DE102011108287A1 - Fiber-reinforced plastic (FRP) composite component for fiber matrix semi-finished product used for motor vehicle, has component region with matrix material which is foamed to form deformation region - Google Patents

Abstract

The FRP composite component (10) has two component regions (11,12) having different mechanical properties. The component regions are formed with matrix materials respectively. One component region (12) with matrix material is foamed to form a deformation region. A fiber layer is extended over the component regions. Independent claims are included for the following: (1) method for manufacturing FRP composite component; and (2) method for manufacturing fiber matrix semi-finished product.

Description

The invention relates to a fiber-reinforced plastic composite component and method for producing the same and a fiber-matrix semifinished product and its production.

In the course of lightweight construction, especially in the automotive sector, composite components of reinforcing fibers in polymeric matrix, even in sandwich construction with a core material of low density, are increasingly being used.

From the prior art, the production of composite structural components, for example in the RTM process (Resin Transfer Molding) is known in which fibers, fiber layers or semi-finished fiber products (so-called Prewovens or preforms) are inserted into a mold cavity of the RTM tool, in a curable polymeric matrix material is injected, which is often thermosetting or elastomeric reaction resins, but which may also be a thermoplastic resin melt. This matrix material is injected by means of pistons from a mostly heated prechamber via distribution channels into the mold cavity, infiltrates the fiber material and hardens depending on the matrix material under heat supply or removal and pressure. To avoid air pockets, the cavity can be evacuated prior to injection.

As an alternative to the RTM process, the SMC (sheet-molding-compound) process is used for the production of composite structural components. In this case, the manufacturing components reinforcing fibers and matrix material, such as glass fibers and a reaction resin, angeteigt and in shape, such as plate or foil form brought to create a fiber-matrix semi-finished, which are then further processed, for example, after cutting by extrusion to finished component can. Accordingly, the properties of the finished component of matrix material and reinforcing fiber, wherein common matrix materials thermosetting reaction resins such as polyester or vinyl ester resins, which are usually mixed with fillers and additives. For extrusion, the fiber-matrix semi-finished product is placed in a heatable pressing tool to make the matrix material of the semi-finished fiber flowable, so that it can penetrate the fiber material ideal; Furthermore, the shaping of the fiber material impregnated with the matrix material takes place in the pressing tool and the shaped component can be removed from the pressing tool when the matrix material has hardened. As an additive, the fiber-matrix semifinished product may have, for example, a release agent which is intended to reach the surface of the semifinished product during the said pressing process in the hot pressing tool in order to prevent the matrix material from adhering to the tool surfaces of the press.

The production of fiber composite sandwich components can be carried out in the so-called RIM process (Reaction Injection Molding). These reinforcing layers, such as glass fiber mats and flat spacer layers, z. B. a core layer, inserted in the intended order in a mold, the mold cavity is filled with a matrix material, so that after curing of this injected matrix sandwich composite component can be removed from the mold.

In this context, the describes DE 198 09 272 A1 a fiber composite sandwich component, in particular a motor vehicle body part, wherein a foamed in a predetermined shape foam core or Schaumkernvorformling is provided to form the spacer core layer of the sandwich construction. Furthermore, two fiber-laid preforms are provided which form the reinforcing structures of the two cover layers of the sandwich construction. For this purpose, reinforcing fiber bundles are superposed in layers of different unidirectional fiber orientation, sewn into a multidirectional or multiaxial fiber fabric and pressed into a predetermined shape in a forming process. The fiber web preforms and the foam core or preform are embedded in a reaction plastic matrix to make the overall composite.

Furthermore, in the DE 10 2006 056 167 A1 discloses a lightweight molded part in sandwich construction and a corresponding manufacturing method. The lightweight molded part comprises a core region made of a lightweight composite material comprising a matrix material and a lightweight filler material based on metal foam granules or hollow or hollow microspheres; as well as superficial or near-surface cover layers which have at least one layer of fiber material and the matrix material. The layer (or layers) of fiber material of the cover layers is (or are) integrated into the matrix material of the core region and thus forms a particularly good composite of the cover layers with the core region.

