DE102021121058A1 - Method for producing a composite component for a vehicle and composite component for a vehicle - Google Patents

Abstract

The invention relates to a method for producing a composite component (10) for a vehicle, in which a support part (12) is first placed in a shaping tool (24). At least one fiber (16) is then introduced into the shaping tool (24). The shaping tool (24) is then closed and the fiber (16) is bonded to the carrier part (12). The invention also relates to a composite component (10) for a vehicle, which is produced using such a method.

Description

The present invention relates to a method for producing a composite component for a vehicle and a correspondingly produced composite component for a vehicle.

During a crash, the door trim of a vehicle must not have any sharp edges in the direction of the occupants or the airbag, or separate components that could endanger the occupants. Due to the strong intrusion during the crash, however, the component integrity is often not given and must be remedied by various optimizations. A major problem is large deflections and strains due to the constraint, causing the part to break. With a given forced deformation, no matter how stable the material or construction, it cannot be expedient. The area often has to be flexible, but this collides with other requirements, such as customer value and/or the component function.

To increase the stability of a door panel, tethers can be integrated on the door panel to prevent fragments from flying off. However, such a construction causes high costs. In addition, tough materials can be used for the door panel, which have a higher elongation. However, this is disadvantageous for the feel and the component rigidity and results in increased weight and higher costs.

Another alternative to increase stability is to press a fiber mesh onto a natural fiber polypropylene mat as a carrier part. This composite component maintains the bond in the event of a crash, so that open-edged fractures do not occur due to bending. Although the upper side tears, the fibers maintain the bond. The disadvantage here is that a silicone stamping tool is required on the rib side for production, which only has a short service life. Furthermore, the continuous fibers create problems in the deep-drawing process.

As an alternative to pressing on a fiber network, a ribbed structure can be sprayed onto a natural fiber polypropylene mat (NF-PP mat) as a carrier part. The problem here is that in the event of a large deflection, especially in the case of a so-called pole crash, the door panel and the ribs break through and form a sharp edge after the beam tears open, since the material is too brittle for the deflection. Such open, sharp-edged fractures are not permitted as they pose a risk to the occupants and the airbag.

Out of DE 198 33 337 A1 and DE 199 60 384 A1 are also back-injected plastic moldings for pillar trims of motor vehicles known, which consist of a thermoplastic material. At least one layer of an open-pored material is completely or partially arranged in the thermoplastic material, with this open-pored material being injected and overmoulded with the thermoplastic material, or the thermoplastic material is fully or partially back-injected with a layer of an open-pored material on the back, with this open-pored material is injected and overmoulded with the thermoplastic material. The porous material is from the group consisting of thermoplastic material, glass fiber, wire, plastic, natural fiber or mixtures thereof.

Finally it's over DE 10 2013 113 230 A1 a method for producing a large-area outer paneling part for a door of a vehicle is known, in which at least one large-area metal sheet metal part forming the outer paneling part is formed into a three-dimensional shape by means of a forming tool, with a plastic reinforcement being applied at least partially to the inside of the formed sheet metal part by back-injection molding and wherein the deformed component provided with the at least one reinforcement is connected to an inner structure made of sheet metal and/or plastic by folding and/or gluing.

The present invention is based on the object of creating a method for producing a composite component and such a composite component which have improved crash behavior.

To solve the problem, a method with the features of claim 1 and a composite component with the features of claim 10 are proposed.

Advantageous configurations of the method are the subject matter of the dependent claims.

In a method for producing a composite component for a vehicle, a support part is first placed in a shaping tool. At least one fiber is then introduced into the shaping tool, and finally the shaping tool is closed and the fiber is bonded to the carrier part.

The integral connection of the at least one fiber to the carrier part creates a punctiform reinforcement of the carrier part. In the event of a crash, this becomes a sharp-edged Breakage or separating parts that could endanger the occupants are prevented. The composite component produced using the method thus has improved crash behavior. In addition, the fibers enable new design options for exterior and/or interior parts of a vehicle. For example, structures can be created on design surfaces in the interior.

