EP2303552A2 - Process for producing a composite component from plastic, composite component produced by this process and use of such a component - Google Patents

Process for producing a composite component from plastic, composite component produced by this process and use of such a component

Info

Publication number
EP2303552A2
EP2303552A2 EP09776931A EP09776931A EP2303552A2 EP 2303552 A2 EP2303552 A2 EP 2303552A2 EP 09776931 A EP09776931 A EP 09776931A EP 09776931 A EP09776931 A EP 09776931A EP 2303552 A2 EP2303552 A2 EP 2303552A2
Authority
EP
European Patent Office
Prior art keywords
layer
composite
structural
fibers
component
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP09776931A
Other languages
German (de)
French (fr)
Inventor
Hans-Jürgen LIEBIG
Dirk Legler
Jan WOKÖCK
Adam Wagner
Thomas Peter
Michael Kölbl
Thomas Stemmer
Petra Heuser
Detlef Mies
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Webasto SE
Bayer Intellectual Property GmbH
Original Assignee
Webasto SE
Bayer MaterialScience AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Webasto SE, Bayer MaterialScience AG filed Critical Webasto SE
Publication of EP2303552A2 publication Critical patent/EP2303552A2/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • 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
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/18—Layered products comprising a layer of metal comprising iron or steel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B32B27/365—Layered products comprising a layer of synthetic resin comprising polyesters comprising polycarbonates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/38—Layered products comprising a layer of synthetic resin comprising epoxy resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B32B5/18—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 characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
    • B62D29/043—Superstructures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/103—Metal fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0221—Vinyl resin
    • B32B2266/0228—Aromatic vinyl resin, e.g. styrenic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/025—Polyolefin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/024—Honeycomb
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
    • B32B2315/08—Glass
    • B32B2315/085—Glass fiber cloth or fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/003—Interior finishings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness

Definitions

  • the invention relates to a method for producing a composite component made of plastic according to claim 1, a composite component produced according to this method according to claim 14 and an advantageous use of such a composite component according to claim 15.
  • a composite component for a vehicle which is composed of an outer skin made of a film and a supporting reinforcing layer, which is composed of a honeycomb structure and in each case one of these two sides covered with glass fibers alarmed polyurethane layer.
  • the production of the composite component takes place in several steps in a mold. Due to the curing times required for the individual layers, the composite part as a whole requires a relatively long cycle time, so that in the case of larger quantities, several parallel production lines with relatively expensive shapes are necessary.
  • the invention is based on the object, a method for producing a composite component made of plastic and a manufactured according to this method
  • the invention provides that the composite component is assembled from two separately produced modules, namely a decorative composite forming the outer skin, comprising a coloring layer, and a structural composite increasing the stability. Due to the separate production of the decorative composite and the structural composite, manufacturing steps can be produced in parallel in partial production lines or completely offline at separate locations. When joining then only the
  • Bonding layer can be introduced, the curing takes place very quickly compared with the prior art.
  • the separate production also makes it possible, for example, to combine different decorative composites with different structural composites, so that different colors and materials for an outer skin and an inner lining arranged thereon, for example, can be modularly assembled individually according to customer requirements by a vehicle manufacturer.
  • the carrier layer of the decorative composite consists of metal, such as aluminum or steel or of thermoplastic or thermosetting plastics.
  • the coloring layer consists of one or more of the following layers: a lacquer and / or a primer and / or a film and / or a fabric layer.
  • the bonding layer for bonding the decorative composite to the structural composite is preferably formed by a foaming or non-foaming polymer.
  • the spacer of the structural layer preferably consists of a paper honeycomb of a polymer foam, such as expanded polystyrene (EPS), expanded Polypropylene (EPP) or expanded polycarbonate (EPC), of melamine, of a metal foam, such as foamed aluminum, of a natural raw material or of a monolithic structure, such as sheet metal, glass fiber reinforced polyurethane (PU-GF), glass fiber reinforced epoxy ( EP-GF) or glass fiber reinforced polycarbonate (PC-GF).
  • EPS expanded polystyrene
  • EPP expanded Polypropylene
  • EPC expanded polycarbonate
  • the at least one cover layer of the structural layer is preferably formed from a fiber layer of glass fibers, glass fiber reinforced polyurethane (PU-GF), natural fibers, polymer fibers, inorganic fibers, metallic fibers or carbon fibers, which are embedded in a plastic matrix of polyamide (PA), polypropylene (PP), Epoxy (EP) or polyurethane (PU) is embedded.
  • PU-GF glass fiber reinforced polyurethane
  • PA polyamide
  • PP polypropylene
  • EP Epoxy
  • PU polyurethane
  • two cover layers are arranged on both sides of the spacer in the structural composite, wherein at least one, particularly preferably both cover layers is connected to an adhesive or liquid plastic penetrating into cavities of the spacer.
  • a structural composite has a particularly high stability with very low weight.
  • At least one splinter protection layer is integrated in the decorative composite and / or in the structural composite.
  • An integration of an anti-shattering layer is described in the older German patent application DE 10 2008 033 923.7, which originates from the same applicant and whose
  • a composite component produced according to the method of the invention described above is particularly preferably used for a vehicle outer skin component, such as vehicle roof module, vehicle door, fender, engine compartment flap, boot lid, rear module, roof shell of a convertible folding top, front or rear spoiler.
  • vehicle outer skin component such as vehicle roof module, vehicle door, fender, engine compartment flap, boot lid, rear module, roof shell of a convertible folding top, front or rear spoiler.
  • CSM process composite spray molding process
  • LFI process long fiber injection process
  • GM-PU process glass fiber mat polyurethane process
  • RTM Resin Transfer Molding
  • SMC Sheet Molding Compound
  • RIM Reaction Injection Molding
  • RRIM process Reinforced Reaction Injection Molding process
  • the at least one splinter protection layer comprises a splinter protection fabric, which preferably consists of polyethylene (PE) and / or polyethylene terephthalate (PET) and / or polyamide (PA) and / or polypropylene (PP) and / or aramid and / or made of elastic polyurethane (PU) and / or of natural or synthetic rubber and / or of a steel fabric.
  • a splinter protection fabric which preferably consists of polyethylene (PE) and / or polyethylene terephthalate (PET) and / or polyamide (PA) and / or polypropylene (PP) and / or aramid and / or made of elastic polyurethane (PU) and / or of natural or synthetic rubber and / or of a steel fabric.
  • the outer skin forming the outer part of the composite component is made of a plastic layer which is already dyed at the supplier in the desired vehicle color.
  • the composite component is used as a vehicle outer skin component, subsequent painting work by the vehicle manufacturer can be completely eliminated.
  • a composite component according to the invention will be explained in more detail using an exemplary embodiment with reference to the drawing. It shows:
  • Fig. 1 shows schematically the modular structure of the composite component
  • FIG. 2 shows schematically the separate production of the decorative composite in a first
  • FIG. 3 schematically shows the introduction of the bonding layer onto the inside of the decorative composite in the first molding tool
  • the composite component 100 shown schematically in FIG. 1 is modularly composed of a decorative composite 110, shown in the upper part
  • the decorative composite 110 consists of at least one carrier layer 114 and at least one coloring layer 112.
