WO2008067901A1 - Method for the production of a composite component - Google Patents

Method for the production of a composite component Download PDF

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Publication number
WO2008067901A1
WO2008067901A1 PCT/EP2007/009925 EP2007009925W WO2008067901A1 WO 2008067901 A1 WO2008067901 A1 WO 2008067901A1 EP 2007009925 W EP2007009925 W EP 2007009925W WO 2008067901 A1 WO2008067901 A1 WO 2008067901A1
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WO
WIPO (PCT)
Prior art keywords
hollow profile
pressure
composite component
injection
encapsulated
Prior art date
Application number
PCT/EP2007/009925
Other languages
German (de)
French (fr)
Inventor
Kai-Uwe Dudziak
Jens Schult
Jörg KÖLLN
Original Assignee
Daimler 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 Daimler Ag filed Critical Daimler Ag
Publication of WO2008067901A1 publication Critical patent/WO2008067901A1/en

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00Casting in, on, or around objects which form part of the product
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B29C2045/14213Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure deforming by gas or fluid pressure in the mould cavity
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14598Coating tubular articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14754Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles being in movable or releasable engagement with the coating, e.g. bearing assemblies

Definitions

  • the invention relates to a method for producing a composite component according to the preamble of claim 1.
  • a generic method is known from DE 100 14 332 C2. According to paragraphs 17 and 34, a hydroforming process is combined with an injection molding process using a combination tool. An undeformed or preformed hollow section is placed between the two halves of the open
  • Combination tool brought after which the hollow profile is brought into its final shape analogous to the hydroforming process by closing the tool.
  • molded plastic components are molded onto the hollow profile formed by fluidic hydroforming in the mold cavity of the tool.
  • the fluid pressure within the hollow profile is maintained until cooling of the composite component in the form of a support pressure.
  • folds and kinks on the hollow profile occur during the forming phase, which can no longer be eliminated.
  • the invention has the object of developing a generic method to the effect that the production of a composite component is made possible in a relatively simple manner and process reliable.
  • the over-molded, cooled areas of the composite component remain dimensionally stable and do not deform further and in the mold in these areas no further free spaces are available, in which a widening of the hollow profile material could occur, the non-encapsulated areas almost arbitrarily by the action of the fluid high internal pressure be deformed.
  • the support pressure which is present in the interior of the injection molding and the casting pressure exerted by the injection molding material to avoid pouring pressure induced sink marks on the hollow profile and therefore counteracts the present until the overmolding hollow profile shape, the forming pressure is at a higher, possibly significantly increased Level.
  • the support pressure can be about as large as the casting pressure, whereby the support pressure can be rather lower, since the inherent stability of the hollow profile can provide a proportion of the total resistance against the forces exerted by the casting pressure in the interior of the hollow profile force. This proportion is dependent on material and wall thickness.
  • the overmolded areas are not affected by forming technology, since they are at least largely cooled and hardened. Furthermore, the retention time of the composite component in the mold during the cooling phase is used to carry out the forming, thereby most advantageously saving production time.
  • injection molding material plastic plastic as well as a light metal is conceivable.
  • the hollow profile in the closed mold by means of fluidic internal high pressure expanded so far until the immediately adjacent to the area to be encapsulated area of the hollow profile of the tool engraving in the circumferential direction circumferential, so continuous.
  • the height of the internal high pressure is dimensioned such that a form gleichconferencede bulge does not occur in the area to be encapsulated. In any case, the pressure is greater than a forming-free support pressure during the extrusion phase.
  • the composite component that forms after the overmolding can then have the property that the cast element is displaceable on the hollow profile.
  • the displaceability may also have a functional character, in which one of the two composite partners (hollow profile or cast element) is held in a relative position relative to the environment and the other composite partner is shifted depending on the momentary requirement.
  • the network partners thus remain permanently movable.
  • the types of applications can span a wide field. You can find, for example, both in automotive technology and in toy technology input.
  • injection molding material is additionally injected into the already overmolded areas during cooling.
  • the injection molding pressure is also present during the cooling phase of the initially injected casting material. This compensates to some extent the degree of shrinkage of the injection molding material during solidification, so that the finished composite component has largely the desired dimensions. It is important that this process takes place when the initially injected casting material is still molten or doughy, so that the homogeneity of the injection molding and thus the stability of the formed casting element are ensured.
  • the injected casting material is supported by means of movable components of the molding tool during the cooling phase.