From the WO 2010/040359 A1 For example, a method of making a polymer composite by resin infiltration is known in which the resin properties are modified for different device areas. The component is in particular a wind turbine blade whose foot end is optimized with respect to its mechanical properties such as fracture toughness, crack propagation speed and rigidity. The method includes the placement of a reinforcing material such as fiber layers in a mold cavity having resin inlets for two different resins having different mechanical properties after curing. The method further comprises simultaneously feeding both resins into different regions of the mold cavity via the respective inlets and transferring the resins to the reinforcing material such that the resins at least partially mix in a third region of the mold cavity. The different mechanical properties are caused by additives added to one of the resins, which may be silica, titania, barium sulfate, and carbon nanotubes.

Based on this prior art, it is the object of the present invention to provide a fiber-reinforced plastic composite component, in particular a fiber-reinforced plastic composite component for a motor vehicle, which on the one hand is particularly light and on the other hand provides areas for receiving deformation energy.

This object is achieved by a fiber-reinforced plastic composite component with the features of claim 1.

Another object is to enable the production of such a plastic composite component.

This object is achieved by a method having the features of claim 5.

Further developments of the plastic composite component and the manufacturing method are set forth in the subclaims.

Furthermore, a fiber-matrix semifinished product for producing the fiber-reinforced plastic composite component having the features of claim 8, a method for producing the fiber-matrix semifinished product having the features of claim 9 and a method for producing the fiber-reinforced plastic composite component having the features of claim 10 disclosed.

A first embodiment of a fiber-reinforced plastic composite component according to the invention has at least two component regions that are equipped with different mechanical properties. In this case, one or more fiber layers, which are present in a composite with at least one matrix material, extend continuously over the component regions of the entire plastic composite component. Under a continuous, ie contiguous fiber layer, arrangements are to be understood in which the fiber layers extend substantially through the entire motor vehicle component but individual smaller areas remain fiber-free, for example, because there are inserts, recesses or the like. According to the invention, the plastic composite component has one or more component regions in which the matrix material is foamed. As a result, deformation regions are formed in particular. By foaming the matrix material in certain areas of the component, its properties can be selectively controlled. The fiber-reinforced plastic composite component is not only particularly lightweight due to the foamed areas, which is particularly important in motor vehicle construction to reduce energy consumption, but is deformable in this foamed area (hence deformation area), so that the plastic composite component can be used particularly suitable in motor vehicle construction, since it has component regions with the deformation region or zones, which in the event of a crash can absorb the impact energy by deformation.

To form the deformation regions and the component regions with unfoamed matrix, it is possible to use matrix materials whose compositions differ. However, the matrix material of the deformation region, if it is mechanically or physically foamed, may have a composition which corresponds to that of the matrix material of the unfoamed component region, since in this case the foaming is effected only by an introduced or after addition of propellant gas vaporized. If a chemically foamed matrix material is used in the deformation region, then its composition will differ, at least with regard to a foaming component which, after activation, splits off a gas for foaming. In this respect, the matrix materials of the plastic composite component, the deformation region of which is chemically foamed, will differ, at least with respect to the remainder of the foaming component remaining after the gas separation.

Of course, the compositions of the matrix materials may also differ in other components. Even with a component with a mechanically or physically foamed deformation region, it is possible to use different matrix materials. If different matrix materials are used, they should at least partially be miscible with each other so that a boundary zone of a mixture of the at least two matrix materials forms in the transition between the component regions, so that overall there is a continuous matrix in the component without sharp boundaries between the different matrix materials.

In the chemically activatable for the elimination of a propellant foaming it can may be a crosslinking component of the matrix material itself, but the matrix material may also include a foaming additive, which optionally also consists of several ingredients.

An embodiment according to the invention of the fiber-reinforced plastic composite component has a sandwich construction, wherein the deformation region with the foamed matrix material forms a core layer with low density of the sandwich, which is arranged between two component regions forming the cover layers of the sandwich with unfoamed matrix material.

As an alternative to the sandwich, a structure of the plastic composite component may comprise the arrangement of the deformation region with the foamed matrix material along the plastic composite component in addition to at least one component region with unfoamed matrix material. In this case, it is particularly appropriate for component regions with unfoamed matrix material to be formed as connection and / or edge regions of the plastic composite component due to their higher strength, between which the deformation region or regions are provided.

