CN105873740B - 结构成型件、机动车装配元件和用于制造结构成型件的方法 - Google Patents
结构成型件、机动车装配元件和用于制造结构成型件的方法 Download PDFInfo
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Abstract
本发明涉及一种三维的结构成型件,其具有分别包括至少一个边缘(2)的预成型的一个或多个有机板材件(1),其中,所述一个或多个有机板材件(1)在所述边缘(2)处至少部分地通过经注塑的塑料材料相互连接。
Description
技术领域
本发明涉及一种结构成型件、一种具有这样的结构成型件的机动车装配元件以及一种用于制造结构成型件的方法。
背景技术
尤其是在机动车结构(例如仪表板、门挡板、中控台、杂物箱和类似物)中的结构成型件是三维构件并且通常由聚碳酸酯-丙烯腈-丁二烯-苯乙烯(PC/ABS)以注塑法制造。为了在简单制造中借助注塑获得结构成型件的足够的稳定性和良好的可填充性,其必须以至少1.5至大约4mm或甚至5mm的壁厚制造。这产生高材料费用并且引起高结构成型件重量。由现有技术已知所谓的有机板材,亦即以塑料浸渍的纤维半成品,其作为用于稳定结构成型件的放入器使用。有机板材在此放入塑料基体中或以塑料基体注塑包封。在这里至少相对于实心塑料成型件获得小的重量减少,然而有机板材的放入和注塑包封是耗费的过程,其除了原本注塑成型件之外还必须考虑塑料基体与有机板材的连接。
发明内容
由现有技术出发,本发明的任务是提供一种结构成型件,其特点在于在非常良好的强度和形状稳定性的情况下的简单结构构造以及同时减少的自重。此外本发明的任务是提供一种机动车装配元件,其具有高功能性、良好的连接选项、但依然具有小的自重。此外本发明的任务是给出一种用于制造结构成型件的方法,其可容易地在没有高技术花费的情况下实现并且能够实现以小的生产周期以批量生产而制造结构成型件。
按照本发明该任务通过一种结构成型件解决,其具有分别包括至少一个边缘的预成型的一个或多个有机板材件。所述一个或多个有机板材件在边缘处至少部分地通过经注塑的塑料材料相互连接。按照本发明仅使用有机板材件,这样其具有至少两个边缘。有机板材件然后通过成型这样成型为一个结构成型件,使得至少所述两个边缘至少部分地通过经注塑的塑料材料相互连接。有机板材件在本发明的范围中是以热塑性塑料浸渍的、织物的、含纤维的平面构件,其通过变形能量的作用、例如通过挤压或深拉在温度影响下能够预成型并且成型为希望的形状。虽然有机板材作为附加部件至今仅用于局部地稳定塑料成型件,但有机板材件在本发明中形成按照本发明的结构成型件的决定性结构元件,其基本上预定结构成型件的几何结构。由此不仅通过使用含纤维的平面构件、而且也通过通常有机板材的优选大约0.6至1.5mm的小壁厚获得明显的重量减少。所述一个或多个有机板材件仅在其边缘处通过经注塑的塑料材料相互连接。通过注塑塑料材料,在各有机板材件之间形成材料锁合连接,这能够实现有机板材件的持久的、稳定的布置结构。在这里分别具有塑料基体的经注塑的塑料材料和有机板材件的在化学上类似的组成辅助形成在小自重下具有高强度和形状稳定性的结构成型件。有机板材件的数量和布置结构基于通过其边缘的连接具体不受限制,从而在按照本发明的结构成型件中可以实现各种希望的几何结构。
按照根据本发明的结构成型件的一种有利扩展方案,至少一个有机板材件包含聚丙烯(PP)和/或长玻璃纤维和/或碳纤维并且尤其是回收碳纤维。使用PP的优点在于,其具有在有利的成本结构下的高可用性的优点。此外由此促进在成形经注塑的塑料材料和有机板材件之间的材料锁合连接的情况下形成非常良好的连接。长玻璃纤维、亦即优选2至50mm长度的玻璃纤维和/或碳纤维并且尤其是回收碳纤维的使用有助于结构成型件的稳定性,其中,回收碳纤维的使用提高结构成型件的耐用性并且有助于其特别有利的成本结构。为了进一步成本降低,优选所有使用的有机板材件包含PP和/或回收碳纤维。回收碳纤维可以一般由碳纤维制造或由其在纤维半成品制造中的后续过程获得并且示例性地在裁切碳纤维半成品时作为边角料产生。
