WO2001054888A1 - Method for producing a lasting connection between a planar lightweight plastic component that has a quality surface and an element - Google Patents

Method for producing a lasting connection between a planar lightweight plastic component that has a quality surface and an element Download PDF

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Publication number
WO2001054888A1
WO2001054888A1 PCT/EP2001/000722 EP0100722W WO0154888A1 WO 2001054888 A1 WO2001054888 A1 WO 2001054888A1 EP 0100722 W EP0100722 W EP 0100722W WO 0154888 A1 WO0154888 A1 WO 0154888A1
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WO
WIPO (PCT)
Prior art keywords
component
plastic
lightweight
quality surface
laser light
Prior art date
Application number
PCT/EP2001/000722
Other languages
German (de)
French (fr)
Inventor
Arnold Gillner
Heidrun Kind
Original Assignee
Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V.
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
Priority claimed from DE10059160A external-priority patent/DE10059160B4/en
Application filed by Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. filed Critical Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V.
Publication of WO2001054888A1 publication Critical patent/WO2001054888A1/en

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Classifications

    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/434—Joining substantially flat articles for forming corner connections, fork connections or cross connections
    • B29C66/4344—Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces
    • B29C66/43441—Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces with two right angles, e.g. for making T-shaped pieces, H-shaped pieces
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • B29C65/1638—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding focusing the laser beam on the interface
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D27/00—Connections between superstructure or understructure sub-units
    • B62D27/02—Connections between superstructure or understructure sub-units rigid
    • B62D27/023—Assembly of structural joints
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1674—Laser beams characterised by the way of heating the interface making use of laser diodes
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/474—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/52—Joining tubular articles, bars or profiled elements
    • B29C66/524—Joining profiled elements
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B29L2031/3014—Door linings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3044—Bumpers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3055—Cars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/762—Household appliances