It is also conceivable, however, a combination of the two aforementioned variants, wherein in a plastic composite component, which generally has a sandwich structure with unfoamed cover layers and foamed core layer, in the region of the otherwise foamed core layer unfoamed component areas are provided approximately at connection and / or edge regions.

In order to produce the fiber-reinforced plastic composite component according to the invention in a process variant in an RTM process, a molding tool is used which has a mold cavity corresponding to the shape of the plastic composite component into which the fiber layer (s) is / are inserted. at least one uncured matrix material which impregnates the fiber layer (s) is injected into the mold cavity at at least one point, but preferably at several points. The uncured matrix material is then foamed in the section or regions provided for forming the deformation region, so that the curing of the matrix material (s) results in the plastic composite component having the at least one deformation region formed by the component region with the cured foamed matrix material.

The foaming of the uncured matrix material can be carried out by alternative means. In one embodiment, the matrix material may be simply mechanically foamed in the tool or sections of the impregnated fiber layers provided in the tool for forming deformation regions, for example when a propellant gas such as air is introduced by suitable injection means into the matrix material penetrating the fiber layers. The matrix material to be foamed may in this case have a composition which corresponds to that of the matrix material of the unfoamed component region or differs therefrom with regard to at least one component.

In order to obtain better and more uniform foam structures, in particular when using different uncured matrix materials, the matrix materials for forming foamed and unfoamed component regions are preferably injected into the mold cavity at at least two locations. In this case, the fiber layer (s) in one of the component regions is impregnated with a matrix material injected at a first location into the mold cavity and the fiber layer (s) impregnated in the other or the other component regions with the other matrix material injected into the mold cavity at a second location. The uncured matrix material, which is provided by foaming to form the deformation region or zones, is of course injected into the mold cavity at a location corresponding to the intended position of the deformation region. The matrix materials injected at the various points to form the different component regions saturate the fiber layers and flow in the boundary zone between the component regions into a mixture.

The non-hardened matrix material to be injected on a deformation area to form a deformation area can be mechanically foamed in advance by the introduction of a propellant gas, in particular air. Alternatively, prior to injection, a physical blowing agent may be added to the uncured matrix material which vaporizes at a desired temperature to allow frothing of the matrix material after injection by controlling the temperature in the tool. In this case, the matrix material to be foamed, apart from the blowing agent, may have a composition which corresponds to that of the matrix material of the unfoamed component region or differs therefrom with regard to at least one component. Also by temperature control, an activatable frothing component can cause chemical foaming of the matrix material in the intended area. However, further possibilities of activation are also conceivable here, for example by electromagnetic waves, such as microwaves, etc. In the case of chemical foaming, the composition of the matrix material to be foamed differs at least in terms of the foaming component from that of the matrix material which is not to be foamed.

A fiber-matrix semi-finished product according to the invention which can be used for producing a fiber-reinforced plastic composite component according to the invention consists of at least one fiber layer and at least one curable matrix material. To form the at least two component regions with different mechanical properties, the fiber-matrix semifinished product has at least two fiber-matrix semifinished product sections, one of which is provided for forming the deformation region comprising a matrix material to which a physical blowing agent has been added or comprising a chemical foaming component.

Such a semifinished product can be produced by first producing at least two doughs of reinforcing fibers and in each case one matrix material, the two doughs differing with regard to the blowing agent or the foaming component. These doughs are placed adjacent to each other or in layers, with a layer of dough containing the propellant / frothing component being sandwiched between two layers of dough without propellant / frothing component to form the fiber-matrix semifinished sections. The fiber-matrix semifinished product is obtained by compression molding the adjacent or layered doughs.

The production of a fiber-reinforced plastic composite component from the fiber-matrix semifinished product then comprises cutting the fiber-matrix semifinished product and inserting it into a flow molding tool in which the semifinished product is brought into component form, at the same time evaporating the physical blowing agent or activating the chemical foaming component such that the matrix material is foamed in the fiber-matrix semifinished product section provided for forming the deformation region. After the matrix materials have hardened, the component region with the hardened foamed matrix material forms the deformation region of the plastic composite component.

