DE102006027599A1 - Profile shaped aerodynamic effective component e.g. airplane wings, airplane control, rotor blade and rotor of wind energy plant, has double walled vane shell and composition is almost free from raw material - Google Patents

Abstract

The aerodynamic effective component has double walled vane shell in load conforming modular sandwich construction. The overall structure is separated in different modular units, leans against at the foundry technology under a reversible casting core (22). The reversibility of the casting core repeats the overall process with similar structural design. The composition is almost free from raw material and the subsequent insertion of another completed module, like a vane tank (2) or a wing inlet with similar construction structure, in exchange with the casting core. An independent claim is also included for a method for manufacturing profile shaped aerodynamic effective component.

Description

The The invention relates to profile-formed, aerodynamically effective Components such as aircraft wings, Aircraft turrets, rotor blades and rotary wing Wind turbines with double (multi) wall wing shells in load-compatible modular sandwich construction (integral composite structure) and the process for their preparation, according to the preamble of Claim 1. The illustration and description of the invention take place by way of example with reference to an aircraft wing the preamble of claim 1.

Of the Modern aircraft construction is characterized by being conventional Structures of profile-formed aerodynamically effective components, the mainly use metal materials (steel, titanium, Aluminum alloys, etc.) more and more through the use of fiber composite materials (GFK, CFK, AFK), suitable plastics (polyamide, Makrolon, etc.), core foams (PUR, acrylic foams, etc.), metal foams (Aluminum) and a suitable adhesive technique (elimination of fasteners) repressed become. The advantages in terms of strength, rigidity and weight savings can also with regard to the occurring load cases (bending and torsion moments, Train, pressure) by a targeted orientation of the fiber layers almost optimally exhausted become. (1) The application of these new material combinations the integral design can in terms of lightweight construction in so-called sandwich constructions be particularly effective.

The Disadvantages in terms of today's application and process engineering for this new materials are certainly in the high workload of Laminating techniques and the complexity of the upcoming strength calculations. (1) In addition When using core structures, the cover layers are made of composite materials either directly laminated on prefabricated core structures or how metallic cover layers glued to them. These disadvantages increase still, if you have a relatively thin one double-walled wing shell wants to realize.

• – grossen Wandstärken der Flügelschalen und anderer Bauteile und der sich dadurch ergebenden Probleme in der Klebetechnik;
• – partielle Ablöseerscheinungen von verstärkenden Elementen;
• – Übernahme von Verbindungstechniken aus der metallischen Bauweise, die nicht „fasergerecht" sind;
• – Flügeltankproblematiken;
• – zusammengesetzte Kernstrukturen;
• – ein einfaches und kostengünstiges Herstellungsverfahren für die Serienproduktion.

Other disadvantages that arise from previous designs to counteract the occurring load cases, such as longitudinal forces, bending moments and torsional moments are shown in the form of:

• - large wall thickness of the wing shells and other components and the resulting problems in the adhesive technology;
• Partial detachment phenomena of reinforcing elements;
• - Adoption of joining techniques from the metallic construction, which are not "fiber-fair";
• - wing tank problems;
• - composite core structures;
• - a simple and cost-effective production process for mass production.

The The object of the invention is to provide a new, more suitable design structure and to describe the manufacturing process, the previous disadvantages fair, or even excludes it.

The Invention solves this object by the characterizing part of claim 1 featured features. Advantageous embodiments are in the dependent claims described.

The Construction structure of the invention and the manufacturing method are attached to seven drawing pages according to the characterizing part of claim 1 using the example of an aircraft wing described.