Definitions

  • the invention relates to a method for producing a permanent connection between a flat, lightweight plastic component with a quality surface and an element.
  • Plastic lightweight components are becoming increasingly important in the product-related industry and here in particular in the automotive sector, especially since the plastic material replaces the classic use of metal in many areas, since these have a significantly lower specific weight, which is particularly important in the automotive industry in the light of energy savings important aspect is.
  • bumpers, doors or door panels, as well as the trunk lid or fenders of cars are made entirely of plastic, as are automotive components, where flexibility regarding external mechanical influences and weight reduction are equally important. This applies in particular to bumpers, which on the one hand have to be flexible in order not to receive permanent damage with every external contact, otherwise they are usually completely replaced. All of the above-mentioned components, in particular bumpers, provide a large area, so that due to their large flat design they have great weight saving potential, which can be used in a targeted manner by reducing the component wall thickness.
  • such components are provided with suitable substructures, for example by providing rib-like features within the component which face away from that surface of the component which, for example, does not appear visually in the automotive sector.
  • suitable substructures for example by providing rib-like features within the component which face away from that surface of the component which, for example, does not appear visually in the automotive sector.
  • the molds which are used for the production of the components in the course of an injection molding process provide correspondingly shaped depressions, on which an increased accumulation of material can form in comparison to the rather thin-walled surface areas of the lightweight plastic components.
  • substructures or ribs not to be produced using an injection molding process, but instead to be retrofitted to the injection molded part, which is considered to be a semi-finished product, at corresponding points on the underside.
  • joining agents or adhesion promoters in the form of adhesive adhesives are used in a manner known per se, which between the corresponding point of the lightweight plastic component and the respective stiffening element can be introduced.
  • this classic joining method reaches its production limits, especially for production on an industrial scale, especially since adhesives have a certain setting time that is too lengthy to be used in high-speed production lines.
  • plastic joining processes such as ultrasonic welding, friction welding or mirror welding, for the joining processes outlined above, since they too can influence the quality surfaces of thin-walled surface components to reduce the quality.
  • the invention is therefore based on the object of specifying a method for producing a permanent connection between a flat plastic lightweight component with a quality surface and an element, such as, for example, ribbing, in such a way that the joining process should take place without impairing the quality surface.
  • the joining process for use on a large industrial scale, i.e. suitable for mass production of lightweight plastic components.
  • the method should be suitable for assembling plastic components that are to be attached to support elements.
  • a method according to the preamble of claim 1 is designed such that the element which preferably reinforces the plastic lightweight component, at least in some areas made of a laser light-transparent material, is attached to a surface of the plastic lightweight component facing away from the quality surface and has at least partial contact areas with this surface ,
  • the contact areas are now using Laser light which is radiated through the laser-transparent, reinforcing element is irradiated in such a way that the laser light energy is at least partially absorbed by the plastic lightweight component and the plastic component enters into a material connection in the manner of a welded connection at the contact areas with the reinforcing element.
  • the energy deposition through light absorption within the lightweight plastic component should be chosen so that the resulting material bond does not affect the geometrical or material properties of the quality surface.
  • the joining process can be carried out quickly, so that it is suitable for use in a fast-running production line.
  • the contact areas exposed to the laser light cool down within a few hundred milliseconds, so that the components available are immediately available for further production immediately after the joining process.
  • Fig. 1 representation for fastening a polymer outer skin to a polymer stiffening or fastening element
  • Fig. 2 representation for fastening a polymer outer skin to a stiffening or fastening element with a metal core.
  • the plastic lightweight component 1 shows a basic illustration for stiffening a flat plastic lightweight component 1, which is designed in the manner of a thin-walled polymer skin and can be used, for example, in the automotive sector as a door panel.
  • the plastic lightweight component 1 has a polymer outer skin 11 which corresponds to the quality surface, the side 12 facing away from the quality surface 11 being intended to be reinforced with a reinforcing element 2, the so-called stiffening element.
  • laser radiation from the stiffening element 2 strikes the contact area 3 between the lightweight plastic component 1 and the reinforcing element 2.
  • the stiffening element 2 is transparent to the wavelength of the laser light used.
  • the material of both joining partners is heated in the region of the contact surface 3 and melted accordingly.
  • the melting process results in a local substance bond, which leads to an intimate solid bond after cooling.
  • a diode laser or a Nd.YAG laser is used as the laser light source for this joining process.
  • the reinforcing element 2 additionally has a metal fastening 4, which is in an intimate joint connection with the stiffening element 2.
  • the metal fastening 4 is used to attach the lightweight plastic component 1, for example to a support structure such as, for example, the body of a motor vehicle.
  • stiffening and fastening elements applied in this way have a good ability to repair, for example, damaged bumpers.
  • the outer skin of a bumper If the outer skin of a bumper is damaged, it can be milled off at the fastening points in such a way that a new component can be reattached to the old carrier by means of laser welding. It is also possible to heat the connection points between the outer skin and the wearer by means of laser radiation and to heat them until the outer skin can be removed. After leveling the joints, a new outer skin can be attached again.
  • connection technology described above can in principle be applied to all components in which it is important to optimize their own weight, the quality properties of at least one outer surface of the product should remain unaffected.
  • the method according to the invention can also be successfully used in the household goods industry, for example in the production of coffee machines or similar products.
  • Plastic surface component Quality surface, underside of reinforcement element, stiffening element, joining area, connection structure, metal component

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • Health & Medical Sciences (AREA)
  • Electromagnetism (AREA)
  • Toxicology (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

The invention relates to a method for producing a lasting connection between a planar lightweight plastic component that has a quality surface and an element. The inventive method is characterized in that the element (2) that consists at least partially of a laser-light transparent material is fastened to a surface facing away from the quality surface (11) and at least partially contacts said surface. The areas of contact (3) are irradiated with laser light that is passed through the element (2) in such a manner that the laser light energy is at least partially absorbed by the lightweight plastic component, thereby materially connecting the lightweight plastic component in the contact areas in the manner of a weld joint. Said material connection does not impair the geometrical or the material condition of the quality surface (11).