  • a complete contact of the injection molding material is secured to the engraving of the mold at any time of the manufacturing process of the composite component, whereby a particularly good surface quality of the formed casting element and a very high dimensional accuracy with respect to the impression on the engraving can be achieved.
  • the hollow profile is formed with a low degree of deformation in the area to be encapsulated, without it gets there for complete contact with the engraving and blocks the space provided for injection molding in the encapsulation or gating.
  • the resulting shape provides a positive connection of the hollow profile with the overmolded material, so that its support on the hollow profile is improved.
  • this shape can be designed if necessary so that the overmolded material layer is just as thin as it the functionality of the formed plastic element requires, whereby the material resources of the overmolded material are spared.
  • the widening can be such that in the areas not intended for the encapsulation, the hollow profile is in contact with the tool engraving, whereby a sealing of the regions not to be encapsulated against the injection molten metal is achieved. In this way, a drainage of the injection molding material is prevented, so that on the one hand the injection molding element to take its desired shape and on the other hand does not overspray the casting material-free areas, which may not be fair optical and functional requirements.
  • FIG. 1 shows a pressure-time diagram of a production process according to the invention.
  • the hollow profile After the hollow profile has been inserted into the mold, the latter is closed.
  • the hollow profile may be a straight tubular or pre-bent and optionally provided with a special cross-section deviating from the circularity of the tubular metal blank.
  • the hollow profile is now sealed at both ends by means of a respective Axialstkovs and filled via at least one of the Axialstempel with a pressurized fluid.
  • a fluid high pressure generating system now the pressurized fluid is tensioned.
  • the dashed curve shows several phases of the manufacturing process.
  • phase A the pressure fluid is tensioned to a pressure p s which is below a forming pressure and corresponds to a support internal pressure that is greater than or equal to the external pressure exerted by the injected casting material on the hollow profile.
  • phase B then takes place the local gating or the encapsulation of the hollow profile through the casting material.
  • the support internal pressure is kept approximately constant.
  • phase C in which the overmolded hollow profile and the molding tool are cooled. This can be done actively by cooling devices in or on the mold.
  • passive cooling without external action is also conceivable, in which the overmolded hollow profile and the molding tool automatically adjust in terms of their process temperatures to the ambient temperature.
  • the pressure of the pressure fluid is increased to a high forming pressure p 0H .
  • the non-overmolded areas of the hollow profile are deformed, wherein side mold elements higher degrees of deformation and / or formations with narrow radii arise.
  • Subsequent forming is reduced in the phase D, the internal pressure to the relaxation of the pressurized fluid and this passed from the finished composite component. Subsequently, the mold is opened and this removed the composite component.
  • the pressure of the pressurized fluid according to the solid line Phase A is different. This is here divided into a phase E and a phase F.
  • the pressure of the pressurized fluid is brought to a low ümformdruck p ÜN , by which the hollow profile is expanded so before encapsulation in the closed mold in the area to be encapsulated that the shape achieved just reached the limit to be taken by the injection later space.
  • a small bulge is formed, via which the hollow profile then forms a positive connection with the injection molding in the injection phase B.
  • the pressure p 0N is reduced to the pressure p s in the phase F, whereby the phase B begins.
  • the further production process remains unchanged from the manufacturing process described above.
  • the injection molding material is pressed in during the phase C, that is to say that casting material is additionally injected into the already overmolded regions.
  • the optionally mentioned support of the injected injection molding material until solidification by means of movable components of the molding tool can also be done in phase C.

Abstract

The invention relates to a method for the production of a composite component, where a tubular metallic hollow profile is subjected to a forming process widening it to a final shape by means of internal high fluid pressure. The hollow profile here is locally overmoulded with an injection-moulding material in a closed mould, while a supportive pressure is generated in the initial hollow profile and is at least equal to the injection pressure exerted by the injection-moulding material. The injection-moulding material used for the overmoulding process is then cooled and, after cooling, the composite component in its in finished form is removed from the mould. To permit relatively simple production of a composite component in a reliable process, it is proposed that, to give its final form, the hollow profile is subjected to a forming process by means of high internal pressure in the closed mould towards the end of, or after, the cooling phase, in its regions where no overmoulding has occurred.

Description

Verfahren zur Herstellung eines Verbundbauteils Method for producing a composite component
Die Erfindung betrifft ein Verfahren zur Herstellung eines Verbundbauteils gemäß dem Oberbegriff des Patentanspruches 1.The invention relates to a method for producing a composite component according to the preamble of claim 1.
