DE102014115608B4 - Composite decorative element, manufacturing method for the same and method for producing the same - Google Patents

Abstract

A composite decorative member manufacturing method comprising: a first mold half (10) provided with a filling groove (11) in which a positioning portion (12) is formed, wherein the positioning portion (12) is formed as a pin and the filling groove (11 ), the positioning portion (12) encloses, and wherein the positioning portion (12) with a contact part (121) and a male part (122) is provided, and wherein the outer diameter of the abutment part (121) is greater than that of the male part (122), and wherein a plurality of input holes (13) communicating with the filling groove (11) are located in the first mold half (10), and wherein the first mold half (10) provides positioning of a connecting accessory (A), and wherein the connecting accessory (A) comprises a Internal threaded hole running connecting portion (A1) which is mounted on the plug part (122), and wherein the plug part (122) and the connecting portion (A1) such a tongue and groove Verbin Forming that the connecting portion (A1) in the region of the male part (122) is arranged hidden, and wherein after attaching the connecting portion (A1) of the connecting accessory (A) on the male part (122) the connection accessory (A) on the system part (121 ) is present; and a second mold half (20) having a base material accommodating space (21) and a plurality of input apertures (22) passing through the second mold half (20) and communicating with the base material accommodating space (21), wherein in the base material accommodating space (FIG. 21) of the second mold half (20) a plurality of laminated composite layers (B) are housed, and wherein the provided with the base material receiving space (21) side of the second mold half (20) opposite to the filling groove (11) side of the first mold half ( 10) is arranged so that the first mold half (10) in alignment of the filling groove (11) on the base material receiving space (21) with the second mold half (20) is connectable.

Description

The invention relates to a composite decorative element, a production mold for the same and a process for producing the same, in particular a composite decorative element according to claim 7, a production mold for the same according to claim 1 and a process for producing the same according to claim 3.

Composite materials, such. As carbon fiber composites have outstanding features of light weight, high strength and high corrosion resistance and were thus widely used in various fields. The carbon fiber composites are typically laminated in a multi-layered manual manner to a heterogeneous accessory as an ornament or reinforcement. The manual lamination processes, however, require a fairly large amount of time. The combination of the carbon fiber composites with the heterogeneous accessory is mostly done by adhesives, which, however, are susceptible to degradation and functional failure. As the carbon fiber composites deteriorate and function fail, the carbon fiber composites can be completely detached from the heterogeneous accessory, resulting in functional failure of the carbon fiber composites. This is therefore in need of improvement.

From the document DE 689 02 334 T2 A method of manufacturing automobile body panels, especially rear spoilers, is known, which method provides that a rear spoiler is fabricated with composite based reinforcement by reaction injection molding techniques, wherein the composite based reinforcement forms the mechanically stressed core of the spoiler and for fabrication in an injection mold is formed such that by reaction injection molding techniques, the reinforcement can be coated with an outer layer of constant polyurethane.

From the document DE 101 60 185 A1 a method is known for producing a fastening structure for an airbag module and an interior trim support, this method providing that a loadable frame of the structure is manufactured with insert elements by arranging the metallic insert elements in cavities of an injection mold designed in such a way that by means of injection molding techniques the frame after which the frame including insert members is provided with an interior trim support by placing the frame in another injection mold such that the interior trim support can be formed around the frame by injection molding techniques, and for the injection molding process steps PU materials are used as material.

From the document DE 10 2008 049 393 A1 For example, there is known a method of making an injection molded article having a fastener insert embedded therein. The method provides that the fastening insert is fixed in a cavity of an injection mold designed for this purpose such that a liquid hardenable filler can be filled into the injection mold by means of injection molding techniques, enclosing the fastening insert and forming the shape of the injection molded part.

The invention has for its object to provide a composite decorative element, a manufacturing mold for the same and a method for producing the same, which avoids the disadvantages mentioned above by simple measures.

This object is achieved by a composite decorative element having the features specified in claim 7, a manufacturing mold for the same, which has the features specified in claim 1, and a method for producing the same, which has the features specified in claim 3. Further advantageous developments of the invention will become apparent from the dependent claims.