Description

Verfahren zur Herstellung einer dauerhaften Verbindung zwischen einem flächigen, Kunststoffleichtbauteil mit einer Qualitätsoberfläche und einem Element Process for producing a permanent connection between a flat, plastic lightweight component with a quality surface and an element
Technisches GebietTechnical field
Die Erfindung bezieht sich ein Verfahren zur Herstellung einer dauerhaften Verbindung zwischen einem flächigen, Kunststoffleichtbauteil mit einer Qualitätsoberfläche und einem Element.The invention relates to a method for producing a permanent connection between a flat, lightweight plastic component with a quality surface and an element.
Stand der TechnikState of the art
Kunststoffleichtbauteile gewinnen in der produktbezogenen Industrie und hier insbesondere im KfZ-Bereich zunehmend an Bedeutung, zumal der Werkstoff Kunststoff in vielen Bereichen die klassische Verwendung von Metall ablöst, da diese ein erheblich geringeres spezifisches Gewicht aufweisen, was insbesondere in der Fahrzeugindustrie im Lichte der Energieeinsparung ein wichtiger Aspekt ist. So werden beispielsweise Stoßfänger, Türen oder Türverkleidungen sowie Kofferraumdeckel oder Kotflügel von Autos vollständig aus Kunststoff gefertigt sowie auch KfZ-Komponenten, bei denen es auf Nachgiebigkeit hinsichtlich äußerer mechanischer Einflüsse sowie auch Gewichtsreduzierung im gleichen Maße ankommt. Dies gilt insbesondere für Stoßfänger, die einerseits nachgiebig sein müssen, um nicht bei jeder äußeren Berührung bleibende Schäden zu erhalten, ansonsten werden sie zumeist vollständig ausgewechselt. Alle vorstehend genannten Komponenten, insbesondere Stoßfänger, sehen eine große Fläche vor, so dass sie aufgrund ihrer großen flächigen Ausbildung ein großes Gewichtseinsparungspotential aufweisen, das durch Reduzierung der Bauteilwandstärke gezielt genutzt werden kann.Plastic lightweight components are becoming increasingly important in the product-related industry and here in particular in the automotive sector, especially since the plastic material replaces the classic use of metal in many areas, since these have a significantly lower specific weight, which is particularly important in the automotive industry in the light of energy savings important aspect is. For example, bumpers, doors or door panels, as well as the trunk lid or fenders of cars are made entirely of plastic, as are automotive components, where flexibility regarding external mechanical influences and weight reduction are equally important. This applies in particular to bumpers, which on the one hand have to be flexible in order not to receive permanent damage with every external contact, otherwise they are usually completely replaced. All of the above-mentioned components, in particular bumpers, provide a large area, so that due to their large flat design they have great weight saving potential, which can be used in a targeted manner by reducing the component wall thickness.
Um einerseits der Forderung nach Gewichtseinsparung nachzukommen und die Wandstärken derartiger flächig ausgebildeter Kunststoffleichtbauteilen zu reduzieren,In order to meet the demand for weight saving and to reduce the wall thickness of such flat plastic lightweight components,
BESTATIGUNGSKOPIE andererseits jedoch eine ausreichende Eigenstabilität der Flächenbauteil gegenüber Verformbarkeit zu gewährleisten, werden derartige Bauteile mit geeigneten Unterstrukturen versehen, beispielsweise durch Vorsehen rippenartiger Ausprägungen innerhalb des Bauteiles, die jener Oberfläche des Bauteils abgewandt gegenüberliegen, die beispielsweise im KfZ-Bereich nicht optisch in Erscheinung tritt. Zur Herstellung derartiger Unterstrukturen in Form von Verrippungen sehen die Gussformen, der für die Herstellung der Bauteile im Rahmen eines Spritzgießverfahrens eingesetzt werden, entsprechend geformte Vertiefungen vor, an denen sich eine vermehrte Materialansammlung ausbilden kann im Vergleich zu den eher dünnwandig ausgebildeten Flächenbereiche der Kunststoffleichtbauteile. Da der Kunststoff jedoch im Verlauf des Spritzgießprozesses und insbesondere in der nach dem Spritzgussprozess anschließenden Abkühlphase stark schrumpft, ergeben sich insbesondere im Bereich der Verrippungen größere Materialansammlungen, wodurch die den Verrippungen abgewandte qualitativ hochwertige Oberfläche des Kunststoffleichtbauteils dergestalt in Mitleidenschaft gezogen wird, dass