These and other advantages are set forth by the following description with reference to the accompanying figures. The reference to the figures in the description is to aid in the description and understanding of the subject matter. Articles or parts of objects which are substantially the same or similar may be given the same reference numerals. The figures are merely a schematic representation of an embodiment of the invention.

Showing:

1 FIG. 2 a schematic side sectional view of an RTM tool for producing the fiber-reinforced plastic composite component according to the invention, FIG.

2a FIG. 2 a schematic side sectional view of a fiber-reinforced plastic composite component according to the invention, FIG.

2 B FIG. 2 a schematic side sectional view of a further fiber-reinforced plastic composite component according to the invention, FIG.

2c a schematic plan view of another inventive fiber-reinforced plastic composite component,

3 a schematic plan view of a fiber-matrix semifinished product with different sections.

In the case of the fiber-reinforced plastic composite component according to the invention, the component properties in various component regions within the plastic composite component are specifically modified, so that the component is designed as required and load-oriented. For example, in order to selectively obtain different properties within the component, such as elastic regions, a multi-gate injection method can be used, into which different matrix materials are injected, which are designed to mix in a confluence over a certain range connect.

An inventive plastic composite component 10 , as in 2a - 2c shown, characterized by at least two component areas 11 . 12 having different mechanical properties, wherein one or more fiber layers 10 ' (as a fiber investor 10 ' in 1 to see) over all component areas 11 . 12 extends. The fiber layer 10 ' lies in the finished plastic composite component in conjunction with the matrix material (s) 7 . 8th in front. According to the invention, the plastic composite component 10 at least one component area 12 on, by the fact that there the matrix material 8th foamed, a particularly lightweight component area 12 forms, which is deformable and thereby a deformation area or energy absorption area 12 of the plastic composite component 10 forms, which can absorb the impact energy in the event of an impact by deformation, which is particularly advantageous for a motor vehicle component. Unlike in the prior art extends in the plastic composite component according to the invention 10 the fiber reinforcement over the entire component 10 , so also in the area 12 with the foamed matrix. The component 10 can, as in 2 B shown in section, be constructed as a sandwich, in which the component areas 11 form the cover layers with non-foamed matrix, while the component area 12 with the Foamed matrix forms the core layer, which is the entire component 10 gives a particularly low weight due to its low density.

Alternatively to a designed as a sandwich component, the component areas 11 . 12 with foamed and not foamed matrix also next to each other, see 2a . 2c , This may be the component areas 11 with unfoamed matrix around connecting areas of the component 10 For example, act with a vehicle body. The through the component areas 11 Bonding areas formed with unfoamed matrix are in this case of high strength, while over the length or area of the component 10 in the middle area of the deformation area 12 is arranged, in particular, when it comes to automotive components 10 acts to be able to absorb the deformation energy in the event of a crash here. Components such as supports, columns, etc. can be carried out according to the invention.

As fiber layer (s) 10 ' For example, fiber arrangements such as fiber mats, woven fabrics, braids, knits or nonwovens consisting of individual fibers, rovings or fiber ribbons are suitable. These may also be hybrid fibers or hybrid fiber arrangements of different fiber materials. The fiber materials may be the usual reinforcing fibers of glass, carbon and polymer, for example thermoplastics such as polyamide, in particular aramid, but also basalt, ceramic, metal or natural fibers are suitable. The fibers may for example be arranged unidirectionally or mutually angled.

To form the matrix in the component 10 can for the component areas 11 . 12 different matrix materials are used, which are the formed areas 11 . 12 give the different mechanical properties. In this case, the different matrix materials may be in the border zones 13 between the component areas 11 . 12 mix together so that there is a mixture of the matrix materials of the adjacent component areas 11 . 12 is present.

Thus, for the formation of the component area 12 with the foamed matrix an uncured matrix material 8th be selected with a composition having an activatable frothing component, which is a chemical foaming of the matrix material 8th provides. For example, by supplying heat, a volatile constituent of the propellant separates, which leads to foaming of the matrix. Other activation methods include, for example, microwaves or other electromagnetic radiation. The matrix material 7 the unfoamed component areas 11 may optionally be up to the activatable foaming the matrix material 8th correspond, in particular, if the activatable frothing component is a foamable additive, which may possibly also comprise a plurality of ingredients.