Ein gattungemäßes Verfahren ist aus der DE 100 14 332 C2 bekannt. Gemäß der dortigen Absätze 17 und 34 wird ein Innenhochdruckumformprozess mit einem Spritzgießverfahren kombiniert, wofür ein Kombinationswerkzeug verwandt wird. Ein unverformtes oder vorgeformtes Hohlprofil wird zwischen die beiden Hälften des offenenA generic method is known from DE 100 14 332 C2. According to paragraphs 17 and 34, a hydroforming process is combined with an injection molding process using a combination tool. An undeformed or preformed hollow section is placed between the two halves of the open
Kombinationswerkzeuges gebracht, wonach durch Schließen des Werkzeugs das Hohlprofil analog zum Innenhochdruckumformverfahren in seine endgültige Form gebracht wird. Hiernach werden an das mittels fluidischen Innenhochdruckes umgeformte im Formhohlraum des Werkzeugs liegende Hohlprofil Kunststoffelemente angespritzt. Der Fluiddruck innerhalb des Hohlprofils wird bis zum Abkühlen des Verbundbauteils in Form eines Stützdruckes aufrechterhalten. Bei diesem Verfahren können jedoch insbesondere dann, wenn eine unsymmetrische Endform des Hohlprofil gewünscht ist, während der Umformphase Auffaltungen und Knickstellen am Hohlprofil entstehen, die nicht mehr zu beseitigen sind. Der Erfindung liegt die Aufgabe zugrunde, ein gattungsgemäßes Verfahren dahingehend weiterzubilden, dass in relativ einfacher Weise und prozesssicher die Herstellung eines Verbundbauteils ermöglicht wird.Combination tool brought, after which the hollow profile is brought into its final shape analogous to the hydroforming process by closing the tool. Thereafter, molded plastic components are molded onto the hollow profile formed by fluidic hydroforming in the mold cavity of the tool. The fluid pressure within the hollow profile is maintained until cooling of the composite component in the form of a support pressure. In this method, however, especially when an asymmetrical final shape of the hollow profile is desired, folds and kinks on the hollow profile occur during the forming phase, which can no longer be eliminated. The invention has the object of developing a generic method to the effect that the production of a composite component is made possible in a relatively simple manner and process reliable.
Die Aufgabe ist erfindungsgemäß durch die Merkmale des Patentanspruches 1 gelöst.The object is achieved by the features of claim 1.
Aufgrund der erfindungsgemäßen Aufweitung im geschlossenen Formwerkzeug, die im Wesentlichen durch den fluidischen Innenhochdruck zustande kommt, wird eine freie mechanische Verformung mit zu hohen axialen Schubkräften und der Gefahr der Einleitung von Querkraftkomponenten vermieden, so dass keine Auffaltungen und Knickstellen auftreten. Dies ist insbesondere dann von herausragender Bedeutung, wenn asymmetrische komplexe Gestaltungen des Hohlprofils gegebenenfalls mit hohen Umformgraden erreicht werden sollen. Um zu vermeiden, dass das Hohlprofil die für den Spritzguss vorgesehene Kavität zumindest teilweise ausfüllt und damit die Anspritzung unvollständig macht oder gar unterbindet, erfolgt die Umformung des Hohlprofils in die Endform erfindungsgemäß erst gegen Ende des Gesamtprozesses bzw. beginnt in der Abkühiphase des Teilprozesses Spritzgießen und betrifft im Wesentlichen nur die nicht-umspritzten Bereiche. Alternativ kann die Umformung auch nach der Abkühlphase erfolgen. Da die umspritzten erkalteten Bereiche des Verbundbauteils formstabil bleiben und sich nicht weiter umformen und im Formwerkzeug in diesen Bereichen auch keine weiteren Freiräume zur Verfügung stehen, in die eine Aufweitung des Hohlprofilmaterials erfolgen könnte, können die nicht-umspritzten Bereiche nahezu beliebig durch die Einwirkung des fluidischen Innenhochdrucks verformt werden. Im Gegensatz zu dem Stützdruck, der während des Spritzgießens in dessen Inneren ansteht und dem vom Spritzgusswerkstoff ausgeübten Gießdruck zur Vermeidung von