Device and method for connecting textile-reinforced structural modules

Abstract

The invention relates to a system for connecting textile-reinforced structural modules along a connecting edge (76), which has a peripheral groove (74) having yarn loops (4). According to the invention, the system comprises a wedge element (410) and two shell elements (420) having a keyway (422) and is intended for insertion into the two peripheral grooves (74) with the overlapping yarn loops (4), wherein, furthermore, the wedge element (410) is intended to be partially extracted from the two keyways (422), which are arranged opposite one another, such that the shell elements (420) are spread apart by means of a wedge effect and the yarn loops (4) can be pulled together. The invention also relates to an apparatus and to a method for producing a textile reinforcement (10), comprising a yarn (2) arranged within a main frame (100), or for producing a textile-reinforced structural module (72), comprising the textile reinforcement (10) and a curable material, wherein a freely shapeable shaping device (200) is provided, on which the structural module is formed. According to the invention, the textile reinforcement (10) can be formed between yarn-holding devices (130, 180), which can be arranged on flexible frame strips (110). The invention also relates to a concrete component consisting of connected concrete structural modules, and to a printer file and a yarn deposition file.

Description

[0001] The invention relates to a device and a method for producing a textile reinforcement, comprising at least one yarn arranged within a base frame, or for producing a textile-reinforced structural module, comprising the textile reinforcement and a curable material, wherein a forming device is provided which includes a free-formable forming layer on whose forming plane the reinforcement or the structural module is formed.

[0002] Devices and methods for producing textile reinforcement are known from the prior art, as is the production of doubly curved shapes or freeform forms. German patent application DE 10 2015 100 438 B3 describes a method for producing precast elements made of textile-reinforced concrete, in which a previously formed tensioning fabric is arranged as reinforcement in a formwork and cast with concrete. For this purpose, the tensioning fabric is first formed from a yarn free of polymer binders using a laying device in a base frame, by laying the yarn under mechanical tension between yarn holding devices arranged on the base frame. The production of curved or freeform components is not possible.

[0003] German patent application DE 198 23 610 B4 discloses a formwork table for the production of doubly curved or free-form components made of hardening materials, in particular concrete. The formwork table comprises a formwork skin, a substructure for its support, and adjustment devices for supporting and reversibly deforming the substructure and thus the formwork skin. The substructure consists of a bendable and plane-deformable grating. Sealing is achieved either by covering the grating with an elastic membrane or by incorporating a deformable, sealing substance into the grating. The subsequent joining of multiple components is provided for. However, it is not possible to fabricate reinforcement, and in particular textile reinforcement, within the formwork table.

[0004] Document EP3.381.637A1 discloses a device according to the preamble of claim 1 and a method according to the preamble of claim 10.

[0005] It is therefore the object of the present invention to offer a device and a method for manufacturing a textile reinforcement and / or a structural module in a formwork table suitable for producing freeform shapes.

[0006] The problem is further solved by a device for producing textile reinforcement, comprising at least one yarn arranged within a base frame, or for producing a textile-reinforced structural module, comprising the textile reinforcement and a curable material, in particular concrete. The textile reinforcement can be designed as a non-woven fabric. In the latter alternative, the device also serves as formwork.

[0007] The structural module is a self-contained module intended as part of a larger, superior structure or component, and is assembled with other structural modules to form the component. Any material that can be poured into a mold and harden there to form a solid structural module is considered a curable material. Within the scope of the present invention, concrete is specifically provided as such a curable material.

[0008] Furthermore, a forming device, preferably freely formable by means of a control unit and comprising a forming layer, is provided as an essential component of the device. The reinforcement or structural module is formed on the forming plane, on the upper surface of the forming layer.

[0009] The preferred control device also includes drive elements, such as motors, and power transmission elements that transmit the force from the drive elements, e.g., by means of pull cables, to the forming position. For alternative forming positions, the control devices also include surface finishing devices such as milling cutters or devices for additive or generative manufacturing.

[0010] Alternatively, non-controllable, non-flexible forming devices are provided, the forming position of which is brought into a desired position, for example in two planes and thus into a freeform shape, in another way, e.g. by processing a forming block, for example designed as a wax block, a steel, wood or foam block, the surface of a sand mold or according to a process of additive or generative manufacturing, and which can accommodate the reinforcement and the curable material on the top, the forming plane.

[0011] According to the invention, yarn holding devices are provided between which the textile reinforcement can be formed by guiding the yarn from a first yarn holding device to a second yarn holding device, and so on, and depositing it on the forming plane. Furthermore, flexible frame strips are provided on which the yarn holding devices can be arranged. The frame strips are flexible to adapt to the topography of the forming layer, even if it has been formed into a freeform shape. A compensation layer can also be used to achieve even better compensation or adaptation between the forming layer and the frame strips.