Another variant of the activatable foaming component is that a crosslinking component of the matrix material 8th even when activated splits off a blowing agent and thus represents the foaming. The other matrix material 7 , which should not foam, must then of course have a different networking component. This matrix material 7 is then advantageous with the matrix material 8th , whose crosslinking component is the foaming component, miscible to the boundary zone 13 form and a steady transition of the matrix between the component areas 11 . 12 to allow.

Is a physical foaming of the matrix material 8th in the component area provided for this purpose 12 planned, with one to the matrix material 8th added propellant, for example, evaporated by heating, thereby causing the foaming, can for the component areas 11 . 12 the same matrix material can be used. The proportion of the matrix material that makes up the component area 12 forms the blowing agent is added, which has volatilized after foaming, so that the compositions of the matrix materials after foaming and curing no longer differ. Of course, nothing speaks against it here too, different matrix materials that form the transition zone 13 miscible, for the component areas 11 . 12 use.

In one embodiment, only a mechanical foaming, for example, by introducing air into the uncured matrix material 8th in the deformation area 12 , respectively. In this case, the matrix material 8th in the deformation area 12 the same as the matrix material 7 in the non-foamed component area 11 or it may be different.

In the figures, components are shown by way of example, each with a deformation region between non-foamed regions, but ultimately also a plurality of deformation regions can be provided in one component, which are separated by non-foamed regions. In this case, more than two matrix materials can be used. If three or more different matrix materials are used, then a border zone is also conceivable which does not lie between two areas but can also arise at the meeting of three areas. Here then the boundary zone has a mixture of all three matrix materials.

The production of such a component 10 settles with an RTM tool 20 with multiple Do the sprues, as in 1 outlined. In the between the closing and angus side mold half 21 . 22 present mold cavity 24 therefore lead the injection devices 23 for the different matrix materials 7 . 8th in the places 23a . 23b , The injection sites 23a . 23b each lie within a portion of the mold cavity 24 , respectively, for the formation of the corresponding component areas 11 . 12 is provided. After the fiber feeder 10 ' into the mold cavity 24 of the RTM tool 20 was inserted, then the non-foamable matrix material 7 which is responsible for the formation of the component areas 11 is selected from the injection devices 23 in the specific places 23a into the mold cavity 24 injected and at the same time to be foamed matrix material 8th that contribute to the formation of the deformation area 12 is selected from the injection device 23 at the specific places 23b injected. The fiber depositor 10 ' becomes in the component areas 11 . 12 with the respective matrix material 7 . 8th impregnated, wherein the matrix materials 7 . 8th in the border zones 13 between the component areas 11 . 12 flow together, mix and connect.

The foaming of the uncured matrix material 8th that the formation of the deformation area 12 provided portion of the fiber insert 10 ' soaked, then in the tool 20 take place, either immediately after injection by the expansion or for example by a temperature increase. An alternative lies in the injection of an already (eg mechanically) foamed uncured matrix material 8th , which then the formation of the deformation area 12 provided section of the fiber insert 10 ' is foamed.

When casting with the matrix materials, care must be taken within the die that, due to the volume increase during foaming, the still liquid matrix can be displaced laterally into the regions which are not to be foamed. Here, for example, a cascade injection could be used at several injection sites, the injection devices in the direction of the flow front or frothing front 23 opens or closes accordingly.

Alternatively, when using a corresponding tool, this can be driven in the foaming area by the predetermined volume.

After curing of the matrix materials 7 . 8th is the one-piece composite component 10 with the slight deformation area 12 and the unfoamed, stronger component areas 11 finished. Of course, one-piece components with even more component areas can be created in the aforementioned manner.

If resin systems are used as matrix materials, then the temperature in the mold cavity becomes for hardening 24 increased, what the tool 20 a heating device 26 and pressure on the impregnated fiber assembly 10 ' exerts by corresponding, pressing pressure generating means of the closing side mold half 21 be activated, wherein, as already mentioned above, the volume increase during foaming of the matrix material 8th Must be taken into account. The heater 26 may also be designed so as to be targeted in the formation of the deformation area 12 provided area of the mold cavity 24 to increase the temperature for activation of the foaming component.

