DE102014011033A1 - Fiber composite plastic component - Google Patents
Fiber composite plastic component Download PDFInfo
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- DE102014011033A1 DE102014011033A1 DE102014011033.8A DE102014011033A DE102014011033A1 DE 102014011033 A1 DE102014011033 A1 DE 102014011033A1 DE 102014011033 A DE102014011033 A DE 102014011033A DE 102014011033 A1 DE102014011033 A1 DE 102014011033A1
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- composite plastic
- plastic component
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- fiber composite
- core
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- 239000000835 fiber Substances 0.000 title claims abstract description 72
- 239000004033 plastic Substances 0.000 title claims abstract description 36
- 239000002131 composite material Substances 0.000 title claims abstract description 32
- 239000011162 core material Substances 0.000 claims abstract description 45
- 239000011159 matrix material Substances 0.000 claims abstract description 19
- 210000002414 leg Anatomy 0.000 claims description 15
- 239000000463 material Substances 0.000 claims description 12
- 238000009745 resin transfer moulding Methods 0.000 claims description 12
- 238000000034 method Methods 0.000 claims description 10
- 239000007788 liquid Substances 0.000 claims description 9
- 238000004519 manufacturing process Methods 0.000 claims description 8
- 238000002347 injection Methods 0.000 claims description 3
- 239000007924 injection Substances 0.000 claims description 3
- 210000000689 upper leg Anatomy 0.000 claims description 2
- 230000015572 biosynthetic process Effects 0.000 claims 1
- 239000006260 foam Substances 0.000 description 14
- 239000011230 binding agent Substances 0.000 description 5
- 238000006073 displacement reaction Methods 0.000 description 4
- 239000004834 spray adhesive Substances 0.000 description 3
- 238000010276 construction Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- BUHVIAUBTBOHAG-FOYDDCNASA-N (2r,3r,4s,5r)-2-[6-[[2-(3,5-dimethoxyphenyl)-2-(2-methylphenyl)ethyl]amino]purin-9-yl]-5-(hydroxymethyl)oxolane-3,4-diol Chemical compound COC1=CC(OC)=CC(C(CNC=2C=3N=CN(C=3N=CN=2)[C@H]2[C@@H]([C@H](O)[C@@H](CO)O2)O)C=2C(=CC=CC=2)C)=C1 BUHVIAUBTBOHAG-FOYDDCNASA-N 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- 238000004873 anchoring Methods 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000006261 foam material Substances 0.000 description 1
- 238000002955 isolation Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 239000012815 thermoplastic material Substances 0.000 description 1
Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
- B29C70/543—Fixing the position or configuration of fibrous reinforcements before or during moulding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/82—Forcing wires, nets or the like partially or completely into the surface of an article, e.g. by cutting and pressing
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- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
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Abstract
Die Erfindung betrifft ein Faserverbund-Kunststoffbauteil mit einem Kernelement (1) und zumindest eine das Kernelement (1) überdeckende Deckschicht (3), die aus zumindest einer, mit einem Matrixmaterial (7) durchtränkten Faserhalbzeuglage (5) aufgebaut ist. Erfindungsgemäß weist das Faserverbund-Kunststoffbauteil zumindest ein Fügeelement (9) auf, das die Faserhalbzeuglage (5) der Deckschicht (3) durchstößt und in das Kernmaterial des Kernelements (1) eingetrieben ist.The invention relates to a fiber composite plastic component having a core element (1) and at least one cover layer (3) covering the core element (1), which is constructed from at least one semi-finished fiber layer (5) impregnated with a matrix material (7). According to the invention, the fiber composite plastic component has at least one joining element (9) which pierces the semifinished fiber layer (5) of the covering layer (3) and is driven into the core material of the core element (1).