in Bereichen der Verrippungen die ansonsten eben ausgebildete Qualitätsoberfläche Dellen bzw. Einbuchtungen erhält, eine Erscheinung, die insbesondere bei Sichtbauteilen nicht akzeptiert werden kann.BESTATIGUNGSKOPIE on the other hand, however, to ensure sufficient inherent stability of the surface component with respect to deformability, such components are provided with suitable substructures, for example by providing rib-like features within the component which face away from that surface of the component which, for example, does not appear visually in the automotive sector. For the production of such substructures in the form of ribs, the molds which are used for the production of the components in the course of an injection molding process provide correspondingly shaped depressions, on which an increased accumulation of material can form in comparison to the rather thin-walled surface areas of the lightweight plastic components. However, since the plastic shrinks considerably in the course of the injection molding process and in particular in the cooling phase that follows after the injection molding process, there is a large accumulation of material, particularly in the area of the ribs, as a result of which the high-quality surface of the lightweight plastic component facing away from the ribs is affected in such a way that in areas of Ribs that otherwise have a quality surface that has just been formed are dented or indented, a phenomenon that cannot be accepted, particularly with exposed components.
Um diese Schrumpfungserscheinungen insbesondere an den vorstehend bezeichneten Stellen an der Qualitätsoberfläche eines Spritzgussteiles zu vermeiden, bedarf es aufwendiger und zeitintensiver Spritzgussvorgänge, bei denen während der Abkühlphase zusätzliches Kunststoffmaterial in die kritischen Bereiche eingebracht wird, um ein „Einfallen" der Qualitätsoberflächen zu verhindern.In order to avoid these signs of shrinkage, in particular at the points on the quality surface of an injection molded part described above, complex and time-consuming injection molding processes are required in which additional plastic material is introduced into the critical areas during the cooling phase in order to prevent the quality surfaces from “sinking in”.
Eine andere Möglichkeit sieht vor, die Unterstrukturen bzw. Verrippungen nicht im Rahmen eines Spritzgussverfahrens herzustellen, sondern nachträglich auf das als Halbfertigprodukt geltende Spritzgussteil an entsprechenden Stellen der Unterseite anzubringen.Another possibility provides for the substructures or ribs not to be produced using an injection molding process, but instead to be retrofitted to the injection molded part, which is considered to be a semi-finished product, at corresponding points on the underside.
Zu diesem Fügeprozess werden in an sich bekannter Weise Füge- bzw. Haftvermittler in Form von Adhäsivklebstoffen eingesetzt, die zwischen der entsprechenden Stelle des Kunststoffleichtbauteils und dem jeweiligen Versteifungselement eingebracht werden. Insbesondere bei Fertigungen im industriellen Maßstab stößt diese klassische Fügemethode jedoch an Produktionsgrenzen, zumal Klebstoffe über eine gewisse Abbindezeit verfügen, die zu langwierig ist, um in schnelllaufenden Fertigungslinien eingesetzt zu werden.For this joining process, joining agents or adhesion promoters in the form of adhesive adhesives are used in a manner known per se, which between the corresponding point of the lightweight plastic component and the respective stiffening element can be introduced. However, this classic joining method reaches its production limits, especially for production on an industrial scale, especially since adhesives have a certain setting time that is too lengthy to be used in high-speed production lines.
Ebenso scheiden an sich bekannte Kunststofffügeprozesse, wie Ultraschallschweißen, Reibschweißen oder Spiegelschweißen für die vorstehend skizzierten Fügevorgänge aus, da auch sie die Qualitätsoberflächen dünnwandiger Flächenbauteile qualitätsmindernd zu beeinflussen vermögen.Also known per se are plastic joining processes, such as ultrasonic welding, friction welding or mirror welding, for the joining processes outlined above, since they too can influence the quality surfaces of thin-walled surface components to reduce the quality.
Darstellung der ErfindungPresentation of the invention