1 shows the entire wing ( 1 ) in breakout view with enlarged individual views and the wing tank extracted ( 2 );

1b shows a side view from the perspective of the wing root ( 8th ) with extracted view contour wing tank ( 2 );

1c shows a sectional side view and an enlarged view, from which the embedding of the exemplified four contemplated wide CFRP tapes ( 16 ), the upper ( 3 ), lower ( 4 ) and inner thin-walled wing shell ( 5 ), the additional embedded front profile ( 14 ), the front ( 12 ) and rear spar (( 13 ) and the integration of a flap holder ( 18 ) into the rear end profile ( 15 ) and the rear spar ( 13 ), in the plastic foam matrix ( 6 ) becomes apparent;

2 shows the module Interior Structure ( 7 );

2 B shows the cross-section of a wing rib ( 10 );

3 shows the procedure for inserting the individual modules in the two-part form;

4 shows the closed mold with the Hartschaumdosiereinrichtungen ( 24 ).

The main advantage of the invention results in the division of the overall structure into different modular units, including a reversible "casting core" (US Pat. 22 ), which is based on the foundry technology; ie the reversibility of the "casting core" makes the entire process repeatable with the same structure structure, and a disguise into each other possible. A "thin", stiff yet highly resilient double-walled (multi-walled) wing shell structure can thus be realized in a simple manner, and the volume of the winged tank is likewise optimized.

• I. obere (3) und untere Flügelschale (4);
• II. das Innenstrukturmodul (7);
• III. der „Gusskern" (22) mit der inneren Flügelschale (5);
• IV. der Flügeltank (2);
• V. die Form;
• VI. die Kunststoffhartschaumdosiereinrichtung (24) mit Zuführungen (25);

The individual modular units are structured as follows:

• I. upper ( 3 ) and lower wing shell ( 4 );
• II. The inner structure module ( 7 );
• III. the "casting kernel" ( 22 ) with the inner wing shell ( 5 );
• IV. The wing tank ( 2 );
• V. the form;
• VI. the plastic hard foam metering device ( 24 ) with feeds ( 25 );

