lower tools of a heated press and the fiber layer impregnated with a heat-curable plastic, for example an epoxy resin with curing agent, which is injected under pressure into the cavity with the fiber layer between upper and lower tools. The procedure is similar in the vacuum injection method whereby, instead of pressure, a vacuum is applied to suck the heat-curable plastic into the fiber layer.
- For automobiles there are employed numerous hollow structural parts, for example the support pillars, door sills, bumpers and the like. Such hollow parts are usually bonded. However, the bonding point can lead to failure. In addition, the dimensional accuracy of bonded hollow parts leaves much to be desired.
- For production of hollow parts by the RTM process it is customary today to use melt cores made of wax. The processes used therefor are very elaborate because of the size of the cores. Further, the great thermal expansion coefficient of the wax requires an elaborate adjustment of the necessary manufacturing facilities. After the actual part production the materials are melted out again. This leaves residual material on the inner tool wall, which firstly increases the part weight and is also judged critically with regard to emissions and lacquer compatibility.
- From WO 02/072328 A1 there is known a support core for production of hollow structural parts made of plastic which contains polyvinylpyrrolinone (PVP) as the water-soluble binding agent.
- In order to wrap the support core there can be employed a braiding machine, whereby the support core is located in the eye of the braiding machine while the reinforcing threads are pulled off from the periphery under high tension. However, the support core according to WO 02/072328 A1 possesses too little breaking strength to withstand such high pull-off forces.
- There have also been employed support cores made of low-melting bismuth alloys. However, because of the high energy input for melting the cores, the high weight and the resulting difficult handling, but also because of the health risk of bismuth vapors, such cores are not employable in practice.
- Further, use is made of support cores made of high-density foamed material which remain within the part and thus lead to a corresponding weight increase.
- The object of the invention is hence to provide, for an RTM process for production of hollow structural parts made of fiber-reinforced plastic, a water-dispersible support core that safely withstands the high pull-off forces upon wrapping with the reinforcing fibers.
- This is achieved according to the invention by the method characterized in claim 1. In the subclaims there are stated advantageous embodiments of the invention.
- The support core employed according to the invention is characterized by the fact that the water-soluble binding agent contains at least partly a silicate. The binding agent preferably employed is a water glass. The binding agent is characterized in that the SiO2/M2O weight ratio is preferably in the range of from 1.6 to 4.0, in particular from 1.8 to 3.5, where M signifies sodium ions and/or potassium ions and/or lithium ions. The binding agent preferably has a solids content of SiO2 and M2O in the range of from 30 to 60 wt %.
- The support core has a relatively small content of binding agent of preferably from 0.5 to 8 wt %, in particular from 1 to 5 wt %, and thus an accordingly high filler content. This achieves high strength, so that it withstands the high pull-off forces upon packing, i.e. wrapping, in particular braiding, with the reinforcing fibers.
- The reinforcing fibers used are preferably carbon fibers. However, it is also possible to employ other reinforcing fibers, for example glass fibers. The packing is preferably carried out with a braiding machine as employed for braiding cables and ropes, whereby the support core occupies the place of the cable core or rope core in the eye of the machine.
- The production of the fiber-reinforced hollow structural part is then preferably effected by the RTM process. That is, the packed support core is placed between the two tools, for example, the upper and lower tools of a heated press, whereupon the reinforcing fibers on the support core are impregnated with a heat-curable plastic, for example an epoxy resin which is injected into the cavity with the support core between the two tool parts. It is possible here to carry out the resin transfer molding (RTM) process by which the heat-curable plastic is pressed into the cavity under a pressure of 10 bar and more, or the vacuum injection process by which the heat-curable plastic is sucked into the cavity. After curing of the resin, demolding is effected and the support core flushed out with water, so that the fiber-reinforced hollow structural part is formed.
- The employed water glass can be for example a sodium silicate. However, it is also possible to employ other water glasses, in particular potassium silicate or also lithium silicate.
- Besides water glass, the binding agent can contain further alkali metal compounds which can be added in solid form or as an aqueous solution, for example sodium hydroxide or potassium hydroxide or, in dissolved form, caustic sodium or caustic potash. Said additives can be used for example to control the modulus (SiO2/M2O ratio) and the solids content.
- The filler consists of a water-insoluble particulate material, preferably at least partly of sand. The sand preferably has an average grain size of from 100 to 500 μm.
- Besides the strength that it gives to the support core, the sand also has an important function in the production of the support core. The support cores for the inventive method are preferably produced by a core shooting machine as described for example in DE 102 00 927 A1 for the production of cores for foundry purposes. Here, a mixture of foundry sand, water-dissolved magnesium sulfate as a binding agent and water is shot into a molding tool. The water is subsequently evaporated to form the foundry core for production of the casting.