The composite component for a vehicle can be an exterior part or an interior part. An exterior part can be, for example, a front hood, a tailgate or a structural component such as a vehicle pillar. An interior part can be a door panel, a console or a dashboard.

The carrier part can also be referred to as a basic component. In an advantageous embodiment, the carrier part is a plate or mat element, which is placed in the shaping tool and formed into a three-dimensional shape by compression molding. Following the compression molding, the edge of the carrier part can be trimmed. Before the carrier part is placed in the forming tool, the same can be placed in a heating device so that the carrier part is heated and calibrated for the forming process. Instead of compression molding, the carrier part can be produced by injection molding.

The forming tool can be formed from two forming tool halves. The cohesive connection of the at least one fiber to the carrier part advantageously takes place within the closed shaping tool. The shaping tool can be an injection molding tool.

In an advantageous embodiment, the carrier part is provided first. For this purpose, a plate-shaped workpiece can first be placed in a heating tool and heated and calibrated for the shaping process. While still warm, the plate-shaped workpiece is placed in a compression molding tool. The compression molding tool is then closed and a three-dimensional carrier part is formed from the plate-shaped workpiece. Edge trimming can take place during or after the compression molding of the carrier part. The carrier part is then placed in an injection molding tool and at least one fiber is introduced into the injection molding tool. For this purpose, either the fiber can be placed on the carrier part, or the fiber can be introduced into the injection mold via channels introduced into the injection mold. The at least one fiber is then cohesively connected to the carrier part. After connecting, the injection molding tool can be opened and the composite component can be removed. Instead of deep-drawing, the carrier part can be produced using the injection molding process. The injection molding tool used here can also be used to materially connect the at least one fiber to the carrier part. Both the feeding of the carrier part into a heating device and the feeding and removal of the carrier part can be automated by means of a robot.

In an advantageous embodiment, the at least one fiber is cohesively connected to the carrier part by injecting plastic into the shaping tool. The bond can be made by injecting the at least one fiber from the fiber side. This is also referred to as back injection. Furthermore, the material connection of the at least one fiber can be achieved by injecting plastic through the carrier part. For this purpose, a passage can be made in the carrier part, via which the plastic is guided to the fiber to be connected. With back injection, the plastic comes from above, that is, from the side of the carrier part facing the fiber, whereas with through-injection, the plastic comes from below, that is, from the side of the carrier part that faces away from the fiber.

In an advantageous embodiment, a large number of fibers are introduced into the shaping tool. As a result, the selective reinforcement of the carrier part can be increased.

In an advantageous embodiment, the at least one fiber is an endless fiber. A continuous fiber has sufficient strength and is also inexpensive.

In an advantageous embodiment, the at least one fiber is blown into the shaping tool. For this purpose, the shaping tool can have one or more channels into which at least one fiber is either blown by an air stream or into which at least one fiber is drawn. If several channels are introduced into the shaping tool, the channels can be connected to one another. The at least one fiber can be blown into the channel or channels of the shaping tool by means of positive or negative pressure. If the channels are connected to one another, then they are arranged in a meandering pattern.

In an advantageous embodiment, the at least one fiber is inserted into the shaping tool by means of a robot. For this purpose, the at least one fiber directly on the component or on the shaping tool by means of a be put down. If the at least one fiber is laid down directly on the shaping tool, the at least one fiber is advantageously laid down in at least one channel introduced into the shaping tool or in several channels introduced into the shaping tool.

In an advantageous embodiment, the at least one fiber is introduced into at least one channel of the shaping tool. In the closed state of the shaping tool, the channel connects to the carrier part.

In an advantageous embodiment, a cross section of the channel is changed by means of a slide. The channel is thus limited by the slider. The slide can be moved towards the carrier part or moved away from the carrier part. As a result, the channel, in particular its cross section, can be enlarged or reduced. Before blowing or drawing into the channel formed by the slider, the slider is moved away from the support member so that a large channel is created. The at least one fiber is then blown or drawn into the channel. After blowing in or drawing in, the slide is moved towards the fiber or the carrier part and presses the fiber onto the carrier part. Finally, the fiber is integrally connected to the carrier part by injecting plastic. If the forming tool has multiple channels, then each channel has a moveable slide.