• Zu I. die obere und untere Flügelschale werden aus bereitliegenden Halbzeugen des gewünschten Werkstoffes passgenau zugeschnitten (bei Faserhalbzeugen ist vorher die Faserausrichtung zu beachten).
• Zu II. das Innenstrukturmodul (7, 2, 2b) besteht aus den Komponenten: Flügelwurzel (8), Flügelabschluss (9), Flügelrippe_kurz (10), Flügelrippe_lang (11), Flügelholm_vorne (12), Flügelholm_hinten (13), Abschlussprofil_vorne (14), Abschlussprofil_hinten (15), CFK_Bänder (16), CFK_Bandklemmeinheiten (17), Klappenhalterungen (18), CFK_Bandklemmeinheiten (19). Das Innenstrukturmodul wird entsprechend 2 komplett vormontiert und die Einzelbauteile an den vorgesehenen Stellen durch geeignete Klebetechnik verbunden; die Anzahl und Breite der CFK_Bänder (16) mit den jeweiligen CFK_Bandklemmeinheiten (17, 19) werden unter Berücksichtigung des Anschlusses der Flügelwurzel (8) an den Flugzeugrumpf, der notwendigen Zuführ-, Fluss- und Druckausgleichsöffnungen (26) und den nötigen Platzverhältnissen für die CFK_Bandklemmeinheiten (17, 19) an der Flügelwurzel (8), an allen Flügelrippen (10, 11) und dem Flügelabschluss (9), konstruktionstechnisch dahingehend optmiert, eine „quasi" dreiwandige Flügelschalenstruktur (Flügelschale_oben, „mittlere CFK_Bänderschale", Flügelschale_innen; desgleichen für den unteren Bereich) zu erreichen. Die CFK_Bänder (16) werden nach Abschluss der Vormontage in der Flügelwurzel (8) und dem Flügelabschluss (9) in den entsprechenden CFK_Bandlemmeinheiten (17, 19) leicht vorgespannt bevor alle anderen CFK_Bandklemmeinheiten die CFK_Bänder über Reibschluss fixieren und so einen geschlossenen „Käfig" ergeben. Mit der Einbettung des Innenstrukturmoduls (7) in der letztendlich ausgeführten Kunststoffhartschaummatrix (6) wird größenteils eine Funktionstrennung der Belastungseinleitungen zu den Flügelschalen bewirkt, die es erlauben das Innenstrukturmodel für anstehende Festigkeitsberechungen und erste Auslegungen als steife Separateinheit anzusehen. Das Abschlussprofil_vorne (14) besitzt zusätzlich geformte Laschen, die in die Kunststoffhartschaum-Matrix integriert sind (1c). Das Abschlussprofil_hinten (15) besitzt entsprechende Öffnungen in denen die Klappenhalterungen (18) durch O_Ringe abgedichtet und federnd gelagert werden (1c). Die Enden sind 90° abgewinkelt und derart geformt, dass sie in den hinteren Teil der Flügelrippe_lang (11) verdrehsicher integriert und verklebt sind. Die Klappenhalterungen (18) werden im Abschlussprofil_hinten (15) und auf dem Flügelholm_hinten (13) gelagert und können durch den Flügelholm und Öffnungen in den Klappenhalterungen direkt mit Verstelleinrichtungen bestückt werden (1c). Zuführ-, Fluss- und Druckausgleichsöffnungen (26) in den entsprechenden Bauteilen bewirken eine gleichmäßige Verteilung des injizierten Kunststoffhartschaumes und einen leichten Überdruck beim Ausschäumen um den erforderlichen Qualitätsstandard der ausgehärteten Schaumstruktur zu erhalten.
• Zu III. Auf dem reversiblen „Gusskern" (22) wird vorher die komplette Flügelschale_innen (5) mittels eines Adhäsionspräparates und Nahtbehandlung an den Stoßstellen fixiert und als Ganzes in das Innenstrukturmodul (7) eingeführt (3).
• Zu IV. der Flügeltank (2) wird komplett vorgefertigt und geprüft, bevor er im Austausch mit dem „Gusskern" (22) eingesetzt und mit der Flügelschale_innen (5) verklebt wird. Die Form des Tanks wird dabei durch geeignete Massnahmen derart gestaltet, dass sie die Festigkeitseigenschaften des Gesamtflügels erhöht. (1, 1b)
• Zu V. die Form wird zweiteilig ausgeführt. Die Formschale_oben (20) und die Formschale_unten (21) sind im Negativ zur äußeren Kontur eines Prototypflügel geformt und enthalten Anschlagkanten und Fixiermarkierungen für die entsprechenden Inlets. Sie werden über entsprechende Aufnahmestifte (23) exakt zueinander positioniert. (3)
• Zu VI. die Kunststoffhartschaumdosiereinrichtungen (24) sind auf steuerbaren, längsachsig verfahrbaren Linearführungen montiert und über einen Zuleitungsschlepp mit einer dosierenden Kunststoffhartschaumpumpe verbunden. Die Zuführungen (25), die aus einfachen Kunststoffrohren bestehen, werden schon bei der Innenstrukturmodul (7) Vormontage miteingelegt und mit entsprechenden Adaptern an die Kunststoffhartschaumdosiereinrichtung (24) angeschlossen. (4)

This division allows the provision or pre-assembly of the individual modules without complex lamination techniques, the almost free composition of materials and the subsequent introduction of a complete other module, such as the wing tank ( 2 ) or a second Wing_Inlet with the same construction structure in exchange with the "casting core" ( 22 ). Further advantages are assigned to the individual modular units:

