CN110385860A - 制造增强部件的方法和部件 - Google Patents

制造增强部件的方法和部件 Download PDF

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CN110385860A
CN110385860A CN201910304104.4A CN201910304104A CN110385860A CN 110385860 A CN110385860 A CN 110385860A CN 201910304104 A CN201910304104 A CN 201910304104A CN 110385860 A CN110385860 A CN 110385860A
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component
insertion portion
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manufacture
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CN110385860B (zh
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约瑟夫·普塔
拉迪姆·日贾尔斯基
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Magna External (bohemia) Co Ltd
Magna Exteriors Bohemia sro
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    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B29C45/1671—Making multilayered or multicoloured articles with an insert
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/08—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles using several expanding or moulding steps
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1285—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being foamed
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/36—Feeding the material to be shaped
    • B29C44/38—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length
    • B29C44/42—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length using pressure difference, e.g. by injection or by vacuum
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
    • 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
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/56—Winding and joining, e.g. winding spirally
    • 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
    • B29C70/34—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 and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • 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
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • 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
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/681—Component parts, details or accessories; Auxiliary operations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
    • B60J5/00—Doors
    • B60J5/04—Doors arranged at the vehicle sides
    • B60J5/042—Reinforcement elements
    • B60J5/0452—Reinforcement elements including foams or expanded materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
    • B60J5/00—Doors
    • B60J5/04—Doors arranged at the vehicle sides
    • B60J5/048—Doors arranged at the vehicle sides characterised by the material
    • B60J5/0481—Doors arranged at the vehicle sides characterised by the material plastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
    • B60J5/00—Doors
    • B60J5/10—Doors arranged at the vehicle rear
    • B60J5/101—Doors arranged at the vehicle rear for non-load transporting vehicles, i.e. family cars including vans
    • B60J5/107—Doors arranged at the vehicle rear for non-load transporting vehicles, i.e. family cars including vans constructional details, e.g. about door frame, panels, materials used, reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
    • B62D29/043—Superstructures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3002—Superstructures characterized by combining metal and plastics, i.e. hybrid parts

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  • Engineering & Computer Science (AREA)
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  • Structural Engineering (AREA)
  • Architecture (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Body Structure For Vehicles (AREA)
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  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

本公开提供了一种由不同材料制造增强部件的方法以及根据该方法制造的部件，在该方法中，在第一步骤(S1)中，在第一模具(10)中通过在所使用的塑料材料进行发泡的情况下进行塑料注塑成型并且用相同塑料材料的插入部分(6)减小部件的大横截面来制造该部件，‑其中，在第二步骤(S2)中，将至少一种类型的纤维围绕所述部件卷绕，‑并且其中，在第三方法步骤(S3)中，在第二模具中(11)用第二塑料材料的塑料对作为整体的该部件进行包覆成型。