In an advantageous embodiment, the carrier part is made of a fiber composite material. The fiber composite material is advantageously a natural fiber polypropylene (NF-PP). The fiber composite material can also be a natural fiber component. Furthermore, the carrier part can be an injection molded part.

In an advantageous embodiment, the at least one fiber is a carbon, glass, hemp, kenaf and/or light-conducting fiber.

In an advantageous embodiment, the plastic used to materially connect the at least one fiber to the carrier part is polypropylene (PP) or acrylonitrile butadiene styrene polycarbonate (ABS-PC).

Furthermore, a composite component for a vehicle is proposed, which is produced using such a method.

• 1 ein Verbundbauteil mit aufgespritzter Rippenstruktur;
• 2 eine schematische Darstellung eines Verfahrens zur Herstellung des Verbundbauteils;
• 3 ein Trägerteil mit einer darauf abgelegten Faser;
• 4 ein Trägerteil mit einer durch Luftstrom aufgebrachten Faser;
• 5 eine schematische Darstellung eine Einblasvorgangs von Fasern in Kanäle eines Spritzgusswerkzeuges und dem anschließenden stoffschlüssigen Verbinden der Fasern mit dem Trägerteil; und
• 6 eine schematische Darstellung eine Einblasvorgangs einer Faser in einen Kanal eines Spritzgusswerkzeuges, der durch einen Schieber begrenzt ist, und dem anschließenden Verpressen der Faser sowie dem stoffschlüssigen Verbinden der Faser mit dem Trägerteil.

A method for producing a composite component, a composite component and further features and advantages are explained in more detail below with reference to exemplary embodiments which are shown schematically in the figures. Here show:

• 1 a composite component with a sprayed-on rib structure;
• 2 a schematic representation of a method for producing the composite component;
• 3 a support member having a fiber deposited thereon;
• 4 a support member having airlaid fiber;
• 5 a schematic representation of a process of blowing fibers into channels of an injection molding tool and the subsequent material connection of the fibers to the carrier part; and
• 6 a schematic representation of a blowing process of a fiber into a channel of an injection molding tool, which is delimited by a slide, and the subsequent compression of the fiber and the material connection of the fiber to the carrier part.

In 1 shows a composite component 10 for a vehicle, not shown, which is presently designed as a door panel.

The composite component 10 has a carrier part 12 and a rib structure 14 applied thereto.

The carrier part 12 is made of a fiber composite material, in particular natural fiber polypropylene (NF-PP).

The rib structure 14 is made of fibers 16 and a plastic 18 which materially connects the fibers 16 to the carrier part 12 . The fibers are continuous fibers and can be carbon, glass, hemp, kenaf or light-conducting fibers. The plastic can be polypropylene (PP) or acrylonitrile butadiene styrene polycarbonate (ABS-PC).

To produce the composite component 10, as in 2 is shown schematically, the carrier part 12 designed as a mat is placed in a heating device 22 by means of a robot 20 . The heating device 22 is then closed and the carrier part 12 is heated and calibrated. Thereafter, the heated carrier part 12 is removed by means of a further robot 20 and fed to a compression molding tool 23 . Thereafter, the compression molding die 23 is closed, and the support member 12 is formed into a three-dimensional shape by compression molding. At the same time, an edge of the carrier part 12 can be trimmed. Subsequently, the three-dimensionally shaped carrier part 12 is removed from the compression molding tool 23 and by means of a robot 20 is inserted into a shaping tool 24 embodied as an injection molding tool 25 . Following this, fibers 16 are introduced into the injection molding tool 25, as will be explained in more detail below. After the fibers 16 have been introduced, they are cohesively connected to the carrier part 12 by injecting the plastic 18 into the injection molding tool 25 with the carrier part 12 . For this purpose, the plastic 18 can be injected from the fiber side. This process is referred to as back injection. Alternatively, the plastic can be injected through the carrier part 12 . A passage (not shown) can be introduced into the carrier part 12 for this purpose. When the plastic 12 has fully cured, the injection molding tool 24 is opened and the robot 20 removes the finished composite component 10.