• To I. the upper and lower wing shell are tailor-made from ready-made semi-finished products of the desired material (with fiber semi-finished products, the fiber orientation must be considered in advance).
• II. The internal structure module ( 7 . 2 . 2 B ) consists of the components: wing root ( 8th ), Wing finishes ( 9 ), Wing rib_short ( 10 ), Wing rib_lang ( 11 ), Wing spar_front ( 12 ), Flügelholm_hinten ( 13 ), Abschlussprofil_vorne ( 14 ), Final profile_back ( 15 ), CFK_bands ( 16 ), CFK_Bandklemmeinheiten ( 17 ), Flap holders ( 18 ), CFK_Bandklemmeinheiten ( 19 ). The inner structure module will be corresponding 2 completely pre-assembled and the individual components connected at the intended locations by suitable adhesive bonding; the number and width of CFK_bands ( 16 ) with the respective CFK_Bandklemmeinheiten ( 17 . 19 ), taking into account the connection of the wing root ( 8th ) to the fuselage, the necessary supply, flow and pressure compensation openings ( 26 ) and the space required for the CFK_Bandklemmeinheiten ( 17 . 19 ) at the wing root ( 8th ), on all wing ribs ( 10 . 11 ) and the wing fin ( 9 ), structurally optimized to achieve a "quasi" three-walled wing shell structure (wing shell upper, middle CFRP band shell, wing shell, and likewise for the lower region). The CFK_bands ( 16 ) after completion of pre-assembly in the wing root ( 8th ) and the wing fin ( 9 ) in the corresponding CFK_Bandlemmeinheiten ( 17 . 19 ) are slightly preloaded before all other CFK_Bandklemmeinheiten fix the CFK_Bändern over frictional engagement and thus provide a closed "cage". 7 ) in the final plastic foam matrix ( 6 ) a function separation of the load introduction to the wing shells is largely effected, which allow the inner structure model for upcoming strength calculations and first interpretations to be regarded as a rigid separation unit. The final profile_front ( 14 ) additionally has shaped tabs which are integrated in the plastic foam matrix ( 1c ). The final profile_back ( 15 ) has corresponding openings in which the flap holders ( 18 ) are sealed by O_ring and spring-mounted ( 1c ). The ends are angled 90 ° and shaped to fit into the rear of the wing rib (FIGS. 11 ) are integrated and glued against rotation. The flap holders ( 18 ) are displayed in the final profile_back ( 15 ) and on the Flügelholm_hinten ( 13 ) and can be equipped by the wing spar and openings in the flap holders directly with adjusting devices ( 1c ). Feed, flow and pressure compensation openings ( 26 ) in the corresponding components cause a uniform distribution of the injected plastic foam and a slight overpressure during foaming in order to obtain the required quality standard of the cured foam structure.
• To III. On the reversible "casting core" ( 22 ) is the complete Flügelschale_innen ( 5 ) fixed by means of an adhesion preparation and seam treatment at the joints and as a whole in the internal structure module ( 7 ) introduced ( 3 ).
• To IV. The wing tank ( 2 ) is completely prefabricated and tested before being exchanged with the "casting core" ( 22 ) and with the Flügelschale_innen ( 5 ) is glued. The shape of the tank is designed by appropriate measures such that it increases the strength properties of the entire wing. ( 1 . 1b )
• To V. the form is carried out in two parts. The mold shell_above ( 20 ) and the Formschale_unten ( 21 ) are formed in the negative to the outer contour of a prototype wing and contain stop edges and Fixiermarkierungen for the corresponding inlets. You will be using appropriate recording pins ( 23 ) positioned exactly to each other. ( 3 )
• To VI. the plastic hard foam metering devices ( 24 ) are mounted on controllable, linear axis movable linear guides and ei over NEN feed line connected to a metering plastic foam pump. Feeds ( 25 ), which consist of simple plastic pipes, are already at the inner structure module ( 7 ) Pre-assembly and with appropriate adapters to the plastic foam metering device ( 24 ) connected. ( 4 )