gießdruckinduzierten Einfallstellen am Hohlprofil und daher unter Beibehaltung der bis zur Umspritzung vorliegenden Hohlprofilform entgegenwirkt, befindet sich der Umformdruck auf einem höheren, gegebenenfalls erheblich gesteigertem Niveau. Der Stützdruck kann in etwa so groß sein wie der Gießdruck, wobei der Stützdruck eher geringer ausfallen kann, da die Eigenstabilität des Hohlprofils einen Anteil an dem Gesamtwiderstand wider die vom Gießdruck ausgeübten in das Innere des Hohlprofils gerichteten Kraft erbringen kann. Dieser Anteil ist Werkstoff- und wanddickenabhängig. Neben der bedarfsgerechten Umformung des Hohlprofils mit niedrigeren Umformgraden unter Anlage an der Werkzeuggravur sind auch Ausformungen hoher Umformgrade prozesssicher möglich, die zur Ausbildung von Nebenformelementen wie beispielsweise Dome oder Ausbauchungen führen. Die umspritzten Bereiche werden umformtechnisch nicht berührt, da diese zumindest weitgehend erkaltet und ausgehärtet sind. Weiterhin wird die Verbleibzeit des Verbundbauteils in dem Formwerkzeug während Abkühlphase genutzt, um die Umformung auszuführen, wodurch höchst vorteilhafter Weise Herstellungszeit eingespart wird. Als Spritzgussmaterial ist Kunststoff wie auch ein Leichtmetall denkbar.Due to the widening according to the invention in the closed mold, which is essentially due to the fluidic internal high pressure, a free mechanical deformation is avoided with excessive axial thrust forces and the risk of introducing lateral force components, so that no folds and kinks occur. This is of particular importance when asymmetrical complex designs of the hollow profile are to be achieved, if appropriate, with high degrees of deformation. In order to avoid that the hollow profile at least partially fills the cavity intended for injection molding and thus makes the gating incomplete or even prevents the forming of the hollow profile in the final shape according to the invention until the end of the entire process or begins in the Abkühiphase the injection molding process and essentially concerns only the non-overmolded areas. Alternatively, the transformation can also take place after the cooling phase. Since the over-molded, cooled areas of the composite component remain dimensionally stable and do not deform further and in the mold in these areas no further free spaces are available, in which a widening of the hollow profile material could occur, the non-encapsulated areas almost arbitrarily by the action of the fluid high internal pressure be deformed. In contrast to the support pressure, which is present in the interior of the injection molding and the casting pressure exerted by the injection molding material to avoid pouring pressure induced sink marks on the hollow profile and therefore counteracts the present until the overmolding hollow profile shape, the forming pressure is at a higher, possibly significantly increased Level. The support pressure can be about as large as the casting pressure, whereby the support pressure can be rather lower, since the inherent stability of the hollow profile can provide a proportion of the total resistance against the forces exerted by the casting pressure in the interior of the hollow profile force. This proportion is dependent on material and wall thickness. In addition to the demand-oriented deformation of the hollow profile with lower degrees of deformation under investment in the tool engraving and formations of high degrees of deformation are process reliable possible, leading to the formation of secondary features such as domes or bulges. The overmolded areas are not affected by forming technology, since they are at least largely cooled and hardened. Furthermore, the retention time of the composite component in the mold during the cooling phase is used to carry out the forming, thereby most advantageously saving production time. As injection molding material plastic as well as a light metal is conceivable.
