DE102009016177A1 - Composite construction part i.e. interior cladding element, for motor vehicle, has double layer part comprising decoration layer and base layer, where functional layer is provided below double layer part - Google Patents

Abstract

The part has a double layer part (3) comprising a decoration layer (1) forming a view side (S), and a base layer (2) that is formed stably below the decoration layer. The decoration layer is made up of bending-resistant fiber composite material. The base layer is connected with the decoration layer by adhesive agent. A functional layer i.e. gated carrier body (4), is provided below the double layer part. The gated carrier body is provided with gated functional elements and/or fastening elements (5). An independent claim is also included for a method for producing a composite construction part.

Description

The The invention relates to a composite component in particular for Interior trim elements of motor vehicles as well as a procedure for its production.

Such composite components are used in many fields of application, for example for covering technical functional elements, decorative surfaces being applied to load-bearing elements in order to meet sophisticated design requirements. Typical examples are interior trim elements of motor vehicles, where increasingly surface films in wood, wood or imitation wood in the form of metallic films are applied to plastic molded or foamed elements. This makes it possible to produce stable cladding elements which achieve the desired visual impression on their surface. Examples include rear-opening thresholds, in which the rear, lying below the closed tailgate threshold range of a combination or SUV cargo space is formed from such a cladding element. This has a noble appearance mediating metal foil sheet on its surface, which may be, for example, corrugated and sitting in a support member made of plastic. Such a composite component is for example from the EP 1 344 687 B1 known.

Problematic in such composite components is the permanent solid connection between the decorative layer and the carrier body. In Of course, all these parts have a considerable amount different coefficients of thermal expansion, which in particular at the high temperature range of up to 100 ° C, motor vehicles are exposed over the year, too extreme stresses between the two components can. So they work against each other significantly, so the danger exists that the bond dissolves over time.

The prior art describes various approaches to this problem. For example, trying to mechanically anchor the decorative parts at their edges in the carrier body, as the DE 10 2004 010 810 A1 shows. Another approach, like him EP 1 693 175 A1 shows, is to deform the decorative part defined before the permanent connection with the support body, so that upon release of the bending when connecting to the support body, a bias arises, which counteracts the temperature-induced stresses during use of the composite component.

outgoing From the described problem of the invention is the task based, a composite component in particular for interior trim elements of motor vehicles in such a way that it in its layer structure particularly stable, but it is so functionally variable that it diverse application options is open.

• – ein insbesondere als Halbzeug hergestelltes Doppel-Lagenteil bestehend aus einer die Sichtseite bildenden Dekorlage und einer diese stabil unterlegenden Basislage aus einem biegesteifen Faserverbundkunststoff-Material, das mit der Dekorlage über einen Haftvermittler verbunden ist, sowie
• – mindestens eine Funktionslage unter dem Doppel-Lagenteil.

This object is achieved by the construction specified in the characterizing part of claim 1, which comprises

• - A particularly produced as semi-finished double-layer part consisting of a visible side forming decorative layer and this stable underlying base layer of a rigid fiber composite plastic material, which is connected to the decorative layer via a bonding agent, and
• - At least one functional position under the double-layer part.

by virtue of the combination of a rigid fiber composite plastic material with the decoration layer connected via the adhesion promoter the latter is so stabilized that temperature stresses and mechanical Loads compensated by the fiber composite plastic material and be caught. To obstruct the composite component at his Destination is the generalized in claim 1 so designated Functional position determined.

Latter can be constructed in different constructive ways and with different ones Functional and / or fasteners are provided, as they in the subclaims and in the description the embodiments explained in more detail become. To avoid repetition is on the appropriate Explanations referenced.

