EP2303552A2 - Procédé pour fabriquer un élément composite en plastique, élément composite fabriqué selon ce processus et utilisation de cet élément - Google Patents

Procédé pour fabriquer un élément composite en plastique, élément composite fabriqué selon ce processus et utilisation de cet élément

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Withdrawn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)
English (en)
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/fr
Withdrawn legal-status Critical Current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 shape; Layered products comprising a layer 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 shape; Layered products comprising a layer 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 shape; Layered products comprising a layer 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

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Composite Materials (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Body Structure For Vehicles (AREA)
  • Laminated Bodies (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Superstructure Of Vehicle (AREA)

Abstract

L'invention concerne un procédé pour fabriquer un élément composite (100) avec les étapes suivantes: 1.1 Fabrication d'un composite décoratif (110) composé d'au moins une couche de support (114) et d'au moins une couche colorante (112), 1.2 fabrication d'un composite structurel (130) composé d'au moins une couche de couverture (132; 136) et d'au moins un espaceur (134) relié à celle-ci, 1.3 introduction d'une couche de liaison (120) entre composite décoratif (110) et composite structurel (130), et 1.4 assemblage du composite structurel (130) et du composite décoratif (110) en faisant durcir la couche de liaison (120).
EP09776931A 2008-08-01 2009-07-02 Procédé pour fabriquer un élément composite en plastique, élément composite fabriqué selon ce processus et utilisation de cet élément Withdrawn EP2303552A2 (fr)

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DE102008035918A DE102008035918A1 (de) 2008-08-01 2008-08-01 Verfahren zur Herstellung eines Verbundbauteils aus Kunststoff und nach diesem Verfahren hergestelltes Verbundbauteil
PCT/EP2009/004794 WO2010012348A2 (fr) 2008-08-01 2009-07-02 Procédé pour fabriquer un élément composite en plastique, élément composite fabriqué selon ce processus et utilisation de cet élément

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EP2303552A2 true EP2303552A2 (fr) 2011-04-06

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US (1) US20110262703A1 (fr)
EP (1) EP2303552A2 (fr)
JP (1) JP2011529803A (fr)
CN (1) CN102112295A (fr)
DE (1) DE102008035918A1 (fr)
WO (1) WO2010012348A2 (fr)

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CN102112295A (zh) 2011-06-29
WO2010012348A3 (fr) 2010-07-22
WO2010012348A2 (fr) 2010-02-04
DE102008035918A1 (de) 2010-02-04
US20110262703A1 (en) 2011-10-27
WO2010012348A8 (fr) 2011-02-17
JP2011529803A (ja) 2011-12-15

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