WO2019007983A1

WO2019007983A1 - Method and device for producing a multi-layer composite component

Info

Publication number: WO2019007983A1
Application number: PCT/EP2018/067995
Authority: WO
Inventors: Jonas BECK; Joachim Starke; Volker ALTSTÄDT; Johannes KNÖCHEL; Mathias MÜHLBACHER
Original assignee: Werkzeugbau Siegfried Hofmann Gmbh
Priority date: 2017-07-06
Filing date: 2018-07-03
Publication date: 2019-01-10
Also published as: DE102017115142A1; EP3648958A1

Abstract

The invention relates to a method for producing a multi-layer composite component (2) which comprises two cover layer elements (3, 4) and a core element (5) arranged between the cover layer elements (3, 4) and connected thereto, said method comprising the following steps: - providing two cover layer elements (3, 4), a core element (5) to be arranged between the cover layer elements (3, 4), and a shaping dummy element (19) simulating the geometric shape of the core element (5) of the finished composite component (2); - introducing the cover layer elements (3, 4) and the dummy element (19) into a tool (6) comprising at least one shaping tool face (7, 9); - reshaping the cover layer elements (3, 4) with use of the shaping dummy element (19) in one or more shaping steps in the tool (6); - removing the dummy element (19) from the tool (6); - introducing the core element (5) between the reshaped cover layer elements (3, 4) into the tool (6); - connecting the cover layer elements (3, 4) to the core element (5), forming the composite component (2) in the tool (6) in such a way that the core element (5) is arranged captively between the cover layer elements (3, 4) and is connected to the cover layer elements (3, 4); - removing the composite component (2) from the tool (6).

Description

DESCRIPTION

Method and device for producing a multilayer composite component

The invention relates to a method and a device for producing a multilayer composite component, which composite component comprises two cover layer elements and a core element arranged between the cover layer elements and connected thereto at least in sections.

Multilayer composite components which comprise two cover layer elements and a core element arranged between the cover layer elements as functional or structural composite component parts are known in the art in various fields of application.

The production of a corresponding composite component, in particular of such a complex geometry, can be comparatively complicated both with regard to the method implemented for producing the composite component and to a device provided for implementing the method. This results from the fact that in the context of the production of the composite component both forming steps for forming individual or several composite component components as well as joining steps for joining individual or several composite component components must be combined in the most efficient manner possible. Optionally, a functionalization of the composite component by tying one or more functional elements to one of the cover layer elements of a corresponding composite component may be required, which, in particular in terms of process technology, can bring additional difficulties.

The invention is based on the object of specifying an efficient method for producing a multilayer composite component, which composite component comprises two cover layer elements and a core element arranged between the cover layer elements and connected thereto at least in sections.

The object is achieved by a method according to claim 1. The dependent claims relate to possible embodiments of the method. The object is further achieved by a device according to claim 13. The dependent claims relate to possible embodiments of the device.

The method described herein is for producing a multilayer composite component. The composite component typically comprises two, in particular flat or planar, cover layer elements and at least one, in particular captive, arranged between the cover layer elements and at least partially, in particular completely, (full) surface connected core element. The composite component thus typically has a sandwich-type structure; the two cover layer elements, more specifically the respective exposed outer surfaces of the two cover layer elements, typically form the outer surfaces of the composite component.

In a cover layer element used according to the method may be, for. Example, to a composite element, which embedded in a thermoplastic or thermosetting plastic matrix textile structure, d. H. in particular one by one, z. B. occasional, fiber assembly formed fiber structure comprises, act. Specifically, it can be a corresponding composite element sonach z. B. to act a thermoplastic or thermoset organic sheet or sheet. It is also conceivable that, in the case of a cover layer element used in accordance with the method, it is a, optionally at least partially, in particular complete, at least in sections, with a surface treatment, ie. H. z. As a corona, laser or plasma treatment, surface side activated metal element, d. H. z. As a metal sheet, d. H. z. As an aluminum or steel sheet, is. A respective cover layer element may have a single-layer or multi-layer structure; a respective cover layer element can thus z. B. be formed by one or more interconnected layers of the same or different materials or functions. For example, at least one layer may be one of structural, ie. H. in particular have the mechanical, properties of the composite component influencing function and at least one (other) layer have a decor function. A respective cover layer element can be plastically deformable or deformable, regardless of its specific configuration, in particular by the action of pressure and / or temperature.

In a core element used according to the method may be, for. B. a foam element, which comprises an open and / or closed-cell foam structure, or a lightweight construction element, which comprises a single or multi-layer lightweight structure, in particular a honeycomb or sandwich structure, or to an electrical or electronic functional element, for. B. in the form of a chip, data storage, energy storage, etc., which comprises at least one electrical or electronic functional structure act. It is also possible that a foamable core element is used. A foamable, d. H. In its density and its volume changeable, core element can be foamed before, during or after the connection of the cover layer elements described in more detail below. Also, a respective core element may have a single or multi-layer structure; a respective core element can z. B. be formed by one or more interconnected layers of the same or different materials or functions. For example, at least one layer may be one of structural, ie. H. have in particular the mechanical, properties of the core element influencing function. It also applies to the core element that this can be plastically deformable or deformable, regardless of its specific configuration, in particular by the action of pressure and / or temperature.