  • the coloring layer 112 later forms the outward facing layer thereof after assembly of the composite component 100.
  • a splinter protection layer 116 is provided on the underside of the carrier layer 114 or embedded therein.
  • the carrier layer 114 of the decorative composite 110 is optionally made of metal, such as aluminum or steel sheet or of thermoplastic or thermosetting plastics, for example in the form of a thermoformed plastic film.
  • the coloring layer 112 consists of a lacquer and / or a primer and / or a film and / or a fabric layer, which are adapted in their color to the desired color of the composite component.
  • the splinter protection layer 116 is preferably made of a fabric which in particular of polyethylene (PE), polyethylene terephthalate (PET), polyamide (PA), polypropylene (PP), aramid, elastic polyurethane (PU), natural or synthetic rubber or made of a steel mesh.
  • a splinter protection layer 116 in the form of an anti-splintering fabric may particularly preferably also be embedded in the carrier layer 114, in particular if it consists of plastic.
  • the connecting layer 120 preferably consists of a foaming or non-foaming polymer, in particular polyurethane foam (PU).
  • the bonding layer 120 preferably has a thickness of about 2 to 2.5 mm. It preferably serves at the same time to a visible on the outer skin in the coloring layer 112 depression of the honeycomb structure of the spacer 134, as in the compression in a mold in the absence of a
  • Decoupling layer can otherwise occur to effectively prevent. If no honeycomb structure is used as a spacer layer 134, but rather a plastic, plastic foam, metal or metal foam, the connecting layer 120 can also have a significantly lower thickness, since its function is then limited to the connection of the decorative composite 110 to the structural composite 130.
  • the structural composite 130 is composed of an upper cover layer 132, a spacer 134 and a lower cover layer 136.
  • a splinter protection layer 138 is arranged, which is similar in structure to the splinter protection layer 116.
  • the splinter protection fabric of the splinter protection layer 116 is in turn preferably embedded in the plastic material of the cover layer 132.
  • the spacer 134 of the structural layer 130 preferably consists of a paper honeycomb whose webs are aligned in the main loading direction of the composite component 100 vertically to the adjacent cover layers 132, 136.
  • the spacer 134 may alternatively be made of a polyurethane foam, a Polymer foam, such as expanded polystyrene (EPS), expanded polypropylene (EPP), or expanded polycarbonate (EPC), melamine, a metal foam, such as foamed aluminum, from a natural raw material, or a monolithic structure, such as sheet, glass fiber reinforced polyurethane (PU-GF), glass fiber reinforced epoxy (EP-GF) or glass fiber reinforced polycarbonate (PC-GF).
  • PU-GF glass fiber reinforced polyurethane
  • EP-GF glass fiber reinforced epoxy
  • PC-GF glass fiber reinforced polycarbonate
  • the spacer 134 is particularly preferably made of a paper honeycomb, for example with a thickness of about 13 mm, wherein the shaft and ceiling of the honeycomb structure have a basis weight of about 115 g per square meter and the waves are preferably formed according to the wave type A.
  • the at least one cover layer 132, 136 of the structure layer 130 consists of a fiber layer, for example of glass fibers, glass fiber reinforced polyurethane (PU-GF), natural fibers, polymer fibers, inorganic fibers, metallic fibers or carbon fibers, which are embedded in a plastic matrix, for example of polyamide (PA ), Polypropylene (PP), epoxy (EP) or polyurethane (PU).
  • the cover layers 132 and 136 are particularly preferably made of polyurethane (PU) having a basis weight of about 300 g per square meter, which is optionally and preferably reinforced by means of a glass fiber mat with a basis weight of about 225 g per square meter.
  • connection to the cover layers 132, 136 is intensified by an adhesive or liquid plastic which penetrates into the cavities of the spacer 134 and penetrates the edge region of the spacer attaches vertical webs.
  • the layer structure of spacers 134 and the two adjacent cover layers 132 and 136 described hitherto is preferably produced by means of the composite spray molding method (CSM method, known from Hennecke GmbH, D-53754 Sankt Augustin) in a mold (CSM tool ) produced. He is in similar form already in the same applicant Wilmingtoncoming DE 100 33 232 C2 shown.
  • CSM method composite spray molding method
  • He is in similar form already in the same applicant Wilmingtoncoming DE 100 33 232 C2 shown.
  • the strength is achieved at very low weight, especially by the penetrating into the region of the vertical webs of the honeycomb and connecting with these plastic (PU).
  • the inventive method provides that the production of the
  • Decor composite 110 and the structure composite 130 is done separately. This can take place in two production lines arranged next to one another, wherein the curing times of the individual layers of the decorative composite 110 and of the structural composite 130 run in parallel and thus, unlike the prior art mentioned at the outset, the entire process time for producing the composite component 100 is not extended, but shortened.
  • the production of the decorative composite 110 and / or of the structural composite 130 can also take place with completely different suppliers at completely different locations.
  • the decorative composite 110 with the coloring layer 112 is laid down in a first molding tool 210 or alternatively produced in this first molding tool 210.
  • the inking layer 112 is preferably by spraying in a layer thickness of 0.03 to 0.06 m (S & R) or in a layer thickness of 0.3 to 0.6 mm (Panadur) in the Inmouldcoating process (IMC process) directly in CSM tool, in the example described the lower mold 210 generated.
  • the production of the structural composite 130 takes place separately in a second method step.
  • the connecting layer 120 is applied to the inside of the carrier layer 114 by means of an injection molding tool 250 provided with at least one nozzle 255.
  • the structure composite 130 is fastened to an upper molding tool 230 or, alternatively, it is placed on the bonding layer 120.
  • the upper mold 230 By compressing the upper mold 230 with the lower mold 210 connects the bonding layer 120 during curing, the structure composite 130 with the decorative composite 110th
  • the finished composite component 100 forms, for example, a roof module or a vehicle door of a vehicle.
  • the invention is also advantageously on other vehicle components, such as fenders, engine compartment doors, trunk lids, rear modules, roof shells of convertible covert, front or rear spoiler feasible and also suitable for other plastic composite components that are not used in the automotive sector.
  • a composite component designed as a vehicle roof module is pressed more strongly in the tool mold.
  • the spacer 134 is omitted and the resulting clearance from below provided with a supporting, the stability of the vehicle roof module enhancing layer, preferably by injection molding in the Long Fiber Injection Molding (LFI-PUR) method of polyurethane with injected fiber material becomes.
  • LFI-PUR Long Fiber Injection Molding

Abstract

The invention relates to a process for producing a composite component (100), said process comprising the following steps: 1.1 a decorative composition (110) is produced from at least one backing layer (114) and at least one colour-imparting layer (112), 1.2 a structural composition (130) is produced from at least one top layer (132; 136) and at least one spacer (134) connected thereto, 1.3 a connecting layer (120) is introduced between the decorative composition (110) and the structural composition (130), and 1.4 the structural composition (130) and the decorative composition (110) are joined together, with the connecting layer (120) being cured.

