WO2019224013A1 - Composite component for a vehicle and method for producing a composite component - Google Patents

Composite component for a vehicle and method for producing a composite component Download PDF

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Publication number
WO2019224013A1
WO2019224013A1 PCT/EP2019/061995 EP2019061995W WO2019224013A1 WO 2019224013 A1 WO2019224013 A1 WO 2019224013A1 EP 2019061995 W EP2019061995 W EP 2019061995W WO 2019224013 A1 WO2019224013 A1 WO 2019224013A1
Authority
WO
WIPO (PCT)
Prior art keywords
component
composite component
matrix material
layer
reinforced
Prior art date
Application number
PCT/EP2019/061995
Other languages
German (de)
French (fr)
Inventor
Anja JÄSCHKE
Francisco Trigueros Morera de la Vall
Original Assignee
Audi 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 Audi Ag filed Critical Audi Ag
Publication of WO2019224013A1 publication Critical patent/WO2019224013A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/02—Side panels
    • B62D25/025—Side sills thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/18—Filling preformed cavities
    • B29C44/188—Sealing off parts of the cavities
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/36—Feeding the material to be shaped
    • B29C44/38—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length
    • B29C44/44—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length in solid form
    • B29C44/445—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length in solid form in the form of expandable granules, particles or beads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/20—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for porous or cellular articles, e.g. of foam plastics, coarse-pored
    • B29C67/207—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for porous or cellular articles, e.g. of foam plastics, coarse-pored comprising impregnating expanded particles or fragments with a binder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/58—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising fillers only, e.g. particles, powder, beads, flakes, spheres
    • B29C70/66—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising fillers only, e.g. particles, powder, beads, flakes, spheres the filler comprising hollow constituents, e.g. syntactic foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/681—Component parts, details or accessories; Auxiliary operations
    • B29C70/683—Pretreatment of the preformed part, e.g. insert
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/74—Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding
    • B29C70/745—Filling cavities in the preformed part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/78—Moulding material on one side only of the preformed part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/043—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/046—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/16—Layered products comprising a layer of metal next to a particulate layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/18—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by an internal layer formed of separate pieces of material which are juxtaposed side-by-side
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B62D29/005—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material preformed metal and synthetic material elements being joined together, e.g. by adhesives

Definitions

  • the invention relates to a composite component for a vehicle according to the preamble of claim 1. Furthermore, the invention relates to a method for producing a composite component.
  • Three-dimensional composite components for vehicles are known in numerous variations.
  • DE 10 2009 034 724 A1 discloses a method for producing a component.
  • a carrier material is inserted into a mold, which can be penetrated by ultraviolet radiation.
  • At least one surface side of the carrier material and an inner surface of the forming tool at least one cavity is formed, at least in regions, by a molding of the inner surface of the molding tool, which can be achieved by filling the molding tool with a casting material before inserting the carrier material or after is filled in the insertion of the carrier material.
  • the casting material is hardened by means of ult raviolet radiation which is emitted by an ultraviolet radiation source arranged outside the forming tool and penetrates the molding tool.
  • the invention is based on the object to provide a composite component for a vehicle and a method for producing a composite component, which can be amplified in a simple manner.
  • This object is achieved by a composite component for a vehicle having the features of patent claim 1 and by a method for producing a composite component having the features of patent claim 17.
  • Advantageous embodiments with expedient developments of the invention are specified in the dependent claims.
  • a preformed member has a reinforcing layer at least at portions of its surface which adheres to the preformed member and comprises a particle foam.
  • a method for producing a composite component comprises the following steps: provision of a preformed component to be reinforced, insertion of the preformed component into the mold cavity of a tool, injection of a matrix material into the mold cavity, curing of the matrix material, Removal of the resulting reinforced composite component.
  • the matrix material contains at least one trigger component which defines a time of hardening of the matrix material.
  • foamable particles are provided, which are enclosed by the matrix material.
  • particle foam preformed components can be easily reinforced.
  • sheet metal reinforcements can be replaced by particle foam, the composition of which can vary by adding metal balls, so that regions with different densities can arise.
  • the composite components can be produced fully automatically, whereby the particle foam can be pressed directly onto the preformed component, so that additional joining operations can be dispensed with.
  • the particle foam consists of a mixture of non-metallic hollow spheres and metal material.
  • the metal material may be in the form of spheres or metal textile, in which non-metallic see hollow balls can be used.
  • the material density of the particle foam can vary, so that regions with different strengths arise, which can be used specifically for the conversion of crash energy or for the reduction of crash forces.
  • a surface treatment for adhesion optimization can be carried out on the coated preformed component at least in the region of the reinforcing layer.
  • a roughness of the surface can be increased by passivation and / or structuring or a bonding agent or a film can be applied to the surface.
  • the combination of metallic and non-metallic particles which expand under pressure and temperature and thus can also produce adhesion between metal balls and non-metallic hollow spheres, can also be used to produce thick-walled components with a good crash energy absorption behavior and good acoustic insulation properties.
  • the metal material can be used in the tempering of the particle foam, so that you can work at low pressures and the components can be heated and cooled, so to speak from the inside, as the metal balls or the metal fabric a faster heat transfer than the non-metallic hollow spheres respectively. This offers great advantages in the manufacturing process, for example in process control, cycle time reduction, etc.
  • this combination of materials is used for battery housings, motor housings and / or structural components.
  • the composite components comprise a stiffening structure which selectively contains weak points and can be fastened to the component to be reinforced via a particle foam component.
  • the stiffening structure can be designed, for example, as a tube or as a lattice structure with vertical and horizontal webs, which can be embedded in the particle foam.
  • the composite components can be modified and additional functions such as the function of a elastic crash layer, take over the function of a compensation layer for different length expansion of the composite layers or the function of a corrosion layer.
  • the particle foam has a low residual block length in the event of a crash, so that a high energy absorption is possible with a small space.
  • embodiments of the composite component according to the invention advantageously enable an improved conversion of crash energy or a higher reduction of crash forces on failure of the composite component.
  • the composite component can be folded in a targeted manner and a buckling prevented.
  • space is gained in the design of the individual composite components, since significantly more crash energy can be absorbed in a small space and crash forces can be reduced.
  • embodiments of the invention provide low-distortion composite components, since no compact reaction takes place in the component. This allows a significant reduction of residual stresses and springback and distortion.
  • a fast machining of the tool geometry is possible, so that test and prototype components as well as small series can be produced in a very short processing time and at low cost.
  • the preformed component may, for example, be a stiffening structure to which the reinforcing layer at least partially adheres.
  • the preformed component may be a hollow profile, on the wall of which the reinforcing layer at least partially adheres.
  • the preformed component may be a weld group with a cavity in which the reinforcing layer adheres to at least one wall at least in certain areas.
  • the particle foam can be foamed from a mixture of non-metallic hollow spheres and / or a metal material and at least one matrix material. the.
  • the particle foam is foamed from non-metallic hollow spheres and at least one matrix material or from the metal material and the at least one matrix material or from non-metallic hollow spheres and the Meta II material and at least one matrix material.
  • the foamable particles are pressed and melted during their expansion with or without metal material to the component.
  • Material, size and properties of the non-metallic hollow spheres can be chosen so that adhesion to the preformed component is formed and a bonding agent layer can be omitted.
  • the metal material can be present for example in the form of metallic hollow spheres or metal textile.
  • cost-effective spheres made of polymer, expanded glass or clay with metallic coating can be used instead of the metallic hollow spheres.
  • the metal textile can be designed, for example, as a scrim and / or fabric and / or knit.
  • the metal textile can be welded to the component to be reinforced and additionally act as a drawstring.
  • the mixture of the metallic hollow spheres and the non-metallic hollow spheres can be selected to implement a desired crash behavior.
  • the matrix material may include at least one trigger component, which may define a time point of curing of the matrix material.
  • the at least one trigger component may, for example, comprise an energetic radiation, temperature and / or moisture-based triggering material.
  • the trigger component comprises an ultraviolet light radiation curable (UV curing) trigger material which bonds with the foamed particles of the particle foam.