Description
Die Erfindung betrifft ein Faserverbund-Kunststoffbauteil nach dem Oberbegriff des Patentanspruches 1, einen Vorformling zum Herstellen eines solchen Faserverbund-Kunststoffbauteils nach dem Oberbegriff des Patentanspruches 8, sowie ein Verfahren zur Herstellung des Faserverbund-Kunststoffbauteils nach dem Patentanspruch 9.The invention relates to a fiber composite plastic component according to the preamble of
Im Automobilbau können komplette Fahrzeugstrukturen, etwa ein Rückwandquerträger oder ein Schweller, im Leichtbau, zum Beispiel als sogenannte Sandwichbauteile mit Schaumkern hergestellt sein. Ein solches Sandwichbauteil kann aus einem inneren Schaubkern sowie, den Schaumkern überdeckende Deckschichten ausgebildet sein. Jede dieser Deckschichten kann aus zumindest einer, mit einem Matrixmaterial durchtränkten Faserhalbzeuglage aufgebaut sein. Der Schaumkern innerhalb des Faserverbund-Kunststoffbauteils wirkt profilaussteifend, wodurch zum Beispiel in einem Crashfall ein frühzeitiges Einknicken des jeweiligen Kunststoffbauteils vermieden werden kann.In automotive construction, complete vehicle structures, such as a rear wall cross member or a sill, can be produced in lightweight construction, for example as so-called sandwich components with a foam core. Such a sandwich component may be formed of an inner Schaubkern as well as the foam core covering cover layers. Each of these cover layers may be composed of at least one semi-finished fiber layer impregnated with a matrix material. The foam core within the fiber composite plastic component acts profile-stiffening, whereby, for example, in a crash, an early buckling of the respective plastic component can be avoided.
Bei der Herstellung eines solchen Sandwichbauteils wird in einem ersten Prozessschritt zunächst zumindest eine Faserhalbzeuglage (alternativ auch eine Vielzahl solcher Lagen) lose auf den Schaumkern aufgelegt. Die Faserhalbzeuglage kann als sogenannte Sub-Preform im Hinblick auf die zu fertigende Bauteilgeometrie als eine sogenannte Sub-Preform endkonturnah vorgeformt sein. Um eine Lagesicherung der noch trockenen Faserhalbzeuglage (das heißt noch nicht mit Matrixmaterial durchtränkt) zu gewährleisten, wird die Faserhalbzeuglage mittels eines Sprühklebers auf den Schaumkern aufgeklebt. Alternativ kann ein sogenannter Binder auf den Schaumkern aufgebracht werden und die Textillage mittels des Binders auf dem Schaumkern befestigt werden.In the production of such a sandwich component, at least one semi-finished fiber layer (alternatively also a multiplicity of such layers) is initially placed loosely on the foam core in a first process step. The semi-finished fiber layer may be preformed as a so-called sub-preform with respect to the component geometry to be produced as a so-called sub-preform near net shape. In order to ensure a secure position of the still-dry semi-finished fiber layer (that is, not impregnated with matrix material), the semifinished fiber layer is glued to the foam core by means of a spray adhesive. Alternatively, a so-called binder can be applied to the foam core and the textile layer can be attached to the foam core by means of the binder.
Durch Applizieren des Sprühklebers oder des Binders werden zusätzliche Stoffe in die Anhaftungsgrenze gebracht. Dadurch wird die Handhabung der Faserhalbzeuglagen deutlich erschwert. Sobald die Faserhalbzeuglage auf dem Schaumkern angelegt ist, wird diese unlösbar sofort fixiert. In der Praxis äußerst sich dies in teilweise verschobenen und/oder ausgerissenen Fasern. Zudem muss jede aufgebrachte Faserhalbzeuglage einzeln verklebt und jeder Teilbereich seitlich nacheinander eingesprüht werden, was fertigungstechnisch aufwendig ist. Ein chemisch arbeitender Binder müsste zudem vor dem Applizieren stark erhitzt werden, was einen zusätzlichen Energie- und Zeitaufwand bewirkt sowie deren Handhabung stark erschwert.By applying the spray adhesive or the binder, additional substances are brought into the adhesion limit. As a result, the handling of the semi-finished fiber layers is significantly more difficult. As soon as the semifinished fiber layer has been applied to the foam core, it is fixed inseparably immediately. In practice, this manifests itself in partially shifted and / or ruptured fibers. In addition, each applied semi-finished fiber layer must be bonded individually and each sub-area sprayed laterally one after the other, which is technically complex. In addition, a chemically working binder would have to be heated considerably before being applied, which would result in additional expenditure of energy and time as well as greatly complicating their handling.
Aus der
Die Aufgabe der Erfindung besteht darin, ein Faserverbund-Kunststoffbauteil bereitzustellen, bei dem in fertigungstechnisch einfacher Weise eine einwandfreie Festlegung der noch trockenen Faserhalbzeuglage auf dem Kernelement ermöglicht wird, ohne die Faserstrukturen zu beschädigen.The object of the invention is to provide a fiber composite plastic component, in which a simple definition of the still-dry semi-finished fiber layer on the core element is made possible in manufacturing technology, without damaging the fiber structures.