In einer bevorzugten Weiterbildung der Erfindung nach Anspruch 2 wird vor dem Umspritzen das Hohlprofil im geschlossenen Formwerkzeug mittels fluidischen Innenhochdrucks soweit aufgeweitet, bis der unmittelbar an den zu umspritzenden Bereich angrenzende Bereich des Hohlprofils an der Werkzeuggravur in Umfangsrichtung umlaufend, also durchgängig anliegt. Hierdurch wird eine Abdichtung der Fuge zwischen dem Hohlprofil und dem Formwerkzeug, die sich an den zu umspritzenden Bereich anschließt, erreicht, so dass kein Gießmaterial aus dem für die Umspritzung vorgesehenen Raum abfließen kann. Die Höhe des Innenhochdrucks ist dabei so bemessen, dass eine formschlussergebende Auswölbung im zu umspritzenden Bereich nicht auftritt. Auf jeden Fall ist der Druck größer als ein umformfreier Stützdruck während der Umspritzphase . Das nach der Umspritzung sich ausbildende Verbundbauteil kann dann die Eigenschaft besitzen, dass das Gusselement auf dem Hohlprofil verschiebbar ist. Dies kann für unterschiedliche Verbauungszwecke vorteilhaft sein, da nur ein einziges Verbundbauteil erforderlich ist um voneinander verschiedene Zusammenbauten zu erzielen. Gegebenenfalls kann die Verschiebbarkeit auch funktionellen Charakter besitzen, in dem einer der beiden Verbundpartner (Hohlprofil oder Gusselement) in bezüglich der Umgebung ortsfester Relativlage gehalten und der jeweils andere Verbundpartner je nach momentaner Anforderung verschoben wird. Die Verbundpartner bleiben damit ständig verschiebbar. Die Anwendungsarten können ein weites Feld umspannen. Sie können beispielsweise sowohl in der Kraftfahrzeugtechnik als auch in der Spielzeugtechnik Eingang finden.In a preferred embodiment of the invention according to claim 2, the hollow profile in the closed mold by means of fluidic internal high pressure expanded so far until the immediately adjacent to the area to be encapsulated area of the hollow profile of the tool engraving in the circumferential direction circumferential, so continuous. In this way, a seal of the joint between the hollow profile and the mold, which adjoins the area to be encapsulated, achieved, so that no casting material can flow out of the space provided for the encapsulation. The height of the internal high pressure is dimensioned such that a formschlussgebende bulge does not occur in the area to be encapsulated. In any case, the pressure is greater than a forming-free support pressure during the extrusion phase. The composite component that forms after the overmolding can then have the property that the cast element is displaceable on the hollow profile. This can be advantageous for different purposes, since only a single composite component is required to achieve mutually different assemblies. Optionally, the displaceability may also have a functional character, in which one of the two composite partners (hollow profile or cast element) is held in a relative position relative to the environment and the other composite partner is shifted depending on the momentary requirement. The network partners thus remain permanently movable. The types of applications can span a wide field. You can find, for example, both in automotive technology and in toy technology input.
In einer weiteren bevorzugten Weiterbildung der Erfindung nach Anspruch 3 wird während des Abkühlens zusätzlich Spritzgussmaterial in die schon umspritzten Bereiche eingespritzt. Hierzu steht der Spritzgießdruck auch während der Abkühlphase des anfangs eingespritzten Gießwerkstoffes an. Dies kompensiert in gewissem Umfang den Schrumpfungsgrad des Spritzgussmaterials beim Erstarren, so dass das fertig ausgebildete Verbundbauteil weitgehend die gewünschten Abmessungen aufweist. Hierbei ist es wichtig, dass dieser Vorgang erfolgt, wenn das anfänglich eingespritzte Gussmaterial noch schmelzflüssig oder teigig ist, so dass die Homogenität des Spritzgusses und damit die Stabilität des ausgebildeten Gusselementes gewährleistet sind.In a further preferred embodiment of the invention according to claim 3 injection molding material is additionally injected into the already overmolded areas during cooling. For this purpose, the injection molding pressure is also present during the cooling phase of the initially injected casting material. This compensates to some extent the degree of shrinkage of the injection molding material during solidification, so that the finished composite component has largely the desired dimensions. It is important that this process takes place when the initially injected casting material is still molten or doughy, so that the homogeneity of the injection molding and thus the stability of the formed casting element are ensured.
In einer weiteren bevorzugten Weiterbildung der Erfindung nach Anspruch 4 wird während der Abkühlphase das eingespritzte Gussmaterial mittels verfahrbarer Bauteile des Formwerkzeuges abgestützt. Dadurch wird zu jeder Zeit des Herstellungsvorgangs des Verbundbauteils eine vollständige Anlage des Spritzgussmaterials an der Gravur des Formwerkzeuges gesichert, wodurch eine besonders gute Oberflächenqualität des ausgebildeten Gusselementes und eine sehr hohe Formtreue bezüglich der Abformung an der Gravur erreicht werden.In a further preferred embodiment of the invention according to claim 4, the injected casting material is supported by means of movable components of the molding tool during the cooling phase. As a result, a complete contact of the injection molding material is secured to the engraving of the mold at any time of the manufacturing process of the composite component, whereby a particularly good surface quality of the formed casting element and a very high dimensional accuracy with respect to the impression on the engraving can be achieved.