  • the non-metallic hollow spheres can be foamed under the effect of temperature and / or pressure and be embodied, for example, as thermoplastic spheres and / or ceramic spheres and / or glass spheres.
  • the non-metallic hollow spheres can be designed as thermoplastic coated blown fabrics.
  • the preformed component can be adhesion-optimized on its surface at least in the region of the reinforcing layer.
  • the material density in the particle foam may be locally different, so that different properties can be achieved.
  • the reinforcing layer can have specific weak points, wherein in the event of a crash, a targeted energy absorption can take place via the particle foam.
  • the reinforcing layer can have a stiffening layer, which can be arranged between the particle foam and the wall of the hollow profile to be reinforced or the welding group to be reinforced.
  • the reinforcing layer can be embodied, for example, as a fiber-reinforced matrix layer or as a metal-textile-reinforced matrix layer or as a metal-textile-reinforced layer with applied non-metallic hollow spheres or as a metal spherical layer.
  • the composite component can be designed, for example, as a body component or as a reinforcing component, which can be introduced into a cavity of a body component to be reinforced.
  • the foamable particles can be expandable non-metallic hollow spheres and / or expandable metallic hollow spheres.
  • the foamable particles may be provided in the mold cavity of the tool prior to injection of the matrix material. Additionally or alternatively, at least a portion of the foamable particles may be admixed with the matrix material prior to injection into the mold cavity of the tool. Furthermore, the matrix material can also be foamed.
  • the at least one trigger component for curing the matrix material can be activated by means of energetic radiation and / or by heating and / or by adding moisture. UV curing resin is preferably used as the trigger component, which enables short cycle times by rapid curing with UV light.
  • the tool may preferably also consist of a transparent material.
  • foamable particles are preferably compressed under heat or fused with water vapor, the process with embedding of the particles in UV-curing resin is more reliable, since no susceptible control technology is required. In addition, significantly thicker-walled composite components can be produced and a high cost savings can be achieved.
  • FIG. 1 is a schematic sectional view of a first embodiment of a composite component according to the invention, which is designed as a body component.
  • FIG. 2 shows a schematic sectional view of a second exemplary embodiment of a composite component according to the invention, which is designed as a reinforcing component and inserted into a flea space of a body component to be reinforced;
  • FIG. 1 is a schematic sectional view of a first embodiment of a composite component according to the invention, which is designed as a body component.
  • FIG. 2 shows a schematic sectional view of a second exemplary embodiment of a composite component according to the invention, which is designed as a reinforcing component and inserted into a flea space of a body component to be reinforced;
  • FIG. 1 is a schematic sectional view of a first embodiment of a composite component according to the invention, which is designed as a body component.
  • FIG. 2 shows a schematic sectional view of a second exemplary embodiment of a composite component according to the invention, which is designed
  • FIG. 3 is a schematic sectional view of a third exemplary embodiment of a composite component according to the invention, which is designed as a body component;
  • FIGS. 1 to 4 are schematic sectional views of a fourth embodiment of a composite component according to the invention, which is designed as a body component.
  • the illustrated exemplary embodiments of a composite component 1 according to the invention for a vehicle each have a preformed component 2, 3, 10.
  • the preformed component 2, 3, 10 has a reinforcing layer 15 at least at partial areas of its surface, which adheres to the preformed component 2, 3, 10 and comprises a particle foam 16.
  • the composite component 1 is designed as a body component 1 A in the illustrated first exemplary embodiment.
  • the illustrated body component 1A is an example of a side skirts of a motor vehicle body.
  • the body component 1A comprises a first hollow profile 2 designed as an open shell and a second closed hollow profile 3, which has two flea spaces 5, 6 separated by a strut 4.
  • the first hollow profile 2 is connected at connection points 8 with the second hollow profile 3 such that an outer wall 3.1 of the second hollow profile 3 covers the open shell of the first hollow profile 2.
  • the hollow sections 2, 3 can for example be welded or glued at the connection points. Additionally or alternatively, other connection techniques, such as mechanical connections can be used.
  • the hollow sections 2, 3 can be made from a light metal, such as aluminum, magnesium, etc., or another suitable ductile material, to implement the concept of lightweight construction.
  • the hollow profiles can be produced from a fiber-plastic composite.
  • the second hollow profile 3 is formed in the illustrated embodiment as an extruded aluminum profile, which forms a closed multi-chamber profile.
  • the first hollow profile 2 is executed in the illustrated embodiment as an open aluminum shell. In this case, a reinforcement is to be introduced into the cavity 7 enclosed by the hollow profiles 2, 3.
  • the two hollow profiles 2, 3 each form a preformed component, and a stiffening structure 10 forms a further preformed component which, prior to the application of the reinforcing layer 15A, is defined in the hollow space 7 bounded by the hollow profiles 2, 3 Body component 1A is introduced.
  • the stiffening structure 10 has a grid structure with a vertical web 12 and a plurality of horizontal webs 13.
  • the reinforcing layer 15A in the illustrated exemplary embodiment adheres to opposite walls 2.1, 3.1 bounding the cavity 7.
  • the reinforcing layer 15 adheres to the vertical and horizontal webs 12, 13 of the stiffening structure 10.
  • the particle foam 16 of the reinforcing layer 15A in the illustrated embodiment is foamed from a mixture of non-metallic hollow spheres 16A, at least one matrix material 17 and a metal material.
  • the metal material in the illustrated embodiment is in the form of metallic hollow spheres 16B.
  • the matrix material 17 includes at least one trigger component which defines a time of curing of the matrix material 17.
  • the at least one trigger component has an energy radiation-based triggering material which cures by UV light.
  • the non-metallic hollow spheres 16A are foamable under the effect of temperature and / or pressure and, in the illustrated embodiment, are designed as thermoplastic spheres.
  • the non-metallic hollow spheres 16A are designed as ceramic balls and / or glass beads and / or as thermoplastically coated blown fabrics.
  • the particle foam 16 has locally different material densities, since regions with metallic hollow spheres 16B and regions with non-metallic hollow spheres 16A are present, wherein the metallic hollow spheres 16B have a greater material density than the non-metallic hollow spheres 16A.
  • the regions of the particle foam 16 with the metallic hollow spheres 16B can absorb larger crash energy levels than the regions of the particle foam 16 with the non-metallic hollow spheres 16A.
  • different properties can advantageously be achieved.
  • the reinforcing layer 15 by the non-metallic hollow spheres 16A targeted vulnerabilities, in the event of a crash, a targeted energy absorption takes place via the particle foam 16.
  • the reinforcing layer 15A in the exemplary embodiment shown has two stiffening layers 18, which are respectively arranged between the particle foam 16 and the wall 2.1, 3.1 of the hollow sections 2, 3 to be reinforced.
  • the stiffening layers 18 are implemented in the illustrated embodiment as a fiber-reinforced matrix layer 18A.
  • the stiffening layers may be implemented as metal-textile-reinforced matrix layers.
  • the metal fabric can be performed as a scrim and / or fabric and / or knitted fabric.
  • the surfaces of the walls 2.1, 3.1 of the hollow sections 2, 3 can be adhesion-optimized in the region of the reinforcing layer 15A.
  • the composite component 1 in the illustrated second exemplary embodiment is embodied as a reinforcing component 1 B which comprises a preformed component embodied as a stiffening structure 10.
  • the stiffening structure 10 has, analogously to the first exemplary embodiment, a grid structure with a vertical web 12 and a plurality of horizontal webs 13.
  • the reinforcing layer 15B adheres to the vertical and horizontal webs 12, 13 of the stiffening structure 10 in the illustrated exemplary embodiment.
  • FIG. 2 the reinforcing member 1 B for the reinforcement of a body component 1 C after completion in a cavity 7 of the body component 1 C introduced.
  • the structure of the body component 1 C of FIG. 2 essentially corresponds to the structure of the body component 1 A from FIG. 1, so that a repeated description of the components already known is dispensed with here.
  • the particle foam 16 of the reinforcing layer 15B is foamed from a mixture of metallic hollow spheres 16B and at least one matrix material 17 in the exemplary embodiment shown.
  • the matrix material 17 contains at least one trigger component which defines the time of curing of the matrix material 17.