• – die Flügeschale_unten (4) wird mittels Anwendung eines Adhäsionspräparates in der Formschale_unten (21) an den entsprechenden Markierungen ausgerichtet und fixiert;
• – der „Gusskern" (22) mit auf ihm fixierter Flügelschale_innen(5) wird in das Innenstrukturmodul (7) eingeführt. Auf die Flügelschale_innen (5) wird dabei auf markierte Bereiche ein geigneter Kleber aufgetragen, der sich beim Einführen mit den entsprechenden Innenflächen des Innenstrukturmoduls (7) verbindet, auf die ebenfalls vorher ein geigneter Kleber aufgetragen wurde; durch die entsprechenden Öffnungen werden nun alle Hartschaumzuleitungen (25) eingeführt;
• – auf diese Einheit wird nun an entsprechende Anlage- und Auflageflächen ebenfalls ein geigneter Kleber aufgetragen und dann komplett über Anlage- und Positionierkanten in die Formschale_unten (21) positionsgenau eingesetzt;
• – die Flügeschale_oben (3) wird mittels Anwendung eines Adhäsionspräparates in der Formschale_oben (20) an den entsprechenden Markierungen ausgerichtet und fixiert;
• – die Formschale_oben (20) wird nun über die Positionier- und Aufnahmebolzen (23) der Formschale_unten (21) zugeführt und zusammengeschraubt (4);
• – alle Hartschaumzuleitungen (25) werden über geeignete Adapter mit der Kunststoffhartschaumdosiereinrichtung (24) verbunden;
• – nach Vorgabe eines genauen und vorher getesteten Befüll- und Ausfahrplanes wird die geschlossene Form über die Kunststoffhartschaumdosiereinrichtung mit einem geigneten flüssigförmigen Kunstoffhartschaum befüllt;
• – nach abgeschlossener Ausdehnung und Aushärtung der Kunststoffhartschaummatrix kann die Form geöffnet und der Flugzeugtragflügel entnommen werden;
• – der „Gusskern" (22) kann nun herausgeführt werden, um ihn durch den Flügeltank (2) oder ein zusätzliches Wing_Inlet mit gleicher Konstruktionsstruktur zu ersetzen und zu verkleben.

The manufacturing process, using the example of the aircraft wing ( 1 ) in 3 shown schematically, is very simple:

• - the Flügeschale_unten ( 4 ) is applied by using an adhesion preparation in the Formschale_unten ( 21 ) aligned and fixed at the corresponding markings;
• - the "casting kernel" ( 22 ) with Flügelschale_innen fixed on it ( 5 ) is transferred to the inner structure module ( 7 ) introduced. On the Flügelschale_innen ( 5 ), a suitable adhesive is applied to marked regions, which upon insertion with the corresponding inner surfaces of the inner structure module ( 7 ), to which a suitable adhesive has also previously been applied; through the corresponding openings all hard foam leads ( 25 ) introduced;
• - This unit is then applied to appropriate investment and bearing surfaces also a suitable adhesive and then completely on investment and positioning edges in the Formschale_unten ( 21 ) accurately positioned;
• - the bowl dish (above) 3 ) is applied by using an adhesion preparation in the Formschale_oben ( 20 ) aligned and fixed at the corresponding markings;
• - the form shell_above ( 20 ) is now transmitted via the positioning and locating pins ( 23 ) the Formschale_unten ( 21 ) and screwed together ( 4 );
• - all hard foam feeders ( 25 ) via suitable adapters with the plastic hard foam dosing ( 24 ) connected;
• - After specifying a precise and previously tested filling and Ausfahrplanes the closed mold is filled via the plastic foam metering with a suitable liquid-like Kunstoffhartschaum;
• - After completion of expansion and curing of the plastic foam matrix, the mold can be opened and removed the aircraft wing;
• - the "casting kernel" ( 22 ) can now be brought out to him by the wing tank ( 2 ) or an additional Wing_Inlet with the same design structure to replace and glue.