Description

Verfahren zur Herstellung eines Verbundbauteils aus Kunststoff, nach diesem Verfahren hergestelltes Verbundbauteil und Verwendung eines solchen A method for producing a composite component made of plastic, composite component produced by this method and use of such
Die Erfindung betrifft ein Verfahren zur Herstellung eines Verbundbauteils aus Kunststoff gemäß Patentanspruch 1 , ein nach diesem Verfahren hergestelltes Verbundbauteil gemäß Patentanspruch 14 und eine vorteilhafte Verwendung eines derartigen Verbundbauteils gemäß Patentanspruch 15.The invention relates to a method for producing a composite component made of plastic according to claim 1, a composite component produced according to this method according to claim 14 and an advantageous use of such a composite component according to claim 15.
Aus der DE 10244 287 A1 ist ein Verbundbauteil für ein Fahrzeug bekannt, das aus einer Außenhaut aus einer Folie und einer tragenden Verstärkungsschicht, die aus einer Wabenstruktur und jeweils einer diese zur beiden Seiten bedeckenden, mit Glasfasern alarmierten Polyurethan-Schicht aufgebaut ist. Die Herstellung des Verbundbauteils erfolgt in mehreren Verfahrensschritten in einer Form. Durch die für die einzelnen Schichten notwendigen Aushärtezeiten benötigt das Verbundteil insgesamt eine relativ lange Taktzeit, so dass bei größeren Stückzahlen mehrere parallele Fertigungslinien mit relativ teuren Formen notwendig sind.From DE 10244 287 A1 a composite component for a vehicle is known, which is composed of an outer skin made of a film and a supporting reinforcing layer, which is composed of a honeycomb structure and in each case one of these two sides covered with glass fibers alarmed polyurethane layer. The production of the composite component takes place in several steps in a mold. Due to the curing times required for the individual layers, the composite part as a whole requires a relatively long cycle time, so that in the case of larger quantities, several parallel production lines with relatively expensive shapes are necessary.
Der Erfindung liegt die Aufgabe zugrunde, ein Verfahren zur Herstellung eines Verbundbauteils aus Kunststoff und ein nach diesem Verfahren hergestelltesThe invention is based on the object, a method for producing a composite component made of plastic and a manufactured according to this method
Verbundbauteil zu schaffen, dessen Herstellung vereinfacht und dessen Prozesszeit bei der Fertigung wesentlich verkürzt werden kann.To provide composite component whose production is simplified and whose process time can be significantly reduced during manufacture.
Diese Aufgabe wird erfindungsgemäß durch die Merkmale des Patentanspruchs 1 bezüglich des Verfahrens und durch die Merkmale des Patentanspruchs 14 bezüglich des Verbundbauteils gelöst. Vorteilhafte Ausgestaltungen der Erfindung sind in den Unteransprüchen angegeben. Eine vorteilhafte Verwendung eines erfindungsgemäß hergestellten Verbundbauteils ist im Patentanspruch 15 angegeben.This object is achieved by the features of claim 1 with respect to the method and by the features of claim 14 with respect to the composite component. Advantageous embodiments of the invention are specified in the subclaims. An advantageous use of a According to the invention produced composite component is given in claim 15.
Die Erfindung sieht im Kern vor, dass das Verbundbauteil aus zwei separat hergestellten Modulen, nämlich einem die Außenhaut bildenden, eine Farbgebende Schicht umfassenden Dekorverbund und einem die Stabilität erhöhenden Strukturverbund mittels einer Verbindungsschicht zusammengefügt wird. Durch die separate Herstellung des Dekorverbunds und des Strukturverbunds können Fertigungsschritte parallel in Teil-Fertigungslinien oder komplett Offline an separaten Orten hergestellt werden. Beim Zusammenfügen muss dann nur noch dieIn essence, the invention provides that the composite component is assembled from two separately produced modules, namely a decorative composite forming the outer skin, comprising a coloring layer, and a structural composite increasing the stability. Due to the separate production of the decorative composite and the structural composite, manufacturing steps can be produced in parallel in partial production lines or completely offline at separate locations. When joining then only the
Verbindungsschicht eingebracht werden, deren Aushärtung verglichen mit dem Stand der Technik sehr schnell erfolgt. Die separate Herstellung ermöglicht es beispielsweise auch, unterschiedliche Dekorverbunde mit unterschiedlichen Strukturverbunden zusammenzufügen, so dass beispielsweise bei einem Fahrzeughersteller unterschiedliche Farben und Materialien für eine Außenhaut und eine daran angeordnete Innenverkleidung individuell nach Kundenwunsch modular zusammengesetzt werden können.Bonding layer can be introduced, the curing takes place very quickly compared with the prior art. The separate production also makes it possible, for example, to combine different decorative composites with different structural composites, so that different colors and materials for an outer skin and an inner lining arranged thereon, for example, can be modularly assembled individually according to customer requirements by a vehicle manufacturer.
Gemäß einer vorteilhaften Ausführungsform besteht die Trägerschicht des Dekorverbunds aus Metall, wie Aluminium oder Stahl oder aus thermoplastischen oder duroplastischen Kunststoffen.According to an advantageous embodiment, the carrier layer of the decorative composite consists of metal, such as aluminum or steel or of thermoplastic or thermosetting plastics.
Gemäß einer weiteren vorteilhaften Ausgestaltung besteht die Farbgebende Schicht aus einer oder mehrerer der folgenden Schichten: einem Lack und/oder einem Primer und/oder einer Folie und/oder einer Stoffschicht. Durch die Auswahl und gegebenenfalls Verbindung der unterschiedlichen Materialien besteht eine große Gestaltungsfreiheit für Farbe, Struktur und Aussehen der Außenhaut.According to a further advantageous embodiment, the coloring layer consists of one or more of the following layers: a lacquer and / or a primer and / or a film and / or a fabric layer. By selecting and optionally connecting the different materials there is a great freedom of design for color, structure and appearance of the outer skin.
Die Verbindungsschicht zur Verbindung des Dekorverbunds mit dem Strukturverbund wird bevorzugt von einem schäumenden oder nicht schäumenden Polymer gebildet.The bonding layer for bonding the decorative composite to the structural composite is preferably formed by a foaming or non-foaming polymer.
Der Abstandshalter der Strukturschicht besteht bevorzugt aus einer Papierwabe, aus einem Polymerschaum, wie expandiertem Polystyrol (EPS), expandiertem Polypropylen (EPP) oder expandiertem Polycarbonat (EPC), aus Melamin, aus einem Metallschaum, wie geschäumtem Aluminium, aus einem natürlichen Rohstoff oder aus einem monolytischen Aufbau, wie Blech, Glasfaser-verstärktem Polyurethan (PU-GF), Glasfaser-verstärktem Epoxy (EP-GF) oder Glasfaser- verstärktem Polycarbonat (PC-GF).The spacer of the structural layer preferably consists of a paper honeycomb of a polymer foam, such as expanded polystyrene (EPS), expanded Polypropylene (EPP) or expanded polycarbonate (EPC), of melamine, of a metal foam, such as foamed aluminum, of a natural raw material or of a monolithic structure, such as sheet metal, glass fiber reinforced polyurethane (PU-GF), glass fiber reinforced epoxy ( EP-GF) or glass fiber reinforced polycarbonate (PC-GF).