The method or the individual method steps are explained in more detail below: In a first method step, two cover layer elements, a core element to be arranged between the cover layer elements, and a shaping dummy element ("dummy element") modeled after the geometric shape, ie in particular the shape, of the core element of the finished composite component, are provided geometric shape of the core element of the finished composite component, ie, the geometric shape of the core element, which has the core element after performing the method, modeled geometric body, the dummy element has correspondingly at least one forming dummy element surface .. The dummy element has a sufficient mechanical and thermal stability, so this is not deformed as part of its use according to the method: the dummy element formed, for example, from metal does not form a composite component, as will be seen below, the dummy element serves in particular To transform the cover layer elements in the desired manner in the implementation of the method. Another function of the dummy element may be to intercept the injection pressure which occurs in the case of any injection molding of at least one functional element or possible injection molding of a functional element structure comprising at least one functional element on a cover layer element.

The dummy element may additionally be provided with various functionalities. For example, the dummy element may be temperature-controlled in order to temper a cover layer element lying against it, ie. H. especially to heat. The temperature of the dummy element can be z. B. by tempering devices integrated in the dummy element, d. H. In particular heaters, and / or be realized by a tempering medium by ström bare or by flow, in particular channel-like, tempering. Furthermore, for example, sensor devices for sensing (detection or determination) of specific, in particular physical, process parameters, d. H. especially temperature and pressure, be integrated.

In a subsequent second method step, the two cover layer elements and the dummy element are introduced individually or jointly into a tool comprising at least one shaping tool surface or contour. The tool can be converted into an open and a closed position. The introduction of the two cover layer elements and of the dummy element into the tool takes place in such a way that the dummy element is arranged in the state introduced into the tool between the cover layer elements. The introduction of the cover layer elements and the dummy element into the tool can be realized, in particular partially or fully automatically, by means of a suitable handling device, which will be discussed in more detail below in connection with the device described herein.

The tool used according to the method is typically a combined forming and injection molding tool; the tool is therefore on the one hand set up, introduced into the tool components, ie according to the method typically the cover layer elements and optionally the core element to reshape, and on the other hand arranged to be introduced into the tool components, ie according to the procedure typically the cover layer elements to inject structures or introduced into the tool components, ie according to the method typically the cover layer elements to overmold with certain structures.

The tool typically includes a first tooling element having a first shaping tool surface, i. E. H. typically a first tool half, and a second tool element movably mounted in a (first) movement axis relative to the first tool element, having a second shaping tool surface or contour, d. H. typically a second mold half. Of course, it is also possible that both tool elements are movably mounted in a (first) movement axis. A space can be formed between the tool elements by corresponding relative movement of the tool elements, in which the two cover layer elements and the dummy element or, in the following, the core element can be introduced. Each of the tool elements can comprise a channel structure which opens into a cavity on the mold side and can be heated by a plasticized or injection-molding compound, optionally optionally heatable, to which a injection unit providing a plasticized or injection-molding compound can be docked (as required) ,

In a following third method step, the two cover layer elements are reshaped. The forming of the two cover layer elements is carried out using the arranged between the cover layer elements dummy element in one or more shaping steps in the tool. The reshaping of the cover layer elements is typically carried out by a taking place in the first axis of movement relative movement of the tool elements transfer (closing movement) of the tool from its open position into its closed position. The cover layer elements are in this case moved on the one hand against an adjacent shaping tool surface and on the other hand against an adjacent shaping dummy element surface, resulting in a shaping of the respective tool surface or dummy element surface following deformation of the respective cover layer element; Of course, it is possible that the two cover layer elements are the same shape or at least partially differently shaped, thus after forming have the same or at least partially different geometric shape.

In a following fourth method step, the dummy element is removed from the tool. Before removal of the dummy element from the tool, the tool is transferred from its closed position to its open position by a relative movement (opening movement) of the tool elements taking place in the first movement axis. The removal of the dummy element from the tool can be realized, in particular partially or fully automatically, via the mentioned or another suitable handling device. In a subsequent fifth method step, the core element is introduced into the tool between the formed cover layer elements. The introduction of the core element into the tool can be realized, in particular partially or fully automatically, via the mentioned handling device.

In a following sixth method step, the cover layer elements and the core element with formation of the composite component in the tool such that the core element is arranged captive between the cover layer elements and, in particular flat, is connected to the two cover layer elements connected. In the sixth step, on the one hand, an at least partially, in particular complete, (full) surface connection of the core element with the two cover layer elements as well as an at least in sections, ie. H. in particular edge-side, surface connection of the cover layer elements, d. H. a compound cover layer element cover layer element, with each other. The z. B. by thermal energy input, a, optionally a solvent comprehensive, adhesive, etc. can be brought about or brought about connection of the core element with the cover layer elements, d. H. the compound cover layer element core element cover layer element, z. B. adhesive, cohesive or cohesive. Before joining the cover layer elements of the core element takes place by a taking place in the first axis of movement relative movement (closing movement) of the tool elements taking place transfer of the tool from its open position to its closed position. In all cases, the core element is arranged captive between the cover layer elements by connecting the two cover layer elements and the core element and connected to the cover layer elements. The connection results in the sandwich component-like structure or the sandwich component-like characteristic of the composite component. As will be seen below, the joining of the two cover layer elements, d. H. the connection cover layer element - cover layer element, done by an injection process.

In a following seventh method step, the composite component is removed from the tool. Before the composite component is removed from the tool, the tool is transferred from its closed position into its open position by a relative movement (opening movement) of the tool elements taking place in the first movement axis. The removal of the composite component from the tool can, in particular partially or fully automatable, be realized via the mentioned or another suitable handling device.

The method enables an efficient production of a corresponding composite component, in particular of such a complex geometry.