Der Erfindung liegt daher die Aufgabe zugrunde, ein Verfahren zur Herstellung einer dauerhaften Verbindung zwischen einem flächigen Kunststoffleichtbauteil mit einer Qualitätsoberfläche und einem Element, wie beispielsweise eine Verrippung, derart anzugeben, dass der Fügeprozess ohne die Beeinträchtigung der Qualitätsoberfläche erfolgen soll. Ferner soll sich der Fügeprozess für den Einsatz in großindustriellem Maßstab, d.h. in der Massenfertigung von Kunststoffleichtbauteilen eignen. Insbesondere soll das Verfahren zur Montage von Kunststoffbauteilen, die an Tragelementen anzubringen sind, geeignet sein.The invention is therefore based on the object of specifying a method for producing a permanent connection between a flat plastic lightweight component with a quality surface and an element, such as, for example, ribbing, in such a way that the joining process should take place without impairing the quality surface. Furthermore, the joining process for use on a large industrial scale, i.e. suitable for mass production of lightweight plastic components. In particular, the method should be suitable for assembling plastic components that are to be attached to support elements.
Die Lösung der der Erfindung zugrundeliegenden Aufgabe ist im Anspruch 1 angegeben. Den Erfindungsgedanken vorteilhaft weiterbildende Merkmale sind Gegenstand der Unteransprüche sowie der Beschreibung in Bezugnahme auf das Ausführungsbeispiel zu entnehmen.The solution to the problem on which the invention is based is specified in claim 1. Features which advantageously further develop the inventive concept are the subject matter of the subclaims and the description with reference to the exemplary embodiment.
Erfindungsgemäß wird ein Verfahren gemäß dem Oberbegriff des Anspruchs 1 derart ausgebildet, dass das vorzugsweise das Kunststoffleichtbauteil verstärkende Element, wenigstens in Teilbereichen aus einem Laserlicht-transparenten Material bestehend, auf einer der Qualitätsoberfläche abgewandten Oberfläche des Kunststoffleichtbauteils angebracht wird und mit dieser Oberfläche wenigstens teilweise Kontaktbereiche aufweist. Die Kontaktbereiche werden nun mittels Laserlicht, das durch das laserlichttransparente, verstärkende Element hindurchgestrahlt wird, derart bestrahlt, dass die Laserlichtenergie wenigstens teilweise vom Kunststoffleichtbauteil absorbiert wird und das Kunststoffbauteil an den Kontaktbereichen mit dem verstärkenden Element eine Stoffverbindung in Art einer Schweißverbindung eingeht. Die Energiedeponierung durch Lichtabsorption innerhalb des Kunststoffleichtbauteils ist gerade so zu wählen, dass die dabei entstehende Stoffverbindung weder die geometrische noch die stoffliche Beschaffenheit der Qualitätsoberfläche beeinträchtigt.According to the invention, a method according to the preamble of claim 1 is designed such that the element which preferably reinforces the plastic lightweight component, at least in some areas made of a laser light-transparent material, is attached to a surface of the plastic lightweight component facing away from the quality surface and has at least partial contact areas with this surface , The contact areas are now using Laser light which is radiated through the laser-transparent, reinforcing element is irradiated in such a way that the laser light energy is at least partially absorbed by the plastic lightweight component and the plastic component enters into a material connection in the manner of a welded connection at the contact areas with the reinforcing element. The energy deposition through light absorption within the lightweight plastic component should be chosen so that the resulting material bond does not affect the geometrical or material properties of the quality surface.
Da das vorstehend bezeichnete Laserstrahlschweißen zum Verfügen keine Haftoder zusätzlichen Fügemittel, wie beispielsweise Adhäsivklebstoffe, benötigt, kann der Fügeprozess schnell durchgeführt werden, so dass er sich für den Einsatz in einer schnelllaufenden Fertigungslinie eignet. Typischerweise erkalten die mit dem Laserlicht beaufschlagten Kontaktbereiche innerhalb weniger hundert Millisekunden, so dass die verfügten Bauteile unmittelbar nach dem Fügeprozess sofort dem weiteren Produktionsfortgang zur Verfügung stehen.Since the laser beam welding described above does not require any adhesives or additional joining means, such as adhesive adhesives, for joining, the joining process can be carried out quickly, so that it is suitable for use in a fast-running production line. Typically, the contact areas exposed to the laser light cool down within a few hundred milliseconds, so that the components available are immediately available for further production immediately after the joining process.