Die Aufgabe ist durch die Merkmale des Patentanspruches 1, des Patentanspruches 8 oder des Patentanspruches 9 gelöst. Bevorzugte Weiterbildungen der Erfindung sind in den Unteransprüchen offenbart.The object is solved by the features of
Die Erfindung beruht auf der Problematik, dass eine stoffschlüssige Anbindung der Faserhalbzeuglage auf dem Kernelement mittels eines chemischen Binders und/oder eines Sprühklebers bei der weiteren Handhabung bis zur Fertigstellung des Faserverbund-Kunststoffbauteils zu einer Beschädigung und/oder Verlagerung der Faserstrukturen führen kann. Die Beschädigung/Verlagerung der Faserstrukturen entsteht hauptsächlich durch das komplexe Fügen mittels Stoffschluss. Vor diesem Hintergrund weist das erfindungsgemäße Faserverbund-Kunststoffteil gemäß dem kennzeichnenden Teil des Patentanspruches 1 zumindest ein Fügeelement auf, dass die Faserhalbzeuglage der Deckschicht nicht mehr chemisch am Kernelement anbindet, sondern vielmehr mechanisch, das heißt die Faserhalbzeuglage der Deckschicht durchstößt und in das Kernmaterial des Kernelementes eingetrieben ist, und zwar unter Verdrängung des Kernmaterials des Kernelementes, wodurch das Fügematerial in kraftschlüssige Verbindung mit dem Kernmaterial kommt. Besonders bevorzugt kann bei einer solchen Anbindung der komplette Lagenaufbau, bestehend zum Beispiel aus 16 bis 19 Faserhalbzeuglagen in einem einzigen Fügeschritt lokal gefügt werden. Die komplette Fixierung der zumindest einen Faserhalbzeuglage auf dem Kernelement kann durch eine entsprechend gewählte Anzahl von Fügeelementen bewerkstelligt werden.The invention is based on the problem that a cohesive connection of the semifinished fiber layer on the core element by means of a chemical binder and / or a spray adhesive during further handling until completion of the fiber composite plastic component can lead to damage and / or displacement of the fiber structures. The damage / displacement of the fiber structures is mainly due to the complex joining by means of material connection. Against this background, the fiber composite plastic part according to the invention according to the characterizing part of
Bevorzugt kann das Material des Fügeelementes ein Kunststoff sein, wodurch eine Korrosion unterbunden wird, die sich gegebenenfalls bei einer Materialpaarung aus Metall und Kohlenstofffasern ergeben würde. Das Kunststoffmaterial des Fügeelementes ist dabei so ausgelegt, dass es materialverschieden zum Matrixmaterial ist. In diesem Fall ist gewährleistet, dass im darauffolgenden RTM-Prozess beim Injizieren der flüssigen Ausgangskomponente des Matrixmaterials das Fügeelement-Material nicht in der flüssigen Matrixmaterial-Komponente auflöst, sondern vielmehr unbeeinflusst von dieser verbleibt.Preferably, the material of the joining element may be a plastic, whereby a corrosion is prevented, which would possibly result in a material combination of metal and carbon fibers. The plastic material of the Fügeelementes is designed so that it is different material to the matrix material. In this case, it is ensured that in the subsequent RTM process when injecting the liquid starting component of the matrix material, the joining element material does not dissolve in the liquid matrix material component, but rather remains unaffected by it.
Bei einem fertiggestellten Faserverbund-Kunststoffbauteil kann eine Oberseite des Elementkopfes des Fügeelementes vom Matrixmaterial des Faserverbund-Kunststoffbauteils weitgehend freigelegt sein, das heißt nach außen sichtbar sein. Insbesondere die Oberseite des Elementkopfes kann dabei flächenbündig in die angrenzende Bauteil-Oberfläche übergehen.In a finished fiber composite plastic component, an upper side of the element head of the joining element can be largely uncovered by the matrix material of the fiber composite plastic component, that is, be visible to the outside. In particular, the top of the element head can go flush in the adjacent component surface.