In einer bevorzugten Weiterbildung der Erfindung nach Anspruch 5 wird vor dem Umspritzen das Hohlprofil im geschlossenen Formwerkzeug in einem ersten Aufweitvorgang mittels fluidischen Innenhochdrucks im zu umspritzenden Bereich soweit ausgeformt, bis die Grenze zum vom Spritzguss später einzunehmenden Raum erreicht ist. Hierdurch wird das Hohlprofil mit geringem Umformgrad in zu umspritzenden Bereich ausgeformt, ohne dass es dort zur vollständigen Anlage an der Gravur gelangt und dabei die für den Spritzguss bei der Umspritzung bzw. Anspritzung vorgesehenen Räume blockiert. Die erzielte Ausformung erbringt einen Formschluss des Hohlprofils mit dem umspritzten Werkstoff, so dass dessen Halt auf dem Hohlprofil verbessert wird. Des Weiteren kann diese Ausformung bei Bedarf so gestaltet sein, dass die umspritzte Werkstoffschicht gerade so dünn wird wie es die Funktionstüchtigkeit des ausgebildeten Kunststoffelementes erfordert, wodurch die Materialressourcen des umspritzten Werkstoffs geschont werden. Die Aufweitung kann derart sein, dass es in den für die Umspritzung nicht vorgesehenen Bereichen zu einer Anlage des Hohlprofils an der Werkzeuggravur kommt, wodurch eine Abdichtung der nicht zu umspritzenden Bereiche gegen die Spritzgussschmelze erreicht wird. Hierdurch wird ein Abfließen des Spritzgussmaterials verhindert, so dass einerseits das auszubildende Spritzgusselement seine wunschgemäße Gestalt annehmen kann und es zum anderen nicht zu einem Überspritzen der gießwerkstofffreien Bereiche kommt, was optischen und funktionellen Ansprüchen eventuell nicht gerecht werden würde .In a preferred embodiment of the invention according to claim 5, the hollow profile in the closed mold in a first expansion process by means of fluidic internal high pressure in the area to be encapsulated formed before the encapsulation until the limit is reached for the later to be taken by the injection molding space. As a result, the hollow profile is formed with a low degree of deformation in the area to be encapsulated, without it gets there for complete contact with the engraving and blocks the space provided for injection molding in the encapsulation or gating. The resulting shape provides a positive connection of the hollow profile with the overmolded material, so that its support on the hollow profile is improved. Furthermore, this shape can be designed if necessary so that the overmolded material layer is just as thin as it the functionality of the formed plastic element requires, whereby the material resources of the overmolded material are spared. The widening can be such that in the areas not intended for the encapsulation, the hollow profile is in contact with the tool engraving, whereby a sealing of the regions not to be encapsulated against the injection molten metal is achieved. In this way, a drainage of the injection molding material is prevented, so that on the one hand the injection molding element to take its desired shape and on the other hand does not overspray the casting material-free areas, which may not be fair optical and functional requirements.
Nachfolgend ist die Erfindung anhand von in der Zeichnung dargestellten Ausführungsbeispielen näher erläutert.The invention is explained in more detail with reference to embodiments shown in the drawing.
Dabei zeigt die Figur 1 ein Druck-Zeit-Diagramm eines erfindungsgemäßen Herstellungsvorgangs .FIG. 1 shows a pressure-time diagram of a production process according to the invention.
Nachdem das Hohlprofil in das Formwerkzeug eingelegt wurde, wird letzteres geschlossen. Das Hohlprofil kann ein geradlinig verlaufender oder vorgebogener und gegebenenfalls mit speziellem von der Kreisrundheit abweichendem Querschnitt ausgestatteter metallischer rohrförmiger Rohling sein. Das Hohlprofil wird nun an beiden Enden mittels jeweils eines Axialstempels abgedichtet und über zumindest einen der Axialstempel mit einem Druckfluid befüllt. Mittels einer Fluidhochdruckerzeugungsanlage wird nun das Druckfluid gespannt . Die strichlierte Kurve zeigt mehrere Phasen des Herstellungsprozesses. In der Phase A wird das Druckfluid auf einen Druck ps gespannt, der unterhalb eines Umformdruckes liegt und einem Stützinnendruck entspricht, der größer oder gleich dem durch den eingespritzten Gusswerkstoff auf das Hohlprofil ausgeübten Außendruck ist. Hierdurch wird das Hohlprofil stabilisiert und ein gussdruckinduziertes Kollabieren des Hohlprofils verhindert. Während der sich unmittelbar anschließenden Phase B erfolgt dann die lokale Anspritzung bzw. die Umspritzung des Hohlprofils durch das Gussmaterial. Der Stützinnendruck wird dabei in etwa konstant gehalten. Hiernach folgt die Phase C, in der das umspritzte Hohlprofil und das Formwerkzeug abgekühlt wird. Dies kann aktiv durch Kühlvorrichtungen im oder am Formwerkzeug erfolgen. Denkbar