  • the at least one trigger component and the metallic hollow balls 16B have already been described in connection with the first exemplary embodiment.
  • the preformed component is a welded group having a cavity, in which the reinforcing layer adheres, at least in regions, to at least one wall delimiting the cavity, analogously to the first exemplary embodiment.
  • the composite component 1 in the exemplary embodiments illustrated is designed as a body component 1 D, 1 E.
  • the body components 1 D, 1 E each comprise a designed as an open shell hollow profile 2 as a preformed component to be reinforced.
  • the respective reinforcing layer 15C, 15D adheres in each case to the wall 2.1 delimiting the cavity 7 in the illustrated exemplary embodiments.
  • the particle foam 16 of the reinforcing layers 15C, 15D is in each case foamed from a mixture of non-metallic hollow spheres 16A and at least one matrix material 17 in the illustrated exemplary embodiments.
  • the matrix material 17 contains at least one trigger component which determines the time of the Curing of the matrix material 17 defined.
  • the at least one trigger component and the non-metallic hollow spheres 16A have already been described in connection with the first exemplary embodiment.
  • the reinforcing layer 15C has a stiffening layer 18B, which is arranged between the particle foam 16 and the wall 2.1 of the hollow profile 2 to be reinforced and reinforces the wall 2.1.
  • the stiffening layer 18 is designed in the illustrated embodiment as a metal-textile-reinforced layer 18B with applied non-metallic hollow spheres 16A.
  • the metal textile 19 can be designed as a scrim and / or fabric and / or knitted fabric.
  • the surface of the wall 2.1 of the hollow profile 2 in the region of the reinforcing layer 15C may be adhesion-optimized.
  • the reinforcing layer 15D in the exemplary embodiment shown has a stiffening layer 18C, which is arranged between the particle foam 16 and the wall 2.1 of the hollow profile 2 to be reinforced and reinforces the wall 2.1.
  • the stiffening layer 18 is executed in the illustrated embodiment as a metal ball layer 18C.
  • the metal fabric 19 can be performed as a scrim and / or fabric and / or knitted fabric.
  • a plurality of webs 14 are introduced into the cavity 7, which are attached to the wall 2.1 of the hollow section 2. Therefore, the reinforcing layer 15D also adheres to these webs 14.
  • the surface of the wall 2.1 of the hollow profile 2 can be adhesively optimized in the region of the reinforcing layer 15C.
  • the method according to the invention for producing a composite component 1 comprises the steps of providing a preformed component 2, 3, 10, inserting the preformed component 2, 3, 10 into the mold cavity of a tool, injecting a matrix material 17 into the mold cavity, and curing. Then, the resulting reinforced composite component 1 is removed from the mold cavity.
  • the matrix material 17 contains at least one trigger component, which defines a time of curing of the matrix material 17.
  • foamable particles 16A, 16B are provided, which are enclosed by the matrix material 17.
  • the foamable particles are expandable non-metallic hollow spheres 16A and / or expandable metallic hollow spheres 16B.
  • the matrix material 17 can also be foamed.
  • at least a portion of the foamable particles 16A, 16B is provided prior to injection of the matrix material 17 in the mold cavity of the tool.
  • at least a portion of the foamable particles 16A, 16B is added to the matrix material 17 prior to injection into the mold cavity of the tool.
  • the at least one trigger component is activated to harden the matrix material 17 by means of energetic radiation and / or by heating and / or by adding moisture.
  • the bodywork component 1A shown in FIG. 1 To produce the bodywork component 1A shown in FIG. 1, first the first hollow profile 2, on the wall 2.1 of which three vertically projecting webs 13 are fastened, is inserted into the mold cavity. Subsequently, the injection of matrix material 17 with admixed fibers takes place so that the corresponding sections of the fiber-reinforced matrix layer 18A are formed between the webs 13, which should be arranged in the finished composite component 1 between the particle foam 16 and the wall 2.1 of the first hollow profile 2 , Subsequently, the foamable particles in the form of non-metallic hollow spheres 16A and metallic hollow spheres 16B are filled according to the desired distribution in the spaces formed between the webs 13 and the first hollow profile 2.
  • the non-metallic hollow spheres 16A and metallic hollow spheres 16B can be mixed with the latter prior to the injection of the matrix material 17.
  • the injection of the matrix material can take place after introduction of the non-metallic hollow spheres 16A and metallic hollow spheres 16B.
  • the web 12 which runs parallel to the wall 2.1 and to which three webs 13 projecting perpendicularly, are attached, so that the lattice structure of the reinforcing structure 10 is formed.
  • the injection of matrix material 17 with admixed fibers takes place, so that the corresponding sections of the fiber-reinforced matrix layer 18A are formed between the webs 13, which should be arranged in the finished composite component 1 between the particle foam 16 and the wall 3.1 of the second hollow profile 3 , Then, the second hollow section 3 is placed and connected to the first hollow section 2. Subsequently, the activation of the at least one trigger component and the hardening of the matrix material 17 takes place. After hardening of the matrix material, the reinforced body component 1A is removed from the mold cavity and further processed or installed on the vehicle.
  • the reinforcing structure 10 is inserted with the webs 12 and 13 in the mold cavity.
  • the mold cavity is designed so that between the walls of the mold cavity and the webs 12 and 13 of the reinforcing structure 10 cavities are formed, in which the mixture for generating the particle foam 16 can be introduced.
  • the particle foam 16 comprises metallic hollow spheres 16B and matrix material 17.
  • the metallic hollow spheres 16B can be mixed with the matrix material 17 before the matrix material is injected.
  • the injection of the matrix material 17 may take place after the introduction of the metallic hollow spheres 16B.
  • the finished reinforcing component 1B is removed from the mold cavity and further processed or introduced into the cavity 7 of the body component 1C.
  • the hollow profile 2 is first inserted into the mold cavity. Subsequently, the metal-textile-reinforced layer 18B with applied non-metallic hollow core is removed. 16A performed stiffening layer 18 along the wall 2.1 of the hollow profile 2 inserted. Subsequently, the foamable particles in the form of non-metallic hollow spheres 16 A are filled into the cavity 7 of the hollow section 2.
  • the non-metallic hollow spheres 16A can be mixed with the matrix material 17 prior to injection of the matrix material 17. Alternatively, the injection of the matrix material can take place after introduction of the non-metallic hollow spheres 16A. Subsequently, the activation of the at least one trigger component and the hardening of the matrix material 17 takes place. After hardening of the matrix material, the reinforced body component 1A is removed from the mold cavity and further processed or installed on the vehicle.
  • the hollow section 2 is first inserted into the mold cavity.
  • the stiffening layer 18 embodied as a metal ball layer 18C is introduced along the wall 2.1 of the hollow profile 2.
  • the foamable particles in the form of non-metallic hollow spheres 16 A are filled into the cavity 7 of the hollow section 2.
  • the non-metallic hollow spheres 16A may be mixed with the matrix material 17 prior to injection.
  • the injection of the matrix material can take place after introduction of the non-metallic hollow spheres 16A.
  • the activation of the at least one trigger component and the hardening of the matrix material 17 takes place.
  • the reinforced body component 1A is removed from the mold cavity and further processed or installed on the vehicle.

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Abstract

The invention relates to a composite component (1) for a vehicle, having a preformed component to be reinforced (2, 3, 10), and to a corresponding method for producing a composite component (1). According to the invention, the preformed component (2, 3, 10) has, at least at partial regions of its surface, a reinforcing layer (15) that adheres to the preformed component (2, 3, 10) and comprises a particle foam (16).

