DE102011118980B4 - Method for producing an outer module with an outer panel for a modular housing component - Google Patents

Abstract

A method for producing an outer module (1) with an outer panel (1 ') for a modular housing component, wherein the outer module (1) has a multilayer structure of a thermoplastic inner lining FVK (4b) and a thermoplastic FVK outer shell (4a) with a thereon arranged outer skin (6), which forms the outer skin (1 '), wherein the thermoplastic FRP inner shell (4b) on the side facing away from the outer shell (4a) side stiffening elements (7,10,11) comprising the steps 4) by cutting and forming a thermoplastic continuous fiber semi-finished product corresponding to an inner shell contour and insert molding with the stiffening elements (7, 10, 11), B) cutting and preforming a thermoplastic continuous fiber semi-finished product according to an outer shell contour, C) inserting the thermoplastic FRP inner shell (4b) and the corresponding outer shell contour preformed ther continuous fiber semi-finished thermoplastic material in a tool (20) and closing the tool (20), D) pressing the preformed thermoplastic continuous fiber semi-finished product with pressure and molding to the FRP outer shell (4a) and joining the FRP inner shell (4b) and the FRP outer shell ( 4a) and obtaining a raw outer module (1 "), E) producing the outer skin (6) on the outer FVK shell (4a) and obtaining the outer module (1).

Description

The invention relates to a method for producing a supporting outer module with an outer panel for a modular housing component, which is in particular a door or trim component of a motor vehicle.

Modular motor vehicle doors or body panels generally have a three-part construction and comprise an inner module to which an outer module outside and inside a door inner lining is attached. The outdoor module may be self-supporting to achieve better handling and easier installation of the module, but usually has no immediate support function of the vehicle door.

If the door interior trim and the exterior module cladding fulfill hardly any structural tasks in the first place, in most cases only the reinforcement areas of the interior module and of the door frame or exterior module serve as crash structures. This may be a diagonal side impact protection, as in the DE 10 2005 009 179 A1 is described. There, a motor vehicle door is disclosed which has a lower weight, is easier to handle in the assembly and also has a higher crash stability. This motor vehicle door has an outer shell corresponding outer module with a Außenbeplankung and an inner shell, which is formed by door narrowing side forming reinforcements. At least one support component for functional components is arranged on the inner side of the inner shell. In this case, the door narrow sides of the inner shell and the carrier component are combined to form a single module component corresponding to the inner module, which is provided with a separate inner door lining.

The DE 10 2004 011 250 B3 deals with the releasable attachment of a plastic outer panel to the door frame by means of rails and hooks. In general, the exterior planking of body components in modern motor vehicle doors is not included in the increase in crash performance and requires because of their low rigidity additional stiffening elements. This is in the DE 10 2008 034 038 A1 a particularly lightweight and rigid reinforcing structure for a side door of a motor vehicle described. This has a door support part for the door outer panel and a reinforcing element for increasing the buckling rigidity of the door in the vertical direction at least over a partial height of the door. However, these stiffening elements are subsequently attached to the frame structure of the outer module. These are necessary, on the one hand to improve the dent resistance to avoid minor damage and to achieve a Class-A surface and also to reduce the vibration sensitivity of the large area to acoustic effects such. B. to prevent drones.

The DE 10 2007 042 418 A1 sets a self-supporting exterior module, which consists of a mounted on a supporting frame planking, represents. The support structure is suitable for easy installation of the modules, but does not contribute as a structural component to increase the crash performance.

Basically, the modular design of motor vehicle doors is a common method to reduce the handling and assembly costs. The outer skin usually comprises only an outer door panel without structural tasks as part of the vehicle body.

Are known from the DE 10 2007 024 163 A1 Modular body parts, in which a planking part made of plastic is mounted on a supporting structure made of steel or light metal. The support structure contributes to a higher rigidity and strength and thereby enables the Class A surface suitability of the plastic skin.

Planking modules for lightweight bodies are also from the DE 10 2005 050 372 A1 known. The self-supporting construction, consisting of a layer structure (transparent plastic, metal reinforcement and paint film on the inside), enables the integration of further functional elements such as solar cells.

The DE 198 09 272 C2 describes a fiber composite sandwich component and its method of manufacture. The core is realized by a foamed in a predetermined shape foam core (produced in a separate manufacturing step in the RIM tool) or Schaumkernvorformling. The topsheets of fiberglass preforms and the foam core or foam core preform are embedded in a reaction plastic matrix to make the overall composite.

So far, the planking is usually not integrated as a structural component in the body concept. Only from the DE 198 09 272 C2 is a stable, structurally strong and rigid Plankungsteil known, which also has a very good crash behavior, but its production process requires a complex, multi-stage process with a reaction matrix.

Proceeding from this, it is the object of the present invention, the process-side sequence and structure in the production of improved in terms of crash performance bearing Multilayer outdoor module, which has the outer panel and the acoustic and optical requirements is met and contributes to the thermal insulation and weight reduction, to improve and to enable shorter cycle times and thus higher volumes.

This object is achieved by an outdoor module with the features of claim 1.

Further developments of the method are carried out in the respective subclaims.

1. A) Bereitstellen der thermoplastischen FVK-Innenschale durch Zuschneiden und Formen eines thermoplastischen Endlosfaserhalbzeugs entsprechend einer Innenschalenkontur und Hinterspritzen mit den Versteifungselementen,
2. B) Zuschneiden und Vorformen eines thermoplastischen Endlosfaserhalbzeugs entsprechend einer Außenschalenkontur,
3. C) Einlegen der thermoplastischen FVK-Innenschale und des entsprechend der Außenschalenkontur vorgeformten thermoplastischen Endlosfaserhalbzeugs in ein Werkzeug und Schließen des Werkzeugs,
4. D) Beaufschlagen des entsprechend der Außenschalenkontur vorgeformten thermoplastischen Endlosfaserhalbzeugs mit Druck und Ausformen zu der FVK-Außenschale und Fügen der FVK-Innenschale und der FVK-Außenschale,
5. E) Erzeugen der Außenhaut (6) an der FVK-Außenschale (4a) und Erhalten des Außenmoduls (1).