Furthermore, a tool for producing the component according to the invention 10 Provide injectables that are in the mold cavity 24 extend into it to a fiber insert inserted there 10 ' penetrate. These can be used for injection of the foamable matrix material 8th into the interior of the fiber insert 10 ' to form a foamed sandwich core 12 , see. 2 B , be used.

In general, to reduce unwanted air pockets, also depending on the selected injection, the mold cavity 24 after inserting the fiber assembly 10 ' and closing the tool halves 21 . 22 before the injection of the matrix materials 7 . 8th be evacuated. This is indicated by the tool 20 a venting channel 25 from the mold cavity 24 on that to a vacuum pump 25a runs.

The matrix materials may include, in addition to the crosslinkable resin, plasticizers, fillers, especially mineral fillers, and reactants, crosslinking agents, anti-fading additives, inhibitors, inert release agents, dyes, flame retardants, conductive additives, and stabilizers.

In general, in RTM processes, resins or resin systems are used as matrix materials to be injected, which have a low viscosity in order to keep the flow resistance during flow through the mold and the fiber arrangement low, so that smaller pressure differences are required for filling. Typically, reaction resins for RTM processes, which are offered as special injection resins, consist of a resin and hardener component. Low reactivity resin systems can be mixed prior to injection. Such resin systems may be more suitable for mechanical and physical foaming, while a highly reactive fast-curing resin system mixed in resin and hardener only immediately in the injection line or in the cavity can be optionally used by means of chemical foaming as a foamable matrix material.

Although RTM processes are usually carried out with resins as matrix materials, in the context of the invention thermoplastic materials are also conceivable as matrix materials, which are then injected in molten form into the cavity with the fiber feeder by means of your extrusion device. The thermoplastic melt containing the matrix in which to form the deformation area 12 provided portion may, for example, be mechanically foamed by air entry. The tool can also have cooling devices for a defined solidification process in addition to heaters. In general, however, tools for resin injection can also be equipped with cooling devices.

The 3 shows a fiber-matrix semi-finished product 5 made of a layer of reinforcing fibers 10 ' in curable matrix materials 7 . 8th consists. In such as Sheet Molding Compounds (SMC) called fiber-matrix semi-finished products 5 they are plate-shaped dough-like molding compounds in film form, in which the reinforcing fibers mixed with the uncured matrix material are ready for processing, for example by means of hot pressing. The reinforcing fibers are usually present in mat, more rarely in fabric form with typical fiber lengths between 25 and 50 mm. When pressing the SMC to the finished component and fasteners can be inserted into the mold, making SMCs are particularly economical. Fillers in the matrix materials are used for cost and further weight reduction.

The different uncured matrix materials 7 . 8th in the case shown form the fiber-matrix semifinished product sections 1 . 2 out. At the boundaries between the sections 1 . 2 is through the mixtures 4 of miscible matrix materials 7 . 8th each the border or transition zone 13 educated. A section 2 of the fiber-matrix semifinished product 5 , which contributes to the formation of the deformation area 12 from the semifinished product 5 to be manufactured component 10 is provided has the matrix material 8th with the added physical blowing agent or the included chemical foaming component, so that the matrix material 8th in this section during a subsequent manufacturing step to the component to the deformation area 12 can be foamed. As already mentioned, the matrix material can 7 the non-foaming sections 1 except for the frothing component the matrix material 8th match, allowing good miscibility in the transition zone 13 is guaranteed.

One from the fiber matrix semifinished product 5 For example, produced in an extrusion tool component 10 can do so with the deformation zone (s) 12 and the firmer areas 11 be designed to fit needs with unfoamed matrix. Also in the finished component 10 then lie in the transition zones 13 mixtures 4 from the matrix materials 7 . 8th in adjoining component areas in front of the sections 1 . 2 of the fiber-matrix semifinished product 5 correspond.

Here too, components are conceivable that are created from the semifinished product in which there are three or more component regions with different mechanical properties. For this purpose, three different matrix resins can be used accordingly. Here, too, a boundary zone can arise when three areas come together, so that a mixture of all three matrix resins is present in this boundary zone.