[0012] The frame strips can be arranged around the base frame to create various geometric shapes such as rectangles, triangles, or polygons with varying dimensions and angles. Open shapes are also possible. The base frame serves as the framework for the yarn, which acts as textile reinforcement. The yarn is stretched between the frame strips. The ends of the frame strips can overlap, forming the corners of the base frame.

[0013] Advantageously, the forming layer comprises a freely formable core layer constructed from core elements. The core elements are movably connected to each other by means of connectors and form a kind of mat or grid.

[0014] The core layer has an outer sealing layer on a forming plane (the top surface of the forming layer, where the reinforcement or structural module is formed) and an inner sealing layer on the plane opposite the forming plane. The inner sealing layer allows fluid pressure to build up in a pressure vessel, the top surface of which is the forming layer. Controllable actuators, such as control cables, can act against this fluid pressure. These actuators are connected to the forming layer or directly to the core layer at pivot points and are driven, for example, by controllable motors. Other types of actuators include pneumatic actuators or mechanical linear drives.

[0015] Furthermore, the space between the outer and inner sealing layers forms a fluid-tight zone, allowing another fluid to be introduced under pressure and, more importantly, stabilizing the outer sealing layer. The individual core elements are connected to each other via overflow openings located in the area of ​​the connectors.

[0016] According to alternative embodiments, the freeform forming layer is designed as a freeform surface, for example, from a mold block, in particular a wax block, a steel, wood, or foam block, in a sand mold, or from a surface produced by additive or generative manufacturing from the materials available for this purpose. These surfaces can be shaped as required, but cannot be modified as flexibly as is the case with the previously described forming layer with its core layer.

[0017] Preferably, the yarn holding devices are designed as horizontal yarn holding devices, comprising a base body and two horizontally arranged yarn holding rollers around which the yarn can be laid in a yarn loop. Alternatively, the yarn holding devices are designed as vertical yarn holding devices and have two vertically arranged yarn holding rollers. The yarn holding rollers are arranged one behind the other in the yarn direction. This allows a yarn loop of the required length to be formed, in particular for creating an edge connection between the structural modules in order to join them together.

[0018] It has proven advantageous to provide a yarn gate or yarn guide through which the yarn exits the horizontal or vertical yarn holder. This allows the yarn to protrude from the yarn holder at a specific angle without the risk of it slipping off the yarn guide rollers. The yarn guide, in particular, offers a high degree of flexibility in this regard. It allows the two ends of the yarn loop to exit at a greater distance from each other, which advantageously already corresponds to a predetermined grid dimension of the reinforcement.

[0019] The resulting yarn loop in the vertical yarn holding device with yarn holder rollers arranged in a vertical axis of rotation has a rotated position compared to the position resulting from the horizontal yarn holding device.

[0020] An advantageous embodiment of the horizontal or vertical yarn holding device has proven to be one in which the base body incorporates an electrically operated holding magnet. This allows the horizontal or vertical yarn holding device to be temporarily and controllably attached to a magnetic surface. The frame strip is the primary suitable surface.

[0021] A further development of this solution offers particular advantages in which the frame strips have longitudinally running, electrically contactable conductor tracks arranged on the surface facing the yarn holding device. These conductor tracks can be connected to a power source, preferably at one end of the conductor tracks or the frame strips. The conductor tracks can supply the holding magnet with electrical energy, enabling it to hold the yarn holding device on the frame strip as long as the power supply is maintained. Furthermore, the horizontal or vertical yarn holding device can be easily removed after the power supply is interrupted. The holding magnet can be designed as a solenoid.

[0022] An advantageous embodiment of the present invention provides a yarn laying device suitable for laying the yarn over the yarn holding devices according to a predetermined pattern, forming the yarn loops there, and thus producing the reinforcement. In conjunction with a suitable control system for the yarn laying device, the production of the reinforcement can be automated.

[0023] In a further development of the previously described embodiment, the yarn laying device includes a yarn impregnation unit that can coat the yarn with a curable, flowable impregnating agent immediately before laying. Alternatively, various methods and materials are provided for fixing the yarns after laying. According to one method, a hybrid fiber is used as the yarn, to which thermoplastic fibers, and thus thermally activatable fibers for bonding, have been added during manufacturing. During thermal activation after yarn laying, the thermoplastic fibers melt and bond together the load-bearing fibers, e.g., carbon fibers. The thermally activatable material then cures as soon as the thermoplastic fibers have cooled and returned to their solid state.

[0024] Another method for fixing the yarn involves impregnating it with a curable fiber matrix material, which stabilizes the yarn. This can be done immediately after the yarn is manufactured, in which case the yarn is used pre-impregnated and must be protected from unwanted premature hardening before use. Alternatively, as described above, the impregnation can be carried out immediately before laying. Reactive resins, such as epoxy resin, or aqueous dispersions, e.g., based on acrylate or styrene-butadiene, are preferred as curable materials. Depending on the material, curing can be achieved by thermal radiation, UV radiation, radiation from an LED lamp, microwave radiation, or similar methods.