The method according to the invention relates to the production of an outer module with an outer panel for a modular housing component. The housing component for which the outer module is provided can therefore be a modular door or a trim component of a motor vehicle or else a device such as a domestic appliance. The outer module has a multi-layer structure of a thermoplastic FRP inner shell and a thermoplastic FRP outer shell with an outer skin arranged thereon, which forms the outer skin. In this case, the thermoplastic FRP inner shell on the side facing away from the outer shell side stiffening elements, whereby the outer module is formed as a supporting component. So it can be integrated, for example, in a modular body element and allows not only a high design freedom and functional integration but also the adaptation of crashbeaufschlagten planking on the vehicle concept. A first embodiment of the method comprises the steps:

1. A) providing the thermoplastic FRP inner shell by cutting and shaping a thermoplastic continuous fiber semi-finished product corresponding to an inner shell contour and injection-molding with the stiffening elements,
2. B) cutting and preforming a thermoplastic continuous fiber semi-finished product according to an outer shell contour,
3. C) inserting the thermoplastic FRP inner shell and the preformed thermoplastic continuous fiber semi-finished product according to the outer shell contour into a tool and closing the tool,
4. D) pressurizing the preformed thermoplastic continuous fiber semi-finished product according to the outer shell contour with pressure and molding to the outer shell of the FVK and joining the FVK inner shell and the FVK outer shell,
5. E) Producing the outer skin (6) on the FVK outer shell (4a) and obtaining the outer module (1).

Conveniently, the thermoplastic FRP outer shell and FRP inner shell may be readily formed from organic sheets as thermoplastic continuous fiber semi-finished products which are plate-shaped continuous fiber reinforced thermoplastic dies having a reinforcing fiber assembly in a thermoplastic resin matrix. As reinforcing fibers are preferably carbon fibers, glass fibers, aramid fibers, metal fibers or combinations thereof in question. The fiber arrangements used often have oriented fibers and include scrims, fabrics, nets, knits, braids, etc. As a thermoplastic matrix plastic find, for example, polyamide (PA), polypropylene (PP), polyphenylene sulfide (PPS), polyetheretherketone (PEEK), polyethylene terephthalate (PET) , Polybutylene terephthalate (PBT) or high density polyethylene (HDPE) use.

According to the invention, it is further possible to produce an outer module whose multi-layer structure between the FRP inner shell and the FRP outer shell has a structural core which is preferably a foam core which is lightweight due to its low density. For this purpose, the method comprises producing the structural core in a cavity formed between the thermoplastic FRP inner shell and the FRP outer shell in the closed mold in a step D1). For this purpose, a foam material is introduced into the cavity by means of a gating system of the tool, in particular by injecting a foamable polymer material which is for example a polyurethane or a physically foamed polyamide, polypropylene.

Alternatively or additionally, a honeycomb structure may be provided as the structural core, which is inserted between the FRP inner shell and the outer shell. The structural core may have a constant or a variable thickness over the surface of the outer module.

By means of this lightweight core sandwich construction, it is possible to achieve a weight reduction of the outer module and the housing component formed therewith. The outer module as a structural component allows the increase of the crash performance by the impact energy is distributed flat on the carrier. Furthermore, the structural core serves to increase the rigidity, wherein the profile of the indentation resistance can be specifically defined via the indentation path by material selection, layer structure and functional elements.

The application of pressure to form the preformed organic sheet in the tool to the outer shell, in step D) can be done in a variant by injection of a gas into the cavity, after which the foaming according to step D1), or the pressurization is caused by the injection of the foamable material in step D1) itself.

In order to produce the outer skin on the FVK outer shell in step E), the joined FVK inner shell and FVK outer shell are subjected to hot pressing or the FVK outer shell is flooded with a polyurethane or a gelcoat. Alternatively, both, first hot pressing and then flooding, are performed.

For flooding, the tool can be partially opened, as far as the layer thickness of the outer skin requires, whereupon the flooding is performed by means of a Angusseinrichtung the Angusssystems in the previously formed gap. Another tool design provides that in the closed tool between the outer shell of Rohausßenmodul from mated outer and inner shell and the tool surface there is a gap for flooding.

When creating the outer skin, whether by hot pressing, flooding or both, preferably a release agent may be used to facilitate demoulding of the outer module with the paintable surface formed thereby. When flooding can be provided as a release agent, an internal release agent of the polyurethane or gel coats. Alternatively, the tool surface can have a permanent release agent coating or a release agent can be applied to the tool surface before step E).

One variant of the method provides that a thermoplastic continuous fiber semi-finished product is used to form the outer shell of the FRP, which has a thermoplastic matrix thickening on one side. For this purpose, a layer of the thermoplastic matrix plastic is formed on the thermoplastic continuous fiber semi-finished product. This matrix thickening is provided as a base for the outer skin and prevents the image of the fiber arrangement on the outer skin. When preforming the thermoplastic continuous fiber semi-finished product, care must then be taken that the matrix thickening comes to lie on the side intended to form the outer skin.

Preferably, the tool used consists of a tool cube / insert with two closing planes, so that steps C) and D) can be performed in a first closing plane of the tool and step E) in a second closing plane of the tool. Preferably, a tool cube / insert can be used which has a tool punch for receiving the inner shell in both closing planes, while the two closing sides of the two closing planes of the tool have a die for forming the outer shell. For example, the second shooting plane may have a gap for flooding between the outer shell and the tool surface of the closing side.