To the fiber-matrix semi-finished product according to the invention 5 that in the sections 1 . 2 matrix materials 7 . 8th provides, which differ at least with respect to a blowing agent / a foaming, are two (or possibly more) doughs made of reinforcing fibers 10 ' and one each of matrix material 7 . 8th made, so that the two doughs at least with regard to the blowing agent / the frothing component, the matrix material 8th added or included therein. To the fiber matrix semifinished product 5 obtained as a plate-shaped molding compound in sheet form, the doughs are arranged adjacent to each other or in layers on top of each other. In the latter case, a layer of the propellant-containing dough is sandwiched between two layers of propellant-free dough, so that a semi-finished product designed in this way can be used to produce a sandwich component. The corresponding to the desired fiber-matrix semi-finished sections 1 . 2 arranged doughs are then used to form the fiber-matrix semifinished product 5 usually pressed in foil form. Conceivable here is also the compression molding in another component-near form.

For the production of the fiber-reinforced plastic composite component 10 from the fiber-matrix semifinished product 5 this is first tailored accordingly and placed in an extrusion press tool. There then takes place under temperature so as to make the matrix material flowable, not only the shaping of the component, but also the foaming of the blowing agent-containing matrix material 8th - possibly already at the flow temperature or at a higher temperature - and curing to the finished fiber reinforced plastic composite component 10 , Will be the matrix material 8th foamed physically, the evaporation of the same at the boiling point of the blowing agent and thereby the desired foam pore formation, the chemical Aufschäumen the selected Aufschäumkomponente is activated, for example, thermally to cleave a gas. The section or sections 2 of the semi-finished product 5 that the matrix material 8th having the foaming component, thus become the deformation region (s) 12 of the component 10 frothed. Here, too, care must be taken within the die that, due to the volume increase during foaming, the still liquid matrix can be displaced laterally into the regions which are not to be foamed. Alternatively, when using a corresponding tool, this can be driven in the foaming area by the predetermined volume.

This is the case in both production variants after the curing of the matrix material (s) 7 . 8th obtained plastic composite component 10 , in addition to the firmer component areas 11 with unfoamed matrix 8th one or more slight deformation areas 12 Thus, not only provides a structure for absorbing the impact energy in the event of a crash, but has due to the reduced density in the deformation region 12 also a lower weight.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 19809272 A1 [0006]
• DE 102006056167 A1 [0007]
• WO 2010/040359 A1 [0008]

Claims (10)