[0025] It is also planned to use a curable fiber matrix material that includes electrically conductive materials (for example, with carbon platelets or nanotubes), or alternatively, an electrically conductive coating for the yarn.

[0026] This makes it possible to produce reinforcement that can be removed from the forming device in a fixed form and used for further purposes, even without subsequent concreting.

[0027] Another embodiment of the yarn depositing device features a coating film application unit that can provide the yarn, at least partially or along a portion of its length, with a protective coating after depositing. The coating forms a kind of tunnel in which the yarn is protected from unwanted lateral displacement while still remaining longitudinally movable enough to allow for length compensation. The coating is applied, for example, as a self-adhesive film or by means of sealing rollers that act on the edges of the coating.

[0028] Another aspect of the present invention relates to a method for producing a textile reinforcement comprising a yarn, or a textile-reinforced structural module comprising the textile reinforcement and a curable material, in particular concrete. A forming position is provided which, if required, is curved at least twice, i.e., in two planes, by means of a control device, or furthermore forms a freeform surface as defined above.

[0029] According to the invention, the textile reinforcement is formed between yarn holding devices, and the yarn holding devices are furthermore arranged on flexible frame strips in any desired configuration, preferably by automated removal from a magazine and placement. The frame strips are in turn arranged in any desired geometric shape to form the base frame.

[0030] The automated arrangement of the yarn holding devices on the flexible frame strips is facilitated by equipping the yarn holding devices with an electrically operated holding magnet. This magnet is activated as soon as the yarn holding device, with its base and the electrical contacts located on its underside, is placed onto the conductor tracks on the frame strip, which are connected to an electrical power source, thus establishing electrical contact. The power supply is then interrupted to facilitate disassembly.

[0031] Preferably, when forming the textile reinforcement, the yarn is laid in such a way that the yarn loops extend outwards, beyond the curing material or the area to be concreted. Advantageously, the yarn loops lie within the edge grooves of the structural module. In any case, it has proven advantageous if the yarn is laid on a device as described above.

[0032] The invention is explained in more detail below with reference to the description of exemplary embodiments and their illustration in the accompanying drawings. The drawings show: Fig. 1 : a schematic top view of an embodiment of a shaping device according to the invention with reinforcement formed between a base frame; Fig. 2 : schematic top views of four different basic frames in different geometric shapes; Fig. 3: a schematic perspective representation of an embodiment of a reinforcement according to the invention as a freeform surface; Fig. 4 : a schematic perspective representation of an embodiment of a frame strip and its application in conjunction with horizontal yarn holding devices; Fig. 5 : a schematic perspective representation of two embodiments of a frame strip with conductor tracks and attached horizontal yarn holding devices; Fig. 6 : a schematic perspective representation of two embodiments of a frame strip with and without a recessed foot; Fig. 7 : a schematic top view of an embodiment of a reinforcement according to the invention, formed within a base frame using horizontal yarn holding devices with yarn guidance; Fig. 8: a schematic top view of an embodiment of a reinforcement according to the invention, formed within a base frame using horizontal yarn holding devices with yarn gate; Fig. 9 : a schematic top view of an embodiment of a reinforcement according to the invention, formed within a base frame using horizontal yarn holding devices with yarn guidance; Fig. 10 : a schematic top view of an embodiment of a reinforcement according to the invention, formed within a base frame using horizontal yarn holding devices with yarn gate; Fig. 11 : a schematic top view of an embodiment of a reinforcement according to the invention, formed within a base frame using horizontal yarn holding devices with yarn gate; Fig. 12: a schematic detail view of an embodiment of a reinforcement according to the invention, formed within a base frame using a horizontal yarn holding device with yarn guidance; Fig. 13 : a schematic detail view of an embodiment of a reinforcement according to the invention, formed within a base frame using a horizontal yarn holding device with yarn gate; Fig. 14 : a schematic perspective representation of an embodiment of a horizontal yarn holding device with yarn gate and inserted yarn loop; Fig. 15 : a schematic side view of a horizontal yarn holding device with yarn gate and yarn loop inserted in two different variants; Fig. 16 : a schematic perspective representation of an embodiment of a horizontal yarn holding device with yarn gate; Fig. 17: a schematic perspective exploded view of an embodiment of a horizontal yarn holding device with yarn gate and holding magnets; Fig. 18 : a schematic perspective representation of an embodiment of a horizontal yarn holding device with yarn guidance; Fig. 19 : a schematic perspective exploded view of an embodiment of a horizontal yarn holding device with yarn gate and holding magnets; Fig. 20 : a schematic perspective representation of an embodiment of a vertical yarn holding device; Fig. 21 : a schematic perspective exploded view of an embodiment of a vertical yarn holding device; Fig. 22 : a schematic side view of two embodiments of a horizontal yarn holding device with yarn gate and inserted yarn loop; Fig. 23 : a schematic cutaway side view of an embodiment of a forming device according to the invention; Fig. 24: schematic top view of two embodiments of a forming device according to the invention; Fig. 25 : a schematic cutaway side view of a detail of an embodiment of a forming device according to the invention; Fig. 26 : a schematic top view of an embodiment of a forming position; Fig. 27 : a schematic perspective detail representation of an embodiment of a forming position; Fig. 28 : a schematic view of an embodiment of a core element; Fig. 29 : a schematic representation of an embodiment of a yarn depositing device with inserted yarn pressure roller and cover film application device; Fig. 30 : a schematic representation of an embodiment of a yarn storage device; and Fig. 31 : a schematic cross-sectional view of a yarn with an applied topcoat.