Advantageously, the method according to the invention avoids the disadvantages of a "one-shot" method in which all individual processes are carried out in a mold cavity and thus require a high technological outlay. Due to the two closing levels and the simultaneous execution of different individual processes, the quantity is hardly limited even with long individual process times.

Furthermore, it may be provided that the shaping of the thermoplastic continuous fiber semi-finished product according to an inner shell contour and back-molding with the stiffening elements for the production of FRP inner shell according to step A) takes place in the same tool. Particularly skillfully, the back injection of the stiffening elements can take place simultaneously with the foaming of the cavity in step D1) through the gating system of the tool, if a PA foam, PP foam is used as the foamable material.

For the back-injected stiffening elements of the FRP inner shell it is also possible to use preferably a thermoplastic plastic which corresponds to the matrix plastic of the thermoplastic continuous fiber semi-finished product. The stiffening elements, which has the inner shell, may be reinforcing ribs, which are molded onto the inner shell. Generally, a suitable molding resin is one that is compatible with the thermoplastic matrix resin of the inner shell and is preferably the same as the thermoplastic matrix resin. The intermediate spaces between the molded ribs can be foamed, also a polyurethane or a foamed polyamide, polypropylene can be used. Further, as stiffening elements beads may be introduced into the inner shell or the inner shell may have wavy areas, which serve to improve the crash performance.

In addition to the stiffening elements according to the invention, the inner shell can have openings and / or molded contours and / or edges of edge areas, mounting and / or attachment elements, the latter in particular for connecting the outer module to an inner module of the modular housing component.

For joining the outer shell and the inner shell in step D), the outer shell and the inner shell of the outer module are connected to the edge regions by crimping, gluing, welding or encapsulation.

Further steps of the method relate to the heating of the continuous fiber semi-finished blanks, wherein the heated thermoplastic FRP shells become malleable, in particular by means of infrared radiation, and holding the continuous fiber semi-finished blanks by conforming grippers for preforming the thermoplastic continuous fiber blanks, wherein the holding of the continuous fiber blanks to the grippers in particular by generating a negative pressure occurs. Furthermore, at least one tool surface for hot pressing and / or for forming the outer shell can be inductively variothermized or tempered with nitrogen. Both the inner shell and the Enlosfaserhalbzeugzuschnitt preformed according to the outer shell contour can be fixed by placing a negative pressure when inserted into the tool.

An outer module produced by the method according to the invention can be used together with an inner module to construct a modular housing component and forms its outer panel.

To connect the inner and outer module can be provided an adhesive seam. Alternatively or additionally, the inner shell of the outer module edge have a slot-like paragraph for insertion into the inner module, additionally or alternatively one or more springs and / or pins that can be accommodated in corresponding grooves or recesses of the inner module.

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. The figures are merely a schematic representation of an embodiment of the invention.

• 1 eine perspektivische Ansicht einer modular aufgebauten Fahrzeugtür mit Außenmodul, Innenmodul und Innenverkleidung,
• 2 eine Innenansicht eines Außenmoduls nach Stand der Technik,
• 3 schematische Seitenschnittansichten durch zwei Fahrzeugtüren aus verbundenen Außen- und Innenmodulen,
• 4 eine Teilquerschnittansicht durch ein Außenmodul,
• 5 eine schematische Querschnittansicht durch einen erfindungsgemäßen Schichtaufbau des Außenmoduls,
• 6 eine perspektivische Innenansicht des Außenmoduls und eine vergrößerte Detailansicht,
• 7 eine schematische Querschnittansicht durch eine Fahrzeugtür aus verbundenem Außen- und Innenmodul,
• 8 einen Vergleich zwischen einem ondulationsfreien Gelege mit einseitiger Matrixaufdickung und einem Organoblech mit onduliertem Gewebe,
• 9 ein Ablaufschema der ersten Verfahrensschritte A) und B),
• 10 ein Ablaufschema der Verfahrensschritte C) bis E) in einem Wendeplattenwerkzeug in einer ersten Ausführungsform,
• 11 ein Ablaufschema der Verfahrensschritte C) bis E) in einem Wendeplattenwerkzeug in einer weiteren Ausführungsform,
• 12 ein Ablaufschema der Verfahrensschritte C) bis E) in einem Wendeplattenwerkzeug in noch einer weiteren Ausführungsform,
• 13 ein Ablaufschema der Verfahrensschritte C) bis E) in einem Wendeplattenwerkzeug in noch einer weiteren Ausführungsform
• 14 schematische Strukturen des Außenmoduls beim Ausschäumen mit PA-Schaum und gleichzeitig Anspritzen der Rippen mit dem PA- bzw. PP-Schaum.

Showing:

• 1 a perspective view of a modular vehicle door with exterior module, interior module and interior trim,
• 2 an interior view of an outer module according to the prior art,
• 3 schematic side sectional views through two vehicle doors of connected outer and inner modules,
• 4 a partial cross-sectional view through an outdoor module,
• 5 a schematic cross-sectional view through a layer structure of the outer module according to the invention,
• 6 an interior perspective view of the outer module and an enlarged detail view,
• 7 a schematic cross-sectional view through a vehicle door from the connected outer and inner module,
• 8th a comparison between an ondulation-free scrim with one-sided matrix thickening and an organic sheet with undulating tissue,
• 9 a flowchart of the first method steps A) and B),
• 10 a flow chart of the process steps C) to E) in a turning tool in a first embodiment,
• 11 a flow chart of method steps C) to E) in a turning tool in a further embodiment,
• 12 a flow chart of the process steps C) to E) in a turning tool in a still further embodiment,
• 13 a flow chart of the process steps C) to E) in a turning tool in a still further embodiment
• 14 schematic structures of the outer module during foaming with PA foam and at the same time molding of the ribs with the PA or PP foam.