In addition, the method makes it possible in particular to form fully consolidated cover layers and thus the production of fully consolidated composite components which do not or only a few pores which may affect the mechanical properties.

Before joining the cover layer elements, the core element can be formed in one or more shaping steps in the shaping tool. The forming of the core element takes place, in particular using the formed cover layer elements, in one or more shaping steps in the tool. The reshaping of the core element is carried out - analogous to the reshaping of the cover layer elements - typically by a taking place in the first axis of movement relative movement (closing movement) of the tool elements transfer of the tool from its open position into its closed position. The core element is in this case indirectly moved over the already formed cover layer elements against respective shaping tool surfaces of the tool elements, resulting in the shaping of the respective tool surface following reshaping of the core element. Corresponding reshaping of the core element can be dispensed with, provided that a core element preformed in its final shape with regard to the finished composite component is used.

Before removing the dummy element from the tool, injection molding of at least one functional element on at least one cover layer element, i. H. in particular on the outside (based on the later composite component) of a respective cover layer element, take place. For injecting a corresponding functional element at least one injection unit is docked to at least one tool element. About the docked injection unit, a plasticized plastic or injection molding compound is molded onto at least one cover layer element to form a corresponding functional element. By virtue of the fact that the dummy element, as mentioned, is of such stable design that it absorbs the injection pressure occurring in the case of any injection molding of at least one functional element, it is easily possible according to the method to produce composite components with functional elements molded onto the cover layer elements, without, as has hitherto been customary, To run the risk that a core element arranged between the cover layer elements is damaged by the injection pressure or possibly even destroyed.

A corresponding functional element may form part of a functional structure that performs one or more functions. A function can, for. B. be a compound of the composite component with a connection component, so that as a functional element z. B. a connecting interface for connecting the composite component with a connection component forming connecting element, ie, for example, a latch / snap element, can be molded. Alternatively or additionally, a function z. As an enhancement of the structural, in particular mechanical properties of the composite component, so as a functional element z. B. a structural reinforcement of the composite component forming reinforcing element, ie, for example, a rib member, can be molded. Alternatively or additionally, a function z. Example, be an attachment of a respective cover layer element to a tool element, so that as a functional element z. B. a Attachment interface for attaching a cover layer element can be molded onto a tool element forming fastener. As a functional element can therefore z. B. a connection interface for connecting the composite component with a connection component forming connecting element and / or a structural reinforcement of the composite component forming reinforcing element and / or a fastening interface for attachment of the cover layer element on a tool element of the tool forming fastener are molded.

In this context, it should also be mentioned that, prior to removal of the dummy element from the tool, injection molding of at least one functional element onto the inner side (relative to the later composite component) of a respective cover layer element can take place. It is therefore an injection of at least one cover layer element possible so that plasticized plastic or injection molding compound can reach the inside (relative to the later composite component) of a respective cover layer element. In this way, certain functional elements can (also) be formed in the interior of the composite component to be produced. To form corresponding functional elements, the dummy element with corresponding, the geometric-constructive shape of the trainees functional elements corresponding, z. B. formed by recesses, contours.

A corresponding functional element may also form part of a function structure that performs one or more functions. A function can, for. As an enhancement of the structural, in particular mechanical properties of the composite component, so as a functional element z. B. a (inner) structural reinforcement of the composite component forming reinforcing element, d. H. z. B. a rib member can be formed.

Before and / or during the forming of at least one cover layer element, an at least partial heating of the cover layer element can take place. In an analogous manner, at least section-wise heating of the core element can take place before and / or during a forming of the core element. For example, at least in sections, heating may take place before introducing the cover layer elements or before introducing the core element into the tool. The heating of the cover sheet element or the core element typically allows a simpler forming. The heating of the cover layer element or of the core element expediently takes place on a temperature defined by the structural structure of the cover layer element or of the core element, above which the cover layer element or the core element can be well formed. For the example of a cover layer element in the form of a composite element mentioned above, heating z. B. to a softening temperature, ie in particular a glass transition temperature, of a matrix forming (thermoplastic) plastic material. The same applies to the core element. The heating of the at least one cover layer element expediently takes place in such a way that the heating makes possible a desired deformation of the cover layer element and a connection to the core element which is favored by the thermal energy input. The Heating of the core element is expedient in an analogous manner such that the heating allows a desired deformation of the core element and by the thermal energy input favored connection with the cover layer elements.

The heating of the at least one cover layer element can, for. B. by at least partially irradiating the at least one cover layer element with a heat radiation generated by a radiation device, d. H. z. As an infrared radiation, and / or by contacting the cover layer element with a heatable or heated surface of a, in particular dynamically temperable, tool element of the tool. The heating of the core element may, for. B. by at least partially irradiating the core element with a heat radiation generated by a radiation device, d. H. z. As an infrared radiation, and / or by contacting the core element with a heated surface of a cover layer element.

It is important to ensure that heating of the cover layer elements does not cause structural damage to the cover layer elements, in particular due to deconsolidation of the cover layer elements; This is possible in particular by controlling the heat introduced into the cover layer elements. The heat should therefore be introduced essentially only into the (immediate) surface or in (immediate) surface regions of the cover layer elements. A control of the amount, penetration, Einbringdauer, etc. of the heat to be introduced should therefore be made with the proviso that a structural damage to the cover layer elements is not possible.