• – Bereitstellen eines Dekorlagen-Teils und eines verformbaren Basislagen-Teils aus einer Faserverbundkunststoff-Platte,
• – Einlegen des Dekor- und Basislagen-Teils in ein offenes Spritzgusswerkzeug,
• – Schließen des Spritzgusswerkzeuges unter Fügen von Dekor- und Basislagen-Teil aneinander zur Bildung des halbzeugartigen Doppel-Lagenteils,
• – Öffnen des Spritzgusswerkzeuges unter Bildung einer Kavität auf der Seite des Basislagen-Teils,
• – Einspritzen eines Kunststoffes in die Kavität zur Anformung der Funktionslage an das Doppellagen-Teil, und
• – Entnahme des so gebildeten mehrlagigen Verbundbauteils aus dem Spritzgusswerkzeug.

The invention further relates to a method for producing a composite component, in particular for interior trim elements of motor vehicles, comprising the following method steps:

• Providing a decorative layer part and a deformable base layer part of a fiber composite plastic plate,
• Inserting the decorative and base layer part into an open injection mold,
• Closing the injection molding tool with joining of decorative and base layer parts to one another to form the semifinished double layer part,
• Opening the injection molding tool to form a cavity on the side of the base sheet part,
• - Injecting a plastic into the cavity for molding the functional position of the double-layer part, and
• - Removal of the multilayer composite component thus formed from the injection mold.

The above approach has the advantage that all components of the composite component are processed in a single tool. In so far not only the functional position in the form of, for example, an injection molding or preferably foam body structure is formed in the injection mold, but at the same time made the connection of the decorative and base layer part to the double-layer part.

The latter can even with simultaneous forming of the fiber composite plastic plate take place with the decorative layer part, including the injection mold acts as a kind of hot press. Preferred embodiments of the method according to the invention arise from the dependent claims of claim 8.

details Features, details and advantages thereof and the invention Composite component will be apparent from the following description of embodiments with reference to the attached Drawings. Show it:

1 to 3 schematic sections of composite components in different embodiments transverse to the sheet direction, and

4 to 9 schematic sections through an injection mold in successive manufacturing intermediate steps for the composite component.

Before on the concrete structure of the respective composite components according to 1 to 3 and their manufacture is discussed, the individual components of the composite component will be set out below in terms of their properties.

Basically, one side of the decorative layer 1 the visible side S of the composite component, due to the choice of material for the decorative layer 1 has a very variable appearance. So the decorative element of the decorative layer 1 be formed as a metallic foil. The metallic foil is usually made of either stainless steel or aluminum, its thickness is between 1 mm and 0.04 mm and more preferably between 0.2 mm and 0.1 mm. The metallic foil is provided with a coating on at least one side. The coating is in the form of an adhesion-promoting, a stable composite to the base layer located under the decorative element 2 ensuring the adhesive layer. Thermosetting reactive adhesives or laminated, adhesion-promoting plastic films have proven to be suitable adhesives. It may also be a coloring, corrosion-inhibiting or limiting, a scratch-resistant or a particularly media-resistant coating or a combination of said coatings.

The decorative element of the decorative layer 1 may also consist of a plastic material, in particular of a plastic film. The thickness of the plastic material is also between 1 mm and 0.04 mm. It is important that the plastic material or the plastic film with respect. Of its / its chemical structure with the plastic materials used in the following is chemically compatible or this same, so that a stable, preferably cohesive bond to the layer located under the decorative element can be produced.

The decorative element of the decorative layer 1 can also consist of a fleece or other textile fabric. The fleece or other textile fabric must in turn be chemically compatible with respect to its chemical structure with the plastic materials used hereinafter or be the same, so that a stable, preferably cohesive composite to that under the decorative layer 1 can be produced layer.

The decorative layer element is present as a prefabricated insert. It is made before inserting into an injection mold 10 (please refer 4 to 9 ), for example, punched or otherwise pre-formed or reshaped, and thus essentially shows the contour of a in the injection molding tool 10 provided recess.