Description

制造增强部件的方法和部件
技术领域
本发明涉及用于制造增强部件的方法和由该方法制造的部件。
背景技术
纤维复合材料由于其高的特殊性能而为轻质构造提供了巨大的可能性。特别在航空和航天工业中，碳纤维增强塑料已经使用了数十年。随着过去十年市场需求的增长，增强纤维已经变得能够以机械工程、建筑和汽车行业感兴趣的价格购得。纤维复合材料的高机械承载性能及其低密度是使用这种新材料的主要激励因素。
纤维复合材料允许结构变得更轻并且因此更有效地使用。在传统的轻质构造中，通常使用空心型材，但也使用泡沫型材。
如今，复杂形状的部件主要以双壳型结构制造，然后结合在一起。在汽车行业中可以发现很多这样的示例。然而，它们的问题在于承载纤维是切断的或不连续的。因此，纤维的有益性能不能被充分利用，这导致部件的更大的重量以及更低的疲劳强度。
汽车行业中的一个示例是车辆后挡板。这些后挡板——以前由金属制成并且在内部上设置有塑料衬里——越来越多地由塑料制成。在现有技术中，连接至片状塑料支承部分的金属框架结构仍用于加强。优选地，框架结构粘合地结合。随后将具有框架结构的支承部分与装饰部分和后窗组合。
本发明的目的是由复合材料制造用于车辆的部件，该复合材料具有用于增强任务的最佳性能并且能够容易地制造。本发明的目的是由复合材料替代金属框架。
发明内容
该目的通过由不同材料制造增强部件的方法来实现，其中，在第一步骤中，在第一模具中通过用所使用的塑料材料的发泡进行反应注塑成型并且通过由相同塑料材料的插入部分减小部件的大横截面来制造部件，其中，在第二步骤中，将至少一种类型的纤维围绕该部件卷绕，并且在第三步骤中，在第二模具中用第二塑料材料的塑料将作为整体的该部件进行包覆成型、或加固/渗透。
这种制造过程非常有效地降低了周期率(cycle rate)，这是由于减少了塑料的发泡量。
在这种情况下，有利的是，插入部分在各种情况下也在第一方法步骤中制造。因此，不再需要用于插入部分的另一生产线。
如果插入部分在各种情况下从相应的先前的制造过程得到，则制造方法能够特别有效地进行。
在通过制造方法制造第一个产品并且因此制造第一个插入部分之后，在通过制造方法进行每次制造时使用相应的先前的通过该方法制造的插入部分。
此处有利的是，插入部分在部件的区域中所填充的横截面达部件的大横截面的值的50％的情况。这样在用塑料发泡之后所留下的必须固化的体积较小。
有利地，插入部分也在部件的下述位置成型及发泡：部件在该位置处的横截面小于最大横截面。
此处有利的是部件的在该位置处的横截面大致对应于插入部分的横截面。
该目的还通过由上述方法制造的部件来实现。该部件是汽车构造中的加强部件。
该方法的特别有利之处在于能够制造下述部件：该部件是车门或车辆挡板、前端模块或侧门的框架。
有利地，该部件之后配装在其他塑料部件上的复合材料中。
附图说明
下面参照附图通过示例描述本发明。
图1示出了通过示例给出的后挡板的实施方式的示意图；
图2示出了通过示例给出的制造方法；
图3示出了框架的平面图和横截面图；
图4示出了制造后和后续产品中的具有插入部分的框架。
具体实施方式
在图1中，示出了后挡板1的主要部件部分。支承部分2作为后挡板的基础并且由纤维增强塑料制成。加强框架3是聚氨酯材料、或任何其他复合材料比如环氧树脂或乙烯基酯的闭合形式、或其他非闭合形式。装饰部分4连接至支承部分2。为了加强后挡板，在该示例性实施方式中提供了由金属制成的加强元件5。加强元件5分别连接至支承部分2。
在图2中，以三个重要的方法步骤示出框架3的制造过程。在步骤S1中，芯部3由PU泡沫制成，其中获得了刚性形式。框架在这种情况下注塑成型并在模具10中发泡。
在第二方法步骤S2中，通过绕线机以连续过程将玻璃纤维或碳纤维围绕发泡的框架3卷绕。随后，在第三方法步骤S3中，在另一模具11中，用复合材料比如环氧树脂或乙烯基酯来加固和/或渗透卷绕有纤维的PU材料的框架3。为此，可以使用与第一方法步骤S1中相同的塑料材料或一些其他塑料材料。
如果希望避免使用金属加强元件5，则框架3必须具有相当大的厚度或大的横截面20、特别是在待制造的后挡板的上边缘的区域3a中更是如此。这种极大的材料厚度不必在整个框架上延伸，这是因为框架的要求在框架的整个长度上是不同的。因此，框架设计成使得框架的横截面在框架的长度上显著变化并仅在高机械装载区域中增大。
因此，框架的横截面从大横截面20变成小横截面21。
然而，由于部件的横截面的大的差异，因此在发泡塑料的制造期间需要等待，直到整个横截面中最大厚度的区域完全固化为止。因此，步骤S1中框架制造的周期时间很长并且这是工业制造中的问题。
该问题通过将插入部分6引入到用于框架发泡的模具10中来解决。插入部分6在具有极大厚度d1的区域3a——该区域3a必须在发泡过程中固化——中起到减小框架的大横截面20的作用。如图3所示，在插入部分6与框架3的外表面之间仍然存在必须固化的残留厚度。
在这种情况下，插入部分6的材料优选地与框架3的其余部分的材料相同。
插入部分6必须可用于相应的方法步骤S1。
因此，在制造期间，在第一方法步骤S1中，PU泡沫的插入部分6与框架3一起在模具10中制造。框架3的模具的形式因此扩展成使得：如可以在图4的示例中观察到的，两个插入部分6在框架3的下部区域6a中用PU材料成型及发泡。在这种情况下，插入部分6的位置优选地位于材料流动路径的末尾，换言之，具有这种较小厚度d2的插入部分6是在模具中的与区域3a的注入点相反的腔中制造的。作为示例性实施方式，插入部分定位在区域6a中，在区域6a中框架3具有小的横截面21并且插入部分6是以较小的厚度d2制造的。
在这种情况下，插入部分的形式和尺寸必须对应于框架的区域3a。在图3a中，仅通过示例描述了矩形横截面。在该示例中，插入部分6“浮动”在反应成型过程的材料中。另一方面，在图3b中，形式的一半被插入部分6填充，并且插入部分以至少一个侧部直接抵靠于模具的壁的方式放置。插入部分的三个外侧部可以放置成直接抵靠于模具的壁。
在将框架3从模具10移除之后，将插入部分6从框架3移除并且去除浇口连接件。如上文所述，对框架3进行了进一步处理。
对于下一个框架3，在过程步骤S1中使用来自先前所实施的过程的步骤S1的插入部分6，并且将该插入部分6置于框架3的模具10中。由于插入元件6的材料是相同的塑料材料，因此能够在不存在任何问题的情况下被PU泡沫包围且结合。因此，在框架3的最大厚度d1的区域中，仅小厚度的泡沫固化，该小厚度具体地为d1-d2。因此可以显著地减少周期时间。
附图标记列表
1 部件
2 支承部分
3 框架
3a 区域
4 装置部分
5 加强部分
6 插入部分
6a 区域
10、11 模具
20 大横截面
21 较小的横截面
d1、d2 厚度