Description

Verbundbauteil für ein Fahrzeug und Verfahren zum Herstellen eines  Composite component for a vehicle and method for manufacturing a
Verbundbauteils  composite component
BESCHREIBUNG: DESCRIPTION:
Die Erfindung betrifft ein Verbundbauteil für ein Fahrzeug gemäß der Gattung des Patentanspruchs 1. Des Weiteren betrifft die Erfindung ein Verfahren zum Herstellen eines Verbundbauteils. Dreidimensional ausgeprägte Verbundbauteile für Fahrzeuge sind in zahlrei- chen Variationen bekannt. So offenbart beispielsweise die DE 10 2009 034 724 A1 ein Verfahren zur Herstellung eines Bauteils. Hierbei wird ein Trägermaterial in ein Formwerkzeug eingelegt, welches von ultravio- letter Strahlung durchdrungen werden kann. Zwischen zumindest einer Ober- flächenseite des Trägermaterials und einer Innenoberflache des Formwerk- zeugs ist zumindest bereichsweise zumindest ein durch eine Ausformung der Innenoberflache des Formwerkzeugs vorgegebener Hohlraum gebildet, wel- cher durch Füllen des Formwerkzeugs mit einem Gussmaterial vor dem Ein- legen des Trägermaterials oder nach dem Einlegen des Trägermaterials aus- gefüllt wird. Das Gussmaterial wird, nachdem der zumindest eine Hohlraum vollständig ausgefüllt und das Trägermaterial exakt positioniert ist, mittels ult ravioletter Strahlung ausgehärtet, welche von einer außerhalb des Formwerk- zeugs angeordneten ultravioletten Strahlungsquelle ausgesendet wird und das Formwerkzeug durchdringt. The invention relates to a composite component for a vehicle according to the preamble of claim 1. Furthermore, the invention relates to a method for producing a composite component. Three-dimensional composite components for vehicles are known in numerous variations. For example, DE 10 2009 034 724 A1 discloses a method for producing a component. Here, a carrier material is inserted into a mold, which can be penetrated by ultraviolet radiation. Between at least one surface side of the carrier material and an inner surface of the forming tool, at least one cavity is formed, at least in regions, by a molding of the inner surface of the molding tool, which can be achieved by filling the molding tool with a casting material before inserting the carrier material or after is filled in the insertion of the carrier material. After the at least one cavity has been completely filled and the carrier material has been exactly positioned, the casting material is hardened by means of ult raviolet radiation which is emitted by an ultraviolet radiation source arranged outside the forming tool and penetrates the molding tool.
Der Erfindung liegt die Aufgabe zu Grunde, ein Verbundbauteil für ein Fahr- zeug und ein Verfahren zum Herstellen eines Verbundbauteils bereitzustellen, welches auf einfache Weise verstärkt werden kann. Diese Aufgabe wird durch ein Verbundbauteil für ein Fahrzeug mit den Merk- malen des Patentanspruchs 1 und durch ein Verfahren zum Herstellen eines Verbundbauteils mit den Merkmalen des Patentanspruchs 17 gelöst. Vorteil- hafte Ausgestaltungen mit zweckmäßigen Weiterbildungen der Erfindung sind in den abhängigen Patentansprüchen angegeben. The invention is based on the object to provide a composite component for a vehicle and a method for producing a composite component, which can be amplified in a simple manner. This object is achieved by a composite component for a vehicle having the features of patent claim 1 and by a method for producing a composite component having the features of patent claim 17. Advantageous embodiments with expedient developments of the invention are specified in the dependent claims.
Um ein Verbundbauteil für ein Fahrzeug bereitzustellen, welches auf einfache Weise verstärkt ist, weist ein vorgeformtes Bauteil zumindest an Teilbereichen seiner Oberfläche eine Verstärkungsschicht auf, welche an dem vorgeformten Bauteil haftet und einen Partikelschaum umfasst. In order to provide a composite member for a vehicle which is easily reinforced, a preformed member has a reinforcing layer at least at portions of its surface which adheres to the preformed member and comprises a particle foam.
Zudem wird ein Verfahren zum Herstellen eines Verbundbauteils vorgeschla- gen, welches die nachfolgenden Schritte umfasst: Bereitstellen eines zu ver- stärkenden vorgeformten Bauteils, Einlegen des vorgeformten Bauteils in den Formhohlraum eines Werkzeugs, Injizieren eines Matrixmaterials in den Form- hohlraum, Aushärten des Matrixmaterials, Entnahme des dadurch entstande- nen verstärkten Verbundbauteils. Erfindungsgemäß beinhaltet das Matrixma- terial mindestens eine Trigger-Komponente, welche einen Zeitpunkt der Aus- härtung des Matrixmaterials definiert. Zudem sind aufschäumbare Partikel vor- gesehen, welche von dem Matrixmaterial umschlossen werden. In addition, a method for producing a composite component is proposed which comprises the following steps: provision of a preformed component to be reinforced, insertion of the preformed component into the mold cavity of a tool, injection of a matrix material into the mold cavity, curing of the matrix material, Removal of the resulting reinforced composite component. According to the invention, the matrix material contains at least one trigger component which defines a time of hardening of the matrix material. In addition, foamable particles are provided, which are enclosed by the matrix material.
Durch den Partikelschaum können vorgeformte Bauteile auf einfache Weise verstärkt werden. Des Weiteren können bei Ausführungsformen der Verbund- bauteile Blechverstärkungen durch Partikelschaum ersetzt werden, dessen Zusammensetzung durch Zusatz von Metallkugeln variieren kann, so dass Be- reiche mit unterschiedlichen Dichten entstehen können. Die Verbundbauteile können vollautomatisch gefertigt werden, wobei der Partikelschaum direkt auf das vorgeformte Bauteil gepresst werden kann, so dass zusätzliche Fügeope- rationen entfallen können. By the particle foam preformed components can be easily reinforced. Furthermore, in embodiments of the composite components, sheet metal reinforcements can be replaced by particle foam, the composition of which can vary by adding metal balls, so that regions with different densities can arise. The composite components can be produced fully automatically, whereby the particle foam can be pressed directly onto the preformed component, so that additional joining operations can be dispensed with.
In einer bevorzugten Ausführung besteht der Partikelschaum aus einem Ge- misch von nichtmetallischen Hohlkugeln und Metallwerkstoff. Der Metallwerk- stoff kann in Form von Kugeln oder Metalltextil vorliegen, in dem nichtmetalli- sehe Hohlkugeln eingesetzt werden können. In einem Hohlraum des zu ver- stärkenden Verbundbauteils kann die Materialdichte des Partikelschaumes variieren, so dass Bereiche mit unterschiedlichen Festigkeiten entstehen, wel- che gezielt zur Umwandlung von Crashenergie bzw. zum Abbau von Crashkräften eingesetzt werden können. An dem beschichteten vorgeformten Bauteil kann zumindest im Bereich der Verstärkungsschicht eine Oberflächen- behandlung zur Haftungsoptimierung durchgeführt werden. So kann beispiels weise eine Rauheit der Oberfläche durch Passivieren und/oder Strukturieren erhöht oder ein Haftvermittler oder eine Folie auf die Oberfläche aufgebracht werden. Durch die Kombination von metallischen und nichtmetallischen Parti- keln, welche unter Druck und Temperatur expandieren und damit auch eine Haftung zwischen Metallkugeln und nichtmetallischen Hohlkugeln erzeugen können, können auch dickwandige Bauteile mit einem guten Crashenergie- absorptionsverhalten und guten akustischen Dämmeigenschaften hergestellt werden. Zudem kann der Metallwerkstoff bei der Temperierung des Partikel schaumes eingesetzt werden, so dass mit geringen Drücken gearbeitet wer- den kann und die Bauteile sozusagen von innen erwärmt und gekühlt werden können, da die Metallkugeln oder das Metalltextil einen schnelleren Wärme- Übergang als die nichtmetallischen Hohlkugeln aufweisen. Das bietet im Her- stellprozess große Vorteile, beispielsweise bei Prozessführung, Zykluszeitre- duzierung usw. Bevorzugt wird diese Materialkombination für Batteriege- häuse, Motorengehäuse und/oder Strukturbauteile eingesetzt. In a preferred embodiment, the particle foam consists of a mixture of non-metallic hollow spheres and metal material. The metal material may be in the form of spheres or metal textile, in which non-metallic see hollow balls can be used. In a cavity of the composite component to be reinforced, the material density of the particle foam can vary, so that regions with different strengths arise, which can be used specifically for the conversion of crash energy or for the reduction of crash forces. A surface treatment for adhesion optimization can be carried out on the coated preformed component at least in the region of the reinforcing layer. Thus, for example, a roughness of the surface can be increased by passivation and / or structuring or a bonding agent or a film can be applied to the surface. The combination of metallic and non-metallic particles, which expand under pressure and temperature and thus can also produce adhesion between metal balls and non-metallic hollow spheres, can also be used to produce thick-walled components with a good crash energy absorption behavior and good acoustic insulation properties. In addition, the metal material can be used in the tempering of the particle foam, so that you can work at low pressures and the components can be heated and cooled, so to speak from the inside, as the metal balls or the metal fabric a faster heat transfer than the non-metallic hollow spheres respectively. This offers great advantages in the manufacturing process, for example in process control, cycle time reduction, etc. Preferably, this combination of materials is used for battery housings, motor housings and / or structural components.