此外,经注塑的塑料材料有利地是热塑性塑料材料、优选含有聚丙烯(PP)的塑料材料。由此获得有机板材件的还较好的复合体,因为其同样具有热塑性塑料基体。结构成型件的最终几何结构的成形可以此外与有机板材件在其边缘处的连接同时进行。因此,附加连接结构、如粘接或形锁合连接不是强制必需的。PP的优点也在于在中等成本结构下的高可用性。
另一个有利扩展方案的特征在于,经注塑的塑料材料是含纤维的,亦即包含纤维并且尤其是长玻璃纤维、尤其是具有2至50mm纤维长度的纤维和/或碳纤维、优选回收碳纤维。含纤维的经注塑的塑料材料的优点在于显著较高的强度和刚度。长玻璃纤维和碳纤维的优点还在于在非常小的自重下的特别高的稳定性、尤其是高强度和形状稳定性并且因此特别良好地适合用于按照本发明的结构成型件。此外结构成型件的材料费用可以通过使用回收碳纤维降低。
进一步有利地,为了改善结构成型件的外观,优选至少一个有机板材件在内侧或外侧、优选在至少一个可见侧上具有织物、优选PP/PET无纺布,亦或由聚酰胺或聚丙烯构成的织物。为了进一步改善外观,优选所有可见侧的有机板材件设有这样的织物。
为了提高功能性和改善按照本发明的结构成型件的紧固,优选在至少一个有机板材件上设置有至少一个连接几何结构和/或功能几何结构和/或支座。这些元件用于简化可安装性和将结构成型件集成到包围的几何结构中。
一种有利扩展方案设置:在至少一个有机板材件上注塑由塑料材料、优选含纤维的塑料材料构成的肋。所述肋用于附加地加强和加固结构成型件,尤其是在承受机械负荷的或处于负载下的成型件中。所述肋优选被这样注塑,使得其连接或加固各有机板材件,因为由此可以获得特别高的刚度并且附加地良好地获得抗扭性。
此外本发明涉及一种机动车装配元件,其具有如上所述的结构成型件。作为机动车装配元件尤其是考虑仪表板、门挡板、中控台、或杂物箱,因为这些结构成型件可非常良好地通过成型一个或多个有机板材件和其在其边缘上通过注塑法的随后连接以足够良好的稳定性制造。按照本发明的机动车装配元件的优点在于容易的可安装性、高功能性、但却非常小的自重。
此外本发明也涉及一种用于制造结构成型件的方法,其优点在于在没有高技术耗费以及成本技术耗费的情况下的容易的可行性。所述方法具有步骤:
-成型分别包括至少一个边缘的一个或多个有机板材件,
-将预成型的所述一个或多个有机板材件放入和设置在注塑模具中,
-关闭注塑模具,并且
-通过注塑塑料材料、尤其是热塑性的含纤维的塑料材料,使所述一个或多个有机板材件在边缘处至少部分地相互连接。
其他的方法步骤、例如有机板材件的冲压、塑料材料或注塑模具的退火等可以完善按照本发明的方法。通过注塑塑料材料以用于在边缘处连接一个或多个有机板材件,以非常节省材料的并且借此节省费用和重量的方式达到有机板材件的稳定的材料锁合连接,而无需使用附加的放入元件用于稳定结构成型件。借此按照本发明的方法的优点在于简单的并且减少耗费的可实施性并且最好地适合用于以高节奏批量生产结构成型件。为了进一步简化,塑料材料是热塑性的含纤维的塑料材料。
对于按照本发明的结构成型件所述的有利效果、扩展方案和优点也应用于按照本发明的机动车装配元件和按照本发明的方法。
按照本发明的方法的一种有利扩展方案设置:至少一个有机板材件由聚丙烯和/或优选具有2至50mm长度的长玻璃纤维和/或碳纤维、并且尤其是回收碳纤维制造;和/或所述塑料材料包含长玻璃纤维和/或碳纤维、尤其是回收碳纤维。聚丙烯能够非常良好地借助注塑法处理并且优点在于在有利的成本结构下的高可用性。通过长玻璃纤维或碳纤维,获得结构成型件的非常高的刚度,其中,通过使用回收碳纤维附加地可以降低用于制造结构成型件的费用。
此外有利地,所述方法具有步骤:将织物、尤其是PP/PET无纺布或由聚酰胺或聚丙烯构成的织物施加在至少一个有机板材件的内侧或外侧、优选至少一个可见侧上。由此可以例如掩盖通过注塑引入的痕迹,其可能不利地影响结构成型件的外观。尤其是在成型有机板材件之前进行这样的织物施加,因为可以因此检测并且完全遮盖所有之后可见的位置。通过使用织物、尤其是PP/PET无纺布或由聚酰胺或聚丙烯构成的织物,其施加可以集成到有机板材件的成型过程中并且因此节省单独的步骤,例如在后续步骤中对结构成型件的植绒。