It has already been mentioned above that the joining of the two cover layer elements can take place by means of an injection process. The bonding of the cover layer elements can be carried out in particular by at least edge-side at least partially encapsulation of the cover layer elements. For encapsulating the cover layer elements at least one injection unit is docked to at least one tool element. About the docked injection unit, a plasticized plastic or injection molding compound is injected; the cover layer elements to be joined are at least partially encapsulated on the edge side. The at least partially peripheral molding of the cover layer elements requires a reliable connection of the two cover layer elements, which are at least partially encapsulated in the region of their respective edges with a plasticized plastic or Spritzgießmasse. The plastic compound surrounds the respective edges of the cover layer elements positively and / or non-positively and / or cohesively; the connection of the cover layer elements is thus realized by a peripheral embracing the cover layer elements by a (solidified) plastic or injection molding. The edge-side connection of the cover layer elements produced in this way has optical significance and, in comparison, little influence on the structural, ie in particular mechanical, properties of the composite component, since these are decisively determined by the connection of the core element to the cover layer elements. The encapsulation or the resulting edge-side connection of the cover layer elements also allows in particular in the region of the edges of the cover layer elements or of the composite component, a near-net shape, in particular near net shape, formation of the composite component, so that little or no post-processing steps for realizing the final geometry or final contour of the composite component are required.

As part of the overmolding of the cover layer elements, at least one (further) functional element, in particular a connecting element forming a connection interface for connecting the composite component to at least one connection component and / or a reinforcing element forming a structural reinforcement of the composite component, can be injection molded. The composite component can be further functionalized or reinforced by the encapsulation.

Before at least marginally at least partially encapsulating the cover layer elements, at least edge-side, at least sectionally, compacting of the cover layer elements realized in particular by a pressing process can be performed. The compacting can be expedient in order to prevent plasticized plastic or injection-molding compound from getting between the cover layer elements during extrusion coating of the cover layer elements.

It has been mentioned that a foamable core element can be used. The core element may, for. B. are foamed after encapsulation of the cover layer elements chemically or physically. The foaming process of the core element provided with chemical or physical foaming or blowing agents may optionally be initiated or promoted by a certain ventilation stroke of the tool.

The invention further relates to a multilayer composite component which comprises two cover layer elements and at least one core element arranged between the cover layer elements and connected thereto at least in sections. The composite component is characterized in that it is produced by a method as described, so that all versions in connection with the method apply analogously to the composite component.

In addition to the method and the composite component, the invention also relates to a device for producing a multilayer composite component, which composite component comprises two cover layer elements and a core element arranged between the cover layer elements. The device comprises a shaping tool which comprises a first tool element having a first shaping tool surface or contour and a second tool element having a second shaping tool surface or contour. At least one tool element is movably mounted relative to the other tool element. The device is set up to carry out the described method, so that all embodiments in connection with the method apply analogously to the device. Conversely, all statements in connection with the device apply analogously to the method. The device is typically assigned a suitable handling device, via which the composite component components to be introduced into the tool can be handled, ie in particular can be introduced into the tool. The handling device may comprise a holding element, which is set up for holding the composite components to be handled. In one variant, the handling device can also be designed as a robot device or comprise such.

The tool may comprise a support element movably mounted in and spaced from the first movement axis in and out of a space which can be formed or formed between the first and the second tool element. The holding element is set up for holding a dummy element and / or core element to be introduced into the tool or to be removed from the tool. A corresponding (only) in one of the first axis of movement different second movement axis movably mounted support member is provided in particular when both tool elements are movably mounted, thus both tool elements in the context of the transfer of the tool from its open to its closed position, or vice versa moves become. A corresponding retaining element can form part of a handling device.

Alternatively, the tool can have a second movement axis, which is different in the first movement axis relative to the first and / or the second tool element and in a second movement axis which is different from the first movement axis and orthogonally oriented in particular to the first movement axis, into and out of a first tool element that can be formed between the first and the second tool element or trained space movably mounted support member. The holding element is set up for holding a dummy element and / or core element to be introduced into the tool or to be removed from the tool. A corresponding mounting element movably mounted in the first movement axis as well as in a second movement axis different from the first movement axis is provided, in particular, if only one tool element is movably mounted, thus only one tool element in the context of the transfer of the tool from its open position into its closed position, or vice versa, is moved. A corresponding retaining element can form part of a handling device.

In all cases, respective first and second axes of motion are typically translation axes.

The holding element can be movably mounted along a guide axis defined by a guide device, in particular between a position retracted into the tool and a position extended from the tool. The guide device comprises a number of coupleable or coupled with the support member, z. B. rail-like or -shaped, guide elements. The guide axis defined by the guide device typically corresponds to the second movement axis. The guide device may be associated with a, in particular (electric) motor drive device, which is set up to generate a driving force displacing the mounting element in a movement.

The holding element typically comprises a holding area for holding at least one dummy element and / or a core element as described in connection with the method.

Embodiments of the invention will be explained with reference to the drawings. Showing:

Fig. 1 is a schematic diagram of a device according to an embodiment;

FIGS. 2 to 8 are each a schematic diagram for illustrating the method steps of FIG

Method according to an embodiment; and

Fig. 9 is a schematic diagram of a composite component according to an embodiment.

Fig. 1 shows a schematic diagram of a device 1 according to an embodiment. The device 1 serves to produce a multilayer composite component 2, which composite component 2 comprises two cover layer elements 3, 4 and a core element 5 arranged between the cover layer elements 3, 4 and connected to the cover layer elements 3, 4. The device 1 is set up for carrying out the method described below for producing a corresponding composite component 2 in connection with FIGS. 2-8, in which the device 1 is shown with a higher degree of detail.