Claims (9)

1.一种由不同材料制造增强部件的方法，
-其中，在第一步骤(S1)中，在第一模具(10)中通过在所使用的塑料材料进行发泡的情况下进行塑料注塑成型并且用相同塑料材料的插入部分(6)减小部件的大横截面来制造所述部件，
-其中，在第二步骤(S2)中，将至少一种类型的纤维围绕所述部件卷绕，
-并且其中，在第三方法步骤(S3)中，在第二模具中(11)用第二塑料材料的塑料对作为整体的所述部件进行包覆成型、或加固或渗透。
2.根据权利要求1所述的方法，其特征在于，所述插入部分(6)在各种情况下也在所述第一方法步骤(S1)中制造。
3.根据权利要求1所述的方法，其特征在于，所述插入部分(6)在各种情况下从相应的先前的制造过程(S1至S3)得到。
4.根据权利要求1所述的方法，其特征在于，所述插入部分(6)在所述部件的区域(3a)中所填充的横截面达所述部件的大横截面(20)的值的50％。
5.根据权利要求1所述的方法，其特征在于，所述插入部分(6)还在所述部件的下述位置(6a)成型及发泡：所述部件的在所述位置(6a)处的横截面(21)小于最大横截面(20)。
6.根据权利要求5所述的方法，其特征在于，所述位置(6a)处的所述横截面(21)大致对应于所述插入部分(6a)的横截面(30)。
7.一种通过根据权利要求1所述的方法制造的部件，其特征在于，所述部件是汽车构造中的加强部件。
8.根据权利要求7所述的部件，其特征在于，所述部件是车门或车辆挡板的框架(3)。
9.根据权利要求7所述的部件，其特征在于，所述部件配装在其他塑料部件上的复合材料中。
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