The present invention relates to an outdoor module 1 for a modular housing component such as a supporting exterior body paneling 1' and their production process. A body outer panel according to the invention 1' specifically, relates to modular driver, passenger, rear side and / or rear doors, roof panels, bumpers, fenders, tailgates, hoods, engine cowlings, compressor / engine covers; Furthermore, the outer modules according to the invention are 1 generally suitable for modular housing, for household appliances such as vacuum cleaners.

The production of the outdoor module 1 takes place according to an embodiment of the invention preferably in a system with two closing levels. In order to keep the cycle times, investment costs and beyond the dimensional tolerances low, a tool cube or insert plate connects the two processing stations with each other. Because metallic paint finishes are not closed Tools can be applied, for example, by in-mold coating, an offline painting is inevitable. Thus, in particular, a metallic finish must be attached to the manufacturing process described here. The sandwich construction of the outer module 1 combines high weight-specific rigidity with good thermal and acoustic insulation. Electromobility plays a key role in increasing range, ride comfort and cost reduction. In addition, the layer structure listed in this service invention disclosure additionally isolates the interior by reducing the sound radiation of the large-area planking due to the high rigidity and absorbing the ambient noise by the foam core.

The outdoor module described for this purpose 1 , by way of example in the figures, a vehicle door exterior module 1 , consists of a multi-layer sandwich construction made of thermoplastic FRP shells 4a , 4b, which are formed from an organic sheet comprising, for example, embedded in a thermoplastic matrix plastic braided aramid fibers and optionally also about a steel net, stiffening elements 7,10,11, which either on the inner half-shell FVK 4b molded as ribs or can be introduced directly into this as beads, a core structure such as a PUR foam, or one of injection molded PA foam, PP foam or a honeycomb structure and in the tool 20 made surface preparation in the form of a paintable outer skin 6 , Due to the high degree of design freedom and functional integration, this design makes it possible to adapt the crash-impacted planking to the vehicle concept by configuring the materials, semi-finished products and geometries. The planking can be optimally integrated as a load-bearing component in a modular body element; this one can, like 1 shows, from an interior lining 3 , an outdoor module 1 (Planking) and an indoor module 2 (Door carrier) be constructed. The door carrier 2 takes in addition to the outdoor module 1 and the interior trim 3 functional units, such as windows, speakers, etc., on.

The outdoor module 1 or the planking is due to its structure acoustic, heat insulating and optical requirements for a Class A surface preparation for the subsequent 3-coat paint and freedom of design. The sandwich construction of the planking also contributes significantly to the importance of thermal insulation and weight reduction in the course of electromobility. Furthermore, the structure offers excellent NVH characteristics, with NVH (Noise, Vibration, Harshness) which are referred to as vibration audible and / or vibration in motor vehicles.

Since in a side impact and side crash (eg, Federal Motor Vehicle Safety Standard Side Impact, FMVSS, 214), the planking as the first vehicle element is in contact with the impact body, the supporting outer skin according to the invention offers 1' as an energy absorbing element by gaining an improvement in crash performance.

With the manufacturing method according to the invention, the investment and manufacturing costs can be reduced, since the floor technology or insert technology, the decoupling in the tool 20 located component number of the clamping force and thus allows a non-linear course. In addition, small dimensional tolerances are guaranteed and short cycle times are possible by using a thermoplastic matrix system. The painting is done in a separate, subsequent step, which is necessary for the realization of metallic effects.

1 shows a modular structure of a motor vehicle door, consisting of an inner module or a door support 2 , to the / on the outside an outdoor module 1 with planking and inside a door inner lining 3 followed. An outdoor module 1 in the prior art is in 2 shown. Such a modular motor vehicle door can be integrated into any vehicle environment and the in 2 illustrated outdoor module 1 Substitute a conventional motor vehicle door. As in the prior art, the door inner lining 3 and the planking 1' in the first place hardly perform any structural tasks, serve in most cases, only the reinforcement areas of the inner module 2 and the door frame 2 ' as part of the exterior module 1 as crash structures. These crash-relevant structures are protected by an approximately diagonal side impact protection 3. ' strengthened. To increase the dent resistance of the outer skin 1' the outdoor module here additionally has a stiffening element 4 ' on.

In general, the outdoor module is suitable 1 especially for use in modular body elements, wherein the structure and the number of individual components in the body element may vary according to the requirement profile.

The multi-layer structure of the outer module according to the invention 1 that the exterior planking 1' for a modular housing component as here provides a vehicle door includes, as in particular in 4 and 5 you can see an inner shell 4b and an outer shell 4a on which the shell 6 is arranged, which forms the outer skin 1 '. Both half shells 4a , 4b are thermoplastic FRP shells, wherein the inner shell 4b on the outside of the shell 4a away-facing side as stiffening ribs 7 having.

The thermoplastic FRP shells 4a , 4b are made of organo sheets.

The term "organic sheet" is understood to mean plate-shaped continuous fiber reinforced thermoplastic pulleys used for components with high strength and low weight. Organic sheets can be thermoformed and enable short process cycles and are also easy to weld. In contrast to metallic sheets, the use of organic sheets eliminates corrosion protection.

Organic sheets can consist of special fiber arrangements which have fibers in defined orientations embedded in the thermoplastic matrix. For example, the fiber arrangements can be fabrics, scrims, knits, etc. In addition to the mentioned reinforcing fibers and matrix systems, of course, all other common types of reinforcing fibers, for. As ceramic fibers, metal fibers, natural fibers other polymer fibers in question; Also, various reinforcing fibers may be combined in a fiber array. The matrix systems mentioned are to be understood as exemplary only and in no way limiting.

The use of a thermoplastic matrix also reduces cycle times compared to duromers. The sandwich construction combines a high weight-specific stiffness in both crash and vibration behavior with good thermal and acoustic insulation. Electromobility plays a key role in increasing range, ride comfort and cost reduction. In addition, the listed layer structure additionally isolates the interior by reducing the sound radiation of the large-area planking due to the high rigidity and absorbing the ambient noise through the foam core.