Weiter Ausführungsbeispiele der Verbundbauteile umfassen eine Verstei- fungsstruktur, welche gezielt Schwachstellen enthält und über eine Partikel- schaumkomponente an dem zu verstärkenden Bauteil befestigt werden kann. Die Versteifungsstruktur kann beispielsweise als Rohr oder als Gitterstruktur mit vertikalen und horizontalen Stegen ausgeführt werden, welche in den Par- tikelschaum eingebettet werden kann. Further exemplary embodiments of the composite components comprise a stiffening structure which selectively contains weak points and can be fastened to the component to be reinforced via a particle foam component. The stiffening structure can be designed, for example, as a tube or as a lattice structure with vertical and horizontal webs, which can be embedded in the particle foam.
Durch Ausführungsformen der Erfindung können die Verbundbauteile modifi- ziert werden und zusätzliche Funktionen wie beispielsweise die Funktion einer elastischen Crashschicht, die Funktion einer Ausgleichsschicht für unter- schiedliche Längenausdehnung der Verbundschichten oder die Funktion einer Korrosionsschicht übernehmen. By embodiments of the invention, the composite components can be modified and additional functions such as the function of a elastic crash layer, take over the function of a compensation layer for different length expansion of the composite layers or the function of a corrosion layer.
Der Partikelschaum weist im Crashfall eine geringe Restblocklänge auf, so dass bei geringem Bauraum eine hohe Energieabsorption möglich ist. Somit ermöglichen Ausführungsformen des erfindungsgemäßen Verbundbauteils in vorteilhafter Weise eine verbesserte Umwandlung von Crashenergie bzw. ei- nen höheren Abbau von Crashkräften beim Versagen des Verbundbauteils er- möglichen. Zudem kann das Verbundbauteil gezielt gefaltet und ein Auskni- cken verhindert werden. Zudem gewinnt man bei der Auslegung der einzelnen Verbundbauteile Bauraum, da auf kleinem Bauraum deutlich mehr Crashener- gie absorbiert bzw. Crashkräfte abgebaut werden können. The particle foam has a low residual block length in the event of a crash, so that a high energy absorption is possible with a small space. Thus, embodiments of the composite component according to the invention advantageously enable an improved conversion of crash energy or a higher reduction of crash forces on failure of the composite component. In addition, the composite component can be folded in a targeted manner and a buckling prevented. In addition, space is gained in the design of the individual composite components, since significantly more crash energy can be absorbed in a small space and crash forces can be reduced.
Des Weiteren stellen Ausführungsformen der Erfindung verzugsarme Ver- bundbauteile zur Verfügung, da im Bauteil keine kompakte Reaktion stattfin det. Dies ermöglicht eine deutliche Reduzierung der Eigenspannungen und des Rückfederns und des Verzuges. Außerdem ist eine schnelle Bearbeitung der Werkzeuggeometrie möglich, so dass Versuchs- und Prototypenbauteile sowie Kleinserien in sehr kurzer Bearbeitungszeit und kostengünstig herge- stellt werden können. Furthermore, embodiments of the invention provide low-distortion composite components, since no compact reaction takes place in the component. This allows a significant reduction of residual stresses and springback and distortion. In addition, a fast machining of the tool geometry is possible, so that test and prototype components as well as small series can be produced in a very short processing time and at low cost.
In vorteilhafter Ausgestaltung des Verbundbauteils kann das vorgeformte Bau- teil beispielsweise eine Versteifungsstruktur sein, an welcher die Verstär- kungsschicht zumindest bereichsweise anhaftet. Alternativ kann das vorge- formte Bauteil ein Hohlprofil sein, an dessen Wand die Verstärkungsschicht zumindest bereichsweise anhaftet. Des Weiteren kann das vorgeformte Bau- teil eine Schweißgruppe mit Hohlraum sein, bei welchem an mindestens einer Wand die Verstärkungsschicht zumindest bereichsweise anhaftet. In an advantageous embodiment of the composite component, the preformed component may, for example, be a stiffening structure to which the reinforcing layer at least partially adheres. Alternatively, the preformed component may be a hollow profile, on the wall of which the reinforcing layer at least partially adheres. Furthermore, the preformed component may be a weld group with a cavity in which the reinforcing layer adheres to at least one wall at least in certain areas.
In weiterer vorteilhafter Ausgestaltung des Verbundbauteils kann der Partikel- schaum aus einem Gemisch von nichtmetallischen Hohlkugeln und/oder ei- nem Metallwerkstoff und mindestens einem Matrixmaterial aufgeschäumt wer- den. Das bedeutet, dass der Partikelschaum aus nichtmetallischen Hohlku- geln und mindestens einem Matrixmaterial oder aus dem Metallwerkstoff und dem mindestens einen Matrixmaterial oder aus nichtmetallischen Hohlkugeln und dem Meta II Werkstoff und mindestens einem Matrixmaterial aufgeschäumt wird. Die aufschäumbaren Partikel werden während ihrer Expansion mit oder ohne Metallwerkstoff an das Bauteil angedrückt und aufgeschmolzen. Mate- rial, Größe und Eigenschaften der nichtmetallischen Hohlkugeln können so gewählt werden, dass eine Haftung am vorgeformten Bauteil entsteht und ein Haftvermittlerschicht entfallen kann. Der Metallwerkstoff kann beispielsweise in Form von metallischen Hohlkugeln oder Metalltextil vorliegen. Des Weiteren können anstatt der metallischen Hohlkugeln kostgünstige Kugeln aus Poly- mer, Blähglas oder Ton mit metallischer Beschichtung eingesetzt werden. Das Metalltextil kann beispielsweise als Gelege und/oder Gewebe und/oder Ge- strick ausgeführt werden. Das Metalltextil kann an dem zu verstärkenden Bau- teil angeschweißt werden und zusätzlich als Zugband fungieren. Die Mischung der metallischen Hohlkugeln und der nichtmetallischen Hohlkugeln kann zur Umsetzung eines gewünschten Crashverhaltens entsprechend gewählt wer- den. In a further advantageous embodiment of the composite component, the particle foam can be foamed from a mixture of non-metallic hollow spheres and / or a metal material and at least one matrix material. the. This means that the particle foam is foamed from non-metallic hollow spheres and at least one matrix material or from the metal material and the at least one matrix material or from non-metallic hollow spheres and the Meta II material and at least one matrix material. The foamable particles are pressed and melted during their expansion with or without metal material to the component. Material, size and properties of the non-metallic hollow spheres can be chosen so that adhesion to the preformed component is formed and a bonding agent layer can be omitted. The metal material can be present for example in the form of metallic hollow spheres or metal textile. Furthermore, cost-effective spheres made of polymer, expanded glass or clay with metallic coating can be used instead of the metallic hollow spheres. The metal textile can be designed, for example, as a scrim and / or fabric and / or knit. The metal textile can be welded to the component to be reinforced and additionally act as a drawstring. The mixture of the metallic hollow spheres and the non-metallic hollow spheres can be selected to implement a desired crash behavior.