[0033] Fig. 1Figure 1 shows a schematic top view of an embodiment of a forming device 200 according to the invention with reinforcement 10 formed within a base frame 100. The forming device 200 stands on a base 1 and is bounded by side walls 212. A forming layer 250 is visible on the top side, which can be shaped according to the requirements of the topography of a reinforcement or a structural module and can also be curved in two directions.

[0034] The base frame 100 is arranged on the forming surface 250. It is formed by frame strips 110 that overlap at their ends and form the corners of the base frame 100. The yarn holding devices, which will be described in detail later, are attached to the frame strips 110. The yarn 2 is laid between these devices and held by them.

[0035] Fig. 2Figure 1 shows schematic top views of four different base frames 100 in different geometric shapes: a square, a triangle, an irregular quadrilateral, and two rectangles. These examples illustrate that an almost unlimited variety of shapes, both open and closed, can be represented for the base frame. Not shown, but also intended, is the use of frame strips 110 that are bendable in the plane or pre-formed to a specific radius.

[0036] Fig. 3 Figure 1 shows a schematic perspective representation of an embodiment of a reinforcement 10 according to the invention as a freeform surface, wherein not only the reinforcement 10, but also the frame strips 110 also assume convex areas 12 and concave areas 14 of the surface.

[0037] The embodiment of a forming device 200 also shown is a solid forming block, in this example a wax block 290, whose surface is designed as a forming layer 250 according to the requirements. To ensure that the reinforcement 10 also forms concave areas, the tension of the yarn 2 during laying must be selected to be correspondingly low. Alternatively, aids such as a cover film 20 can be used; compare this with the description of the yarn laying device 300 ( Figures 29 and 30 and related description).

[0038] Fig. 4Figure 1 shows a schematic perspective view of an embodiment of a frame strip 110 and its application in conjunction with horizontal yarn holding devices 130. In view a), the horizontal yarn holding devices 130 are placed on the frame strip 110 at the desired distance and in the desired arrangement. This results in the arrangement shown in view b). View c) shows how the frame strip 110, when placed on a surface that is curved and has convex and concave areas, adopts the shape of this surface. Vertical holding devices 180 (not shown here) can be used in the same way (see Figure 1). Figures 20 , 21 ) are set up.

[0039] Fig. 5Figure 1 shows a schematic perspective view of two embodiments of a frame strip 110 with conductor tracks 120 and attached horizontal yarn holding devices 130. View a) shows the horizontal yarn holding devices 130 attached to the frame strip 110 at different intervals, also showing the conductor tracks 120 and a connecting cable 122 for supplying electrical power. View b) shows the horizontal yarn holding devices 130 at uniform intervals.

[0040] The electrical energy supplied to the conductor tracks 120 via the connecting line 122 enables the horizontal yarn holding device 130 to adhere to the frame strip 110 by magnetic force (compare Fig. 17 and related description).

[0041] Fig. 6Figure 1 shows a schematic perspective view of two embodiments of a frame strip 110, with and without a countersunk foot 115. The countersunk foot 115 is suitable for fixing the frame strip 110 in a relatively rigid material, such as a block of wax (compare Figure 1). Fig. 3 and related description) or sand, by pressing the counterfeit feet 115 into the wax or sand.

[0042] Fig. 7 Figure 1 shows a schematic top view of an embodiment of a reinforcement 10 according to the invention, formed within a base frame 100 formed by frame strips 110, using horizontal yarn holding devices 130 with yarn guidance 138. The horizontal yarn holding device 130 results in the yarn loop 4 being positioned with a horizontal axis. However, the yarn loop 4 can still be moved to a different position even after hardening. The same application is described in the Figures 8, 9, 10 and 11 shown.

[0043] The yarn guidance system allows the yarn 2 approaching a yarn loop 4 and the yarn 2 exiting a yarn loop to spread apart in a predefined grid. The grid dimension corresponds to the diameter of a steering cylinder 140 (see figure). Fig. 12 and associated description) as well as the distance between the horizontal yarn holding devices 130.