1

Flugzeugtragflügel_gesamt

2

wing tank

3

Flügelschale_oben

4

Flügelschale_unten

5

Flügelschale_innen

6

Plastic foam matrix

7

Internal structure module

8th

wing root

9

wing completion

10

Flügelrippe_kurz

11

Flügelrippe_lang

12

Flügelholm_vorne

13

Flügelholm_hinten

14

Abschlussprofil_vorne

15

Abschlussprofil_hinten

16

CFK_Band

17

CFK_Bandklemmeinheit

18

flap bracket

19

CFK_Bandklemmeinheit

20

Formschale_oben

21

Formschale_unten

22

"Casting core"

23

Formschalenfixierstift_m_Scheibe and mother

24

Kunststoffhartschaumdosiereinrichtung

25

Foam supply

26

Feed, flow and pressure equalization opening

Quoted Non-Patent Literature (in part):

(1) Composites - Materials in aircraft, also material of the future for fast ships? (Scratching, Gerhard; Pospischil, Lars)

Claims (2)

Profilformed, aerodynamically effective components such as aircraft wings, aircraft stabilizers, rotor blades and rotary blades of wind turbines with double-walled (multi-walled) wing shells in load-compatible modular sandwich construction (integral composite structure) and the process for their preparation, characterized in that the structure in various modular units, including a reversible "casting core" ( 22 ), based on the foundry technology, is divided; - that this reversibility of the "casting core" ( 22 ) the entire process can be repeated with the same structural structure, thus making nesting possible; - that the individual modular units are structured as follows: I. upper ( 3 ) and lower wing shell ( 4 ); II. The inner structure module ( 7 ); III. the "casting kernel" ( 22 ) with the inner wing shell ( 5 ); IV. The wing tank ( 2 ) or additional Wing_Inlet; V. the form; VI. the plastic hard foam metering device ( 24 ) with feeds ( 25 ); - That this division the provision and pre-assembly of the individual modules without complex lamination techniques, the almost free composition of materials and the subsequent introduction of a complete other module, such as the wing tank ( 2 ) or a second Wing_Inlet with the same design structure, in exchange with the "casting core" ( 22 ); - that the upper ( 3 ) and lower wing shell ( 4 ) from ready-made semi-finished products of the desired material are cut to fit before, - that the inner structure module ( 7 ) from the components: wing root ( 8th ), Wing finishes ( 9 ), Wing rib_short ( 10 ), Wing rib_lang ( 11 ), Wing spar_front ( 12 ), Flügelholm_hinten ( 13 ), Abschlussprofil_vorne ( 14 ), Final profile_back ( 15 ), CFK_bands ( 16 ), CFK_Bandklemmeinheiten ( 17 ), Flap holders ( 18 ), CFK_Bandklemmeinheiten ( 19 ) consists; - that the inner structure module ( 7 ) completely preassembled accordingly and the individual components are connected at the intended locations by suitable adhesive bonding; - that the number and width of CFK_bands ( 16 ) with the respective CFK_Bandklemmeinheiten ( 17 . 19 ) taking into account the connection of the wing root ( 8th ) to the fuselage, the necessary supply, flow and pressure compensation openings ( 26 ) and the space required for the CFK_Bandklemmeinheiten ( 17 . 19 ) at the wing root ( 8th ), on all wing ribs ( 10 . 11 ) and the wing fin ( 9 ), structurally optimized to achieve a "quasi" three-walled wing shell structure (wing shell upper, "middle CFRP band shell", wing shell, and likewise for the lower region); - that the CFK_bands ( 16 ) after completion of pre-assembly in the wing root ( 8th ) and the wing fin ( 9 ) in the corresponding CFK_Bandlemmeinheiten ( 17 . 19 ) are slightly preloaded before all other CFK_Bandklemmeinheiten fix the CFK_Bänder over frictional engagement and thus give a closed "cage" (structural unit), - that with the embedding of the inner structure module ( 7 ) in the final plastic foam matrix ( 6 ) a function separation of the load introduction to the wing shells is effected, which allow the inner structure model for upcoming strength calculations and first interpretations to be regarded as a rigid separate structural unit; - that the final profile_first ( 14 ) has additionally formed tabs integrated in the plastic foam matrix; - that the final profile_back ( 15 ) has corresponding openings, in which the flap holders ( 18 ) are sealed and resiliently supported by O_rings and the ends are angled 90 ° and shaped, and inserted into the rear of the wing rib (FIGS. 11 ) are integrated and glued