Provided the functional layer is a foam structural body this is done by foaming a thermoplastic Plastic produced. As thermoplastic material comes basically any foamable thermoplastic Plastic in question, preferably ABS, PA, PP, EPDM or misery used. The thermoplastic material includes a blowing agent, which releases a propellant and so the foaming process conditionally. Here, between chemical and physical blowing agents distinguished. Chemical blowing agents set during the Plasticizing via chemical reactions a propellant gas free. Chemical blowing agents are usually referred to as so-called masterbatch added in granular form and together with the later foaming plastic in the flight of an injection molding machine plasticized. Physical blowing agents are in the so-called supercritical Condition under high pressures of an already plasticized Added plastic melt.

The Lowering of the melt viscosity by the gaseous Propellant is a welcome side effect here. By mixing and homogenization under high dynamic pressure forms a single-phase Plastic / gas mixture. After injection of the single-phase plastic / gas mixture In a tool, the pressure drop causes the gas to escape from the mixture possible and thus foaming initiated.

Due to the process, the foam structure is present as a so-called integral foam structure; it has a gradual density decrease from outside to inside. Their outdoor areas are to be regarded as compact and closed. The main advantages of integral foams are seen in weight reduction with the same component height and increased flexural rigidity with the same mass application. A training of functional or fastening elements in the compact outer regions of the integral foam structure is possible (see 2 and 3 ).

Important is in turn that the plastic matrix of the integral foam with respect their chemical composition with the other plastic materials used chemically compatible or equal to this, so that one stable bond to the optionally located under the foam structure Layer can be produced. The plastic matrix can be finely divided inorganic particles (eg talc, glass fibers, calcium carbonate) Be provided with the nucleation (nucleation) and ultimately favor the foaming process.

The decorative layer underlying base layer of a rigid fiber composite plastic material consists of a fiber fabric in a thermoplastic resin matrix; the abbreviation FVK plate 2 should be used here throughout. The FRP plate 2 softens under the influence of heat and is deformable in this state. The transformation of the rigid FRP board 2 This can also be done by the method of an injection molding tool 10 or from in an injection mold 10 located sliders done. The fiber fabric may consist of glass, aramid or carbon fiber or a combination thereof. The thickness of the FRP plate 2 can vary and must be determined according to a specific component situation. Care must be taken in the case of the thermoplastic matrix to ensure that it is chemically compatible or the same as the other plastic materials used, so that a stable bond to the optionally above or below the rigid FRP board 2 can be produced layer. The FRP plate 2 is also available as a prefabricated insert.

Instead of of the above-mentioned foam structural body as a functional layer under the double-layer part of decorative layer and fiber composite plastic material a molded carrier body may be provided. This consists of a thermoplastic plastic material and can be filled with reinforcing fibers. there is to select the thermoplastic material so that it used the rest of its chemical composition Plastic materials similar or equal to this, so that a stable bond with these is possible.

The connection between decorative layer 1 and the underlying FVK plate base 2 is achieved primarily via a material connection. However, it is also possible to additionally strengthen the connection via a positive connection. In this case, at least one embraces under the decorative layer 1 lying layer that the decorative layer 1 forming decorative element at least in some areas.

in the Below are now various embodiments for composite components according to the invention discussed in more detail.

So shows 1 a version in which the decor layer 1 and FVK plate base 2 existing double-layer part 3 with a molded carrier body 4 is connected as a functional position. The carrier body 4 has integrally molded functional and / or fastening elements 5 on. The functional elements may, for example, be spacers or stiffening ribs. As fastening elements are for example latching noses, recesses, threaded openings or the like.

The production of the composite component according to 1 takes place initially outside of an injection mold by a possibly shaping hot pressing of the decorative element of the decorative layer 1 with the rigid FVK plate 2 , so that these a kind of semi-finished product in the form of double-layer part 3 form, which subsequently into a side of an injection molding tool 10 is inserted. To the underside of the double-layer part 3 becomes a carrier body 4 under formation of functional and / or fasteners 5 molded. This can also lead to a penetration of the rigid FVK plate 2 through the material of the carrier body 4 come.

It is contrary to in 1 shown representation also possible to dispense with the functional and / or fastening elements forming carrier body and spray on only at individual points functional and / or fasteners.

