Braid extension element and method for manufacturing a fiber composite component

Abstract

Fiber composite component with a core (2) and at least one braid extension element (1) for connection to the core (2) of the fiber composite component, wherein the braid extension element (1) is detachably attached to the core (2), characterized in that a profile end piece (3) is provided between the braid extension element (1) and the core (2), the contour of which corresponds on a first side to that of the core (2) and on a second side to that of the braid extension element (1).

Description

[0001] The invention relates to a fiber composite component with a core and at least one braid extension element for connection to a core of a fiber composite component, and to a method for manufacturing a fiber composite component with a core using such a braid extension element.

[0002] It is also known from the prior art to produce fiber composite components, for example made of CFRP or GFRP, using a braiding process on cores, especially foam cores. The braiding process serves as preparation for the process of manufacturing the final components, for example, the RTM process. Until now, the cores generally had to be made larger than the later usable component length to ensure a completely braided component. In prior art processes, the cores are therefore made relatively large and shortened to the desired final component dimensions after the shaping component manufacturing (for example, in the RTM process). This method has two disadvantages. Firstly, shortening the fiber composite component...On the one hand, resources are wasted in the core, and on the other hand, the tools for component manufacturing have to be relatively large if the necessary extension section is only removed at the very end of a manufacturing process.

[0003] Furthermore, DE 10 2004 028 075 A1 discloses a method for producing a fiber composite semi-finished product in which an additional core is used that forms the braided core.

[0004] Further prior art in the present technical field, which reflects the preamble of claim 1, is disclosed in documents DE 601 01 638 T2 and DE 10 2009 058 487 A1.

[0005] Against this background, the object of the invention is to provide a means by which fiber composite components can be manufactured with an increased material utilization rate and at a lower cost.

[0006] This problem is solved by using a braid extension element according to claim 1 and by using a method for manufacturing a fiber composite component according to claim 5.

[0007] According to the invention, a fiber composite component is proposed comprising a core and at least one braid extension element for connection to the core of the fiber composite component, which is detachably attached to the core. Furthermore, a profile end piece is provided between the braid extension element and the core, the contour of which corresponds on one side to that of the core and on the other side to that of the braid extension element. A "braid extension element" is defined as any component that is attached to the core of a fiber composite component in order to completely encircle the component-specific core and that is detachably and only temporarily attached to the core. The component-specific core is the core that remains in the finished fiber composite component. A foam core is typically used for this purpose.The detachable attachment of the braid extension element to the core can be achieved using various fastening methods known from the prior art. For example, a thread can be foamed into the core, into which the braid extension is screwed. Alternatively, toggle fasteners can be used.

[0008] In a favorable embodiment of the fiber composite component, the braiding extension element is modular, with each module being adaptable to different core shapes. To ensure the complete braiding process of the fiber composite component without any disruption at the transition to the braiding extension element, it is advantageous for the latter to form a continuation of the core shape, at least in some sections. This means that the braiding extension element provides a flush transition from the edge of the core without any breaks, steps, or the like.

[0009] The detachable fastening, for example via a thread, ensures that the braided extension element of the fiber composite component is reusable. This significantly reduces process costs. The need to detach and dispose of the extension, which was previously formed as a single piece on the core, including the associated costly fiber material, is eliminated.

[0010] The invention further relates to a method for manufacturing a fiber composite component with a core to which at least one braid extension element is detachably attached, as described above. According to the invention, a profile end piece is provided between the braid extension element and the core, the contour of which corresponds on one side to that of the core and on the other side to that of the braid extension element. The use of a profile end piece increases the versatility of the braid extension element for use with any foam core shape. This means that a braid extension element, once adapted to the contour of the profile end piece, can be used with any foam core, as long as the profile end piece is used. The different contours of the respective cores are compensated for by the first side of the profile end piece.

[0011] The profile end piece can be attached to the core in various ways. For example, it can be foamed in place, or it can be attached to the core using a bayonet fitting or other quick-release fastener. It is generally possible for the profile end piece to remain in the finished fiber composite component.