against rotation; - that the flap holders ( 18 ) in the final profile_back ( 15 ) and on the Flügelholm_hinten ( 13 ) and can be fitted directly with adjusting by the wing spar and openings in the flap holders; that supply, flow and pressure compensation openings ( 26 ) in the corresponding components, to obtain a uniform distribution of the injected plastic foam and is achieved by the overpressure during foaming the required quality standard of the cured foam structure; - that on the reversible "casting core" ( 22 ) before the complete Flügelschale_innen ( 5 ) fixed by means of an adhesion preparation and seam treatment at the joints and as a whole in the internal structure module ( 7 ) is introduced; - that the wing tank ( 2 ) completely prefabricated and tested in exchange with the "casting core" ( 22 ), with the Flügelschale_innen ( 5 ) and the shape of the tank is thereby designed by appropriate measures such that it increases the strength properties of the entire wing; - That the mold is made in two parts; - that the Formschale_oben ( 20 ) and the Formschale_unten ( 21 ) are formed in the negative to the outer contour of a prototype wing, stop edges and Fixiermarkierungen for the corresponding inlets and contain them via corresponding receiving pins ( 23 ) are positioned exactly to each other; - that the plastic hard foam metering devices ( 24 ) are mounted on controllable, linear axis movable linear guides and are connected via a feeder towing with a dosing plastic hard foam pump; - that the allocations ( 25 ), which consist of simple plastic pipes, already during the pre-assembly of the internal structure module ( 7 ) and with appropriate adapters to the plastic hard foam metering device ( 24 ) are connected; - That the plastic foam in conjunction with the wing shells by him own good adhesive properties prevents separation of reinforcing elements and complete inlets; - that for angled components where the "casting core" ( 22 ) can not be led out after completion of filling and curing of the plastic foam matrix in one, a so-called "lost casting core" is developed, which has the required strength properties only for the duration of the completed filling and curing of the plastic foam matrix, then partially coincides in itself and, for example the residues can be sucked out; - That the partial and multiple embodiment of the invention for large-scale profile-shaped aerodynamically effective components eg passenger aircraft is given by the application of the "lost casting core". The method for producing according to claim 1, characterized in that - the fluff tray (below) 4 ) by use of an adhesion preparation in the Formschale_unten ( 21 ) is aligned and fixed on the corresponding markings; - that the "casting kernel" ( 22 ) with Flügelschale_innen fixed on it ( 5 ) in the internal structure module ( 7 ) is introduced; - that on the Flügelschale_innen ( 5 ) a suitable adhesive is applied to marked areas, which upon insertion into the corresponding inner surfaces of the inner structure module ( 7 ), to which a suitable adhesive has also previously been applied; - that through the corresponding openings now all hard foam leads ( 25 ) are introduced; - That on this completed inner structure module now also a suitable adhesive applied to corresponding contact and bearing surfaces and then uniformly over investment and positioning edges in the Formschale_unten ( 21 ) on the Flügelschale_unten ( 4 ) is used positionally accurate; - that the bowl dish is up ( 3 ) by use of an adhesion preparation in the Formschale_oben ( 20 ) is aligned and fixed on the corresponding markings; - that the Formschale_oben ( 20 ) with the Flügelschale_oben ( 3 ) now on the positioning and receiving bolts ( 23 ) the Formschale_unten ( 21 ) is fed and screwed together; - that all hard foam leads ( 25 ) via suitable adapters with the plastic hard foam dosing device ( 24 ) get connected; - That, after specifying a precise and previously tested filling and Ausfahrplanes the closed mold is filled on the plastic foam blanker with a suitable liquid-like Kunstoffhartschaum; - After completed expansion and curing of the plastic foam matrix, the mold is opened and the component is removed; - that the "casting kernel" ( 22 ) is now brought out to him by the wing tank ( 2 ) or an additional Wing_Inlet with the same design structure to replace and glue.