ist alternativ auch ein passives Abkühlen ohne äußere Einwirkung, in dem das umspritzte Hohlprofil und das Formwerkzeug hinsichtlich ihrer Prozesstemperaturen sich selbständig an die Umgebungstemperatur angleicht. Während der Abkühlphase C, in der das Gussmaterial erstarrt und sich damit das angespritzte Gusselement festigt, wird der Druck des Druckfluids auf einen hohen Umformdruck p0H gesteigert. Hierdurch werden die nicht-umspritzten Bereiche des Hohlprofils umgeformt, wobei Nebenformelemente höherer Umformgrade und/oder Ausformungen mit engen Radien entstehen. Nacherfolgter Umformung wird in der Phase D der Innendruck bis zur Entspannung des Druckfluids abgebaut und dieses aus dem fertigen Verbundbauteil geleitet. Anschließend wird das Formwerkzeug geöffnet und diesem das Verbundbauteil entnommen.After the hollow profile has been inserted into the mold, the latter is closed. The hollow profile may be a straight tubular or pre-bent and optionally provided with a special cross-section deviating from the circularity of the tubular metal blank. The hollow profile is now sealed at both ends by means of a respective Axialstempels and filled via at least one of the Axialstempel with a pressurized fluid. By means of a fluid high pressure generating system now the pressurized fluid is tensioned. The dashed curve shows several phases of the manufacturing process. In phase A, the pressure fluid is tensioned to a pressure p s which is below a forming pressure and corresponds to a support internal pressure that is greater than or equal to the external pressure exerted by the injected casting material on the hollow profile. As a result, the hollow profile is stabilized and prevents casting pressure-induced collapse of the hollow profile. During the immediately subsequent phase B then takes place the local gating or the encapsulation of the hollow profile through the casting material. The support internal pressure is kept approximately constant. This is followed by phase C, in which the overmolded hollow profile and the molding tool are cooled. This can be done actively by cooling devices in or on the mold. Alternatively, passive cooling without external action is also conceivable, in which the overmolded hollow profile and the molding tool automatically adjust in terms of their process temperatures to the ambient temperature. During the cooling phase C, in which the casting material solidifies and thus solidifies the molded casting element, the pressure of the pressure fluid is increased to a high forming pressure p 0H . As a result, the non-overmolded areas of the hollow profile are deformed, wherein side mold elements higher degrees of deformation and / or formations with narrow radii arise. Subsequent forming is reduced in the phase D, the internal pressure to the relaxation of the pressurized fluid and this passed from the finished composite component. Subsequently, the mold is opened and this removed the composite component.
In Abwandlung vom geschilderten Herstellungsprozess kann der Druck des Druckfluids gemäß der durchgezogenen Linie die Phase A auch anders verlaufen. Diese ist hier aufgegliedert in eine Phase E und eine Phase F. In der Phase E wird der Druck des Druckfluids auf einen niedrigen ümformdruck pÜN gebracht, durch den das Hohlprofil vor dem Umspritzen im geschlossenen Formwerkzeug auch im zu umspritzenden Bereich so aufgeweitet wird, dass die dabei erzielte Ausformung gerade die Grenze zum vom Spritzguss später einzunehmenden Raum erreicht. Hierbei wird eine kleine Ausbauchung gebildet, über die das Hohlprofil dann in der Anspritzphase B mit dem Spritzguss einen Formschluss eingeht. Nach Beendigung der ersten Aufweitung und Bildung der kleinen Ausbauchung wird in der Phase F der Druck p0N auf den Druck ps verringert, wodurch die Phase B beginnt. Der weitere Herstellungsablauf bleibt gegenüber dem oben beschriebenen Herstellungsprozess unverändert.In a modification of the described manufacturing process, the pressure of the pressurized fluid according to the solid line Phase A is different. This is here divided into a phase E and a phase F. In the phase E, the pressure of the pressurized fluid is brought to a low ümformdruck p ÜN , by which the hollow profile is expanded so before encapsulation in the closed mold in the area to be encapsulated that the shape achieved just reached the limit to be taken by the injection later space. In this case, a small bulge is formed, via which the hollow profile then forms a positive connection with the injection molding in the injection phase B. After completion of the first expansion and formation of the small bulge, the pressure p 0N is reduced to the pressure p s in the phase F, whereby the phase B begins. The further production process remains unchanged from the manufacturing process described above.