The outdoor module according to the invention 1 is particularly suitable for use in modular bodywork elements. These can according to the in 1 be constructed shown motor vehicle door. The structure and the number of individual components in the body element can vary according to the requirement profile. Due to the simple handling and the quick installation of the planking module according to the invention 1 the production costs are significantly reduced again.

The planking module 1 protrudes in the assembled state beyond the contour of the support module 2 to cover the parting plane between them. In this parting line, as in 3 shown, for mounting the planking module 1 to the carrier 2 a circumferential adhesive bond 9 be applied in the edge regions, such as with a Sikaflex® adhesive, Sika Germany GmbH, Stuttgart. This adhesive connection 9 can be removed with a necessary repair of the internal units. To the planking 1 after repair again to the carrier 2 To add, can be an adhesive edge again 9 be applied.

Because of the good formability of the organo sheet in the warm state and the resulting shape independence of the inner and outer shell 4a , 4b sandwich components, a high degree of design freedom (especially the outer shell 4a ) and the transition area between the planking module 1 and carriers 2 be designed in different ways. So can the inner shell 4b the planking 1 as a kind of insert 2b in the door carrier 2 be inserted ( 3 , left), with the bond 9 done in the border area. The initiation of the planking 1 absorbed power in the door carrier 2 can also by a tongue and groove principle 9 ' , 9 "to be improved ( 3 , right), where here the inner shell 4b the planking 1 in the edge area as a spring 9 ' is formed, which in a corresponding groove 9 " in the edge area of the interior module 2 intervenes. The circulating adhesive connection 9 can be integrated into the tongue and groove connection, wherein for mounting the adhesive 9 in the groove 9 " or on the spring 9 ' can be applied. Of course, also differently than shown, the inner shell 4b Have grooves in the springs of the inner module 2 can intervene.

If the complete layer structure of the present invention is used, the in 4 and 5 illustrated layer structure of the fiber composite sandwich component before. This consists of two half shells 4a and 4b made of organic sheets, taking for the outer shell 4a Preferably, a scrim is used, which is thickened on one side with matrix to prevent the marking of the fiber structure on the surface (see. 8th ), while the inner shell 4b consists of a crash-resistant organic sheet, for example, embedded in a thermoplastic matrix C-fibers, steel filaments and aramid fibers. Furthermore, the layer structure comprises a structural core 5 (eg made of PUR foam or PA foam), an outer skin 6 (eg flooding with PUR lacquer) and back-injected stiffening ribs 7 with locally foamed spaces 8th and the already mentioned adhesive bond (primer) 9 , The layer structure can, as 4 shows, in its thickness along the outer module 1 vary. So can the between the shells 4a and 4b sandwiched foam core 5 decrease from a maximum thickness of, for example, 15 mm to 5 mm, with no foam core material between the half-shells in the edge region 4a , 4b. The outer shell 4a , which may possibly be thickened with matrix plastic, see below, is here formed from an organic sheet with a thickness of 0.8 mm, on which the outer skin 6 forming lacquer layer is applied with a layer thickness of 1 mm. The organic sheet for the inner shell 4b here is 1.2 mm thick. So can the half shells 4a , 4b differ not only in thickness, but possibly also in terms of the configuration, the fabric or the fabric as well as the fiber or matrix materials.

Depending on the mechanical, optical and acoustic requirements of the described layer structure of the planking module 1 vary. Furthermore, the density of the foam core 5 be varied or the core completely omitted (eg for wheel arches). Also the material of the outer skin 6 and their attachment to / on the outer shell 4a may vary.

Reinforcements on the inner organo sheet 4b in the form of beads 10 or ribs 7 lend to the outdoor module 1 additional rigidity ( 6 ).

The shaping of z. B. wavy areas 11 the inner shell 4b (see. 7 ) and the use of a flexible adhesive 9 are possibilities to achieve a certain degree of resilience in the event of a crash, which is necessary for the absorption of force over the entire push-in distance, the resistance test FMVSS 214 445 mm, and maintain the structural integrity, without sacrificing the design freedom of the outer skin 1' to influence negatively. In the event of a side crash, the load-bearing paneling described in the invention allows 1 in contrast to conventional side impact protection elements, which direct the force only selectively into the side walls, the two-dimensional force transmission via the inner module 2 (Carrier) to the side walls (A / B / C columns). The wavy areas 11 , which have a suitable deformation structure geometry, represent deformable areas that in the outer module 1 are integrated.

The contact between the two half-shells 4a 4b can be produced in the edge regions by gluing or crimping or in-mold assembly or welding of the organic sheets in order to meet the optical and mechanical requirements. The edge areas can thus be made accurately and compensate for possible inaccuracies when draping the organic sheet. The sealing of the parting plane between the two flat half-shells 4a , 4b also prevents moisture from entering the core structure 5 ,

Another key issue in large plastic parts is the adjustment of thermal expansion and the associated gap size. The anisotropic behavior of fiber composites may be present in the present planking 1 be balanced constructively by suitable material combinations and corresponding ply structures to comply with low tolerances. If you choose for the outer shell 4a a clutch, the fiber proportions in the layers can be ideally adjusted differently than with fabrics according to the requirements. In fabrics, the fiber orientations are orthogonal, although fiber proportions are adjustable in the different directions, but not as easy as in the open.

8th shows the setting of the thermal expansion and the compensation of fiber marks / sink marks by scrims with one-sided matrix thickening 6 ' (left in the 8th ) compared to the tissue (shown on the right). Although an orthogonal course of the fibers 40,41 is shown here also in the ondulationsfreien scrim, but it can be easily deviated from the laying of the fiber arrangements by the fibers are stored load case oriented.