At the in 2 shown composite component is the double-layer part 3 from decorative layer 1 and FVK plate base 2 with a Schaumstrukturkör by 6 underlying, at its compact with respect to the foam structure lower outer region with integrally molded functional and / or fastening elements 5 is provided.

The production of this composite component takes place analogously to the composite component according to 1 initially outside an injection mold 10 by a, possibly shaping hot pressing of the decorative element of the decorative layer 1 with a layer of the FRP plate 2 so that this turn that Double-layer part 3 form in a kind of semi-finished product. The semi-finished product is then in a side of an injection molding tool 10 inserted, the injection mold 10 closed and to the bottom of the double-layer part 3 molded with a blowing agent mixed plastic melt. The formation of the foam structure is defined by a ventilation stroke of the injection molding tool 10 via a dipping edge or located in the injection mold slide can be realized. Functional and / or fastening elements can be formed by the compact edge layer of the foam structure.

It is also possible to attach to the underside of the foam structure 6 a carrier body 4 to inject and on this functional and / or fasteners 5 train.

A corresponding composite component is in 3 shown. On a decorative layer 1 is a first layer of a FRP board 2 arranged. At the bottom of the FRP board 2 there is a foam structural body 6 , on the underside of a second support layer of a rigid FVK plate 7 is located, on which functional and / or fasteners 9 are formed. It is alternatively conceivable, at the bottom of the second support position of the rigid FVK plate 7 again a carrier body 4 with functional and / or fastening elements 9 to install.

The production of the composite component according to 3 takes place, analogous to the composite components according to 1 and 2 initially outside of an injection mold by a possibly shaping hot pressing the decorative layer 1 with the first layer of the rigid FVK plate 2 so this is a double-layered part 3 form in a kind of semi-finished product. The semi-finished product is inserted into one side of an injection molding tool. In the opposite side of the injection molding tool, the second support layer of the rigid FVK plate 7 inserted. The injection mold is closed and a mixed with a blowing agent plastic melt through the second layer of the rigid FRP board 7 under formation of functional and / or fasteners 9 injected at the bottom. The passage of the propellant-added plastic melt through the lower FRP plate layer 7 can be done either through homogeneously distributed pores, but also through corresponding passages 8th be favored in it.

Deviating from 3 it is also possible, in turn, a support body with the formation of functional and / or fasteners to the underside of the FVK plate layer 7 to mold. By dispensing with this carrier body, these functional and / or fastening elements can also only at individual locations of the FVK plate layer 7 be sprayed directly on it.

Based on 4 to 9 Now, a special manufacturing method for a composite component according to 2 explained in more detail. Like from the 4 to 9 becomes clear, this is an injection molding tool 10 with two mold halves 11 . 12 used. In relation to the 4 upper mold half 12 is in the usual way an injection channel 13 provided at a central location for a thermoplastic injection molding material.

According to 4 is now a decorative layer 1 and a pre-tempered, rigid FRP board 2 provided and into the opened injection molding tool 10 brought in. At the decorative layer 1 and / or the FRP plate 2 is - as not shown in detail in the figure - applied a layer of a suitable adhesion promoter.

In the next intermediate production step according to 5 become decor layer 1 and FVK plate 2 together on the lower half of the mold 11 fixed, for which corresponding vacuum suction channels or other devices for receiving the two elements 1 . 2 are provided. The temperature control of the bending-resistant FRP plate at bypass temperatures 2 should be adjusted so that its plastic matrix softens and reshaping is possible.

As in 5 indicated by two arrows, the injection molding tool 10 closed, creating a semi-finished composite between decorative layer 1 and FVK plate 2 almost produced in a hot pressing process. At the same time there is a transformation of the two joining partners 1 . 2 instead of putting this through the lead 14 on the upper half of the mold 12 in the corresponding recess 15 be pressed in ( 6 ).