According to the invention, there is provided a composite ornamental forming mold comprising:
a first mold half provided with a filling groove in which a positioning portion is formed, wherein the positioning portion is formed as a pin and the filling groove surrounds the positioning portion, and wherein the positioning portion is provided with a abutment portion and a male portion, and wherein the outer diameter of Anlageteils is greater than that of the male part, and wherein a plurality of communicating with the Füllnut input openings are in the first mold half, and wherein the first mold half provides for the positioning of a connecting accessory, and wherein the connecting accessory has a female threaded hole designed as a connecting portion which on the male part is plugged, and wherein the male part and the connecting portion produce a tongue and groove connection, that the connecting portion is arranged hidden in the region of the male part, and wherein after attaching the connecting portion of the Verbindungszube Listen to the plug-in part the connection accessories abuts the system part; and
a second mold half having a base material accommodating space and a plurality of through the second mold half communicating with the base material accommodating space Having input openings therein, wherein a plurality of laminated composite layers are accommodated in the base material accommodating space of the second mold half, and wherein the side of the second mold half provided with the base material accommodating space is disposed opposite to the side of the first mold half provided with the filling groove such that the first mold half is in alignment the filling groove is connectable to the base material receiving space with the second mold half.

According to the invention there is provided a method of manufacturing a composite decorative element comprising the steps of:

step I Positioning the connection accessory on the positioning portion of the first mold half, wherein the connection accessory has a connection portion and the first mold half has a Füllnut, and wherein inside the Füllnut a positioning is formed, which is provided with a contact part and a male part, and wherein the connecting portion to Part is hidden in the region of the male part of the positioning and arranged on the bottom side abuts the system part;

step II : Positioning laminated composite layers in a base material receiving space of the second mold half;

step III By bonding the first mold half to the second mold half such that the connecting accessory abuts against the composite layers after bonding;

step IV Injecting plastic compound, wherein a plurality of input holes communicating with the filling groove are in the first mold half, and wherein the second mold half has a plurality of input holes communicating with the base material accommodating space, and the plastic mass is filled through the input holes, the plastic mass one Comprise bonding compound and a plurality of fibers, and wherein the different lengths of fibers and running in different directions in the bonding compound are mixed, and wherein after filling the plastic mass, the plastic mass passes into the filling groove of the first mold half and seep into the composite layers, such that the plastic mass is located between the first and the second mold half;

step V : Curing of the plastic compound by increasing the temperature after the step IV wherein the fibers contained in the plastic mass have seeped into the composite layers after curing, resulting in a decorative composite panel, wherein the plastic mass in the Füllnut cures to a connecting portion which encloses the connection accessories, the plastic compound connecting the connecting portion and the composite plate ; and

step VI : Mold removal of a composite trim element from the first and second mold halves after the step V ,

According to the invention, there is provided a composite decorative element comprising:
a decorating composite panel consisting of a plurality of composite layers joined by the bonding compound and the fibers, the fibers being of different lengths and extending in different directions;
a connection accessory which is attached to one side of the decorating composite plate and provided with a connecting portion, wherein the connecting accessory is a nut and the connecting portion is a female threaded hole; and
a number of connection portions corresponding to the number of the connection accessories, which are attached to the outside of the connection accessory and connected to one side of the decorating composite panel.

Due to the manufacturing form, the composite decorative element can be produced quickly. By filling in plastic compound to bond composites, a reliable bond is ensured, increasing structural integrity after bonding. In addition, the composite trim member may be attached to an article by the connection accessory and known fasteners. Thus, the problem with the failure of adhesives does not occur. In addition, the adhesion is improved and extended life.

In the following the invention and its embodiments will be explained in more detail with reference to the drawing. In the drawing shows:

1 a section through a decomposed, inventive manufacturing mold for composite decorative elements;

2 a section through the inventive manufacturing mold for composite decorative elements;

3 a flow diagram of a method according to the invention for producing a composite decorative element with the provided for composite decorative elements manufacturing mold;

4 a section through the composite decorative element according to the invention, which is made with the provided for composite decorative elements manufacturing mold;

5 a perspective view of the composite decorative element according to the invention, which is made with the provided for composite decorative elements manufacturing mold;

6 a perspective view of the composite decorative element according to the invention, which is attached to a wheel rim;

7 a section through the composite decorative element according to the invention, which is attached to a wheel rim;

8th a schematic representation of the composite decorative element according to the invention, which is attached to a car door handle; and

9 a schematic representation of the composite decorative element according to the invention, which is attached to a bumper.