• a) Aufbringen der Matrixschicht 6' über Extruder und Breitschlitzdüse auf das Organoblech in dessen Herstellprozess. Während der Organoblech-Herstellung wird z. B. mittels einer Doppelband-Presse die Extrusion zwischengeschaltet. Bei der Extrusion wird die zusätzliche Matrixschicht 6' in einem kontinuierlichen Verfahren durch eine Breitschlitzdüse gepresst. Es entsteht eine Matrixschicht 6' mit dem Querschnitt der Düse in beliebiger Länge. Durch die Wahl eines kompatiblen thermoplastischen Werkstoffs erfolgt so ein Stoffschluss mit dem Matrixmaterial 50 des Organoblechs.
• b) Aufbringen der Matrixschicht 6' über zusätzliche Folie(n) auf das Organoblech in dessen Herstellprozess. Während der Organoblech-Herstellung werden z. B. mittels einer Doppelband-Presse eine oder mehrere Folien zusätzlich eingezogen und auf das Organoblech mittels Druck und Temperatureinwirkung stoffschlüssig aufgetragen.
• c) Aufbringen der Matrixschicht 6' über zusätzlicher Coextrusion (2-K-Folien) auf das Organoblech in dessen Herstellprozess. Während der Organoblech-Herstellung wird die Coextrusion(s)-Anlage mit zwei bis drei Einschneckenextrudern ggf. unterschiedlicher Baugrößen zwischengeschaltet. Dieses Konzept stellt eine optimale Homogenisierung der Materialien sicher und ermöglicht den Einsatz verschiedener Werkstoffe je Lage. Die so erzeugte Matrixschicht 6' wird so nach dem Austritt aus dem Extrusionswerkzeug auf das Organoblech laminiert.

The surface preparation plays for the use of the outer module 1 in the field of vision an essential role. Due to the one-sided application of an additional, approx. 0.2 mm thick matrix layer 6 ' on the outside organo sheet ( 8th , left), on the one hand prevents the "protrusion" of fibers 40, 41 and, on the other hand, prevents the possible signing off of the fabric structure over time. Thicker layers 6 ' should be avoided as they may tend to crack. The one-sided application of an additional matrix layer 6 ' can be done in different ways:

• a) applying the matrix layer 6 ' via extruder and slot die on the organic sheet in its production process. During organo sheet production z. B. interposed by means of a double-belt press the extrusion. During extrusion, the additional matrix layer becomes 6 ' pressed in a continuous process through a slot die. It creates a matrix layer 6 ' with the cross section of the nozzle in any length. By choosing a compatible thermoplastic material so a material bond with the matrix material 50 of organic sheet.
• b) applying the matrix layer 6 ' via additional film (s) on the organic sheet in its production process. During organo sheet production z. B. additionally fed by means of a double-belt press one or more films and applied cohesively to the organic sheet by means of pressure and temperature action.
• c) applying the matrix layer 6 ' via additional coextrusion (2-K films) on the organic sheet in its production process. During organo sheet production, the coextrusion (s) system is interposed with two to three single screw extruders, possibly of different sizes. This concept ensures optimal homogenisation of the materials and allows the use of different materials per layer. The matrix layer produced in this way 6 ' is thus laminated after exiting the extrusion die on the organic sheet.

The inventive method is in 9 to 13 shown divided into two processing stations I, II. At the first station I is the forming of the outer organic sheet and the joining / foaming of the half-shells 4a , 4b instead. In the second station II the surface preparation takes place. Since both processes run in parallel, a finished component is created per cycle.

9 describes the preforming process of the organic sheet blanks 4 for the production of the two half-shells 4a . 4b , The inner half shell 4b is already in a "conventional" tool 20 ' completely prefabricated / formed and in the tool 20 ' back-injected during the organic sheet cutting 4 for the half shell outside 4a during transport to the floor mold 20 just heated and on the gripper 30 is preformed and only in the floor mold 20 gets its final shape. The organic sheet blanks 4 can be done by collets with pneumatic cylinders / servomotors 32 held on the gripper body under a defined bias. The organic sheet blanks 4 be both for the inner shell 4b as well as for the outer shell 4a for example by means of an infrared radiator 31 heated, so that they are bend soft and can adapt to the contoured gripper shape, with vacuum suction 33 the organic sheet 4 tighten to the gripper contour. Through the cylinders / engines 32 a defined tracking of the organo sheet during the preforming can take place. While the preformed organo sheet 4 for the inner shell 4b in the tool 20 ' can be prefabricated, is the preformed organo sheet blank 4 for the outer shell to the floor mold 20 transported and inserted there in the first closing level.

10 and 11 illustrate the process steps of hot pressing and flooding in the closing level II. In hot pressing ( 10 ) becomes the tool surface and / or material surface, such as the matrix thickening 6 ' on the outer shell 4a through a corresponding tempering device 23 warmed up. By melting the addition of the organic sheet 4 applied matrix layer 6 ' and the pressurization, an improvement of the surface is achieved. If the tool surface is heated, this can, for. B. by the inductive, variothermic mold temperature control 23 happen. Heating the outer surface of the outer shell 4a is z. B. with an IR emitter 31 possible, which enters the closing level II before closing the tool. Also conceivable are temperature control systems 23 which via a gas (eg nitrogen) the tool 20 temper.

At the same time for hot pressing in closing level II is on the stamp page on the tool cube / insert 20 the closing level I the already finished molded and back-injected inner shell 4b inserted. For the outer shell 4a the organo sheet blank 4 is in the heated and preformed state in the die side 21a of the tool. The stamp page is located in the tool cube / insert 20 and the die side 21a (later outside of the planking) on the closing side 21 ,

After closing the tool 20 is in the closing level I between the inner shell 4b and the organic sheet blank 4 Gas injected (eg GIT technique 22 ) and the hollow body "inflated". This will make the organo sheet blank 4 pressed against the mold wall of the die and forms the outer half-shell 4a out. Because of the better bond adhesion is in the still warm state of the resulting cavity on the Angusssystem 24 foamed up with PUR. The resulting sandwich composite is made by turning the tool cube 20 by 180 ° or alternatively by 90 ° (with longer curing time or intermediate / or end QS station to 90 ° or 270 ° position) implemented.