In einer besonders bevorzugten technischen Realisierung kann das Fügeelement nicht bolzenförmig, sondern vielmehr im Profil klammerartig ausgebildet sein. Entsprechend kann der Elementkopf als ein Steg ausgebildet sein, dessen Enden unter Bildung eines U-Profils mittels Klammer-Schenkeln abragen.In a particularly preferred technical realization, the joining element can not be bolt-shaped, but rather be designed in the form of a clip in profile. Accordingly, the element head may be formed as a web whose ends project to form a U-profile by means of clip legs.
Es ist von großer Bedeutung, dass beim Eintreiben des Fügeelementes die Faserstruktur der Faserhalbzeuglage weitgehend unbeschädigt verbleibt. Vor diesem Hintergrund kann das Fügeelement eine geringe Querschnittsfläche von zum Beispiel etwa 1 mm2 aufweisen. Entsprechend kann das Fügeelement im Querschnitt drahtförmig ausgebildet sein, und zwar mit einem rechtwinkligen oder kreisförmigen Querschnitt.It is of great importance that the fiber structure of the semi-finished fiber layer remains largely undamaged when driving the joining element. Against this background, the joining element may have a small cross-sectional area of, for example, about 1 mm 2 . Accordingly, the joining element may be formed in wire-shaped in cross section, with a rectangular or circular cross-section.
Die Klammer-Schenkeln des U-profilförmigen Fügeelementes kann zumindest im Fertigungszustand, das heißt im noch unverformten Zustand, im Wesentlichen rechtwinklig vom kopfseitigen Steg des Fügeelementes abragen.The bracket legs of the U-profile-shaped joining element can protrude substantially at right angles from the head-side web of the joining element, at least in the manufacturing state, that is to say in the still undeformed state.
In diesem Fall können die beiden Klammer-Schenkeln beim Eintreiben in Flucht mit der Eintriebsrichtung (E) am Vorformling angesetzt und eingetrieben werden.In this case, the two clip legs can be attached to the preform and driven in when driving in alignment with the input direction (E).
Eine ausreichend große Verbindungsfestigkeit zwischen dem Fügeelement und der Faserhalbzeuglage sowie dem Kernelement ist für die weiteren Prozessschritte von großer Bedeutung. Vor diesem Hintergrund können die beiden Klammer-Schenkeln des Fügeelementes außenseitig jeweils Führungsflanken aufweisen. Diese können unter Querschnittsverjüngung keilförmig in Richtung auf die freien Stirnseiten der Klammer-Schenkeln zulaufen. Beim oben dargelegten Eintreiben übt das verdrängte Kernmaterial eine Querkraftkomponente auf, die Führungsflanken der Klammer-Schenkel aus. Dadurch werden die Klammer-Schenkel unter Bildung von Hinterschnitten aufeinander zu verlagert.A sufficiently large bond strength between the joining element and the semi-finished fiber layer and the core element is of great importance for the further process steps. Against this background, the two clip legs of the joining element can each have guide flanks on the outside. These can taper in a wedge shape under cross-sectional taper in the direction of the free end faces of the clip legs. In the driving described above, the displaced core material exerts a transverse force component, the guiding flanks of the clip legs. As a result, the clip legs are shifted towards each other to form undercuts.
Nach erfolgtem Eintreiben des zumindest einen Fügeelementes ist die zumindest eine Faserhalbzeuglage unter Bildung eines Vorformlings ausreichend fest am Kernelement befestigt. Anschließend kann in einem Injektionsvorgang die noch trockene Faserhalbzeuglage mit einer flüssigen Ausgangskomponente des Matrixmaterials durchtränkt werden. Bevorzugt wird die flüssige Ausgangskomponente des Matrixmaterials in einem RTM-Prozess injiziert, bei dem der Vorformling in eine Kavität des eines RTM-Werkzeugs eingelegt wird. Mittels der nach außen freigelegten Elementköpfe der Fügeelemente kann eine lagerichtige Positionierung des Vorformlings im RTM-Werkzeug erfolgen, bei der die Elementköpfe in Anlage mit der, die Kavität definierenden Formflächen des RTM-Werkzeuges gebracht werden. Anschließend kann bei geschlossener Werkzeug-Kavität die noch flüssige Ausgangskomponente des Materixmaterials unter Druck und Wärme in die Faserhalbzeuglage injiziert werden.After the driving in of the at least one joining element, the at least one semi-finished fiber layer is fixed sufficiently firmly to the core element to form a preform. Subsequently, in an injection process, the still-dry semifinished fiber layer can be impregnated with a liquid starting component of the matrix material. Preferably, the liquid starting component of the matrix material is injected in an RTM process, in which the preform is inserted into a cavity of the RTM tool. By means of the element heads of the joining elements exposed to the outside, it is possible to position the preform in the RTM tool in the correct position, in which the element heads are brought into contact with the forming surfaces of the RTM tool defining the cavity. Subsequently, with the mold cavity closed, the still liquid starting component of the material of the material can be injected under pressure and heat into the semi-finished fiber layer.