The invention relates to a method for producing composite decorative elements by means of a production mold, wherein the production mold is a first mold half 10 and a second mold half 20 having.

The first half of the mold 10 is with a filling groove 11 provided in which a positioning section 12 is trained. In the illustrated embodiment, the filling groove 11 designed as an annular groove. The filling groove 11 encloses the positioning section 12 , The filling groove 11 should not be limited in form. That is, this may be square or polygonal. The positioning section 12 is designed as a pin and with a plant part 121 and a plug-in part 122 Mistake. The outer diameter of the plant part 121 is larger than that of the male part 122 , In the first half of the mold 10 There are several with the filling groove 11 communicating input ports 13 , At an end surface of the first mold half 10 are several guide pins 14 educated. The first half of the mold 10 provides for the positioning of a connection accessory A. In the illustrated embodiment, the first mold half is used 10 the positioning of a connecting accessory A designed as a screw nut. The connecting accessory A has a connecting section A1 designed as an internally threaded hole, which contacts the male part 122 is plugged. The plug-in part 122 and the connecting portion A1 form a tongue and groove connection, such that the connecting portion A1 in the region of the male part 122 is tucked away. After attaching the connecting portion A1 of the connecting accessory A on the male part 122 is the connection accessory A on the system part 121 at.

The second half of the mold 20 has a base material storage room 21 and a plurality of through the second mold half 20 continuous, with the base material receiving space 21 communicating input ports 22 on. On a bottom surface of the second mold half 20 are several guide holes 23 educated. In the base material reception room 21 the second half of the mold 20 Several laminated composite layers B are accommodated. The composite layers B are carbon fiber layers. The one with the base material reception room 21 provided side of the second mold half 20 is opposite to the filling groove 11 provided side of the first mold half 10 arranged so that the first half of the mold 10 in alignment of the filling groove 11 on the base material reception room 21 with the second half of the mold 20 is connectable.

• I: Positionieren des Verbindungszubehörs A auf dem Positionierabschnitt 12 der ersten Formhälfte 10, derart, dass der Verbindungsabschnitt A1 des Verbindungszubehörs A zum Teil im Bereich des Steckteils 122 des Positionierabschnitts 12 versteckt angeordnet ist und bodenseitig am Anlageteil 121 anliegt;
• II: Positionieren der laminierten Verbundstoffschichten B im Grundmaterial-Aufnahmeraum 21 der zweiten Formhälfte 20;
• III: Verbinden der ersten Formhälfte 10 mit der zweiten Formhälfte 20, derart, dass die Führungszapfen 14 der ersten Formhälfte 10 in die Führungslöcher 23 der zweiten Formhälfte 20 eingreifen, wobei das Verbindungszubehör A nach dem Verbinden gegen die Verbundstoffschichten B anliegt;
• IV: Einfüllen von Kunststoffmasse C durch die Eingabeöffnungen 13, 22 in die erste und die zweite Formhälfte 10, 20, wobei die Kunststoffmasse C eine Verbindungsmasse C1 und mehrere Fasern C2 enthält. Bei der Verbindungsmasse C1 handelt es sich um Harz [wie z. B. Epoxidharz, Polyurethan oder Vinylesterharz]. Bei den Fasern handelt es sich um Kohlenstofffasern, Glasfasern, Mineralfasern wie z. B. Basaltfasern, Asbestfasern, usw. oder Chemiefasern. Die unterschiedlich langen und in unterschiedlichen Richtungen verlaufenden Fasern C2 sind in die Verbindungsmasse C1 gemischt. Beim Einfüllen der Kunststoffmasse C durch die Eingabeöffnungen 13, 22 in die erste und die zweite Formhälfte 10, 20 gelangt die durch die erste Formhälfte 10 gefüllte Kunststoffmasse C in die Füllnut 11 der ersten Formhälfte 10, während die durch die zweite Formhälfte 20 gefüllte Kunststoffmasse C ins Innere der in der zweiten Formhälfte 20 befindlichen Verbundstoffschichten B einsickert. Gleichzeitig befindet sich die Kunststoffmasse C zwischen der ersten und der zweiten Formhälfte 10, 20;
• V: Aushärten der in die erste, die zweite Formhälfte 10, 20 eingefüllten Kunststoffmasse C, wenn die erste und die zweite Formhälfte 10, 20 nach dem Schritt IV erwärmt werden, wobei die in der Kunststoffmasse C befindlichen Fasern C2 nach dem Aushärten in die Verbundstoffschichten B eingesickert sind, wodurch sich eine verzierende Verbundplatte 30 ergibt, wobei die in der Füllnut 11 befindliche Kunststoffmasse C zu einem Verbindungsabschnitt 40 aushärtet, der das Verbindungszubehör A umschließt, wobei die Kunststoffmasse C den Verbindungsabschnitt 40 und die Verbundplatte 30 verbindet; und
• VI: Entformen eines Verbundstoff-Zierelements von der ersten und der zweiten Formhälfte 10, 20 nach dem Aushärten der Kunststoffmasse C.