Fiber-reinforced plastic composite component ( 10 ) (FVK) from at least two component areas ( 11 . 12 ) having different mechanical properties, wherein the plastic composite component ( 10 ) at least one continuous fiber layer ( 10 ' ), which extends over the component areas ( 11 . 12 ) and in a composite with at least one matrix material ( 7 . 8th ), characterized in that at least one of the component regions ( 11 . 12 ) by a foamed matrix material ( 8th ) as a deformation area ( 12 ) of the plastic composite component ( 10 ) is trained. Fiber-reinforced plastic composite component ( 10 ) according to claim 1, characterized in that the foamed matrix material ( 8th ) of the deformation area ( 12 ) has a composition, - that of a composition of a matrix material ( 7 ) of the unfoamed component area ( 11 ), or - which differs from a composition of the matrix material ( 7 ) of the unfoamed component area ( 11 ) differs at least with respect to a foaming component, wherein the differing matrix materials ( 7 . 8th ) at least partially mixed in a transition between the component regions ( 11 . 12 ) a border zone ( 13 ) forming. Fiber-reinforced plastic composite component ( 10 ) according to claim 2, characterized in that the foaming component is a crosslinking component of the matrix material ( 8th ) itself or a foaming additive. Fiber-reinforced plastic composite component ( 10 ) according to at least one of claims 1 to 3, characterized in that the plastic composite component ( 10 ) has a sandwich construction, wherein the deformation region ( 12 ) with the foamed matrix material ( 8th ) forms a core layer, the between two outer layers forming component areas ( 11 ) with unfoamed matrix material ( 7 ), and / or that the deformation area ( 12 ) with the foamed matrix material ( 8th ) along the plastic composite component ( 10 ) in addition to at least one component areas ( 11 ) with unfoamed matrix material ( 7 ), in particular connecting and / or edge regions of the plastic composite component ( 10 ) by component areas ( 11 ) with unfoamed matrix material ( 7 ) between which the deformation region ( 12 ) is provided. Method for producing a fiber-reinforced plastic composite component ( 10 ) according to at least one of claims 1 to 4, comprising the steps of: - providing a molding tool ( 20 ) with a mold cavity ( 24 ) according to a form of the plastic composite component ( 10 ) and inserting the at least one fiber layer ( 10 ' ) in the mold cavity ( 24 ), - injecting at least one uncured matrix material ( 7 . 8th ) in the mold cavity ( 4 ) in at least one place ( 23a . 23b ) and impregnating the fiber layer ( 10 ' ), - foaming the uncured matrix material ( 8th ) in at least one for forming a deformation area ( 12 ) provided portion of the impregnated fiber layer ( 10 ' ), - hardening the matrix material ( 7 . 8th ) and obtaining the plastic composite component ( 10 ), wherein the component area ( 11 . 12 ) with the cured foamed matrix material ( 8th ) the deformation area ( 12 ). Method according to claim 5, comprising the steps: - injecting the matrix material ( 7 . 8th ) in at least two places ( 23a . 23b ) in the mold cavity ( 24 ), wherein the uncured matrix material to be foamed ( 8th ) in at least one part ( 23b ) injected into a region of the mold cavity ( 24 ) leading to the formation of a deformation area ( 12 ) and the non-foamed uncured matrix material ( 7 ) in at least one place ( 23a ) injected into a region of the mold cavity ( 24 ), which is used to form a non-foamed component area ( 11 ), - let the matrix materials flow into each other ( 7 . 8th ) in the border zone ( 13 ) between the component areas ( 11 . 12 ) to a mixture ( 4 ). A method according to claim 5 or 6, characterized in that the foaming of the uncured matrix material ( 8th ) by - mechanical foaming by supplying a propellant gas, in particular air, takes place or - physical foaming by evaporation of a propellant, the uncured matrix material ( 8th ) has been previously added, or - chemical foaming takes place by activating a blowing agent which comprises a foaming component of the matrix material ( 8th ), whose composition is at least as regards the frothing component of a composition of the matrix material ( 7 ) of the unfoamed component area ( 11 ) is different. Fiber matrix semi-finished products ( 5 ) for producing a fiber-reinforced plastic composite component ( 10 ) according to at least one of claims 1 to 4, wherein the fiber matrix semifinished product ( 5 ) of at least one fiber layer ( 10 ' ) and at least one curable matrix material ( 7 . 8th ), characterized in that the fiber matrix semifinished product ( 5 ) for forming the at least two component regions ( 11 . 12 ) having different mechanical properties, at least two fiber-matrix semifinished product sections ( 1 . 2 ), one of which is used to form the deformation area ( 12 ), a matrix material ( 8th ) to which a physical blowing agent is added or which comprises a chemical foaming component. Method for producing a fiber-matrix semifinished product ( 5 ) according to claim 8, comprising the steps of: - producing at least two doughs of reinforcing fibers ( 10 ' ) and in each case a matrix material ( 7 . 8th ), wherein the two doughs differ with regard to the propellant or the frothing component, arranging the at least two doughs adjacent to each other or in layers, wherein a layer of the dough with the propellant or the frothing component sandwiched between two layers of the dough without propellant or frothing component to form the at least two fiber-matrix semi-finished sections ( 1 . 2 ) and press forming the adjacent or layered doughs to the fiber-matrix semifinished product ( 5 ). Method for producing a fiber-reinforced plastic composite component ( 10 ) using the fiber-matrix semifinished product ( 5 ) according to claim 8, comprising the steps of: - cutting the fiber matrix semifinished product ( 5 ) and inserting into a flow molding tool, - molding the fiber matrix semifinished product ( 5 ) in the extrusion tool to the plastic composite component ( 10 ), thereby - foaming of the matrix material ( 8th ) in which to form the deformation area ( 12 ) provided fiber matrix semifinished product section ( 1 . 2 by evaporation of the physical blowing agent or activation of the chemical foaming component, curing of the matrix materials ( 7 . 8th ), wherein the component area ( 11 . 12 ) with the cured foamed matrix material ( 8th ) the deformation area ( 12 ) of the plastic composite component ( 10 ).

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