Es zeigen:Show it:
In der
Wie aus den Figuren weiter hervorgeht, ist das Fügeelement
Gemäß der perspektivischen Darstellung aus der
Bei einem Verfahren zur Herstellung des in der
Anschließend wird die Werkzeugkavität
Nach erfolgter Aushärtung des Matrixmaterials
In den
ZITATE ENTHALTEN IN DER BESCHREIBUNG QUOTES INCLUDE IN THE DESCRIPTION
Diese Liste der vom Anmelder aufgeführten Dokumente wurde automatisiert erzeugt und ist ausschließlich zur besseren Information des Lesers aufgenommen. Die Liste ist nicht Bestandteil der deutschen Patent- bzw. Gebrauchsmusteranmeldung. Das DPMA übernimmt keinerlei Haftung für etwaige Fehler oder Auslassungen.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.
Zitierte PatentliteraturCited patent literature
- WO 2014/075198 A1 [0005] WO 2014/075198 A1 [0005]
Claims (10)
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DE102014011033.8A DE102014011033B4 (en) | 2014-07-25 | 2014-07-25 | Process for producing a fiber composite plastic component |
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DE102014011033.8A DE102014011033B4 (en) | 2014-07-25 | 2014-07-25 | Process for producing a fiber composite plastic component |
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DE102014011033A1 true DE102014011033A1 (en) | 2016-01-28 |
DE102014011033B4 DE102014011033B4 (en) | 2019-08-29 |
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Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE10342183A1 (en) * | 2003-09-08 | 2005-05-25 | Röhm GmbH & Co. KG | Force application region in sandwich structures e.g. for aircraft or vehicles, comprises reinforcement that connects the outer skins |
DE102008043314A1 (en) * | 2008-10-30 | 2010-05-12 | Airbus Deutschland Gmbh | Method and device for reinforcing a substrate or a textile of a core structure of a component, for example an aircraft or spacecraft, component, for example an aircraft or spacecraft, and aircraft or spacecraft |
DE102009010292A1 (en) * | 2009-02-24 | 2010-08-26 | Bayerische Motoren Werke Aktiengesellschaft | Process for producing a fiber-reinforced plastic component |
DE102009026458A1 (en) * | 2009-05-25 | 2010-12-09 | Airbus Operations Gmbh | Structural component and manufacturing method for a structural component |
DE102011120636A1 (en) * | 2011-12-09 | 2013-06-13 | Airbus Operations Gmbh | Fiber composite component assembly having at least two plate-shaped fiber composite components and method for producing the same |
WO2014075198A1 (en) | 2012-11-13 | 2014-05-22 | Woodwelding Ag | Manufacturing plastic composite articles |
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2014
- 2014-07-25 DE DE102014011033.8A patent/DE102014011033B4/en not_active Expired - Fee Related
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE10342183A1 (en) * | 2003-09-08 | 2005-05-25 | Röhm GmbH & Co. KG | Force application region in sandwich structures e.g. for aircraft or vehicles, comprises reinforcement that connects the outer skins |
DE102008043314A1 (en) * | 2008-10-30 | 2010-05-12 | Airbus Deutschland Gmbh | Method and device for reinforcing a substrate or a textile of a core structure of a component, for example an aircraft or spacecraft, component, for example an aircraft or spacecraft, and aircraft or spacecraft |
DE102009010292A1 (en) * | 2009-02-24 | 2010-08-26 | Bayerische Motoren Werke Aktiengesellschaft | Process for producing a fiber-reinforced plastic component |
DE102009026458A1 (en) * | 2009-05-25 | 2010-12-09 | Airbus Operations Gmbh | Structural component and manufacturing method for a structural component |
DE102011120636A1 (en) * | 2011-12-09 | 2013-06-13 | Airbus Operations Gmbh | Fiber composite component assembly having at least two plate-shaped fiber composite components and method for producing the same |
WO2014075198A1 (en) | 2012-11-13 | 2014-05-22 | Woodwelding Ag | Manufacturing plastic composite articles |
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