[0044] Fig. 8 Figure 1 shows a schematic top view of an embodiment of a reinforcement 10 according to the invention, formed within a base frame 100 using horizontal yarn holding devices 130 with yarn gate 136. The grid dimension of the reinforcement 10 is determined exclusively by the distances between the horizontal yarn holding devices 130. In the illustration (also in Fig. 7 ) the yarn 2 runs longitudinally from the horizontal yarn holding devices 130, which corresponds to a right angle to the frame strip 110.

[0045] The Figures 9 and 10Each shows a schematic top view of an embodiment of a reinforcement 10 according to the invention, formed within a base frame 100 using horizontal yarn holding devices 130, once with yarn guidance 138 at Fig. 9 and once with Garntor 136 at Fig. 10 Unlike the Figures 7 and 8 The yarn 2 runs at an angle of 45° from the horizontal yarn holding devices 130 or to the frame strip 110.

[0046] Fig. 11 Figure 1 shows a schematic top view of an embodiment of a reinforcement 10 according to the invention, formed within a base frame 100 using horizontal yarn holding devices 130 with yarn gate 136. Here, the yarn 2 of the reinforcement 10 is oriented at an angle other than 90° or 45°.

[0047] Instead of the horizontal yarn holding device 130, a vertical yarn holding device 180 can also be used (see below). Fig. 20 , 21) are used. The same applies to the embodiments described in the Figures 7 to 10 are shown.

[0048] Fig. 12 Figure 1 shows a schematic detail view of an embodiment of a horizontal yarn holding device 130 with yarn guidance 138 and yarn holding rollers 134. An essential element of the yarn guidance 138 is the steering cylinder 140. Its diameter D defines the distance between the incoming and outgoing yarn 2 and thus ensures, at least in this area, the grid dimension of the resulting structure of the reinforcement 10.

[0049] Fig. 13 Figure 1 shows a schematic detail view of an embodiment of a horizontal yarn holding device 130 with a base body 132 and the yarn gate 136. Several yarns 2 enter and exit the yarn gate 136 after each yarn loop 4 has been formed over yarn holder rollers 134. The yarns 2 can exit the yarn gate 136 at any angle.

[0050] The surface of the yarn gate 136 is designed with a correspondingly low-friction surface such that the force exerted on the yarn 2 is minimized, particularly through friction. Preferably, the yarn gate is made of metal, a composite material, or another suitable material, which is in the form of a thick bar and shaped to grip the yarn 2 and hold it in the intended position. This also applies to the yarn guide 138 and the design of the surfaces in contact with the yarn 2.

[0051] Fig. 14Figure 1 shows a schematic perspective view of an embodiment of a horizontal yarn holding device with yarn gate 136 and inserted yarn loop 4 (right-hand illustration) and a yarn loop 4 without a horizontal yarn holding device 136. The yarn 2 can be a simple yarn, as shown, or a roving, a plied yarn, or a plied roving. This applies to all embodiments in which a simple yarn is shown.

[0052] The difference between the two illustrations clarifies the effect of the horizontal yarn retaining device 136, which defines a specific position of the yarn loop 4, its orientation plane 6. Without the horizontal yarn retaining device 136, the yarn loop 4 assumes an undefined position, tilting into an arbitrary orientation plane 6, whereas with the horizontal yarn retaining device 136, it is oriented in a substantially vertical position, or alternatively at a specific angle deviating from the vertical. The angle of the orientation plane 6 is important for the subsequent use of the reinforcement, at the outer edge of which the yarn loops 4 emerge and are available for use, in particular for connecting structural modules.

[0053] Fig. 15Figure 1 shows a schematic side view of a horizontal yarn holding device 130 with yarn gate 136 and yarn loops 4 formed from the yarn 2, inserted in two different configurations. The yarn 2 is preferably laid down automatically, with the yarn tension also being adjusted according to the respective requirements. View a) shows the yarn 2 before demolding, so that it is on the forming position 250 (see, among others, Figure 2). Fig. 23 ) rests, view b) after demolding and under high tension.

[0054] Fig. 16 Figure 1 shows a schematic perspective view of an embodiment of a horizontal yarn holding device 130 with yarn gate 136. A base body 132 accommodates the two yarn holding rollers 134. For this purpose, these are each arranged on a support block 135, which is inserted into a groove in the base body 132.