Neben dem Fügen von verstärkenden Elementen, die lediglich der Erhöhung der Eigenstabilität dienen, ist es auch möglich, Strukturbauteile an einem flächig ausgebildeten Kunststoffleichtbauteil im Wege des vorstehend skizzierten Laserstrahlschweißens anzubringen, die selbst eine Verbindungsstruktur aufweisen, beispielsweise einen Metallrahmen vorsehen, der wiederum mit einer weiteren Trägerstruktur verbindbar ist. Somit ist es beispielsweise möglich, beliebig ausgebildete Funktionsbauteile an eine entsprechende Stelle eines flächigen Kunststoffleichtbauteiles anzufügen, ohne dass die Qualitätsoberfläche des Kunststoffleichtbauteils nachhaltig beeinflusst wird.In addition to the joining of reinforcing elements, which only serve to increase the inherent stability, it is also possible to attach structural components to a flat plastic lightweight component by means of the laser beam welding outlined above, which themselves have a connecting structure, for example provide a metal frame, which in turn provides another Support structure is connectable. It is thus possible, for example, to add functional components of any design to a corresponding location on a flat plastic lightweight component without the quality surface of the plastic lightweight component being permanently influenced.
Kurze Beschreibung der ErfindungBrief description of the invention
Die Erfindung wird nachstehend ohne Beschränkung des allgemeinen Erfindungsgedankens anhand von Ausführungsbeispielen unter Bezugnahme auf die Zeichnung exemplarisch beschrieben. Es zeigen: Fig. 1 Darstellung zur Befestigung einer Polymer-Aussenhaut an ein Polymerversteifungs- bzw. Befestigungselement, sowieThe invention is described below by way of example without limitation of the general inventive concept using exemplary embodiments with reference to the drawing. Show it: Fig. 1 representation for fastening a polymer outer skin to a polymer stiffening or fastening element, and
Fig. 2 Darstellung für eine Befestigung einer Polymer-Aussenhaut an ein Versteifungs- bzw. Befestigungselement mit Metallkern.Fig. 2 representation for fastening a polymer outer skin to a stiffening or fastening element with a metal core.
Wege zur Ausführung der Erfindung, gewerbliche VerwendbarkeitWAYS OF CARRYING OUT THE INVENTION, INDUSTRIAL APPLICABILITY
In Fig. 1 ist eine Prinzipdarstellung zur Versteifung eines flächig ausgebildeten Kunststoffleichtbauteils 1 gezeigt, das in Art einer dünnwandigen Polymerhaut ausgebildet ist und beispielsweise im KfZ-Bereich als Türverkleidung eingesetzt werden kann. Das Kunststoffleichtbauteil 1 weist eine Polymeraussenhaut 11 auf, die der Qualitätsoberfläche entspricht, wobei die der Qualitätsoberfläche 11 abgewandte Seite 12 zur Verstärkung mit einem verstärkenden Element 2, dem sogenannten Versteifungselement, verfügt werden soll. Hierzu fällt Laserstrahlung von Seiten des Versteifungselementes 2 auf den Kontaktbereich 3 zwischen dem Kunststoffleichtbauteil 1 und dem verstärkenden Element 2. Das Versteifungselement 2 ist für die Wellenlänge des eingesetzten Laserlichtes transparent beschaffen. Über Wärmeleitung wird bei Kontakt beider Fügepartner, also durch kraftbeaufschlagtes Aneinanderpressen des Kunststoffleichtbauteils 1 gegen das Versteifungselement 2, das Material beider Fügepartner im Bereich der Kontaktfläche 3 aufgeheizt und entsprechend aufgeschmolzen. Durch den Aufschmelzvorgang kommt es zu einer lokalen Stoffverbindung, die nach entsprechendem Erkalten zu einer innigen festen Verbindung führt.1 shows a basic illustration for stiffening a flat plastic lightweight component 1, which is designed in the manner of a thin-walled polymer skin and can be used, for example, in the automotive sector as a door panel. The plastic lightweight component 1 has a polymer outer skin 11 which corresponds to the quality surface, the side 12 facing away from the quality surface 11 being intended to be reinforced with a reinforcing element 2, the so-called stiffening element. For this purpose, laser radiation from the stiffening element 2 strikes the contact area 3 between the lightweight plastic component 1 and the reinforcing element 2. The stiffening element 2 is transparent to the wavelength of the laser light used. When the two joining partners come into contact with one another, that is, by pressing the plastic lightweight component 1 against the stiffening element 2 with force, the material of both joining partners is heated in the region of the contact surface 3 and melted accordingly. The melting process results in a local substance bond, which leads to an intimate solid bond after cooling.