Die wenigstens eine Deckschicht der Strukturschicht wird bevorzugt aus einer Faserschicht aus Glasfasern, Glasfaserverstärktem Polyurethan (PU-GF), Naturfasern, Polymerfasern, anorganischen Fasern, metallischen Fasern oder Carbonfasern gebildet, die in eine Kunststoffmatrix aus Polyamid (PA), Polypropylen (PP), Epoxy (EP) oder Polyurethan (PU) eingebettet ist.The at least one cover layer of the structural layer is preferably formed from a fiber layer of glass fibers, glass fiber reinforced polyurethane (PU-GF), natural fibers, polymer fibers, inorganic fibers, metallic fibers or carbon fibers, which are embedded in a plastic matrix of polyamide (PA), polypropylene (PP), Epoxy (EP) or polyurethane (PU) is embedded.
In einer besonders bevorzugten Ausführungsform sind beim Strukturverbund zwei Deckschichten zu beiden Seiten des Abstandshalters angeordnet, wobei wenigstens eine, besonders bevorzugt beide Deckschichten mit einem in Hohlräume des Abstandshalters eindringenden Kleber oder flüssigen Kunststoff verbunden ist. Ein derartiger Strukturverbund weist eine besonders hohe Stabilität bei sehr geringem Gewicht auf.In a particularly preferred embodiment, two cover layers are arranged on both sides of the spacer in the structural composite, wherein at least one, particularly preferably both cover layers is connected to an adhesive or liquid plastic penetrating into cavities of the spacer. Such a structural composite has a particularly high stability with very low weight.
Es ist weiterhin bevorzugt, wenn wenigstens eine Splitterschutzschicht in den Dekorverbund und/oder in den Strukturverbund integriert ist. Eine Integration einer Splitterschutzschicht ist in der älteren, auf dieselben Anmelder zurückgehenden deutschen Patentanmeldung DE 10 2008 033 923.7 beschrieben, derenIt is further preferred if at least one splinter protection layer is integrated in the decorative composite and / or in the structural composite. An integration of an anti-shattering layer is described in the older German patent application DE 10 2008 033 923.7, which originates from the same applicant and whose
Offenbarungsgehalt hiermit zum Gegenstand der vorliegenden Anmeldung gemacht wird.The disclosure content is hereby made the subject of the present application.
Besonders bevorzugt ist ein Verfahren, bei dem die Herstellung des Dekorverbunds und das Einbringen der Verbindungsschicht nacheinander in einem ersten Formwerkzeug erfolgt, während die Herstellung des Strukturverbunds in räumlicher Distanz zu den anderen Verfahrensschritten erfolgt, so dass der fertige Strukturverbund als Zwischenprodukt in ein zweites Formwerkzeug eingelegt werden kann und beide Formwerkzeuge nach Einbringen einer Verbindungsschicht zwischen Dekorverbund und Strukturverbund zum Zusammenfügen des Verbundbauteils zusammengedrückt werden. Ein nach dem vorstehend beschriebenen erfindungsgemäßen Verfahren hergestelltes Verbundbauteil wird besonders bevorzugt für ein Fahrzeug- Außenhautbauteil, wie Fahrzeug-Dachmodul, Fahrzeugtür, Kotflügel, Motorraumklappe, Kofferraumklappe, Heckmodul, Dachschale eines Cabriolet- Faltverdecks, Front- oder Heckspoiler verwendet. Die hohe Oberflächenqualität des Dekorverbunds und die Stabilitätserhöhung durch den Strukturverbund prädestinieren in Verbindung mit der flexiblen Färb- und Strukturgebung und den kurzen Taktzeiten die Verwendung des erfindungsgemäßen Verfahrens zur Herstellung von Außenhautbauteilen von Fahrzeugen.Particularly preferred is a method in which the production of the decorative composite and the introduction of the bonding layer takes place successively in a first mold, while the production of the structural composite takes place in spatial distance from the other process steps, so that the finished structural composite inserted as an intermediate in a second mold can be compressed and both molds after introduction of a bonding layer between the decorative composite and structural composite for joining the composite component. A composite component produced according to the method of the invention described above is particularly preferably used for a vehicle outer skin component, such as vehicle roof module, vehicle door, fender, engine compartment flap, boot lid, rear module, roof shell of a convertible folding top, front or rear spoiler. The high surface quality of the decorative composite and the increase in stability due to the structural composite predestined in conjunction with the flexible dyeing and structuring and the short cycle times, the use of the method according to the invention for the production of outer skin components of vehicles.
Gemäß einer weiteren vorteilhaften Ausgestaltung ist die wenigstens eine derAccording to a further advantageous embodiment, the at least one of
Schichten des Dekorverbunds und/oder des Strukturverbunds im Composite Spray Moulding-Verfahren (CSM-Verfahren) und/oder im Long Fibre Injection-Verfahren (LFI-Verfahren) und/oder im Glasfaser-Matten-Polyurethan-Verfahren (GM-PU- Verfahren) und/oder im Resin Transfer Moulding-Verfahren (RTM-Verfahren) und/oder im Sheet Moulding Compound- Verfahren (SMC-Verfahren) und/oder im Reaction Injection Moulding-Verfahren (RIM-Verfahren) und/oder im Reinforced Reaction Injection Moulding-Verfahren (RRIM-Verfahren) und/oder im Spritzguss- Verfahren hergestellt.Layers of the decorative composite and / or the structural composite in the composite spray molding process (CSM process) and / or in the long fiber injection process (LFI process) and / or in the glass fiber mat polyurethane process (GM-PU process ) and / or in Resin Transfer Molding (RTM) and / or Sheet Molding Compound (SMC) and / or Reaction Injection Molding (RIM) and / or Reinforced Reaction Injection Molding process (RRIM process) and / or produced by injection molding.
Die wenigstens eine Splitterschutzschicht weist ein Splitterschutz-Gewebe auf, das bevorzugt aus Polyethylen (PE) und/oder aus Polyethylenterephthalat (PET) und/oder aus Polyamid (PA) und/oder aus Polypropylen (PP) und/oder aus Aramid und/oder aus elastischem Polyurethan (PU) und/oder aus natürlichem oder synthetischem Kautschuk und/oder aus einem Stahlgewebe besteht.The at least one splinter protection layer comprises a splinter protection fabric, which preferably consists of polyethylene (PE) and / or polyethylene terephthalate (PET) and / or polyamide (PA) and / or polypropylene (PP) and / or aramid and / or made of elastic polyurethane (PU) and / or of natural or synthetic rubber and / or of a steel fabric.