[0055] Fig. 17Figure 1 shows a schematic perspective exploded view of an embodiment of a horizontal yarn holding device 130 with yarn gate 136, as already shown in Figure 2. Fig. 16 described. Furthermore, the holding magnet 160 is visible, which is arranged on the underside of the base body 132 and screwed there. The holding magnet 160, for example designed as a solenoid or preferably as a flat coil, has contacts 162, the distance between which corresponds to that of the conductor tracks 120 on the frame strip 110 (compare Fig. 5 and related description). The holding magnet 160 can be supplied with electrical energy via the contacts 162 as soon as the horizontal yarn holding device 130 is placed on the frame strip 110. The same applies to other yarn holding devices as soon as a corresponding base body 132 is equipped with the holding magnet 160 and the contacts 162 (see also Fig. 21 and related description).

[0056] It is further evident that not only can the guidance of the yarn 2, of which only a cross-section is shown, be controlled in the plane, but also its vertical position can be predetermined. For this purpose, both the yarn holder rollers 134 and the yarn gate 136' are attached to the base body 132 in an alternative embodiment with an elevated position. To attach the yarn holder rollers 134 in an elevated position, an elevated support bracket 135' is provided.

[0057] Fig. 17 This illustrates the modular nature of the horizontal yarn holding device 130, as the elements are interchangeable.

[0058] Fig. 18 Figure 1 shows a schematic perspective view of an embodiment of a horizontal yarn holding device 130 with yarn guidance 138. For further details, please refer to the explanations regarding... Fig. 12 referred

[0059] Fig. 19Figure 1 shows a schematic perspective exploded view of an embodiment of a horizontal yarn holding device 130 with yarn guide 138 and holding magnets 160. Reference is made to the explanations regarding the Figure 12 and 17 referred.

[0060] Fig. 20 shows a schematic perspective representation and Fig. 21A schematic perspective exploded view of an embodiment of a vertical yarn holding device 180. Like the horizontal yarn holding device 130, this device comprises a base body 132, which in a preferred modular embodiment has the same structure and connection options. At the position where, in the horizontal yarn holding device 130, only the yarn gate 136 or the yarn guide 138 are attached, a separate module is attached to the vertical yarn holding device 180. This module has, mounted on a vertical base 182, the yarn holding rollers 134 and the yarn gate 136, which are vertically aligned with their axis of rotation.

[0061] The vertical yarn holding device 180 makes it possible to form the yarn loop 4, which is formed over the yarn holder rollers 134, in a substantially horizontal orientation compared to the horizontal yarn holding device. Furthermore, a holding magnet 160 with contacts 162 for screwing onto the underside of the base body 132 is provided.

[0062] Fig. 21 This illustrates the modular nature of the vertical yarn holding device 180, as the elements are interchangeable.

[0063] Fig. 22Figure 1 shows a schematic side view of two embodiments of a horizontal yarn holding device 130 with yarn gate 136 and inserted yarn loop 4, with particular attention paid to the fixation of the yarn 2. In view a), the fixation on the forming surface 250 is achieved by pressing the impregnated yarn onto it or by applying a preferably self-adhesive cover film 20 over it (compare also the yarn depositing device 300 according to the description of the Figures 29 and 30 ).

[0064] View b) shows two different horizontal yarn holding devices 130 which differ in their working height, with reference also to the explanation of Fig. 17Reference is made to [reference]. In any case, according to this embodiment, it is provided that the yarns 2 are joined together without having to rest on the forming layer 250. The bonding is carried out analogously to view a) by bonding using an impregnation or with an additional aid.

[0065] Fig. 23 Figure 1 shows a schematic cutaway side view of an embodiment of a forming device 200 according to the invention, as preferably provided for forming the required curvature or freeform shape. As shown, for example, in Fig. 1 As is known, the forming device 200 is placed on the base 1 and comprises, in addition to the side walls 212, a base 214. In order to obtain a closed space for a pressure vessel 210, into which a fluid 230 can be filled and a fluid pressure 234 achieved, the top must also be covered. This is done by means of the forming layer 250.

[0066] For a more detailed explanation of the forming layer 250, see below. Fig. 25 and the associated description is referenced. The forming layer 250 has an internal sealing layer 228 on its underside, which faces the pressure vessel 210. In addition, a side membrane 222 and a horizontal membrane 224 are provided towards the bottom 214 for improved sealing against the side wall 212. The connection between the forming layer 250 and the side wall 212 is made by a sliding device 226, which allows unimpeded vertical movement of the edge region of the forming layer 250 relative to the side wall 212.

[0067] A fluid pump 232 is provided to introduce the fluid 230 into the pressure vessel 210 and to control the fluid pressure 234 of the fluid 230. This pump delivers the fluid 230 through a fluid inlet 236 into the pressure vessel 210 and builds up the required internal pressure there.

[0068] After the fluid pressure 234 is applied, the forming platform 250 has a uniform curvature 202. To achieve the desired surface topography of the forming platform 250, it is pulled towards the ground 214 at several points against the fluid pressure 234. For this purpose, control cables 244 are provided on the forming platform 250 at pivot points 246, which can be pulled by control motors 242. The control motors 242 are controlled by a control unit 240. This unit determines which of the control motors 242 must pull the corresponding control cable 244 and by what length to achieve the desired height of the forming platform 250 at the respective position.