此外按照本发明的方法的特征在于另一个有利的步骤,即,在至少一个有机板材件上安装至少一个连接几何结构和/或功能几何结构和/或支座,由此简化结构成型件的功能性以及其集成到周围的几何结构和结构中。功能元件的安装可以同样优选在注塑模具中进行。
为了提高刚度、弯曲刚度和抗扭性,所述方法的特征在于另一个有利的步骤,即,向至少一个有机板材件上注塑肋。有利地,所述注塑这样实施,使得肋连接或加固有机板材件,因为因此进行结构成型件、尤其是也针对扭力的特别良好的加固。所述注塑可以再次有利地在注塑模具中进行。
基于按照本发明的解决方案以及其扩展方案得出如下优点:
-结构成型件的优点在于在高功能性下的简单结构。
-所述结构成型件具有高的稳定性、刚度、形状稳定性和抗扭性。
-结构成型件重量小。
-连接几何结构、支座和功能元件可简单地集成。
-机动车装配元件高度功能性,可简单安装并且在此有小的自重。
-制造可简单地在没有高的技术耗费和成本技术耗费的情况下本身以高节奏批量生产实现。
附图说明
本发明其他的细节、特征和优点由后续的说明和附图得出。在附图中:
图1示出按照一种有利扩展方案的结构成型件的制造的示意图。
具体实施方式
借助实施例详细解释本发明。在图1中仅示出按照本发明的结构成型件的在这里关注的部件,所有其余元件出于明了性被省略。此外相同的附图标记说明相同的构件。
图1示意性示出结构成型件10的制造,所述结构成型件示例性地以杂物箱的形式构成。此外结构成型件10在这里示例性地具有三个通过有机板材件1形成的基本构件。有机板材件1例如由大型有机板材冲出并且通过成型构造而获得希望的三维形状。每个有机板材件1在此具有多个边缘2。然后有机板材件1放入注塑模具中。有机板材件1的放入和设置在此这样进行,即,有机板材件1的要连接的边缘2相对置。在关闭注塑模具之后,这样注塑具有优选热塑性的、尤其是含有PP的塑料材料的塑料注塑物料,使得塑料材料附着在有机板材件1的边缘2上并且对置的有机板材件1通过其边缘2连接。优选地,塑料材料在此在其整个长度上遮盖边缘2。在图1中,附图标记3描述有机板材件1的连接部,在塑料材料的塑料注塑结束之后获得所述连接部。可看出:塑料材料连接部3仅遮盖预成型的有机板材件1的边缘2,由此有机板材件1在有机板材件1的边缘2上的材料锁合连接通过塑料材料连接部3形成。
优选地,经注塑的塑料材料包含纤维。含纤维的经注塑的塑料材料的纤维材料此外优选包含玻璃纤维(长玻璃纤维)和/或碳纤维并且尤其是回收碳纤维。
有机板材件优选具有引入聚丙烯基体中的长玻璃纤维和/或碳纤维和在下面进一步优选的回收碳纤维。
此外图1的结构成型件10具有以肋4的形式的加固元件。肋4优选连接不同的有机板材件1并且用于加强结构成型件10的形状稳定性。肋4有利地由与有机板材件1的塑料材料连接部3相同的塑料材料形成。
为了改善可连接性、集成能力和提高功能性,结构成型件10附加地具有至少一个连接几何结构5和支座6。其他元件可以补充结构成型件10。
本发明在前的说明只用于说明性的目的并且不用于限制本发明的目的。在本发明的范围中,不同的改变和修改是可能的,而不会离开本发明以及等效物的范围。
附图标记列表
1 有机板材件
2 有机板材件的边缘
3 有机板材件的边缘之间的连接部
4 肋
5 连接几何结构
6 支座
10 结构成型件
Claims (26)
1.一种结构成型件,其具有分别包括至少一个边缘(2)的一个或多个有机板材件(1),其中,所述一个或多个有机板材件(1)在所述边缘(2)处至少部分地通过经注塑的塑料材料相互连接,其中,所述塑料材料仅遮盖所述边缘(2),由此通过所述塑料材料形成所述有机板材件(1)在所述边缘(2)上的材料锁合连接,并且所述塑料材料和所述有机板材件具有在化学上类似的组成。
2.按照权利要求1所述的结构成型件,其特征在于,至少一个有机板材件(1)包含聚丙烯和/或长玻璃纤维和/或碳纤维。
3.按照权利要求1所述的结构成型件,其特征在于,至少一个有机板材件(1)包含回收碳纤维。