Typischerweise werden für diesen Fügeprozess als Laserlichtquelle ein Diodenlaser oder auch ein Nd.YAG-Laser eingesetzt.Typically, a diode laser or a Nd.YAG laser is used as the laser light source for this joining process.
In Fig. 2 weist das verstärkende Element 2 zusätzlich eine Metall-Befestigung 4 auf, die in einem innigen Fügeverbund mit dem Versteifungselement 2 steht. Die Metall- Befestigung 4 dient der Anbringung des Kunststoffleichtbauteils 1 , beispielsweise an einer Trägerstruktur wie beispielsweise der Karosserie eines KfZs Auch in diesem Fall erfolgt die Verbindung des verstärkenden Elementes 2, das im Ausführungsbeispiel gemäß Fig. 2 zusätzlich die Funktion eines Tragelementes erhält, mit dem vorstehend beschriebenen Laserstrahlschweißen.In FIG. 2, the reinforcing element 2 additionally has a metal fastening 4, which is in an intimate joint connection with the stiffening element 2. The metal fastening 4 is used to attach the lightweight plastic component 1, for example to a support structure such as, for example, the body of a motor vehicle. In this case, too, the reinforcing element 2, which in the Embodiment according to FIG. 2 additionally receives the function of a support element, with the laser beam welding described above.
Ein weiterer Vorteil des erfindungsgemäßen Verfahrens besteht darin, dass die auf diese Weise aufgebrachten Versteifungs- und Befestigungselemente eine gute Reparaturfähigkeit beispielsweise von beschädigten Stoßfängern aufweisen. Bspw. bei einer Beschädigung der Aussenhaut eines Stoßfängers kann dieser an den Befestigungsstellen derart abgefräst werden, dass ein neues Bauteil mittels Laserschweißen auf dem alten Träger wieder befestigt werden kann. Auch ist es möglich die Verbindungsstellen zwischen der Aussenhaut und dem Träger mittels Laserstrahlung aufzuheizen und soweit zu erwärmen, bis die Aussenhaut abgezogen werden kann. Nach Einebnen der Fügestellen kann dann wieder eine neue Aussenhaut befestigt werden.Another advantage of the method according to the invention is that the stiffening and fastening elements applied in this way have a good ability to repair, for example, damaged bumpers. For example. If the outer skin of a bumper is damaged, it can be milled off at the fastening points in such a way that a new component can be reattached to the old carrier by means of laser welding. It is also possible to heat the connection points between the outer skin and the wearer by means of laser radiation and to heat them until the outer skin can be removed. After leveling the joints, a new outer skin can be attached again.
Die vorstehend beschriebene Verbindungstechnologie kann grundsätzlich an allen Bauteilen angewandt werden, bei denen es auf die Optimierung ihres Eigengewichtes ankommt, wobei die Qualitätseigenschaften wenigstens einer Aussenoberfläche des Produktes unbeeinflusst bleiben sollen. Neben Kunststoffflächenbauteilen im KfZ-Bereich kann das erfindungsgemäße Verfahren auch in der Haushaltswarenindustrie erfolgreich eingesetzt werden, beispielsweise bei der Herstellung von Kaffeemaschinen oder ähnlichen Produkten. The connection technology described above can in principle be applied to all components in which it is important to optimize their own weight, the quality properties of at least one outer surface of the product should remain unaffected. In addition to plastic surface components in the motor vehicle sector, the method according to the invention can also be successfully used in the household goods industry, for example in the production of coffee machines or similar products.
BezugszeichenlisteLIST OF REFERENCE NUMBERS
Kunststoffflächenbauteil Qualitätsoberfläche Unterseite Verstärkungselement, Versteifungselement Fügebereich Verbindungsstruktur, Metallbauteil Plastic surface component, quality surface, underside of reinforcement element, stiffening element, joining area, connection structure, metal component