[0069] The side of the forming layer 250 facing away from the pressure vessel 210 has a forming plane designed as an outer sealing layer 264. This prevents contamination of the interior of the forming layer 250 and ensures a substantially flat surface, regardless of the internal structure of the forming layer 250. This ensures that the outer sealing layer 264, where it rests on a core layer 252 (see Figure 264), is formed by the outer sealing layer 264. Fig. 25 (and the description there) of the forming layer 250 does not sink locally, it is provided that a fluid pressure is built up between the inner sealing layer 228 and the outer sealing layer 264. For this purpose, a pump 260 is used, which delivers another fluid through the pressure vessel 210 via a supply line 262 to the forming layer 250.

[0070] Fig. 24Figure 1 shows a schematic top view of two embodiments of a forming device 200 according to the invention, showing the distribution of the pivot points 246 under the forming position 250. The distribution of the pivot points 246 can be selected differently depending on the requirements. Additionally, pivot points 246 are also distributed in the edge region to enable control of the position of the forming position 250 in the edge region, in the immediate vicinity of the side walls 212.

[0071] Fig. 25 Figure 1 shows a schematic cutaway side view of a detail of an embodiment of a forming device 250 according to the invention, in which the base 214, the horizontal membrane 224 and the control motor 242 inside the pressure vessel 210 are also visible. The control cable 244, pulled by the control motor 242, is connected at pivot point 246 to the forming position 250 and in particular to the core position 252 inside the forming position 250.

[0072] The core layer 252 consists of individual, interconnected core elements 254. To prevent the fluid 230 from the pressure vessel 210 from entering the core layer 252, the side of the core layer 252 facing the pressure vessel 210 is sealed by means of the inner sealing layer 228. The core elements 254 are fluidically connected to each other via overflow openings 258 and mechanically connected via connectors 256. They are also provided with an iron insert 257.

[0073] The upper side of the shaping layer 250, on the other hand, is provided with the outer sealing layer 264, the function of which has already been explained in the sections on Fig. 23It was mentioned. Furthermore, the horizontal yarn holding device 130 is mounted on the outer sealing layer by means of a frame strip 110, with an additional compensating layer 266 arranged between the frame strip 110 and the outer sealing layer 264. The compensating layer 266 enables compensation between the curvature of the outer sealing layer 264 and the flat base surface of the base body 132. Instead of a compensating layer 266, the frame strip 110 alone, equipped with appropriate height compensation properties, can also be used.

[0074] The Figures 26 and 27 Each shows a section of an embodiment of the core layer 252, with Fig. 26 in a schematic top view and with Fig. 27A schematic perspective detail view. The special structure allows for easy stretching and compression during shaping without permanent deformation, and the formation of a homogeneous surface without unwanted deformations or protruding areas.

[0075] Fig. 28 Figure 1 shows a schematic view of an embodiment of a core element 254 with inner sealing layer 228 and outer sealing layer 264. The iron insert 257 inside and in the connectors 256 enables interaction with a magnet.

[0076] Fig. 29Figure 1 shows a schematic representation of an embodiment of a yarn depositing device 300 with yarn pressure roller 314 and a topcoat application device 320, both of which are in use as shown. The yarn 2 is unwound from a spool and passes through a yarn impregnation device 310, where an impregnating agent 8 is applied to the yarn 2. The impregnated yarn 2 is guided by a yarn guiding device 312 and applied to the forming layer 250. Immediately after application, the yarn is also pressed down by means of the yarn pressure roller 314.

[0077] This is immediately followed by the application of a cover film 20, which is also fed from a roller, a cover film dispenser 322, and pressed onto the yarn 2 and against the forming layer 250 by means of a cover film pressure roller 324. This covers and secures the yarn 2 (compare Fig. 31and associated description). The yarn 2 is secured against lateral displacement and against lifting from the forming layer 250, particularly in concavely shaped areas.

[0078] Fig. 30 shows a schematic representation of an embodiment of a yarn storage device 300, which is made of Fig. 29 This corresponds, however, without the yarn pressure roller 314 and the cover film pressure roller 324 being in use.