Ebenso vorteilhaft ist es, wenn die den Abschluss des Verbundbauteils nach außen bildende Außenhaut aus einer Kunststoffschicht besteht, die bereits beim Zulieferer in der gewünschten Fahrzeugfarbe eingefärbt wird. Dadurch können bei Verwendung des Verbundbauteils als Fahrzeug-Außenhautbauteil nachträgliche Lackierarbeiten beim Fahrzeughersteller völlig entfallen. Nachfolgend wird ein erfindungsgemäßes Verbundbauteil anhand eines Ausführungsbeispiels unter Bezugnahme auf die Zeichnung näher erläutert. Es zeigt:It is equally advantageous if the outer skin forming the outer part of the composite component is made of a plastic layer which is already dyed at the supplier in the desired vehicle color. As a result, when the composite component is used as a vehicle outer skin component, subsequent painting work by the vehicle manufacturer can be completely eliminated. Hereinafter, a composite component according to the invention will be explained in more detail using an exemplary embodiment with reference to the drawing. It shows:
Fig. 1 schematisch den modularen Aufbau des Verbundbauteils ausFig. 1 shows schematically the modular structure of the composite component
Dekorverbund, Verbindungsschicht und Strukturverbund; Fig. 2 schematisch die getrennte Herstellung des Dekorverbunds in einem erstenDecor composite, bonding layer and structural composite; Fig. 2 shows schematically the separate production of the decorative composite in a first
Formwerkzeug und des Strukturverbunds separat davon;Mold and the structural composite separately from it;
Fig. 3 schematisch das Einbringen der Verbindungsschicht auf die Innenseite des Dekorverbunds im ersten Formwerkzeug; undFIG. 3 schematically shows the introduction of the bonding layer onto the inside of the decorative composite in the first molding tool; FIG. and
Fig.4 schematisch das Zusammenfügen des Dekorverbunds und des4 shows schematically the joining of the decorative composite and the
Strukturverbunds durch Zusammendrücken beider Formwerkzeuge.Structural composite by compressing both molds.
Das in Fig. 1 schematisch gezeigte Verbundbauteil 100 setzt sich modular zusammen aus einem im oberen Teil dargestellten Dekorverbund 110, einerThe composite component 100 shown schematically in FIG. 1 is modularly composed of a decorative composite 110, shown in the upper part
Verbindungsschicht 120 und einem im unteren Teil dargestellten Strukturverbund 130.Connecting layer 120 and a structural composite 130 shown in the lower part.
Der Dekor-Verbund 110 besteht aus wenigstens einer Trägerschicht 114 und wenigstens einer Farbgebenden Schicht 112. Die Farbgebende Schicht 112 bildet später nach dem Zusammenfügen des Verbundbauteils 100 die nach außen weisende Schicht desselben. Optional ist an der Unterseite der Trägerschicht 114 oder in diese eingebettet eine Splitterschutzschicht 116 vorgesehen. Die Trägerschicht 114 des Dekorverbunds 110 besteht wahlweise aus Metall, wie Aluminium oder Stahlblech oder aus thermoplastischen oder duroplastischen Kunststoffen, beispielsweise in Form einer tiefgezogenen Kunststofffolie. Die Farbgebende Schicht 112 besteht aus einem Lack und/oder einem Primer und/oder einer Folie und/einer Stoffschicht, die in ihrer Farbgebung an die gewünschte Farbe des Verbundbauteils angepasst sind. Die Splitterschutzschicht 116 besteht bevorzugt aus einem Gewebe, welches insbesondere aus Polyethylen (PE), Polyethylenterephthalat (PET), Polyamid (PA), Polypropylen (PP), Aramid, elastischem Polyurethan (PU), natürlichem oder synthetischem Kautschuk oder einem Stahlgewebe hergestellt ist. Eine Splitterschutzschicht 116 in Form eines Splitterschutz-Gewebes kann besonders bevorzugt auch in die Trägerschicht 114 eingebettet sein, insbesondere wenn diese aus Kunststoff besteht.The decorative composite 110 consists of at least one carrier layer 114 and at least one coloring layer 112. The coloring layer 112 later forms the outward facing layer thereof after assembly of the composite component 100. Optionally, a splinter protection layer 116 is provided on the underside of the carrier layer 114 or embedded therein. The carrier layer 114 of the decorative composite 110 is optionally made of metal, such as aluminum or steel sheet or of thermoplastic or thermosetting plastics, for example in the form of a thermoformed plastic film. The coloring layer 112 consists of a lacquer and / or a primer and / or a film and / or a fabric layer, which are adapted in their color to the desired color of the composite component. The splinter protection layer 116 is preferably made of a fabric which in particular of polyethylene (PE), polyethylene terephthalate (PET), polyamide (PA), polypropylene (PP), aramid, elastic polyurethane (PU), natural or synthetic rubber or made of a steel mesh. A splinter protection layer 116 in the form of an anti-splintering fabric may particularly preferably also be embedded in the carrier layer 114, in particular if it consists of plastic.
Die Verbindungsschicht 120 besteht bevorzugt aus einem schäumenden oder nicht schäumenden Polymer, insbesondere aus Polyurethanschaum (PU). Die Verbindungsschicht 120 weist bevorzugt eine Stärke von etwa 2 bis 2,5 mm auf. Sie dient bevorzugt gleichzeitig dazu, eine auf der Außenhaut in der Farbgebenden Schicht 112 sichtbare Durchdrückung der Wabenstruktur des Abstandshalters 134, wie sie beim Zusammenpressen in einer Form beim Fehlen einerThe connecting layer 120 preferably consists of a foaming or non-foaming polymer, in particular polyurethane foam (PU). The bonding layer 120 preferably has a thickness of about 2 to 2.5 mm. It preferably serves at the same time to a visible on the outer skin in the coloring layer 112 depression of the honeycomb structure of the spacer 134, as in the compression in a mold in the absence of a
Entkopplungsschicht sonst auftreten kann, wirkungsvoll zu verhindern. Sofern keine Wabenstruktur als Abstandshalter-Schicht 134 verwendet wird, sondern ein Kunststoff, Kunststoffschaum, Metall oder Metallschaum, kann die Verbindungsschicht 120 auch eine deutlich geringere Stärke aufweisen, da ihre Funktion dann auf die Verbindung des Dekorverbunds 110 mit dem Strukturverbund 130 beschränkt ist.Decoupling layer can otherwise occur to effectively prevent. If no honeycomb structure is used as a spacer layer 134, but rather a plastic, plastic foam, metal or metal foam, the connecting layer 120 can also have a significantly lower thickness, since its function is then limited to the connection of the decorative composite 110 to the structural composite 130.