In the in 12 illustrated variant of the method, the omission of the gas injection is provided. Here is by the PUR injection with the Angusssystem 24 the organic sheet blank 4 to the tool wall 21a pressed on, to the outer shell 4a trained and foamed.

Is through the pure matrix thickening 6 ' and the final hot pressing can not achieve sufficient surface quality, the surface for producing the outer skin can be produced after the sandwich production 6 be flooded with PUR. When flooding, shown in 11 , finds the preparation of the surface of the outer half shell 4a from the matrix-thickened organo-sheet. This is the template 21b the closing level II slightly larger and creates when closing a gap between the outer shell 4a and the tool surface 21b , In this gap then the PUR injected as a half-shell. It is also conceivable flooding a half shell with a gelcoat. This gelcoat serves as a protective layer on molded parts made of fiber-reinforced plastics and seals the component against moisture and protects against pressure damage. The flooding serves to prepare for the Class A surface and, first, to provide adhesion to PA and, secondly, to prevent adhesion to the tool.

To stick to the tool 20 To prevent, three possibilities are conceivable:

PUR material with internal release agent

The use of internal release agents in (fiber-reinforced) plastics causes a better impregnation of the fibers and thus increase the strength of the composite materials. The basic requirement is a chemically well-tuned system in which the internal release agent can sufficiently penetrate the intended production cycle. Other benefits of using internal release agents when processing PUR systems include streamlining or shortening production cycles through increased levels of automation and enabling very short cure times by eliminating unproductive drying / coating times. There are reproducible molding surfaces created because variations are avoided by different release agent and transfer, whereby quality controls are simplified. A higher surface compaction which can also be achieved in this way results in lower emissions ("fogging" reduction). In addition, surface tensions of> 40 mN / m can be realized so that direct further processing (bonding or painting) is possible, which enables massive cost savings. The better wetting or impregnation of the reinforcing scrims leads to components with higher mechanical load capacity. Furthermore, due to minimally necessary amount of release agent (no overspray, etc.), which also reduces release agent-related emissions, costs can be further optimized. Thus, the sustainability of the processes is improved due to the use of only actually required amounts of raw materials.

Coat tool surface

The coating of the tool surface to prevent adhesion protects the tool surfaces from abrasive wear, whereby the formation of the moldings, which arise as a result of the adhesion of the molding material to the tool surface, is observed. For example, hard coatings provide protection. In industrial practice, nitrides and oxides based on chromium and titanium have prevailed in the first place, such as TiN, CrN, CroMult, CromOx and others. These hard material layer systems can be tailored to the respective application and do not form, like conventional coatings, troublesome macroparticles. In addition to corrosion protection and wear reduction, the flow behavior of the molding compound and the mold release behavior can be substantially improved by the hard coating and the tendency to Formbelagsbildung be significantly reduced. Furthermore, the coating of the tool surface, the moving parts (standard parts such as ejector and controls are exposed to strong adhesive wear) protected and beyond even can be completely dispensed with the traditional lubrication of the tool.

use separate release agents

Here, only the PUR foam cavity 21b wetted with a commercially available release agent. When closing the tool 20 a pressure is built up and a PUR foam in the cavity 21b injected. Advantages of the separate use of release agents are that the tool surfaces are very easy to mold and good adhesion between thermoplastic and PUR foam can be achieved. The ejection of the component is easy and there are only low demolding forces required. However, a separate application of the release agent as an additional process step and its carryover is not necessarily effective.

A further variant according to the invention combines the hot pressing and flooding in the closing level II.

13 FIG. 12 shows an embodiment of the method employing the physic-fast foaming of PA / or PP at a density of about 100 g / m3 in place of the gas injection technique and PUR injection by the MuCell method, wherein the cavity filling and the stiffening of the stiffening ribs. FIG 7 take place in the closing level I. The MuCell process is a physical process for foaming thermoplastics. As propellant nitrogen or carbon dioxide are used.

Optionally, in addition, as described above, as a "half-shell" in addition PUR or gel coat can be used by flooding for Class A preparation and protection against pressure and sealing. Optionally, a layer can be sprayed onto the tool surface as the outermost cover layer on the opened tool.

In physical foaming ( 13 ) is used to form the outer shell 4a provided organic sheet blank 4 preformed in the closing side 21a the closing level I by means of a gripper 30 inserted and there with a vacuum suction 33 fixed, as well as the inner shell 4b , or to the formation of the inner shell 4b provided organic sheet blank 4 preformed in the tool cube 20 , After closing the tool 20 the PA injection takes place through the foam nozzle 24 ,

In one variant, the PA plastic ribs / PP plastic ribs 11 doing so in solid injection molding to the inner shell 4b molded, while the foam core 5 produced in foam injection molding ( 14a ) and so a Einstofflösung ("adhesion") is given. It is almost foamed from the inside out.

14b shows the process step of spraying the PA foam through the organic sheet 4 through, with the plastic rib 11 made entirely of PA foam. This not only saves weight (material efficiency), but also allows the component to withstand lower warpage. Further advantages are a higher impression quality and an improved crystallization, which contributes to a higher rigidity of the component. Relative to the manufacturing process, there are advantages in terms of shorter cycle times, lower clamping forces and a reduction in viscosity, since the blowing agent takes over the Nachdruckfunktion. Furthermore, a parallel pressure adjustment via the cascade control can be carried out, which ensures a sequential filling of the component and a defined, slow, pressure-reduced injection ("drive profile") allows.