The method according to the invention for producing a composite ornamental element with the above-mentioned composite mold intended for composite decorative elements comprises the following steps:

• I : Position the connection accessory A on the positioning section 12 the first half of the mold 10 such that the connecting portion A1 of the connecting accessory A partly in the region of the male part 122 of the positioning section 12 is arranged hidden and bottom side of the plant part 121 bears;
• II Position the laminated composite layers B in the base material receiving space 21 the second half of the mold 20 ;
• III : Connecting the first half of the mold 10 with the second half of the mold 20 , such that the guide pins 14 the first half of the mold 10 in the guide holes 23 the second half of the mold 20 engage, wherein the connecting accessory A is applied after bonding against the composite layers B;
• IV : Filling of plastic compound C through the input openings 13 . 22 in the first and the second mold half 10 . 20 , wherein the plastic mass C contains a bonding compound C1 and a plurality of fibers C2. The bonding compound C1 is resin [such as. Epoxy resin, polyurethane or vinyl ester resin]. The fibers are carbon fibers, glass fibers, mineral fibers such. As basalt fibers, asbestos fibers, etc. or man-made fibers. The differently long and running in different directions fibers C2 are mixed in the bonding compound C1. When filling the plastic compound C through the input openings 13 . 22 in the first and the second mold half 10 . 20 passes through the first half of the mold 10 filled plastic compound C in the filling groove 11 the first half of the mold 10 while passing through the second half of the mold 20 filled plastic compound C inside the in the second mold half 20 leached composite layers B. At the same time is the Plastic compound C between the first and the second mold half 10 . 20 ;
• V : Curing the in the first, the second half of the mold 10 . 20 filled plastic mass C, when the first and the second mold half 10 . 20 after the step IV are heated, wherein the located in the plastic mass C fibers C2 are seeped into the composite layers B after curing, resulting in a decorative composite panel 30 which results in the filling groove 11 located plastic compound C to a connecting portion 40 hardens, which encloses the connection accessory A, wherein the plastic compound C, the connecting portion 40 and the composite panel 30 links; and
• VI : Mold removal of a composite decorative element from the first and second mold halves 10 . 20 after curing of the plastic mass C.

In fabricating a composite trim member having the composite form of composite molding, the connecting accessory A is in the first mold half 10 and the composite layers B in the second mold half 20 inserted, wherein the manufacturing process is completed after connecting the two mold halves, the filling and curing of plastic mass. By the arrangement of the filling groove 11 and the positioning section 12 the first half of the mold 10 For example, the connecting accessory A can be connected to the composite layers B after the filling and hardening of plastic compound. At the same time, the connection section results 40 , The manufacturing process is very simple. By thoroughly pouring plastic compound, the plastic mass C can completely seep into the composite layers B, the composite layers B being connected to the connection accessory A, and the connecting portion 40 results. Thus, a high production efficiency is achieved, whereby the adhesive strength of the manufactured construction is increased. At the same time, the quality of products is improved.

The composite trim element fabricated with the composite molding compound has a decorative composite panel 30 , a connection accessory A and a number of connection portions corresponding to the number of connection accessories A. 40 on.