Der Strukturverbund 130 setzt sich zusammen aus einer oberen Deckschicht 132, einem Abstandshalter 134 und einer unteren Deckschicht 136. Optional ist oberhalb der oberen Deckschicht 132 eine Splitterschutzschicht 138 angeordnet, die in ihrem Aufbau der Splitterschutzschicht 116 ähnelt. Das Splitterschutzgewebe der Splitterschutzschicht 116 ist wiederum bevorzugt in das Kunststoffmaterial der Deckschicht 132 eingebettet. Bei einem unfallbedingten Bruch eines als Fahrzeug- Außenhautteil verwendeten Verbundbauteils verhindern beide Splitterschutzschichten 116 bzw. 138 ein scharfkantiges Brechen der benachbarten tragenden Schichten 114 bzw. 132, 136 sowohl an der Außenseite als auch an der Innenseite.The structural composite 130 is composed of an upper cover layer 132, a spacer 134 and a lower cover layer 136. Optionally, above the upper cover layer 132, a splinter protection layer 138 is arranged, which is similar in structure to the splinter protection layer 116. The splinter protection fabric of the splinter protection layer 116 is in turn preferably embedded in the plastic material of the cover layer 132. In the event of an accidental breakage of a composite component used as a vehicle outer skin part, both splinter protection layers 116 and 138 prevent a sharp-edged breaking of the adjacent supporting layers 114 and 132, 136 both on the outside and on the inside.
Der Abstandshalter 134 der Strukturschicht 130 besteht bevorzugt aus einer Papierwabe, deren Stege in der Haupt-Belastungsrichtung des Verbundbauteils 100 vertikal zu den benachbarten Deckschichten 132, 136 ausgerichtet sind. Der Abstandshalter 134 kann auch alternativ aus einem Polyurethan-Schaum, aus einem Polymerschaum, wie expandiertem Polystyrol (EPS), expandiertem Polypropylen (EPP), oder expandiertem Polycarbonat (EPC), aus Melamin, aus einem Metallschaum, wie geschäumtem Aluminium, aus einem natürlichen Rohstoff oder aus einem monolytischen Aufbau, wie Blech, Glasfaser-verstärktem Polyurethan (PU-GF), Glasfaser-verstärktem Epoxy (EP-GF) oder Glasfaser-verstärktem Polycarbonat (PC-GF) bestehen. Der Abstandshalter 134 besteht besonders bevorzugt aus einer Papierwabe, beispielsweise mit einer Stärke von etwa 13 mm, wobei Welle und Decke der Wabenstruktur ein Flächengewicht von jeweils etwa 115 g pro Quadratmeter aufweisen und die Wellen bevorzugt gemäß der Wellenart A ausgebildet sind.The spacer 134 of the structural layer 130 preferably consists of a paper honeycomb whose webs are aligned in the main loading direction of the composite component 100 vertically to the adjacent cover layers 132, 136. The spacer 134 may alternatively be made of a polyurethane foam, a Polymer foam, such as expanded polystyrene (EPS), expanded polypropylene (EPP), or expanded polycarbonate (EPC), melamine, a metal foam, such as foamed aluminum, from a natural raw material, or a monolithic structure, such as sheet, glass fiber reinforced polyurethane (PU-GF), glass fiber reinforced epoxy (EP-GF) or glass fiber reinforced polycarbonate (PC-GF). The spacer 134 is particularly preferably made of a paper honeycomb, for example with a thickness of about 13 mm, wherein the shaft and ceiling of the honeycomb structure have a basis weight of about 115 g per square meter and the waves are preferably formed according to the wave type A.
Die wenigstens eine Deckschicht 132, 136, der Strukturschicht 130 besteht aus einer Faserschicht, beispielsweise aus Glasfasern, Glasfaserverstärktem Polyurethan (PU-GF), Naturfasern, Polymerfasern, anorganischen Fasern, metallischen Fasern oder Carbonfasern, die in eine Kunststoffmatrix, beispielsweise aus Polyamid (PA), Polypropylen (PP), Epoxy (EP) oder Polyurethan (PU) eingebettet ist. Die Deckschichten 132 und 136 bestehen besonders bevorzugt aus Polyurethan (PU) mit einem Flächengewicht von etwa 300 g pro Quadratmeter, das optional und bevorzugt jeweils mittels einer Glasfasermatte mit einem Flächengewicht von etwa 225 g pro Quadratmeter armiert ist.The at least one cover layer 132, 136 of the structure layer 130 consists of a fiber layer, for example of glass fibers, glass fiber reinforced polyurethane (PU-GF), natural fibers, polymer fibers, inorganic fibers, metallic fibers or carbon fibers, which are embedded in a plastic matrix, for example of polyamide (PA ), Polypropylene (PP), epoxy (EP) or polyurethane (PU). The cover layers 132 and 136 are particularly preferably made of polyurethane (PU) having a basis weight of about 300 g per square meter, which is optionally and preferably reinforced by means of a glass fiber mat with a basis weight of about 225 g per square meter.
Besonders bevorzugt ist es, wenn bei einem offenzelligen Aufbau des Abstandshalters 134, beispielsweise in Form einer Wabenstruktur, die Verbindung zu den Deckschichten 132, 136 durch einen Kleber oder flüssigen Kunststoff intensiviert wird, der in die Hohlräume des Abstandshalters 134 eindringt und sich im Randbereich der vertikalen Stege anlagert.With an open-cell structure of the spacer 134, for example in the form of a honeycomb structure, the connection to the cover layers 132, 136 is intensified by an adhesive or liquid plastic which penetrates into the cavities of the spacer 134 and penetrates the edge region of the spacer attaches vertical webs.
Der bis hierher beschriebene Schichtenaufbau aus Abstandshalter 134 und den beiden benachbarten Deckschichten 132 und 136 wird bevorzugt mittels des Composite Spray Moulding-Verfahrens (CSM-Verfahren; bekannt durch die Firma Hennecke GmbH, D-53754 Sankt Augustin) in einer Form (CSM-Werkzeug) hergestellt. Er ist in ähnlicher Form bereits in der auf dieselbe Anmelderin zurückgehenden DE 100 33 232 C2 dargestellt. Die Festigkeit wird dabei bei sehr geringem Gewicht vor allem durch den in den Bereich der vertikalen Stege der Waben eindringenden und sich mit diesen verbindenden Kunststoff (PU) erzielt.The layer structure of spacers 134 and the two adjacent cover layers 132 and 136 described hitherto is preferably produced by means of the composite spray molding method (CSM method, known from Hennecke GmbH, D-53754 Sankt Augustin) in a mold (CSM tool ) produced. He is in similar form already in the same applicant zurückcoming DE 100 33 232 C2 shown. The strength is achieved at very low weight, especially by the penetrating into the region of the vertical webs of the honeycomb and connecting with these plastic (PU).
Das erfindungsgemäße Verfahren sieht vor, dass die Herstellung desThe inventive method provides that the production of the
Dekorverbunds 110 und des Strukturverbunds 130 separat erfolgt. Dies kann in zwei nebeneinander angeordneten Fertigungslinien erfolgen, wobei die Aushärtezeiten der einzelnen Schichten des Dekorverbunds 110 und des Strukturverbunds 130 parallel laufen und somit im Gegensatz zum eingangs erwähnten Stand der Technik die gesamte Prozesszeit zur Herstellung des Verbundbauteils 100 nicht verlängert, sondern verkürzt wird. Die Herstellung des Dekorverbunds 110 und/oder des Strukturverbunds 130 kann auch bei völlig unterschiedlichen Zulieferern an völlig unterschiedlichen Orten erfolgen.Decor composite 110 and the structure composite 130 is done separately. This can take place in two production lines arranged next to one another, wherein the curing times of the individual layers of the decorative composite 110 and of the structural composite 130 run in parallel and thus, unlike the prior art mentioned at the outset, the entire process time for producing the composite component 100 is not extended, but shortened. The production of the decorative composite 110 and / or of the structural composite 130 can also take place with completely different suppliers at completely different locations.