[0012] According to the invention, the method involves braiding the core with fibers after the braiding extension element has been indirectly attached to it. The semi-finished component is then subjected to the corresponding manufacturing process (for example, RTM). Only after this process is the braiding extension element removed from the core or the profile end piece.

[0013] In a further advantageous embodiment, the braiding extension element is used as a positioning element for the fiber composite component to be manufactured in the manufacturing tool. For this purpose, the braiding extension element can have corresponding shapes such as recesses or the like, which interact with complementary counter-forms in the tool in such a way that the component to be manufactured can be fixed in position within the tool via the braiding extension element.

[0014] Other advantageous embodiments of the invention are characterized in the dependent claims or are described in more detail below together with the description of the preferred embodiment of the invention with reference to the figures. The figures show: Fig. 1 A side sectional view of a braid extension element on a core; Fig. 2 A side sectional view of a braid extension element on a core with a profile end piece; Fig. 3 A side sectional view from Fig. 2 with braided core and profile end piece

[0015] The figures are schematic examples. Identical reference symbols denote identical parts in all views.

[0016] In Fig. Figure 1 shows a braid extension element 1 attached to a core 2 of a fiber composite component to be manufactured according to the prior art, shown in a side sectional view. The braid extension element 1 is modular and attached to the core 2 via the screw connection (not shown). The transition between the core 2 and the braid extension element 1 is flush, with the braid extension element 1 forming a continuation of the core 2. Recesses 5 in the side region of the braid extension element 1 are provided to allow the braid extension element 1 to simultaneously serve as a positioning element for the fiber composite component in the manufacturing tool.

[0017] In Fig. In a lateral section view, a braid extension element 1 is indirectly attached to the core 2 via a profile end piece 3. The profile end piece 3 has a complementary shape to the core 2 on the left side and a complementary shape to the braid extension element 1 on the right side. By using the profile end piece 3, it is possible to use a pre-shaped braid extension element 1 with different shapes of the end section of the core 2.

[0018] Fig. 3 shows the execution according to Fig.2, wherein a braid 4 is provided around the core 2 and the profile end piece 3, extending to the outer edge of the core 2 beyond the profile end piece 3. The illustrated arrangement is subjected to the manufacturing process (for example, the RTM process) in the embodiment shown, after which the braid extension element 1 is removed. In principle, it is possible to design the braid extension element 1 to be reusable, but it is also possible to provide it as a cost-effective disposable element.

[0019] The invention is not limited in its implementation to the preferred embodiments specified above. Rather, a number of variants are conceivable which make use of the solution presented even in fundamentally different designs.

Claims

[1] Fiber composite component with a core (2) and at least one braid extension element (1) for connection to the core (2) of the fiber composite component, wherein the braid extension element (1) is detachably attached to the core (2), characterized by , that between the braid extension element (1) and the core (2) a profile end piece (3) is provided, the contour of which corresponds on a first side to that of the core (2) and on a second side to that of the braid extension element (1). [2] Fiber composite component according to claim 1, characterized by , that the braid extension element (1) is modular. [3] Fiber composite component according to one of claims 1 or 2, characterized by , that the braid extension element (1) forms at least a partial continuation of the shape of the core (2). [4] Fiber composite component according to at least one of the preceding claims, characterized by , that the braid extension element (1) is reusable. [5] Method for producing a fiber composite component according to one of claims 1 to 4, wherein at least one braid extension element (1) is detachably attached to the core (2), characterized by , that a profile end piece (3) is provided between the braid extension element (1) and the core (2), the contour of which corresponds on a first side to that of the core (2) and on a second side to that of the braid extension element (1). [6] Method according to claim 5, characterized by , that the core (2) is a foamed foam core and the profile end piece (3) is foamed in. [7] Method according to one of claims 5 or 6, characterized by , that at least the core (2) is braided with fibers and the braiding extension element (1) is subsequently removed. [8] Method according to any one of claims 5 to 6, characterized by, that at least the core (2) and the profile end piece (3) are braided with fibers and the braiding extension element (1) is subsequently removed. [9] Method according to any one of claims 5 to 8, characterized by , that the braid extension element (1) is used as a positioning element for the fiber composite component to be manufactured in the manufacturing tool.

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