[0079] Fig. 31 Figure 1 shows a schematic cross-sectional view of a yarn 2 with applied top film 20, which was previously treated with the impregnating agent 8 and pressed on. Reference symbol list

[0080] 1 Base 2 Yarn 4 Yarn loop 5 Loop holder 6 Orientation plane 8 Impregnating agent 10 Reinforcement 12 Concave area 14 Convex area 16 Shear reinforcement 20 Cover film 80 Beam 100 Base frame 110 Frame strip 115 Recessed foot 120 Conductor track 122 Connection cable 130 Yarn holding device, horizontal yarn holding device 132 Base body 134 Yarn holding roller 135, 135' Support bracket 136, 136' Yarn gate 138 Yarn steering 140 Steering cylinder 160 Holding magnet 162 Contact 180 Yarn holding device, vertical yarn holding device 182 Vertical base 200 Shaping device 202 Curvature 210 Pressure vessel 212 Side wall 214 Bottom 222 Side diaphragm 224 Horizontal diaphragm 226 Sliding device 228 Inner sealing layer 230 Fluid 232 Fluid pump 234 Fluid pressure 236 Fluid inlet 240 Control device 242 Control motor 244 Actuator, control cable 246 Pivot point 250 Forming layer 252 Core layer 254 Core element 256 Connector 257 Iron insert 258 Overflow opening 260 Pump 262 Supply line 264 Forming plane, outer sealing layer 266 Compensation layer 290 Forming blockWax block 300 Yarn deposit device 310 Yarn impregnation device 312 Yarn guide device 314 Yarn pressure roller 320 Cover film application device 322 Cover film dispenser 324 Cover film pressure roller Diameter (steering cylinder)

Claims

1. Device for producing a textile reinforcement (10), comprising at least one yarn (2) arranged within a base frame (100), or for producing a textile-reinforced structural module (72) comprising the textile reinforcement (10) and a curable material, wherein a shaping device (200) is provided, which comprises a free-formable shaping layer (250), on whose shaping plane (264) the reinforcement (10) or the structural module (72) is formed, wherein yarn holding devices (130, 180) are provided, between which the textile reinforcement (10) can be formed, characterized in that bendable frame strips (110) are also provided, on which the yarn holding devices (130, 180) can be arranged, wherein the frame strips (110) can be arranged on the base frame (100).

2. Device according to claim 1, wherein the shaping layer (250) comprises a free-formable core layer (252) formed from core elements (254), which has an outer sealing layer (264) on its shaping plane (264) (264) on its forming plane (264) and an inner sealing layer (228) on the plane opposite the forming plane (264), which enables the build-up of a fluid pressure (234) against which controllable actuators (244) connected to the core layer (252) at articulation points (246) can act.

3. Device according to claim 1, wherein the free-formable shaping layer (250) is designed as a free-form surface of a shaping block (290).

4. Device according to one of claims 1 to 3, wherein the yarn holding devices are designed as horizontal yarn holding devices (130) comprising a base body (132) and two horizontally arranged yarn holder rollers (134) around which the yarn (2) can be placed in a yarn loop (4).

5. Device according to claim 4, wherein a yarn gate (136, 136') or a yarn guide (138) is provided through which the yarn (2) exits from the horizontal yarn holding device (130), and / or wherein the yarn holding devices are designed as vertical yarn holding devices (180) and have vertically arranged yarn holder rollers (134).

6. Device according to one of claims 4 or 5, wherein the base body (132) has an electrically operable holding magnet (160), wherein furthermore the frame strips (110) have longitudinally extending conductor tracks (120) that can be electrically contacted from the surface facing the yarn holding device (130, 180) (120) which can be connected to a power source ( ) and supply the holding magnet (160) with electrical energy so that it holds the yarn holding device (130, 180) on the frame strip (110).

7. Device according to one of claims 1 to 6, wherein a yarn laying device (300) is provided which is suitable for laying the yarn (2) over the yarn holding devices (130, 180) according to a predetermined pattern and producing the reinforcement (10).

8. Device according to claim 7, wherein thermoplastic fibers that can be thermally activated are provided as a fiber matrix material and form a hybrid yarn together with the fibers suitable for load transfer, or wherein the yarn (2) is pre-impregnated with a curable, flowable impregnating agent as the fiber matrix material or is provided with the impregnation by the fiber matrix material immediately before deposition, for which purpose the yarn deposition device (300) has a yarn impregnation device (310).

9. Device according to claim 7 or 8, wherein the yarn depositing device (300) has a cover film application device (320) which can provide the yarn (2) with at least a partial cover layer (20) after deposition.

10. Method for producing a textile reinforcement (10) comprising a yarn (2), or for producing a textile-reinforced structural module (72) comprising the textile reinforcement (10) and a curable material which is applied after production of a textile reinforcement (10), wherein a free-formable molding layer (250) is provided, wherein the textile reinforcement (10) is formed between yarn holding devices (130, 180) on the free-formable shaping layer (250), characterized in that the yarn holding means (130, 180) are further arranged on bendable frame strips (110), wherein the frame strips (110) are arranged on the free-formable shaping layer (250) to form the base frame (100).

11. Method according to claim 10, wherein the yarn (2) is laid in such a way that yarn loops (4) protrude outwardly from the curable material.

12. Method according to claim 10 or 11, wherein the yarn (2) is laid on a device according to one of claims 1 to 9.

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