In ersten Verfahrensschritt gemäß Figur 2 wird der Dekorverbund 110 mit der Farbgebenden Schicht 112 nach unten in ein erstes Formwerkzeug 210 eingelegt oder alternativ in diesem ersten Formwerkzeug 210 hergestellt. Die Farbgebende Schicht 112 wird bevorzugt durch Sprühen in einer Schichtdicke von 0,03 bis 0,06 rnm (S&R) oder in einer Schichtdicke von 0,3 bis 0,6 mm (Panadur) im Inmouldcoating-Verfahren (IMC-Verfahren) unmittelbar im CSM-Werkzeug, im beschriebenen Beispiel dem unteren Formwerkzeug 210, erzeugt.In the first method step according to FIG. 2, the decorative composite 110 with the coloring layer 112 is laid down in a first molding tool 210 or alternatively produced in this first molding tool 210. The inking layer 112 is preferably by spraying in a layer thickness of 0.03 to 0.06 m (S & R) or in a layer thickness of 0.3 to 0.6 mm (Panadur) in the Inmouldcoating process (IMC process) directly in CSM tool, in the example described the lower mold 210 generated.
Die Herstellung des Strukturverbunds 130 erfolgt in einem zweiten Verfahrensschritt separat davon.The production of the structural composite 130 takes place separately in a second method step.
Im dritten Verfahrensschritt gemäß Figur 3 wird auf die Innenseite der Trägerschicht 114 mittels eines mit wenigstens einer Düse 255 versehenen Spritzwerkzeuges 250 die Verbindungsschicht 120 aufgetragen.In the third method step according to FIG. 3, the connecting layer 120 is applied to the inside of the carrier layer 114 by means of an injection molding tool 250 provided with at least one nozzle 255.
Im vierten Verfahrensschritt gemäß Figur 4 ist der Strukturverbund 130 an einem oberen Formwerkzeug 230 befestigt oder alternativ dazu auf die Verbindungsschicht 120 aufgelegt. Durch Zusammendrücken des oberen Formwerkzeugs 230 mit dem unteren Formwerkzeug 210 verbindet die Verbindungsschicht 120 beim Aushärten den Strukturverbund 130 mit dem Dekorverbund 110.In the fourth method step according to FIG. 4, the structure composite 130 is fastened to an upper molding tool 230 or, alternatively, it is placed on the bonding layer 120. By compressing the upper mold 230 with the lower mold 210 connects the bonding layer 120 during curing, the structure composite 130 with the decorative composite 110th
Das fertige Verbundbauteil 100 bildet beispielsweise ein Dachmodul oder eine Fahrzeugtür eines Fahrzeugs. Die Erfindung ist jedoch auch an anderen Fahrzeug- Bauteilen, wie beispielsweise Kotflügeln, Motorraumklappen, Kofferraumklappen, Heckmodulen, Dachschalen von Cabriolet-Verdecken, Front- oder Heckspoiler vorteilhaft realisierbar und auch für andere Kunststoff-Verbundbauteile geeignet, die nicht im Kraftfahrzeugbereich eingesetzt werden.The finished composite component 100 forms, for example, a roof module or a vehicle door of a vehicle. However, the invention is also advantageously on other vehicle components, such as fenders, engine compartment doors, trunk lids, rear modules, roof shells of convertible covert, front or rear spoiler feasible and also suitable for other plastic composite components that are not used in the automotive sector.
In den Randbereichen wird ein als Fahrzeug-Dachmodul ausgebildetes Verbundbauteil in der Werkzeugform stärker gepresst. Hier wird der Abstandshalter 134 weggelassen und der entstehende Freiraum von unten mit einer tragenden, die Stabilität des Fahrzeug-Dachmoduls erhöhenden Schicht versehen, die bevorzugt durch Spritzen im Long Fibre Injection Moulding-Verfahren (LFI-PUR-Verfahren) aus Polyurethan mit eingedüstem Fasermaterial hergestellt wird. Diese Randbereiche erhöhter Festigkeit befinden sich nach der Montage eines als Fahrzeug-Dachmodul ausgebildeten Verbundbauteils in den Flanschbereichen des Dachrahmens in Höhe der Kleberaupen (siehe hierzu die ältere Anmeldung DE 10 2008 033 923.7). In the edge regions, a composite component designed as a vehicle roof module is pressed more strongly in the tool mold. Here, the spacer 134 is omitted and the resulting clearance from below provided with a supporting, the stability of the vehicle roof module enhancing layer, preferably by injection molding in the Long Fiber Injection Molding (LFI-PUR) method of polyurethane with injected fiber material becomes. These edge areas of increased strength are located after the installation of a vehicle roof module designed as a composite component in the flange of the roof frame in the amount of Kleberaupen (see the earlier application DE 10 2008 033 923.7).
BezugszeichenlisteLIST OF REFERENCE NUMBERS
100 Verbundbauteil 134 Abstandshalter100 composite component 134 spacers
110 Dekor-Verbund 136 Deckschicht110 Decor composite 136 Cover layer
112 Farbgebende Schicht 138 Splitterschutzschicht112 Coloring layer 138 Anti-splintering layer
114 Trägerschicht 210 (unteres) Formwerkzeug114 carrier layer 210 (lower) mold
116 Splitterschutzschicht 230 (oberes) Formwerkzeug116 Shatter protection layer 230 (upper) mold
120 Verbindungsschicht 250 Spritzwerkzeug120 bonding layer 250 injection mold
130 Strukturverbund 255 Düse130 structural composite 255 nozzle
132 Deckschicht 132 topcoat

Claims

Patentansprüche claims
1. Verfahren zur Herstellung eines Verbundbauteils (100), insbesondere eines Fahrzeug-Außenhautbauteils, wie Fahrzeug-1. A method for producing a composite component (100), in particular a vehicle outer skin component, such as vehicle
Dachmodul, Fahrzeugtür, Kotflügel, Motorraumklappe, Kofferraumklappe, Heckmodul, Dachschale eines Cabriolet-Verdecks, Front- oder Heckspoilers, mit folgenden Verfahrensschritten:Roof module, vehicle door, mudguard, engine compartment flap, trunk lid, rear module, roof shell of a convertible top, front or rear spoiler, with the following process steps:
1.1 Herstellung eines Dekorverbunds (110) aus wenigstens einer Trägerschicht (114) und wenigstens einer Farbgebenden Schicht (112),1.1 producing a decorative composite (110) from at least one carrier layer (114) and at least one coloring layer (112),
1.2 Herstellung eines Strukturverbunds (130) aus wenigstens einer Deckschicht (132; 136) und wenigstens einem mit dieser verbundenen Abstandshalter (134),1.2 production of a structural composite (130) from at least one cover layer (132; 136) and at least one spacer (134) connected thereto,
1.3 Einbringen einer Verbindungsschicht (120) zwischen Dekorverbund (110) und Strukturverbund (130), und1.3 introducing a connecting layer (120) between the decorative composite (110) and structural composite (130), and
1.4 Zusammenfügen des Strukturverbunds (130) und des Dekorverbunds (110) unter Aushärtung der Verbindungsschicht (120).1.4 Assembly of the structural composite (130) and the decorative composite (110) with curing of the bonding layer (120).