Advantageously, the method according to the invention makes it possible to reduce the assembly, functional and manufacturing costs, since the component is a self-supporting module 1 can be made in a tool. There are low manufacturing tolerances by in-mold assembly and connecting the processing steps through the tool cube / insert 20 achievable. The sandwich construction with a light core 5 offers a weight reduction and with the planking as a structural component can increase the crash performance by the energy far outside flat on the support 2 is distributed.

The modular design of the housing component allows a low handling effort, the component itself offers a comfort gain due to low vibration sensitivity / NVH or increase in rigidity and a simple repair concept. The high design freedom is associated with a Class A surface and functional elements such as strain waves can be structurally integrated into the inner half shell because of the design independence. The course of the indentation resistance and the dent resistance can be specifically defined by the choice of material, layer structure, functional elements via the indentation path. Function integration represents a further potential for cost savings. Furthermore, short cycle times and higher quantities can be realized. The planking 1 or the outdoor module 1 is not yielding and thus high quality, and has a very good thermal insulation and a very good acoustic behavior.

Claims (10)

Method for producing an outer module (1) with an outer paneling (1 ') for a modular housing component, wherein the outer module (1) has a multilayer construction of a thermoplastic inner lining of the FRP (4b) and a thermoplastic FRP outer shell (4a) with one thereon arranged outer skin (6), which forms the outer skin (1 '), wherein the thermoplastic FRP inner shell (4b) on the side facing away from the outer shell (4a) side stiffening elements (7,10,11) comprising the steps : A) providing the thermoplastic FRP inner shell (4b) by cutting and shaping a thermoplastic continuous fiber semi-finished product in accordance with an inner shell contour and back-molding with the reinforcing elements (7, 10, 11), B) cutting and preforming a thermoplastic continuous fiber semi-finished product according to an outer shell contour, C) inserting the thermoplastic FRP inner shell (4b) and the thermoplastic preformed semi-finished fiber preform preformed according to the outer shell contour into a tool (20) and closing the tool (20), D) applying pressure and forming to the preformed thermoplastic continuous fiber semi-finished product to the outer FRP shell (4a) and joining the FRP inner shell (4b) and the FRP outer shell (4a) and obtaining a raw outer module (1 "), E) Producing the outer skin (6) on the FVK outer shell (4a) and obtaining the outer module (1). Method according to Claim 1 comprising the step D1) of producing a structural core (5) in a cavity formed in the closed mold (20) between the thermoplastic FRP inner shell (4b) and the FRP outer shell (4a), wherein the production of the structural core (5) comprises Introducing a foam material and in particular by injecting a foamable polymer material into the cavity by means of a gate system (24) of the tool (20), wherein the foamable material is a polyurethane or a physically foamed polyamide, polypropylene. Method according to Claim 2 wherein the pressurization in step D) is done by injecting a gas into the cavity or by step D1). Method according to at least one of Claims 1 to 3 wherein the production of the outer skin (6) on the FVK outer shell (4a) in step E) by hot pressing the Rohaußenmoduls (1 ") and / or flooding the FVK outer shell (4a) of the Rohaußenmoduls (1") with a polyurethane or a gelcoat takes place, wherein the flooding takes place in particular after a partial opening of the tool (20) by means of a gating system (24). Method according to Claim 4 , wherein in step E) in the production of the outer skin (6) a release agent is used, which is an internal release agent of the polyurethane or the gelcoat, or which is in the form of a permanent coating on a tool surface or applied before step E) on the tool surface becomes. Method according to at least one of Claims 1 to 5 comprising the step B0) forming a thermoplastic matrix thickening (6 ') on one side of the thermoplastic continuous fiber semi-finished product used to form the outer shell (4a), the preforming according to the outer shell contour with the matrix thickening (6') pointing outwards as the base for the outer skin (6) takes place. Method according to at least one of Claims 1 to 6 wherein the tool (20) comprises a tool cube / insert (20) with two closing planes (I, II), wherein steps C) and D) in a first closing plane (I) of the tool (20) and step E) in a second closing plane (II) of the tool (20) takes place and wherein in particular the tool cube (20) in each closing plane (I, II) has a tool punch for receiving the inner shell (4b) and the two closing sides (21a, 21b) of the two closing levels ( I, II) of the tool (20) have a die for forming the outer shell (4a). Method according to at least one of Claims 1 to 7 wherein the molding of the thermoplastic continuous fiber semi-finished according to an inner shell contour and injection molding with the stiffening elements (7,10,11) from step A) in the tool (20), in particular with step D1) by the Angusssystem (24) of the tool (20) takes place and Cutting and preforming the thermoplastic continuous fiber semi-finished according to the inner shell contour and insertion into the tool (20). Method according to at least one of Claims 1 to 8th comprising the steps of - back-molding the FRP inner shell (4b) with a thermoplastic material corresponding to a matrix plastic of the thermoplastic continuous fiber semi-finished product for producing the stiffening elements (7, 10, 11), and / or - foaming spaces between the stiffening elements (7, 10,11) with a foamable material, in particular a polyurethane or a physically foamed polyamide / polypropylene. Method according to at least one of Claims 1 to 9 comprising at least one of the steps: - crimping, welding or encapsulation of the outer and the inner shell (4a, 4b) at an edge region of the outer module (1) for joining the FVK inner shell (4b) and the FVK outer shell (4a) in Step D), and / or - for preforming the continuous thermoplastic fiber blank blanks, heating in particular by means of infrared radiation and holding the continuous fiber blank blanks by shape-adapted grippers (30), wherein the holding of the continuous fiber blank blanks takes place on the grippers (30), in particular by generating a negative pressure, and / or Tempering at least one tool surface for hot pressing and / or forming the outer shell (4a) inductively, variothermally or with nitrogen, and / or - fixing the inner shell (4b) and corresponding to the outer shell contour preformed continuous fiber blank blanks when inserted into the tool (20) by generating a negative pressure.

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