In the next intermediate production step according to 7 becomes the injection mold 10 reopened, taking the decor layer 1 and FVK plate 2 formed double-layer part 3 on the lower half of the mold 11 remains. This is achieved by a defined stroke of the upper mold half 12 a cavity 16 on the side of the FRP plate 2 formed, into - like 8th shows - a plastic melt containing a blowing agent 17 is injected. The plastic melt combines with the FRP board 2 and forms the foam structural body after cooling 6 , After opening the injection mold 10 can the part thus produced - as indicated by the arrow in 9 is indicated - be removed.

As in the 4 to 9 not shown, may be prior to injection of the plastic melt 17 in addition to the upper mold half 12 a FRP plate to form a support layer are inserted. This will after the injection of art fabric material into the cavity 16 a composite component produced in that 3 shown corresponds.

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - EP 1344687 B [0002]
• DE 102004010810 A1 [0004]
• - EP 1693175 A1 [0004]

Claims (12)

Composite component, in particular for interior trim elements of motor vehicles, characterized by - a double-layer part produced in particular as a semi-finished product ( 3 ) consisting of a visible side (S) forming decorative layer ( 1 ) and a stable base layer ( 2 ) made of a rigid fiber composite plastic material, with the decorative layer ( 1 ) is connected via a bonding agent, and - at least one functional position ( 4 . 6 ) under the double layer part ( 3 ). Composite component according to claim 1, characterized in that the functional layer is a molded carrier body ( 4 ) acts. Composite component according to claim 2, characterized in that with the carrier body ( 4 ) with molded functional and / or fastening elements ( 5 ) has. Composite component according to Claim 1, characterized in that the functional layer is a foam structural body ( 6 ) in particular acts with a closed surface. Composite component according to claim 4, characterized in that on the double-layer part ( 3 ) facing away from the surface of the foam structural body ( 6 ) integrally inserted or foamed functional and / or fastening elements ( 5 ) are arranged. Composite component according to claim 4, characterized in that the foam structural body ( 6 ) on the double layer part ( 3 ) facing away from a support layer ( 7 ) is connected from a rigid fiber composite plastic material. Composite component according to claim 6, characterized in that functional and / or fastening elements ( 5 ) on the foam structural body ( 6 ) facing away from the support layer ( 7 ) are provided, which by a molded-on, further support body or by the support layer ( 7 ) via passageways ( 8th ) passing through foam structural mixtures ( 9 ) are formed. Method for producing a composite component, in particular for interior trim elements of motor vehicles, according to one of the preceding claims, characterized by the following method steps: - providing a decorative layer part ( 1 ) and a deformable base layer part ( 2 ) made of a fiber composite plastic board, - inserting the decorative and base layer part ( 1 . 2 ) in an open injection mold ( 10 ), - closing the injection molding tool ( 10 ) with joining of decorative and base layer part ( 1 . 2 ) to each other to form the semifinished double-layer part ( 3 ), - Opening the injection molding tool ( 10 ) to form a cavity ( 16 ) on the side of the base layer part ( 2 ), - injection of a plastic ( 17 ) into the cavity ( 16 ) for shaping the functional position ( 4 . 6 ) to the double-layer part ( 3 ), and - removal of the multilayer composite component thus formed from the injection molding tool ( 10 ). A method according to claim 8, characterized in that when closing the injection molding tool ( 10 ) for joining decorative and base layer part ( 1 . 2 ) to each other these parts ( 1 . 2 ) are formed simultaneously. A method according to claim 8 or 9, characterized in that by adding a blowing agent in the in the cavity ( 16 ) injected plastic ( 17 ) the foam structural body ( 6 ) is formed. Method according to one of claims 8 to 10, characterized in that in the cavity formed by opening ( 16 ) of the injection molding tool ( 10 ) in addition to the double-layer part ( 3 ) opposite mold half ( 12 ) of the injection molding tool ( 10 ) the support layer part ( 7 ) is inserted and sprayed or foamed. Method according to one of claims 8 to 11, characterized in that the foam structure body ( 6 ) during its foaming simultaneously functional and / or fasteners ( 9 ) to the foam structural body ( 6 ) optionally by penetrating the support layer part ( 7 ) are formed.