2. Verfahren nach Anspruch 1 , dadurch gekennzeichnet, dass die Trägerschicht (114) des Dekorverbunds (110) aus Metall, wie Aluminium oder Stahl oder aus thermoplastischen oder duroplastischen Kunststoffen besteht.2. The method according to claim 1, characterized in that the carrier layer (114) of the decorative composite (110) made of metal, such as aluminum or steel or of thermoplastic or thermosetting plastics.
3. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass die Farbgebende Schicht (112) aus einer oder mehrerer der folgenden3. The method of claim 1 or 2, characterized in that the coloring layer (112) of one or more of the following
Schichten besteht: einem Lack und/oder einem Primer und/oder einer Folie und/oder einer Stoffschicht.Layers consists of: a lacquer and / or a primer and / or a film and / or a fabric layer.
4. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die Verbindungsschicht (120) aus einem schäumenden oder nicht schäumenden Polymer gebildet wird. 4. The method according to any one of the preceding claims, characterized in that the connecting layer (120) is formed from a foaming or non-foaming polymer.
5. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass der Abstandshalter (134) der Strukturschicht (130) aus einer Papierwabe, aus einem Polyurethan-Schaum, aus einem Polymer- Schaum, wie expandiertem Polystyrol (EPS), expandiertem Polypropylen (EPP) oder expandiertem Polycarbonat (EPC), aus Melamin, aus einem5. The method according to any one of the preceding claims, characterized in that the spacer (134) of the structural layer (130) of a paper honeycomb, a polyurethane foam, a polymer foam, such as expanded polystyrene (EPS), expanded polypropylene (EPP ) or expanded polycarbonate (EPC), melamine, from a
Metallschaum, wie geschäumtem Aluminium, aus einem natürlichen Rohstoff oder aus einem monolytischen Aufbau, wie Blech, Glasfaserverstärktem Polyurethan (PU-GF), Glasfaser-verstärktem Epoxy (EP-GF) oder Glasfaser-verstärktem Polycarbonat (PC-GF) besteht.Metal foam, such as foamed aluminum, from a natural raw material or from a monolithic structure, such as sheet metal, glass fiber reinforced polyurethane (PU-GF), glass fiber reinforced epoxy (EP-GF) or glass fiber reinforced polycarbonate (PC-GF) consists.
6. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die wenigstens eine Deckschicht (132, 136) der Strukturschicht (130) aus einer in eine Kunststoffmatrix aus Polyamid (PA), Polypropylen (PP), Epoxy (EP) oder Polyurethan (PU) eingebetteten Faserschicht aus Glasfasern, Glasfaserverstärktem Polyurethan (PU-GF),6. The method according to any one of the preceding claims, characterized in that the at least one cover layer (132, 136) of the structural layer (130) from a in a plastic matrix of polyamide (PA), polypropylene (PP), epoxy (EP) or polyurethane ( PU) embedded fiber layer of glass fibers, glass fiber reinforced polyurethane (PU-GF),
Naturfasern, Polymerfasern, anorganischen Fasern, metallischen Fasern oder Carbonfasern gebildet ist.Natural fibers, polymer fibers, inorganic fibers, metallic fibers or carbon fibers is formed.
7. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass zwei Deckschichten (132, 136) zu beiden Seiten des7. The method according to any one of the preceding claims, characterized in that two cover layers (132, 136) on both sides of
Abstandshalters (134) angeordnet sind.Spacers (134) are arranged.
8. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die wenigstens eine Deckschicht (132, 136) mit einem in Hohlräume des Abstandshalters (134) eindringenden Kleber oder flüssigen Kunststoff verbunden ist.8. The method according to any one of the preceding claims, characterized in that the at least one cover layer (132, 136) with a in cavities of the spacer (134) penetrating adhesive or liquid plastic is connected.
9. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass wenigstens eine Splitterschutzschicht (116, 138) in den Dekorverbund (110) und/oder in den Strukturverbund (130) integriert ist. 9. The method according to any one of the preceding claims, characterized in that at least one splinter protection layer (116, 138) in the decorative composite (110) and / or in the structural composite (130) is integrated.
10. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die Verfahrensschritte 1.1 und 1.3 nacheinander in einem ersten Formwerkzeug (210) erfolgen.10. The method according to any one of the preceding claims, characterized in that the method steps 1.1 and 1.3 take place successively in a first mold (210).
11. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass der Verfahrensschritt 1.2 in räumlicher Distanz zu den anderen Verfahrensschritten erfolgt.11. The method according to any one of the preceding claims, characterized in that the method step 1.2 takes place in spatial distance from the other method steps.
12. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass das Zwischenprodukt des Verfahrensschritts 1.2 in ein zweites Formwerkzeug (230) eingelegt wird.12. The method according to any one of the preceding claims, characterized in that the intermediate product of the process step 1.2 in a second mold (230) is inserted.
13. Verfahren nach einem der Ansprüche 10 bis 12, dadurch gekennzeichnet, dass der Verfahrensschritt 1.4 durch Zusammendrücken des ersten Formwerkzeugs (210) mit dem zweiten Formwerkzeug (230) erfolgt.13. The method according to any one of claims 10 to 12, characterized in that the method step 1.4 by compressing the first mold (210) with the second mold (230).
14. Verbundbauteil, hergestellt nach wenigstens einem der vorhergehenden Verfahrensansprüche 1 bis 13.14. Composite component, produced according to at least one of the preceding method claims 1 to 13.
15. Verwendung eines Verbundbauteils gemäß Anspruch 14 für ein Fahrzeug- Außenhautbauteils, wie Fahrzeug-Dachmodul, Fahrzeugtür, Kotflügel, Motorraumklappe, Kofferraumklappe, Heckmodul, Dachschale eines Cabrioiet-Verdecks, Front- oder Heckspoiier. 15. Use of a composite component according to claim 14 for a vehicle outer skin component, such as vehicle roof module, vehicle door, fenders, engine compartment flap, trunk lid, rear module, roof shell of a convertible top, front or rear Spoiier.
EP09776931A 2008-08-01 2009-07-02 Process for producing a composite component from plastic, composite component produced by this process and use of such a component Withdrawn EP2303552A2 (en)

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DE102008035918A DE102008035918A1 (en) 2008-08-01 2008-08-01 Method for producing a composite component made of plastic and composite component produced by this method
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