The decorating composite panel 30 consists of a plurality of composite layers B, which are connected by the bonding compound C1 and the fibers C2. The bonding compound C1 is resin [such as. Epoxy resin, polyurethane or vinyl ester resin]. The fibers are carbon fibers, glass fibers, mineral fibers such. As basalt fibers, asbestos fibers, etc. or man-made fibers. The fibers C2 are of different lengths and extend in different directions.

The connection accessory A is on one side of the decorating composite panel 30 attached and provided with a connecting portion A1. In the illustrated embodiment, the connecting accessory A is a nut and the connecting portion A1 is a female threaded hole.

The connecting sections 40 the number of which corresponds to that of the connection accessories A are attached to the outside of the connection accessory A, with one side of the decorating composite panel 30 results. In the illustrated embodiment, the connecting portion 40 cylindrically shaped. This can also be square or polygonal. In 1 and 2 is a connection section 40 shown for description. The number and position of the decorating composite panel 30 arranged connecting sections 40 should not be limited. In the 4 to 6 are two on the decorating composite panel 30 arranged connecting sections 40 shown.

In 6 to 8th the application of the composite decorative element according to the invention is shown. At the connecting section 40 facing away, the other side of the decorative composite panel 30 Colors, patterns, labels, etc. may be appropriate. On an article D connected to the composite decorative element, there is an object for fitting the connection section 40 certain counterpart D1 provided. At the connection becomes the connection section 40 of the composite decorative element according to the invention passed through the counter portion D1, whereupon a fastener E in the connecting portion 40 is introduced to make the connection with the connection accessory A. In the illustrated embodiment, the connecting accessory A is designed as a nut and the fastening element E as a screw. Conversely, the connection accessory A can be designed as a screw and the fastening element E as a corresponding nut.

According to 6 and 7 the article D connected to the composite decorative element according to the invention is designed as a wheel rim, so that the composite decorative element according to the invention can serve as a decoration for the article D. According to 8th and 9 The object D can be designed as a car door handle and as a bumper. When assembling the composite decorative element according to the invention on the car door handle or on the bumper, the composite decorative element according to the invention in addition to the decoration by its material property, the reinforcement of the substructure. By connecting the connection accessory A with the fastening element E results in a higher adhesive strength than is achieved by adhesives. In addition, the functional failure due to deterioration of the material property is excluded, so that long-term use is ensured.

LIST OF REFERENCE NUMBERS

10

first half of the mold

11

filling slot

12

positioning

121

plant part

122

male member

13

input port

14

spigot

20

second mold half

21

Base material receiving space

22

input port

23

pilot holes

30

decorating composite panel

40

connecting portion

I

Position the connection accessory

II

Positioning laminated composite layers

III

Connecting two mold halves

IV

Filling in plastic compound

V

Harden

VI

unmolding

A

connection accessories

A1

connecting portion

B

Composite layer

C

Plastic compound

C1

connecting material

C2

fiber

D

object

D1

countersection

e

fastener

Claims (9)