Es sei im Übrigen noch erwähnt, dass während der Phase C das Nachdrücken des Spritzgussmaterial erfolgt, das heißt, dass zusätzlich Gussmaterial in die schon umspritzten Bereiche eingespritzt wird. Die optional erwähnte Abstützung des eingespritzten Spritzgussmaterials bis zur Erstarrung mittels verfahrbarer Bauteile des Formwerkzeuges kann ebenfalls in der Phase C von statten gehen. Incidentally, it should also be mentioned that the injection molding material is pressed in during the phase C, that is to say that casting material is additionally injected into the already overmolded regions. The optionally mentioned support of the injected injection molding material until solidification by means of movable components of the molding tool can also be done in phase C.

Claims

Patentansprüche claims
1. Verfahren zur Herstellung eines Verbundbauteils, wobei ein rohrförmiges metallisches Hohlprofil mittels fluidischen Innenhochdrucks in eine Endform aufweitend umgeformt wird und wobei das Hohlprofil in einem geschlossenen Formwerkzeug mit einem Spritzgusswerkstoff lokal umspritzt wird, während im Ausgangshohlprofil ein Stützdruck erzeugt wird, der dem vom Spritzgusswerkstoff ausgeübten Gießdruck unter Beibehaltung der Hohlprofilform entgegenwirkt, wonach der umspritzte Spritzgusswerkstoff abgekühlt und nach der Abkühlung das fertig ausgebildete Verbundbauteil dem Formwerkzeug entnommen wird, dadurch gekennzeichnet, dass die Umformung des Hohlprofils in seinen nicht-umspritzten Bereichen mittels Innenhochdrucks in die Endform im geschlossenen Formwerkzeug gegen Ende des Gesamtprozesses oder nach der Abkühlphase erfolgt.1. A method for producing a composite component, wherein a tubular metallic hollow profile by means of fluidic internal high pressure is formed expanding into a final shape and wherein the hollow profile is encapsulated in a closed mold with an injection molding material locally, while in the output hollow profile, a support pressure is generated, which is exerted by the injection molding material Counteracts casting pressure while maintaining the hollow profile shape, after which the overmolded injection molded material is cooled and removed after cooling the finished composite component of the mold, characterized in that the deformation of the hollow profile in its non-encapsulated areas by means of internal high pressure in the final mold in the closed mold towards the end of Whole process or after the cooling phase takes place.
2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass vor dem Umspritzen das Hohlprofil im geschlossenen Formwerkzeug mittels fluidischen Innenhochdrucks soweit aufgeweitet wird, bis der unmittelbar an den zu umspritzenden Bereich angrenzende Bereich des Hohlprofils an der Werkzeuggravur anliegt. 2. The method according to claim 1, characterized in that prior to encapsulation, the hollow profile is expanded in the closed mold by fluidic internal high pressure until the immediately adjacent to the area to be encapsulated area of the hollow profile rests on the tool engraving.
3. Verfahren nach einem der Ansprüche 1 oder 2, dadurch gekennzeichnet, dass während des Abkühlens zusätzlich Spritzgussmaterial in die schon umspritzten Bereiche eingespritzt wird.3. The method according to any one of claims 1 or 2, characterized in that injection molding material is additionally injected into the already overmolded areas during cooling.
4. Verfahren nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass während der Abkühlphase das eingespritzte Gussmaterial mittels verfahrbarer Bauteile des Formwerkzeuges abgestützt wird.4. The method according to any one of claims 1 to 3, characterized in that during the cooling phase, the injected casting material is supported by means of movable components of the molding tool.
5. Verfahren nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass vor dem Umspritzen das Hohlprofil im geschlossenen Formwerkzeug in einem ersten Aufweitvorgang mittels fluidischen Innenhochdrucks im zu umspritzenden Bereich soweit ausgeformt wird, bis die Grenze zum vom Spritzguss später einzunehmenden Raum erreicht ist. 5. The method according to any one of claims 1 to 4, characterized in that prior to encapsulation, the hollow profile is formed in the closed mold in a first expansion process by fluidic internal high pressure in the area to be encapsulated until the limit is reached to be occupied by the injection later space.
PCT/EP2007/009925 2006-12-06 2007-11-16 Method for the production of a composite component WO2008067901A1 (en)

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WO2011023258A1 (en) * 2009-08-27 2011-03-03 Daimler Ag Method for producing a composite component
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WO2008125232A3 (en) * 2007-04-13 2009-03-12 Daimler Ag Composite component and a method and device for producing the composite component
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