- In order for the mixture of filler, water-dissolved binding agent and water, which is preferably employed for shooting according to the invention, to have the fluidity necessary for shooting into the molding tool, it has proved expedient that the sand content of the filler is at least 30 wt %.
- Further, the filler preferably contains plastic particles, normally with an average grain size of from 100 μm to 2 mm. The plastic particles are preferably formed from shredded plastic waste. In order for the particles to be of rather spherical configuration, it is preferable to employ plastic pellets. The spherical shape accordingly increases the above-mentioned fluidity of the mixture of filler, dissolved binding agent and water. The plastic particles in addition increase the elasticity of the support core, i.e. reduce its brittleness. At the same time, the weight of the support cores can be substantially lowered by the use of plastic particles as the filler. Preferably, the content of plastic in the filler is at least 10 wt %. However, it can also be considerably higher, amounting to 50 wt % and more. This makes it possible to obtain substantially lighter and thus accordingly more easily handled cores.
- A weight reduction of the cores is further attainable with ceramic particles or hollow glass spheres. The ceramic particles can be formed for example by fly ash. Because the fly ash particles are likewise of rather spherical configuration, they at the same time ensure the fluidity necessary for shooting. This is of course especially true of hollow glass spheres as a filler. The average particle size of the ceramic particles and the hollow glass spheres can be for example from 50 to 800 μm.
- The water content of the molding material, i.e. of the mixture of filler, binding agent and water, is preferably from 0.2 to 5 wt % based on the weight of the filler. This ensures the processability of the molding material upon insertion into the molding tool, for example, by shooting or pressing. However, the water content is chosen as low as possible, because the support core must be dried before demolding in order for it to possess the necessary strength.
- A preferred molding material consists for example of from 0.5 to 5 wt %, in particular from 1 to 2 wt %, of silicate-containing water-soluble binding agent, with a SiO2/M2O ratio preferably in the range of from 1.6 to 4.0, where M signifies sodium ions and/or potassium ions and/or lithium ions, and a solids content of from 30 to 60%; and balance sand.
- According to the inventive method there can be produced any hollow structural parts made of fiber-reinforced plastic. In the automobile sector there are to be mentioned in particular the support pillars, i.e. the A-, B- and C-pillars, door sills and bumpers as examples of such fiber-reinforced hollow structural parts.
Claims (15)
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102007026229A DE102007026229A1 (en) | 2007-06-05 | 2007-06-05 | Process for producing a structural hollow component made of fiber-reinforced plastic |
DE102007026229.0 | 2007-06-05 | ||
PCT/EP2008/003749 WO2008148452A2 (en) | 2007-06-05 | 2008-05-09 | Method for the production of a structural hollow part from fiber-reinforced plastic |
Publications (1)
Publication Number | Publication Date |
---|---|
US20100212816A1 true US20100212816A1 (en) | 2010-08-26 |
Family
ID=39942064
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/451,868 Abandoned US20100212816A1 (en) | 2007-06-05 | 2008-05-09 | Method for producing a hollow structural part made of fiber-reinforced plastic |
Country Status (5)
Country | Link |
---|---|
US (1) | US20100212816A1 (en) |
EP (1) | EP2155459A2 (en) |
JP (1) | JP2010528896A (en) |
DE (1) | DE102007026229A1 (en) |
WO (1) | WO2008148452A2 (en) |
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CN109153196A (en) * | 2016-05-11 | 2019-01-04 | 康蒂泰克Mgw有限公司 | Method for manufacturing pressurizing air tracheae |
US10994501B2 (en) * | 2017-01-11 | 2021-05-04 | Beijing Automotive Group Co. Ltd. | Method for molding hollow vehicle part, hollow vehicle part and automobile |
US11577478B2 (en) * | 2016-03-02 | 2023-02-14 | Lm Wp Patent Holding A/S | Method of molding a shell part of a wind turbine blade |
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JP2012196861A (en) * | 2011-03-22 | 2012-10-18 | Toray Ind Inc | Method for manufacturing hollow fiber reinforced plastic |
TWI504495B (en) * | 2012-06-12 | 2015-10-21 | Mitsubishi Rayon Co | Method for forming fiber reinforced plastic and forming device thereof |
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Also Published As
Publication number | Publication date |
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EP2155459A2 (en) | 2010-02-24 |
JP2010528896A (en) | 2010-08-26 |
WO2008148452A2 (en) | 2008-12-11 |
WO2008148452A3 (en) | 2009-02-26 |
DE102007026229A1 (en) | 2008-12-11 |
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