The fibers 16 can be inserted into the shaping tool 24 by means of the robot 20, as is shown schematically in 3 is shown. For this purpose, the fibers 16 are placed on the carrier part 12, or the robot places the fibers in channels 26 of the injection molding tool 25.

Alternatively, the fibers 16 can be blown or drawn into channels 26 of the injection molding tool 24, as is shown in FIGS 4 and 5 is shown. The fibers can be blown into the channels 26 by an air flow by means of overpressure or underpressure. When the fibers 16 are blown or drawn into the channels 26, the channels 26 are interconnected and form a meander shape as shown in FIG 4 is shown.

As in 5 is shown, the carrier part 12 is inserted into the injection molding tool 25 and closed, so that the channels 26 adjoin the carrier part 12 . The fibers 16 are then blown into the channels 26 . The fibers 16 are then cohesively connected to the carrier part 12 by injecting the plastic 18 into the injection molding tool 25, in particular back-injecting it. This creates the rib structure 14 on the carrier part 12 .

In 6 an alternative embodiment is shown. In this embodiment, the channel 26 is delimited by a slide 24 that can be moved. As in 6 As can be seen, the slide 28 is initially at a distance from the carrier part 12 inserted into the injection molding tool 25 and thus forms a large channel 26 . The fibers 16 are then blown into the channel 26 . The slide 28 then moves towards the carrier part 12 or towards the fibers 16 and presses the fibers 16 onto the carrier part 12. Finally, the fibers 16 are cohesively connected to the carrier part 12 by back-injection molding with the plastic 18, whereby the rib structure 14 on the carrier part 12 arises.

The integral connection of the fibers 16 to the carrier part 12 creates a punctiform reinforcement of the carrier part 12 . In the event of a crash, this prevents sharp-edged breakage or separating parts that could endanger the occupants. The composite component 10 produced by means of the method thus has improved crash behavior. In addition, the fibers 16 enable new design options for exterior and/or interior parts of a vehicle. For example, structures can be created on design surfaces in the interior.

Reference List

10

composite component

12

carrier part

14

rib structure

16

fiber

18

plastic

20

robot

22

heating device

23

compression molding tool

24

shaping tool

25

injection molding tool

26

channel

28

slider

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was 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.

Patent Literature Cited

• DE 19833337 A1 [0006]
• DE 19960384 A1 [0006]
• DE 102013113230 A1 [0007]

Claims (11)

Method for producing a composite component (10) for a vehicle, comprising the following steps: a. Inserting a carrier part (12) into a shaping tool (24); b. inserting at least one fiber (16) into the forming tool (24); and c. Closing the shaping tool (24) and cohesively connecting the at least one fiber (16) to the carrier part (12). procedure after claim 1 , characterized in that the at least one fiber (16) is cohesively connected to the carrier part (12) by injecting plastic (18) into the shaping tool (24). procedure after claim 1 or 2 , characterized in that a plurality of fibers (16) are introduced into the shaping tool (24). procedure after claim 1 or 2 , characterized in that the at least one fiber (16) is a continuous fiber. Method according to one of the preceding claims, characterized in that the at least one fiber (16) is blown or drawn into the shaping tool (24). Method according to one of the preceding claims, characterized in that the at least one fiber (16) is inserted into the shaping tool (24) by means of a robot (20). Method according to one of the preceding claims, characterized in that the at least one fiber (16) is introduced into at least one channel (26) of the shaping tool (24). procedure after claim 7 , characterized in that a cross section of the channel (26) is changed by means of a slide (28). Method according to one of the preceding claims, characterized in that the carrier part (12) is made of a fiber composite material. Method according to one of the preceding claims, characterized in that the fiber (16) is a carbon, glass, hemp, kenaf and/or a light-conducting fiber (16). Composite component (10) for a vehicle produced by a method according to one of Claims 1 until 10 .

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