Production mold for composite decorative elements, comprising: a first mold half ( 10 ) with a filling groove ( 11 ), in which a positioning section ( 12 ), wherein the positioning section ( 12 ) is designed as a pin and the filling groove ( 11 ) the positioning section ( 12 ), and wherein the positioning section ( 12 ) with a plant part ( 121 ) and a plug-in part ( 122 ), and wherein the outer diameter of the plant part ( 121 ) greater than that of the male part ( 122 ), and wherein several with the filling groove ( 11 ) communicating input ports ( 13 ) in the first half of the mold ( 10 ), and wherein the first mold half ( 10 ) provides for the positioning of a connecting accessory (A), and wherein the connecting accessory (A) has a connecting portion (A1) designed as a female threaded hole, which on the male part ( 122 ) is plugged, and wherein the male part ( 122 ) and the connecting portion (A1) form such a spring-groove connection, that the connecting portion (A1) in the region of the male part ( 122 Hidden, and wherein after attaching the connecting portion (A1) of the connecting accessory (A) on the male part ( 122 ) the connection accessory (A) on the system part ( 121 ) is present; and a second mold half ( 20 ) containing a basic material receiving space ( 21 ) and a plurality of through the second mold half ( 20 ) continuous, with the base material receiving space ( 21 ) communicating input ports ( 22 ), wherein in the base material receiving space ( 21 ) of the second mold half ( 20 ) a plurality of laminated composite layers (B) are housed, and wherein the with the base material receiving space ( 21 ) provided side of the second mold half ( 20 ) opposite to the filling groove ( 11 ) provided side of the first mold half ( 10 ) is arranged so that the first half of the mold ( 10 ) in alignment of the filling groove ( 11 ) on the base material receiving space ( 21 ) with the second mold half ( 20 ) is connectable. Production mold according to claim 1, characterized in that the filling groove ( 11 ) of the first half of the mold ( 10 ) is formed as an annular, square or polygonal groove. A method of making a composite trim member, comprising the steps of: step I : Positioning a connection accessory (A) on a positioning section ( 12 ) a first mold half ( 10 ), wherein the connection accessory (A) has a connecting portion (A1) and the first mold half ( 10 ) a filling groove ( 11 ), and wherein inside the filling groove ( 11 ) the positioning section ( 12 ) is formed, which with a plant part ( 121 ) and a plug-in part ( 122 ), and wherein the connecting portion (A1) partly in the region of the male part ( 122 ) of the positioning section ( 12 ) is hidden and bottom side of the plant part ( 121 ) is present; step II : Positioning laminated composite layers (B) in a base material receiving space ( 21 ) a second mold half ( 20 ); step III : Connecting the first half of the mold ( 10 ) with the second mold half ( 20 ) such that the connection accessory (A) abuts against the composite layers (B) after bonding; step IV : Filling of plastic compound (C), whereby several with the filling groove ( 11 ) communicating input ports ( 13 ) in the first half of the mold ( 10 ), and wherein the second mold half ( 20 ) a plurality of with the base material receiving space ( 21 ) communicating input ports ( 22 ), and wherein the plastic compound (C) through the input openings ( 13 . 22 ), wherein the plastic compound (C) is a bonding compound (C1) and a plurality of fibers (C2), and wherein the differently long and running in different directions fibers (C2) in the bonding compound (C1) are mixed, and wherein after the filling of the plastic mass (C), the plastic mass (C) in the filling groove ( 11 ) of the first half of the mold ( 10 ) and infiltrated into the composite layers (B), such that the plastic mass (C) between the first and the second mold half (C) ( 10 . 20 ) is located; step V : Curing of the plastic compound (C) by increasing the temperature after the step IV in which the fibers (C2) located in the plastic compound (C) have infiltrated into the composite layers (B) after curing, resulting in a decorative composite panel ( 30 ), wherein in the filling groove ( 11 ) located plastic mass (C) to a connecting portion ( 40 ), which encloses the connection accessory (A), wherein the plastic compound (C) the connecting portion ( 40 ) and the composite panel ( 30 ) connects; and step VI In: demolding the composite decorative element from the first and second mold halves ( 10 . 20 ) after the step V , Method according to claim 3, characterized in that the bonding compound (C1) is resin. A method according to claim 4, characterized in that it is in the resin for the bonding compound (C1) dealing with epoxy resin, polyurethane or Vinylesterharz. A method according to claim 3, characterized in that the fibers (C2) are carbon fibers, glass fibers, mineral fibers, basalt fibers, asbestos fibers or man-made fibers. Composite decorative element comprising: a decorative composite panel ( 30 ) consisting of a plurality of composite layers (B) connected by a bonding compound (C1) and by fibers (C2), the fibers (C2) being of different lengths and extending in different directions; a connection accessory (A) attached to one side of the decorative composite panel (A) 30 ) and provided with a connecting portion (A1), wherein the connecting accessory (A) is a nut and the connecting portion (A1) is a female threaded hole; and a number of connection sections corresponding to the number of connection accessories (A) ( 40 ) attached to the outside of the connection accessory (A) and to one side of the decorating composite panel (FIG. 30 ) are connected. The composite decorative element according to claim 7, characterized in that the bonding compound (C1) is epoxy resin and the composite layers (B) are carbon layers. Composite decorative element according to claim 7, characterized in that the connecting portion ( 40 ) is cylindrical, square or polygonal.

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