In weiterer vorteilhafter Ausgestaltung des Verbundbauteils kann das Matrix- material mindestens eine Trigger-Komponente beinhalten, welche einen Zeit punkt der Aushärtung des Matrixmaterials definieren kann. Die mindestens eine Trigger-Komponente kann beispielsweise ein energetisch strahlungs-, temperatur- und/oder feuchtigkeitsbasiertes Triggermaterial aufweisen. Vor- zugsweise umfasst die Trigger-Komponente ein durch ultraviolette Lichtstrah- lung härtendes (UV härtendes) Triggermaterial, welches sich mit den aufge- schäumten Partikeln des Partikelschaums verbindet. In a further advantageous embodiment of the composite component, the matrix material may include at least one trigger component, which may define a time point of curing of the matrix material. The at least one trigger component may, for example, comprise an energetic radiation, temperature and / or moisture-based triggering material. Preferably, the trigger component comprises an ultraviolet light radiation curable (UV curing) trigger material which bonds with the foamed particles of the particle foam.
In weiterer vorteilhafter Ausgestaltung des Verbundbauteils können die nicht- metallischen Hohlkugeln unter Temperatureinwirkung und/oder Druckeinwir- kung aufschäumen und beispielsweise als Thermoplastkugeln und/oder Kera- mikkugeln und/oder Glaskugeln ausgeführt sein. Zudem können die nichtme- tallischen Hohlkugeln als mit Thermoplast beschichtete Blähstoffe ausgeführt werden. In weiterer vorteilhafter Ausgestaltung des Verbundbauteils kann das vorge- formte Bauteil zumindest im Bereich der Verstärkungsschicht an seiner Ober- fläche haftoptimiert sein. In a further advantageous embodiment of the composite component, the non-metallic hollow spheres can be foamed under the effect of temperature and / or pressure and be embodied, for example, as thermoplastic spheres and / or ceramic spheres and / or glass spheres. In addition, the non-metallic hollow spheres can be designed as thermoplastic coated blown fabrics. In a further advantageous embodiment of the composite component, the preformed component can be adhesion-optimized on its surface at least in the region of the reinforcing layer.
In weiterer vorteilhafter Ausgestaltung des Verbundbauteils kann die Material- dichte im Partikelschaum lokal unterschiedlich sein, so dass unterschiedliche Eigenschaften erzielt werden können. Zudem kann die Verstärkungsschicht gezielte Schwachstellen aufweisen, wobei im Crashfall eine gezielte Energie- absorption über den Partikelschaum erfolgen kann. In a further advantageous embodiment of the composite component, the material density in the particle foam may be locally different, so that different properties can be achieved. In addition, the reinforcing layer can have specific weak points, wherein in the event of a crash, a targeted energy absorption can take place via the particle foam.
In weiterer vorteilhafter Ausgestaltung des Verbundbauteils kann die Verstär- kungsschicht eine Versteifungsschicht aufweisen, welche zwischen dem Par- tikelschaum und der Wand des zu verstärkenden Hohlprofils oder der zu ver- stärkenden Schweißgruppe angeordnet werden kann. Hierbei kann die Ver- steifungsschicht beispielsweise als faserverstärkte Matrixschicht oder als me- talltextilverstärkte Matrixschicht oder als metalltextilverstärkte Schicht mit ap- plizierten nichtmetallischen Hohlkugeln oder als Metallkugelschicht ausgeführt werden. In a further advantageous embodiment of the composite component, the reinforcing layer can have a stiffening layer, which can be arranged between the particle foam and the wall of the hollow profile to be reinforced or the welding group to be reinforced. In this case, the reinforcing layer can be embodied, for example, as a fiber-reinforced matrix layer or as a metal-textile-reinforced matrix layer or as a metal-textile-reinforced layer with applied non-metallic hollow spheres or as a metal spherical layer.
Das Verbundbauteil kann beispielsweise als Karosseriebauteil oder als Ver- stärkungsbauteil ausgeführt werden, welches in einen Hohlraum eines zu ver- stärkenden Karosseriebauteils eingeführt werden kann. The composite component can be designed, for example, as a body component or as a reinforcing component, which can be introduced into a cavity of a body component to be reinforced.
In vorteilhafter Ausgestaltung des Verfahrens können die aufschäumbaren Partikel expandierbare nichtmetallische Hohlkugeln und/oder expandierbare metallische Hohlkugeln sein. In an advantageous embodiment of the method, the foamable particles can be expandable non-metallic hollow spheres and / or expandable metallic hollow spheres.
In weiterer vorteilhafter Ausgestaltung des Verfahrens kann zumindest ein Teil der aufschäumbaren Partikel vor der Injektion des Matrixmaterials in dem Formhohlraum des Werkzeugs bereitgestellt werden Zusätzlich oder alternativ kann zumindest ein Teil der aufschäumbaren Partikel dem Matrixmaterial vor dessen Injektion in den Formhohlraum des Werkzeugs beigemischt werden. Des Weiteren kann auch das Matrixmaterial aufgeschäumt werden. In weiterer vorteilhafter Ausgestaltung des Verfahrens kann die mindestens eine Trigger-Komponente zum Aushärten des Matrixmaterials mittels energe- tischer Strahlung und/oder durch Erhitzen und/oder durch Zugabe von Feuch- tigkeit aktiviert werden. Vorzugsweise wird als Trigger-Komponente UV här- tendes Harz verwendet, welches durch das schnelle Aushärten mit UV-Licht kurze Zykluszeiten ermöglicht. Hierbei kann das Werkzeug bevorzugt auch aus einem transparenten Werkstoff bestehen. Durch das vollkommene Um- schließen von geschäumten Partikeln, kann für das fertige Verbundbauteil eine gute Hydrolyse-Beständigkeit erzielt werden. Da die schäumbaren Parti- kel bevorzugt unter Wärme verpresst oder mit Wasserdampf verschmolzen werden, ist das Verfahren mit Einbettung der Partikel in UV härtendes Harz prozesssicherer, da keine anfällige Regeltechnik erforderlich ist. Zudem kön- nen deutlich dickwandigere Verbundbauteile hergestellt und eine hohe Kos- tenersparnis erreicht werden. In a further advantageous embodiment of the method, at least part of the foamable particles may be provided in the mold cavity of the tool prior to injection of the matrix material. Additionally or alternatively, at least a portion of the foamable particles may be admixed with the matrix material prior to injection into the mold cavity of the tool. Furthermore, the matrix material can also be foamed. In a further advantageous embodiment of the method, the at least one trigger component for curing the matrix material can be activated by means of energetic radiation and / or by heating and / or by adding moisture. UV curing resin is preferably used as the trigger component, which enables short cycle times by rapid curing with UV light. In this case, the tool may preferably also consist of a transparent material. By completely surrounding foamed particles, good hydrolysis resistance can be achieved for the finished composite component. Since the foamable particles are preferably compressed under heat or fused with water vapor, the process with embedding of the particles in UV-curing resin is more reliable, since no susceptible control technology is required. In addition, significantly thicker-walled composite components can be produced and a high cost savings can be achieved.
Die vorstehend in der Beschreibung genannten Merkmale und Merkmalskom- binationen sowie die nachfolgend in der Figurenbeschreibung genannten und/oder in den Figuren alleine gezeigten Merkmale und Merkmalskombinati- onen sind nicht nur in der jeweils angegebenen Kombination, sondern auch in anderen Kombinationen oder in Alleinstellung verwendbar, ohne den Rahmen der Erfindung zu verlassen. Es sind somit auch Ausführungen als von der Er- findung umfasst und offenbart anzusehen, die in den Figuren nicht explizit ge- zeigt oder erläutert sind, jedoch durch separierte Merkmalskombinationen aus den erläuterten Ausführungen hervorgehen und erzeugbar sind. The features and feature combinations mentioned above in the description, as well as the features and feature combinations mentioned below in the description of the figures and / or shown alone in the figures, can be used not only in the respectively indicated combination but also in other combinations or alone, without departing from the scope of the invention. Embodiments are therefore also encompassed and disclosed by the invention, which are not explicitly shown or explained in the figures, but which emerge and can be generated by separated combinations of features from the embodiments explained.