The device 1 comprises a shaping tool 6. The tool 6 is a combined forming and injection molding tool; the tool 6 is therefore set up on the one hand, introduced into the tool 6 components, d. H. According to the method typically the cover layer elements 3, 4 and optionally the core element 5, to reshape, and on the other hand set, to introduced into the tool 6 components, d. H. according to the method, the cover layer elements 3, 4, to inject structures or introduced into the tool 6 components, d. H. according to the method, the cover layer elements 3, 4, to be overmoulded with certain structures.

The tool 6 comprises a first tool element 8 (first tool half) having a first shaping tool surface 7 or contour and a second tool element 10 (second tool half) having a second shaping tool surface 9 or contour. The tool elements 8, 10 in each case comprise a plasticized, in particular thermoplastic, opening into a tool-side cavity (not designated), Plastic mass 25, 27 can flow through, optionally heatable, channel structure 20, 21 include, to which a plasticized plastic mass providing injection unit 22, 23 (as needed) can be docked.

In the exemplary embodiment shown in FIG. 1, the first tool element 8 is movably mounted relative to the second tool element 10 in a first movement or translation axis indicated by the vertically aligned double arrow P1. By corresponding movements of the first tool element 8 relative to the second tool element 10, the tool 6 can be transferred from an open position shown in Fig. 1 in a closed position, not shown in FIG. 1, and vice versa. Of course, it is also conceivable in principle that the second tool element 10 is mounted in a corresponding manner relative to the first tool element 8 movable. It is also conceivable that both tool elements 8, 10 are mounted in a corresponding manner movable relative to each other.

The tool 6 comprises a second movement or movement direction, which is different in the first movement axis relative to the first and / or the second tool element 8, 10 and in a direction different from the first movement axis, in particular oriented orthogonally to the first movement axis, indicated by the horizontally oriented double arrow P2 Translational axis in and out of a between the first and the second tool element 8, 10 can be formed or formed intermediate space 1 1 movably mounted support member 12th

The support element 12 can be moved in the first movement axis between the upper position shown in FIG. 1 in a lower position, not shown in the figures, in which it can at least partially rest on the second tool element 10. The support member 12 can be in the second axis of movement between the position shown in Fig. 1 located within the gap 1 1 position of a not shown in the figures outside the gap 1 1 position to move.

The holding element 12 is designed to hold a dummy element 19 and / or core element 5 to be inserted into the tool 6 or to be removed from the tool 6 and for this purpose comprises a holding area for holding dummy or core element 19, 5. The holding element 12 forms part of a Handling device 15.

For the case, not shown in the figures, in which both tool elements 8, 10 are mounted so as to be movable relative to one another, thus both tool elements 8, 10 are moved from its open position into its closed position, or vice versa, during the transfer of the tool 6, can be sufficient only in the second axis of movement in and out of the intermediate space 1 1 movably mounted support member 12.

The holding element 12 is along a guide axis defined by a guide means 16, in particular between the in the tool 6 and the intermediate space 1 first retracted position and one of the tool 6 and the intermediate space 1 1 extended position, movably mounted. The guide device 16 comprises a number of couplable or coupled to the support member 12, z. B. rail-like or - shaped, guide elements 17. The defined by the guide means 16 guide axis corresponds to the second axis of movement. The guide means 16 may be associated with a, in particular (electric) motor drive means (not shown) which is arranged to generate a driving force displacing the support member 12 in a movement.

An exemplary embodiment of a method implementable with the device 1 comprises the following method steps described in more detail in connection with FIGS. 2 to 8:

In a first method step not shown in greater detail in the figures, two cover layer elements 3, 4, a core element 5 to be arranged between the cover layer elements 3, 4 and a flat surface, as well as one of the geometric shape, d. H. in particular the shape of the core element 5 of the finished composite component 2 imitated, forming dummy element 19 is provided. The dummy element 19 is one of the geometric shape of the core element 5 of the finished composite component 2, d. H. the geometric shape of the core element 5, which has the core element 5 after performing the method, modeled geometric body; the dummy element 19 has shaping dummy element surfaces 19a, 19b. The dummy element 19 has sufficient mechanical and thermal stability, so that this does not deform in the context of its use according to the method. The Z. Metal formed dummy element 19 does not form a composite component; The dummy element 19 is used in particular to transform the cover layer elements 3, 4 in the desired manner in the context of carrying out the method. The dummy element 19 can, as will be seen below, also serve to absorb the injection pressure that occurs when one or more functional elements 24 are injected onto a cover layer element 3, 4.

The dummy element 19 may be provided with various functionalities. For example, the dummy element 19 can be tempered in order to temper a covering layer elements 3, 4 resting against it, ie. H. especially to heat. The temperature capability of the dummy element 19 can be controlled by tempering devices (not shown) integrated into the dummy element 19, ie. H. in particular heaters, and / or be implemented by a tempering medium, in particular channel-like, tempering be realized. Further, for example, in the dummy element 19 sensor devices (not shown) for sensing (detection) certain, in particular physical, process parameters, d. H. especially temperature and pressure, be integrated.

In a following second method step, cf. 2, 3, the two cover layer elements 3, 4 and the dummy element 19 are introduced individually or jointly into the tool 6. For introducing the dummy element 19 into the tool 6, the handling device 15 is used, ie the support member 12 is moved into the intermediate space 1 1. The introduction of the two cover layer elements 3, 4 and the dummy element 19 into the tool 6 takes place in such a way that the dummy element 19 is arranged in the state introduced into the tool 6 between the cover layer elements 3, 4.