4.按照权利要求1至3之一所述的结构成型件,其特征在于,所述经注塑的塑料材料是热塑性塑料材料。
5.按照权利要求1至3之一所述的结构成型件,其特征在于,所述经注塑的塑料材料是含聚丙烯的塑料材料。
6.按照权利要求1至3之一所述的结构成型件,其特征在于,所述经注塑的塑料材料包含纤维。
7.按照权利要求1至3之一所述的结构成型件,其特征在于,所述经注塑的塑料材料包含长玻璃纤维和/或碳纤维。
8.按照权利要求1至3之一所述的结构成型件,其特征在于,所述经注塑的塑料材料包含回收碳纤维。
9.按照权利要求1至3之一所述的结构成型件,其特征在于,至少一个有机板材件(1)在内侧或外侧上具有织物。
10.按照权利要求1至3之一所述的结构成型件,其特征在于,至少一个有机板材件(1)在至少一个可见侧上具有织物。
11.按照权利要求1至3之一所述的结构成型件,其特征在于,在至少一个有机板材件(1)上设置有至少一个连接几何结构(5)和/或功能几何结构和/或支座(6)。
12.按照权利要求1至3之一所述的结构成型件,其特征在于,在至少一个有机板材件(1)上注塑有由塑料材料构成的肋(4)。
13.按照权利要求12所述的结构成型件,其特征在于,所述肋(4)被这样注塑,使得其连接或加固所述有机板材件(1)。
14.一种机动车装配元件,该机动车装配元件具有按照权利要求1至13之一所述的结构成型件。
15.按照权利要求14所述的机动车装配元件,其特征在于,该机动车装配元件是仪表板、门挡板、中控台或杂物箱。
16.一种用于制造结构成型件(10)的方法,具有步骤:
-成型分别包括至少一个边缘(2)的一个或多个有机板材件(1),
-将预成型的所述一个或多个有机板材件(1)放入和设置在注塑模具中,
-关闭注塑模具,并且
-通过注塑塑料材料使所述一个或多个有机板材件(1)在所述边缘(2)处而至少部分地相互连接,其中,所述塑料材料仅遮盖所述边缘(2),由此通过所述塑料材料形成所述有机板材件(1)在所述边缘(2)上的材料锁合连接,并且所述塑料材料和所述有机板材件具有在化学上类似的组成。
17.按照权利要求16所述的方法,其特征在于,所述塑料材料是热塑性的含纤维的塑料材料。
18.按照权利要求16或17所述的方法,其特征在于,至少一个有机板材件(1)由聚丙烯和/或长玻璃纤维和/或碳纤维制造;和/或所述塑料材料包含聚丙烯和/或长玻璃纤维和/或碳纤维。
19.按照权利要求16或17所述的方法,其特征在于,所述至少一个有机板材件(1)由回收碳纤维制造;和/或所述塑料材料包含回收碳纤维。
20.按照权利要求16或17所述的方法,其特征在于,包括步骤:在至少一个有机板材件(1)的内侧或外侧上施加织物。
21.按照权利要求20所述的方法,其特征在于,包括步骤:在成型所述有机板材件(1)之前,在至少一个有机板材件(1)的内侧或外侧上施加织物。
22.按照权利要求16或17所述的方法,其特征在于,包括步骤:在至少一个有机板材件(1)的至少一个可见侧上施加织物。
23.按照权利要求22所述的方法,其特征在于,包括步骤:在成型所述有机板材件(1)之前,在至少一个有机板材件(1)的至少一个可见侧上施加织物。
24.按照权利要求16或17所述的方法,其特征在于,包括另一个步骤:在至少一个有机板材件(1)上安装至少一个连接几何结构(5)和/或功能几何结构和/或支座(6)。
25.按照权利要求16或17所述的方法,其特征在于,包括另一个步骤:向至少一个有机板材件(1)上注塑肋(4)。
26.按照权利要求25所述的方法,其特征在于,所述注塑这样实施,使得所述肋(4)连接或加固所述有机板材件(1)。
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US9278655B2 (en) * | 2011-08-08 | 2016-03-08 | Faurecia Interior Systems, Inc. | Foldable substrates for motor vehicles and methods for making the same |