Claims

Patentansprüche claims
1. Verfahren zur Herstellung einer dauerhaften Verbindung zwischen einem flächigen, Kunststoffleichtbauteil mit einer Qualitätsoberfläche und einem Element, dadurch gekennzeichnet, dass das Element, wenigstens in Teilbereichen aus einem Laserlicht-transparenten Material bestehend, auf einer der Qualitätsoberfläche abgewandten Oberfläche angebracht wird und mit dieser Oberfläche wenigstens teilweise Kontaktbereiche aufweist, dass die Kontaktbereiche mittels Laserlicht, das durch das Element hindurchgestrahlt wird, derart bestrahlt wird, dass die Laserlichtenergie wenigstens teilweise vom Kunststoffleichtbauteil absorbiert wird und das Kunststoffbauteil an den Kontaktbereichen mit dem Element eine Stoffverbindung in Art einer Schweißverbindung eingeht und dass die dabei entstehende Stoffverbindung weder die geometrische noch die stoffliche Beschaffenheit der Qualitätsoberfläche beeinträchtigt.1. A method for producing a permanent connection between a flat, plastic lightweight component with a quality surface and an element, characterized in that the element, at least in some areas consisting of a laser light-transparent material, is attached to a surface facing away from the quality surface and with this surface has at least partially contact areas, that the contact areas are irradiated by means of laser light which is irradiated through the element in such a way that the laser light energy is at least partially absorbed by the lightweight plastic component and the plastic component enters into a material connection in the manner of a welded connection at the contact areas with the element and that The resulting bond does not affect the geometric or material properties of the quality surface.
2. Verfahren nach Anspruch 1 , dadurch gekennzeichnet, dass das Element eine das Kunststoffleichtbauteil mechanisch verstärkendes Element ist.2. The method according to claim 1, characterized in that the element is a mechanically reinforcing element of the lightweight plastic component.
3. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass das Kunststoffleichtbauteil ein KfZ-Bauteil ist, insbesondere ein Stoßfänger, eine Tür- oder Kotflügelverkleidung oder ein Kofferraumdeckel.3. The method according to claim 1 or 2, characterized in that the plastic lightweight component is a motor vehicle component, in particular a bumper, a door or fender trim or a trunk lid.
4. Verfahren nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass das Kunststoffleichtbauteil eine Wanddicke im mm- Bereich und darunter aufweist. 4. The method according to any one of claims 1 to 3, characterized in that the lightweight plastic component has a wall thickness in the mm range and below.
5. Verfahren nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass die Wahl des Laserlichtes hinsichtlich Wellenlänge und Strahlungsenergie derart getroffen werden, dass das von dem Kunststoffleichtbauteil absorbierte Laserlicht einen Schweissprozess an der der Qualitätsoberfläche abgewandten Oberfläche im Bereich der Kontaktbereiche hervorruft, der ein in das Kunststoffleichtbauteil hineinreichende Tiefenwirkung aufweist, sodass die Qualitätsoberfläche unbeeinträchtigt bleibt.5. The method according to any one of claims 1 to 4, characterized in that the selection of the laser light in terms of wavelength and radiation energy are made such that the laser light absorbed by the plastic lightweight component causes a welding process on the surface facing away from the quality surface in the area of the contact areas, which a has a depth effect reaching into the lightweight plastic component, so that the quality surface remains unaffected.
6. Verfahren nach einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, dass Form, Größe sowie die Wahl der Anbringung des verstärkenden Elements sowie die Anzahl der an das Kunststoffleichtbauteil anzubringenden Elemente nach Maßgabe der Reduzierung der Wandstärke des Kunststoffleichtbauteils durchgeführt.6. The method according to any one of claims 1 to 5, characterized in that the shape, size and the choice of attachment of the reinforcing element and the number of elements to be attached to the plastic lightweight component are carried out in accordance with the reduction in the wall thickness of the plastic lightweight component.
7. Verfahren nach einem der Ansprüche der Ansprüche 1 bis 6, dadurch gekennzeichnet, dass das Element mit einer Verbindungsstruktur fest verfügt ist, die eine Befestigung des Kunststoffleichtbauteils an einer Trägerstruktur über das verstärkende Element ermöglicht. 7. The method according to any one of claims 1 to 6, characterized in that the element is fixedly provided with a connecting structure which enables the lightweight plastic component to be fastened to a carrier structure via the reinforcing element.
PCT/EP2001/000722 2000-01-25 2001-01-24 Method for producing a lasting connection between a planar lightweight plastic component that has a quality surface and an element WO2001054888A1 (en)

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DE10059160A DE10059160B4 (en) 2000-01-25 2000-11-29 Flat vehicle component, namely bumper, door or fender trim or boot lid
DE10059160.4 2000-11-29

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Publication number Priority date Publication date Assignee Title
CN102387943A (en) * 2009-04-07 2012-03-21 杜拉汽车车身及玻璃系统有限公司 Light shade for motor vehicle
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FR2980429A1 (en) * 2011-09-23 2013-03-29 Peugeot Citroen Automobiles Sa Method for manufacturing plastic panel used to protect e.g. side door of car from shocks, involves defining cell by wall spacing zones, where cell is filled with air and delimited by sealed mechanical connection formed by laser welding line
CN103946067A (en) * 2011-09-23 2014-07-23 标致·雪铁龙汽车公司 Protective panel to be attached onto a portion of the body of a motor vehicle, and method for manufacturing such a panel
CN103946067B (en) * 2011-09-23 2016-11-16 标致·雪铁龙汽车公司 For being fixed on the protection board in a motor vehicle body part and manufacture method thereof
FR2990666A1 (en) * 2012-05-15 2013-11-22 Peugeot Citroen Automobiles Sa Plastic protective panel for protecting e.g. side door of car from shocks, has vent assuring communication between wall spacing areas and outside of panel, where each area defines cell that is filled with air and delimited by sealed linkage

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