Ausführungsbeispiele der Erfindung sind in der Zeichnung dargestellt und wer- den in der nachfolgenden Beschreibung näher erläutert. In der Zeichnung be- zeichnen gleiche Bezugszeichen Komponenten bzw. Elemente, die gleiche bzw. analoge Funktionen ausführen. Hierbei zeigt/zeigen: Embodiments of the invention are illustrated in the drawings and will be explained in more detail in the following description. In the drawing, like reference numerals denote components or elements that perform the same or analog functions. Hereby shows / show:
Fig. 1 eine schematische Schnittdarstellung eines ersten Ausführungs- beispiels eines erfindungsgemäßen Verbundbauteils, welches als Karosseriebauteil ausgeführt ist; Fig. 2 eine schematische Schnittdarstellung eines zweiten Ausfüh- rungsbeispiels eines erfindungsgemäßen Verbundbauteils, wel- ches als Verstärkungsbauteil ausgeführt und in einen Flohlraum eines zu verstärkenden Karosseriebauteils eingeführt ist; 1 is a schematic sectional view of a first embodiment of a composite component according to the invention, which is designed as a body component. FIG. 2 shows a schematic sectional view of a second exemplary embodiment of a composite component according to the invention, which is designed as a reinforcing component and inserted into a flea space of a body component to be reinforced; FIG.
Fig. 3 eine schematische Schnittdarstellung eines dritten Ausführungs- beispiels eines erfindungsgemäßen Verbundbauteils, welches als Karosseriebauteil ausgeführt ist; und 3 is a schematic sectional view of a third exemplary embodiment of a composite component according to the invention, which is designed as a body component; and
Fig. 4 eine schematische Schnittdarstellung eines vierten Ausfüh- rungsbeispiels eines erfindungsgemäßen Verbundbauteils, wel- ches als Karosseriebauteil ausgeführt ist. Wie aus Fig. 1 bis 4 ersichtlich ist, weisen die dargestellten Ausführungsbei- spiele eines erfindungsgemäßen Verbundbauteils 1 für ein Fahrzeug jeweils ein vorgeformtes Bauteil 2, 3, 10 auf. Erfindungsgemäß weist das vorgeformte Bauteil 2, 3, 10 zumindest an Teilbereichen seiner Oberfläche eine Verstär- kungsschicht 15 auf, welche an dem vorgeformten Bauteil 2, 3, 10 haftet und einen Partikelschaum 16 umfasst. 4 is a schematic sectional view of a fourth embodiment of a composite component according to the invention, which is designed as a body component. As can be seen from FIGS. 1 to 4, the illustrated exemplary embodiments of a composite component 1 according to the invention for a vehicle each have a preformed component 2, 3, 10. According to the invention, the preformed component 2, 3, 10 has a reinforcing layer 15 at least at partial areas of its surface, which adheres to the preformed component 2, 3, 10 and comprises a particle foam 16.
Wie aus Fig. 1 weiter ersichtlich ist, ist das Verbundbauteil 1 im dargestellten ersten Ausführungsbeispiel als Karosseriebauteil 1 A ausgeführt. Bei dem dar- gestellten Karosseriebauteil 1A handelt es sich beispielhaft um einen Seiten- schweller einer Kraftfahrzeugkarosserie. Das Karosseriebauteil 1A umfasst ein als offene Schale ausgeführt erstes Hohlprofil 2 und ein zweites geschlos- senes Hohlprofil 3, welches zwei, durch eine Strebe 4 getrennte Flohlräume 5, 6 aufweist. Das erste Hohlprofil 2 ist an Verbindungsstellen 8 so mit dem zwei- ten Hohlprofil 3 verbunden, dass eine Außenwand 3.1 des zweiten Hohlprofils 3 die offene Schale des ersten Hohlprofils 2 abdeckt. Die beiden HohlprofileAs is further apparent from FIG. 1, the composite component 1 is designed as a body component 1 A in the illustrated first exemplary embodiment. The illustrated body component 1A is an example of a side skirts of a motor vehicle body. The body component 1A comprises a first hollow profile 2 designed as an open shell and a second closed hollow profile 3, which has two flea spaces 5, 6 separated by a strut 4. The first hollow profile 2 is connected at connection points 8 with the second hollow profile 3 such that an outer wall 3.1 of the second hollow profile 3 covers the open shell of the first hollow profile 2. The two hollow profiles
2, 3 können an den Verbindungsstellen beispielsweise verschweißt oder ver- klebt werden. Zusätzlich oder alternativ können auch andere Verbindungs- techniken, wie beispielsweise mechanische Verbindungen eingesetzt werden. Die Hohlprofile 2, 3 können zur Umsetzung des Leichtbaugedankens aus ei- nem Leichtmetall, wie Aluminium, Magnesium usw., oder einem anderen ge- eigneten duktilen Material hergestellt werden. Alternativ können die Hohlpro- file aus einem Faser-Kunststoff-Verbund hergestellt werden. Das zweite Hohl- profil 3 ist im dargestellten Ausführungsbeispiel als Strangpressprofil aus Alu- minium ausgebildet, welches ein geschlossenes Mehrkammerprofil bildet. Das erste Hohlprofil 2 ist im dargestellten Ausführungsbeispiel als offene Alumini- umschale ausgeführt. Hierbei soll in den von den Hohlprofilen 2, 3 einge- schlossenen Hohlraum 7 eine Verstärkung eingebracht werden. 2, 3 can for example be welded or glued at the connection points. Additionally or alternatively, other connection techniques, such as mechanical connections can be used. The hollow sections 2, 3 can be made from a light metal, such as aluminum, magnesium, etc., or another suitable ductile material, to implement the concept of lightweight construction. Alternatively, the hollow profiles can be produced from a fiber-plastic composite. The second hollow profile 3 is formed in the illustrated embodiment as an extruded aluminum profile, which forms a closed multi-chamber profile. The first hollow profile 2 is executed in the illustrated embodiment as an open aluminum shell. In this case, a reinforcement is to be introduced into the cavity 7 enclosed by the hollow profiles 2, 3.
Wie aus Fig. 1 weiter ersichtlich ist, bilden die beiden Hohlprofile 2, 3 jeweils ein vorgeformtes Bauteil, und eine Versteifungsstruktur 10 bildet ein weiteres vorgeformtes Bauteil, welches vor dem Aufbringen der Verstärkungsschicht 15A in den von den Hohlprofilen 2, 3 begrenzten Hohlraum 7 des Karosserie- bauteils 1A eingeführt ist. Die Versteifungsstruktur 10 weist eine Gitterstruktur mit einem vertikalen Steg 12 und mehreren horizontalen Stegen 13 auf. Wie aus Fig. 1 weiter ersichtlich ist, haftet die Verstärkungsschicht 15A im darge- stellten Ausführungsbeispiel an gegenüberliegenden den Hohlraum 7 begren- zenden Wänden 2.1 , 3.1 . Zudem haftet die Verstärkungsschicht 15 an den vertikalen und horizontalen Stegen 12, 13 der Versteifungsstruktur 10. As can also be seen from FIG. 1, the two hollow profiles 2, 3 each form a preformed component, and a stiffening structure 10 forms a further preformed component which, prior to the application of the reinforcing layer 15A, is defined in the hollow space 7 bounded by the hollow profiles 2, 3 Body component 1A is introduced. The stiffening structure 10 has a grid structure with a vertical web 12 and a plurality of horizontal webs 13. As can also be seen from FIG. 1, the reinforcing layer 15A in the illustrated exemplary embodiment adheres to opposite walls 2.1, 3.1 bounding the cavity 7. In addition, the reinforcing layer 15 adheres to the vertical and horizontal webs 12, 13 of the stiffening structure 10.