DE102011118980B4 (de) * | 2011-11-19 | 2018-08-02 | Daimler Ag | Verfahren zur Herstellung eines Außenmoduls mit einer Außenbeplankung für eine modular aufgebaute Gehäusekomponente |
PL2819824T3 (pl) * | 2012-03-02 | 2017-06-30 | Johnson Controls Gmbh | Sposób wytwarzania tylnej ściany oparcia siedzenia |
DE102013013419A1 (de) * | 2013-08-10 | 2014-03-06 | Daimler Ag | Verfahren und Vorrichtung zur Herstellung eines Sandwichbauteils |
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2014
- 2014-03-20 DE DE102014205231.9A patent/DE102014205231A1/de not_active Withdrawn
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2015
- 2015-02-24 CN CN201580003243.3A patent/CN105873740B/zh active Active
- 2015-02-24 EP EP15706461.9A patent/EP3119578A1/de not_active Withdrawn
- 2015-02-24 WO PCT/EP2015/053769 patent/WO2015139920A1/de active Application Filing
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2016
- 2016-09-19 US US15/269,766 patent/US20170008206A1/en not_active Abandoned
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CN1048814A (zh) * | 1989-07-17 | 1991-01-30 | 利比-欧文斯-福特公司 | 模塑复合材料 |
EP0730947A2 (de) * | 1995-03-08 | 1996-09-11 | Eybl-Durmont Ag | Verkleidungsteile aus Faserverbundmatten sowie Verfahren zu deren Herstellung |
CN1412466A (zh) * | 2001-10-08 | 2003-04-23 | 拜尔公司 | 用于框架结构的合成结构制品 |
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Also Published As
Publication number | Publication date |
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EP3119578A1 (de) | 2017-01-25 |
WO2015139920A1 (de) | 2015-09-24 |
DE102014205231A1 (de) | 2015-09-24 |
CN105873740A (zh) | 2016-08-17 |
US20170008206A1 (en) | 2017-01-12 |
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