The cover layer elements 3, 4 can be heated at least in sections before being introduced into the tool 6. The heating of the cover layer elements 3, 4 may, for. B. by means of a in Figs. 2, 3 not shown, but in Fig. 6 radiation device 26, for. B. as infrared radiation, heat radiation produced.

In a following third method step, cf. Fig. 4, the two cover sheet elements 3, 4 are transformed. The forming of the two cover layer elements 3, 4 takes place by using the dummy element 19 arranged between them in one or more shaping steps. The reshaping of the cover layer elements 3, 4 takes place by a taking place in the first axis of movement relative movement (closing movement) of the tool elements 8, 10 taking place transfer of the tool 6 from its open position shown in FIGS. 2-3 in its in z. B. Fig. 4 shown closed position. The cover layer elements 3, 4 are in this case moved on the one hand against a respective adjacent forming tool surfaces 7, 9 and on the other hand against respective adjacent forming dummy element surfaces 19a, 19b, resulting in a shaping of the respective tool surfaces 7, 9 or dummy element surfaces 19a, 19b following deformation of the cover layer elements 3, 4 results.

FIG. 4 shows that during or after the shown forming of the cover layer elements 3, 4, molding of at least one functional element 24 on at least one cover layer element 3, 4 can take place. The tool element 8 is formed in the region of the tool surface 7 with a recess 29 (compare FIGS. 2, 3) which is diametrically opposed to the shape of the functional element 24 to be sprayed. For injection-molding of a corresponding functional element 24, an injection unit 22 is docked or moved up to a tool element 8 so that the plastic mass 25 provided via the injection unit 22 can be injected via the tool element-side channel structure 20 into the tool cavity. In this way, a plasticized plastic compound 25 is injected onto a cover layer element 3 via the injection unit 22 to form a corresponding functional element 24. The pressure (injection pressure) of the plastic mass 25 when the plastic compound 25 enters the tool cavity can be at least partially intercepted by the dummy element 19. Of course, an injection molding of a functional element 24 could alternatively or additionally also take place via the injection unit 23, which is lower in FIGS. 2-8 and which would be docked or moved up to the tool element 10 for this purpose.

As a functional element 24 z. B. a connection interface for connecting the composite component 2 with a connection component forming connecting element and / or a structural reinforcement of the composite component 2 forming reinforcing element and / or - as in Fig. 4 shown by way of example - a fastening interface for attachment of the cover layer element 3 on a tool element 8 of the tool 6 forming fastener are molded.

Alternatively or additionally, it is also possible that, prior to removal of the dummy element 19 from the tool 6, molding of at least one functional element on the inside (relative to the later composite component) of a respective cover layer element 3, 4 can take place. It is therefore an injection of at least one cover layer element 3, 4 possible, so that plasticized plastic or injection molding compound on the inside (relative to the subsequent composite component 2) of a respective cover layer element 3, 4 can pass. In this way, certain functional elements can (also) be formed in the interior of the composite component 2 to be produced. To form corresponding functional elements, the dummy element 19 with corresponding, corresponding to the geometric-constructive shape of the trainees functional elements, z. B. formed by recesses, contours (not shown) may be provided.

A corresponding functional element may also form part of a function structure that performs one or more functions. A function can, for. As an enhancement of the structural, in particular mechanical, properties of the composite component 2, so that as a functional element z. B. a (inner) structural reinforcement of the composite component 2 forming reinforcing element, d. H. z. B. a rib member can be formed.

In a following fourth method step, cf. 5, the dummy element 19 is removed from the tool 6. Before removal of the dummy element 19 from the tool 6 takes place by a taking place in the first axis of movement relative movement (opening movement) of the tool elements 8, 10 taking place transfer of the tool 6 from its closed position to its open position. The removal of the dummy element 19 from the tool 6 is realized, in particular partially or fully automatically, via the handling device 15.

In a following fifth method step, cf. 6, the core element 5 is introduced into the tool 6 between the deformed cover layer elements 3, 4. The introduction of the core element 5 into the tool 6 is realized, in particular partially or fully automatically, via the handling device 15. In the fifth method step, both the cover layer elements 3, 4 and the core element 5 which is not preformed in the exemplary embodiment can be heated at least in sections. The heating of the cover layer elements 3, 4 and the core element 5 may, for. B. by means of one or - as shown in Fig. 6 by way of example - several radiation devices 26, z. B. as infrared radiation, generated heat radiation. The heating of the cover layer element 3, 4 could alternatively or additionally be effected by the contacting of the cover layer elements 3, 4 with a heatable or heated surface of a, in particular dynamically temperable, tool element 8, 10 of the tool 6. The heating of the core element 5 could alternatively or additionally be achieved by contacting the core element 5 with a heated surface of a cover layer element 3, 4 or outside of the tool 6. In all cases, care is taken to ensure that heating of the cover layer elements 3, 4 does not cause structural damage to the cover layer elements 3, 4, in particular due to deconsolidation; This is possible in particular by controlling the heat introduced into the cover layer elements 3, 4. The heat should therefore be introduced essentially only into the (immediate) surface or into (immediate) surface regions of the cover layer elements 3, 4.

In a following sixth method step, cf. 7, the cover layer elements 3, 4 are formed so as to form the composite component 2 such that the core element 5 is arranged captively between the cover layer elements 3, 4 and is (fully) flat with the cover layer elements 3, 4. Before connecting the cover layer elements 3, 4 with the core element 5 is carried out by a taking place in the first axis of movement relative movement (closing movement) of the tool elements 8, 10 taking place transfer of the tool 6 from its open position to its closed position. In all cases, the core element 5 is arranged captively between the cover layer elements 3, 4 by joining the two cover layer elements 3, 4 and the core element 5. The connection results in the sandwich component-like structure or the sandwich component-like characteristic of the composite component 2.

The joining of the cover layer elements 3, 4 with the core element 5 may, for. B. by a thermal energy input, a, optionally a solvent comprehensive, adhesives take place. The compound of the cover layer elements 3, 4 with the core element 5 can therefore z. B. cohesive, adhesive, cohesive, etc. be.

The joining of the cover layer elements 3, 4 takes place by an injection process; In this case, the cover layer elements 3, 4 are at least peripherally encapsulated. For the edge-side encapsulation of the cover layer elements 3, 4, an injection unit 23 is docked or pulled up to a tool element 10, so that the provided via the injection unit 23, typically thermoplastic, plastic mass 27 can be injected via the tool element side channel structure 21 into the mold cavity. In this way, a plasticized plastic compound 27 is injected around the edges of the cover layer elements 3, 4 via the injection unit 23 with formation of a corresponding peripheral coating 28. The plastic compound 27 surrounds the respective edges of the cover layer elements 3, 4 positively and / or non-positively and / or cohesively; the connection of the cover layer elements 3, 4 is thus realized by the edge-side extrusion coating 28 of the cover layer elements 3, 4 by a (solidified) plastic compound 27. Of course, an encapsulation of the cover layer elements 3, 4 could alternatively or additionally also take place via the upper injection unit 22 in FIGS. 2-8, which would be docked or moved up to the tool element 8 for this purpose.

In front of an edge-side at least partially encapsulation of the cover layer elements 3, 4, at least one edge-side, at least sectionally, compacting the cover layer elements 3, 4 realized in particular by a pressing process can be performed. The compacting may be expedient to prevent that plasticized plastic or injection molding material passes between the cover layer elements 3, 4 in the context of extrusion coating of the cover layer elements 3, 4. A correspondingly compact composite component 2 is shown in FIG. 9, which shows a detail of a basic illustration of a composite component 2 according to an exemplary embodiment in a sectional representation; it can be seen that the composite component 2 is compacted in the region of the (lateral) edges of the cover layer elements 3, 4 indicated by the arrow 30 and has a volume reduced in comparison here.

As part of the overmolding of the cover layer elements 3, 4, at least one functional element, in particular a connecting element forming a connection interface for connecting the composite component 2 to at least one connection component and / or a reinforcing element forming a structural reinforcement of the composite component 2, can be injection molded. The composite component 2 can be further functionalized or reinforced by the encapsulation.

Before or during the joining of the cover layer elements 3, 4, the core element 5 can be formed in one or more shaping steps. The forming of the core element 5 is carried out, in particular using the formed cover layer elements 3, 4, in one or more shaping steps in the tool 6. The reshaping of the core element 5 takes place - analogous to the reshaping of the cover layer elements 3, 4 - by the in the first movement axis relative movement (closing movement) of the tool elements 8, 10 taking place transfer of the tool 6 from its open position to its closed position. The core element 5 is in this case indirectly moved over the already formed cover layer elements 3, 4 against respective shaping tool surfaces 7, 9 of the tool elements 8, 10, resulting in a shaping of the respective tool surface 7, 9 following reshaping of the core element 5. A corresponding forming of the core element 5 can be dispensed with, provided that a core element 5 already preformed in its final shape with regard to the finished composite component 2 is used.

In a following seventh process step, cf. 8, the composite component 2 is removed from the tool 6. Before removal of the composite component 2 from the tool 6 takes place by a taking place in the first axis of movement relative movement (opening movement) of the tool elements 8, 10 successful transfer of the tool 6 from its closed position to its open position. The removal of the composite component 2 from the tool 6 can be realized, in particular partially or fully automatically, via the handling device 15.

In a cover layer element 3, 4 may be z. B. to a composite element, ie, for example, to organic sheet or sheet, which embedded in a thermoplastic or thermosetting plastic matrix textile structure, ie in particular a by a, z. B. occasional, fiber assembly formed fiber structure comprises, act. It is also conceivable for a cover layer element 3, 4 to be one, optionally at least in sections surface-activated metal element, ie, for example, a metal sheet, ie, for example, an aluminum or steel sheet.

A core element 5 may be a foam element comprising an open and / or closed-cell foam structure, or a lightweight construction element comprising a single-layer or multi-layer lightweight structure, in particular a honeycomb or sandwich structure, or an electrical or electronic Functional element, for. B. in the form of a chip, data storage, energy storage, etc., which comprises at least one electrical or electronic functional structure act. It is also possible that a foamable core element 5 is used. A foamable core element 5 may, for. B. before, during or after the described bonding of the cover layer elements 3, 4 are foamed.

Claims

PAT EN TAN SPRU

1 . Method for producing a multilayer composite component (2) which comprises two cover layer elements (3, 4) and a core element (5) arranged between the cover layer elements (3, 4) and at least partially connected thereto, characterized by the following steps:

Providing two cover layer elements (3, 4), a core element (5) to be arranged between the cover layer elements (3, 4) and a shaping dummy element (19) modeled on the geometric shape of the core element (5) of the finished composite component (2);

Inserting the cover layer elements (3, 4) and the dummy element (199 into a tool (6) comprising at least one shaping tool surface (7, 9),

Forming the cover layer elements (3, 4) using the forming dummy element (19) in one or more shaping steps in the tool (6),

Removing the dummy element (19) from the tool (6),

Inserting the core element (5) between the formed cover layer elements (3, 4) into the tool (6),

- Connecting the cover layer elements (3, 4) with the core element (5) to form the composite component (2) in the tool (6) such that the core element (5) between the cover layer elements (3, 4) arranged captive and, in particular flat , is connected to the cover layer elements (3, 4),

- Removing the composite component (2) from the tool (6).

2. The method according to claim 1, characterized in that prior to removal of the dummy element (19) from the tool (6) an injection molding of at least one functional element (24) on at least one cover layer element (3, 4).

3. The method according to claim 2, characterized in that as a functional element (24) a connection interface for connecting the composite component (2) with a connection component forming connecting element and / or a reinforcement of the composite component (2) forming reinforcing element and / or a mounting interface for fastening the cover layer element (3, 4) to a tool element (8, 10) of the tool (6) forming fastener is formed.

4. The method according to any one of the preceding claims, characterized in that prior to bonding and / or during the joining of the cover layer elements (3, 4) with the core element (5) to form the composite component (2) in the tool (6) in such a way the core element (5) is captively held between the cover layer elements (3, 4) arranged and, in particular flat, with at least one cover layer element (3, 4) is connected, forming the core element (5), in particular using the formed cover layer elements (3, 4), in one or more shaping steps in the forming tool (6 ) he follows.

5. The method according to any one of the preceding claims, characterized in that the forming of a cover layer element (3, 4) and / or the core element (5) by moving at least one tool element (3, 4) in the direction of a closed position of the tool (6) ,

6. The method according to any one of the preceding claims, characterized in that before and / or during the forming of at least one cover layer element (3, 4) at least partially heating the cover layer element (3, 4) and / or before and / or during a forming of the Core element (5) at least partially heating of the core element (5).

7. The method according to claim 6, characterized in that the heating of the at least one cover layer element (3, 4) by at least partially irradiating the at least one cover layer element (3, 4) with a heat radiation and / or by contacting the cover layer element (3, 4) with a heatable or heated surface of a tool element (8, 10) of the tool (6), and the heating of the core element (5) by at least partially irradiating the core element (5) with a heat radiation and / or by a contacting of the Core element (5) with a heated surface of a cover layer element (3, 4) takes place.

8. The method according to any one of the preceding claims, characterized in that the bonding of the cover layer elements (3, 4) in the tool (6) by at least marginal at least partially encapsulation of the cover layer elements (3, 4).

9. The method according to any one of the preceding claims, characterized in that the introduction of the dummy element (19) and / or the core element (5) in the tool (6) by retracting a dummy element (19) and / or the core element (5) a holding support element (12), which is movably mounted along a guideway defined by a guide device (16), in particular between a position retracted into the tool (6) and a position extended from the tool (6), or by inserting the dummy element ( 19) and / or the core element (5) in the tool (6).

10. The method according to any one of the preceding claims, characterized in that as a cover sheet element (3, 4) a composite element, which in a thermoplastic or thermosetting plastic matrix embedded textile structure comprises, or one, optionally at least partially with a surface treatment surface side activated, metal element is used.

1 1. Method according to one of the preceding claims, characterized in that the core element (5) comprises a foam element which comprises an open or closed-cell foam structure, or a lightweight construction element which comprises a single-layer or multi-layer lightweight structure, in particular a sandwich structure, or an electrical or electronic one Functional element comprising at least one electrical or electronic functional structure is used.

12. The method according to any one of the preceding claims, characterized in that a foamable core element (5) is used, wherein the core element (5) before, during or after the joining of the cover layer elements (3, 4) with the core element (5) is foamed ,

13. Device (1) for producing a multilayer composite component (2), in particular according to the method according to one of the preceding claims, which composite component (2) two cover layer elements (3, 4) and between the cover layer elements (3, 4) arranged and with this at least partially connected core element (5), characterized by:

a shaping tool (6) which has a first tool element (8) having a first shaping tool surface (7) and a second tool element (2) movably mounted in a first movement axis relative to the first tool element (8) and has a second shaping tool surface (9) 10).

14. The device according to claim 13, characterized by a second movement axis, which is different from the first movement axis, into and out of an intermediate space (1 1) which can be formed or formed between the first and the second tool element (8, 10), movably mounted mounting element (12), which is designed to hold a dummy element (19) and / or core element (5) to be introduced into the tool (6) or to be removed from the tool (6).

15. The apparatus of claim 13, characterized by a in the first movement axis relative to the first and / or the second tool element (8, 10) and in a different movement axis of the second movement axis in and out of a between the first and the second tool element (8, 10) can be formed or formed movable intermediate space (1 1) movably mounted holding element (12), which for holding a in the tool (6) to be introduced or from the tool (6) to be removed dummy element (19) and / or core element (5 ) is set up.

16. The apparatus according to claim 14 or 15, characterized in that the

Supporting element (12) along a by a guide device (16) defined guide track, in particular between a in the tool (6), in particular in the intermediate space (1 1), retracted position and one of the tool (6), in particular the intermediate space (1 1), extended position, is movably mounted.

17. Multi-layer composite component (2), which comprises two cover layer elements (3, 4) and between the cover layer elements (3, 4) arranged and at least partially connected thereto core element (5). characterized in that it is made by a method according to any one of claims 1 to 12.