Wie aus Fig. 1 weiter ersichtlich ist, ist der Partikelschaum 16 der Verstär- kungsschicht 15A im dargestellten Ausführungsbeispiel aus einem Gemisch von nichtmetallischen Hohlkugeln 16A, mindestens einem Matrixmaterial 17 und einem Metallwerkstoff aufgeschäumt. Hierbei liegt der Metallwerkstoff im dargestellten Ausführungsbeispiel in Form von metallischen Hohlkugeln 16B vor. Das Matrixmaterial 17 beinhaltet mindestens eine Trigger-Komponente, welche einen Zeitpunkt der Aushärtung des Matrixmaterials 17 definiert. Im dargestellten Ausführungsbeispiel weist die mindestens eine Trigger-Kompo- nente ein energetisch strahlungsbasiertes Triggermaterial auf, welches durch UV-Licht aushärtet. Die nichtmetallischen Hohlkugeln 16A sind unter Tempe- ratureinwirkung und/oder Druckeinwirkung aufschäumbar und im dargestellten Ausführungsbeispiel als Thermoplastkugeln ausgeführt. Alternativ können die nichtmetallischen Hohlkugeln 16A als Keramikkugeln und/oder Glaskugeln und/oder als mit Thermoplast beschichtete Blähstoffe ausgeführt werden. 1, the particle foam 16 of the reinforcing layer 15A in the illustrated embodiment is foamed from a mixture of non-metallic hollow spheres 16A, at least one matrix material 17 and a metal material. In this case, the metal material in the illustrated embodiment is in the form of metallic hollow spheres 16B. The matrix material 17 includes at least one trigger component which defines a time of curing of the matrix material 17. In the exemplary embodiment shown, the at least one trigger component has an energy radiation-based triggering material which cures by UV light. The non-metallic hollow spheres 16A are foamable under the effect of temperature and / or pressure and, in the illustrated embodiment, are designed as thermoplastic spheres. Alternatively, the non-metallic hollow spheres 16A are designed as ceramic balls and / or glass beads and / or as thermoplastically coated blown fabrics.
Wie aus Fig. 1 weiter ersichtlich ist, weist der Partikelschaum 16 lokal unter- schiedliche Materialdichten auf, da Bereiche mit metallischen Hohlkugeln 16B und Bereich mit nichtmetallischen Hohlkugeln 16A vorhanden sind, wobei die metallischen Hohlkugeln 16B eine größere Materialdichte aufweisen als die nichtmetallischen Hohlkugeln 16A. Zudem können die Bereiche des Partikel- schaums 16 mit den metallischen Hohlkugeln 16B größere Crashenergiemen- gen absorbieren als die Bereiche des Partikelschaums 16 mit den nichtmetal- lischen Hohlkugeln 16A. Dadurch können in vorteilhafter weise unterschiedli- che Eigenschaften erzielt werden. So weist die Verstärkungsschicht 15 durch die nichtmetallischen Hohlkugeln 16A gezielte Schwachstellen auf, wobei im Crashfall eine gezielte Energieabsorption über den Partikelschaum 16 erfolgt. As can also be seen from FIG. 1, the particle foam 16 has locally different material densities, since regions with metallic hollow spheres 16B and regions with non-metallic hollow spheres 16A are present, wherein the metallic hollow spheres 16B have a greater material density than the non-metallic hollow spheres 16A. In addition, the regions of the particle foam 16 with the metallic hollow spheres 16B can absorb larger crash energy levels than the regions of the particle foam 16 with the non-metallic hollow spheres 16A. As a result, different properties can advantageously be achieved. Thus, the reinforcing layer 15 by the non-metallic hollow spheres 16A targeted vulnerabilities, in the event of a crash, a targeted energy absorption takes place via the particle foam 16.
Wie aus Fig. 1 weiter ersichtlich ist, weist die Verstärkungsschicht 15A im dar- gestellten Ausführungsbeispiel zwei Versteifungsschichten 18 auf, welche je- weils zwischen dem Partikelschaum 16 und der Wand 2.1 , 3.1 der zu verstär- kenden Hohlprofile 2, 3 angeordnet sind. Die Versteifungsschichten 18 sind im dargestellten Ausführungsbeispiel als faserverstärkte Matrixschicht 18A aus- geführt. Alternativ können die Versteifungsschichten als metalltextilverstärkte Matrixschichten ausgeführt werden. Hierbei kann das Metalltextil als Gelege und/oder Gewebe und/oder Gestrick ausgeführt werden. Zudem können die Oberflächen der Wände 2.1 , 3.1 der Hohlprofile 2, 3 im Bereich der Verstär- kungsschicht 15A haftoptimiert werden. 1, the reinforcing layer 15A in the exemplary embodiment shown has two stiffening layers 18, which are respectively arranged between the particle foam 16 and the wall 2.1, 3.1 of the hollow sections 2, 3 to be reinforced. The stiffening layers 18 are implemented in the illustrated embodiment as a fiber-reinforced matrix layer 18A. Alternatively, the stiffening layers may be implemented as metal-textile-reinforced matrix layers. Here, the metal fabric can be performed as a scrim and / or fabric and / or knitted fabric. In addition, the surfaces of the walls 2.1, 3.1 of the hollow sections 2, 3 can be adhesion-optimized in the region of the reinforcing layer 15A.
Wie aus Fig. 2 weiter ersichtlich ist, ist das Verbundbauteil 1 im dargestellten zweiten Ausführungsbeispiel als Verstärkungsbauteil 1 B ausgeführt, welche ein als Versteifungsstruktur 10 ausgeführtes vorgeformtes Bauteil umfasst. Die Versteifungsstruktur 10 weist analog zum ersten Ausführungsbeispiel eine Gitterstruktur mit einem vertikalen Steg 12 und mehreren horizontalen Stegen 13 auf. Wie aus Fig. 2 weiter ersichtlich ist, haftet die Verstärkungsschicht 15B im dargestellten Ausführungsbeispiel an den vertikalen und horizontalen Ste- gen 12, 13 der Versteifungsstruktur 10. Wie aus Fig. 2 weiter ersichtlich ist, ist das Verstärkungsbauteil 1 B zur Verstärkung eines Karosseriebauteils 1 C nach der Fertigstellung in einen Hohlraum 7 des Karosseriebauteils 1 C eingeführt. Hierbei entspricht der Aufbau des Karosseriebauteils 1 C aus Fig. 2 im We- sentlichen dem Aufbau des Karosseriebauteils 1 A aus Fig. 1 , so dass hier auf eine wiederholende Beschreibung der bereits bekannten Komponenten ver- zichtet wird. As is further apparent from FIG. 2, the composite component 1 in the illustrated second exemplary embodiment is embodied as a reinforcing component 1 B which comprises a preformed component embodied as a stiffening structure 10. The stiffening structure 10 has, analogously to the first exemplary embodiment, a grid structure with a vertical web 12 and a plurality of horizontal webs 13. As can also be seen from FIG. 2, the reinforcing layer 15B adheres to the vertical and horizontal webs 12, 13 of the stiffening structure 10 in the illustrated exemplary embodiment. It can also be seen from FIG the reinforcing member 1 B for the reinforcement of a body component 1 C after completion in a cavity 7 of the body component 1 C introduced. Here, the structure of the body component 1 C of FIG. 2 essentially corresponds to the structure of the body component 1 A from FIG. 1, so that a repeated description of the components already known is dispensed with here.
Wie aus Fig. 2 weiter ersichtlich ist, ist der Partikelschaum 16 der Verstär- kungsschicht 15B im dargestellten Ausführungsbeispiel aus einem Gemisch von metallischen Hohlkugeln 16B und mindestens einem Matrixmaterial 17 aufgeschäumt. Analog zum ersten Ausführungsbeispiel beinhaltet das Matrix- material 17 mindestens eine Trigger-Komponente, welche den Zeitpunkt der Aushärtung des Matrixmaterials 17 definiert. Die mindestens eine Trigger- Komponente und die metallischen Hohlkugeln 16B wurden bereits in Verbin- dung mit dem ersten Ausführungsbeispiel beschrieben. As can also be seen from FIG. 2, the particle foam 16 of the reinforcing layer 15B is foamed from a mixture of metallic hollow spheres 16B and at least one matrix material 17 in the exemplary embodiment shown. Analogous to the first exemplary embodiment, the matrix material 17 contains at least one trigger component which defines the time of curing of the matrix material 17. The at least one trigger component and the metallic hollow balls 16B have already been described in connection with the first exemplary embodiment.
Bei einem alternativen nicht dargestellten Ausführungsbeispiel des Verbund- bauteils 1 ist das vorgeformte Bauteil eine Schweißgruppe mit Hohlraum, bei welchem die Verstärkungsschicht analog zum ersten Ausführungsbeispiel zu- mindest bereichsweise an mindestens einer den Hohlraum begrenzenden Wand anhaftet. In an alternative exemplary embodiment of the composite component 1, which is not illustrated, the preformed component is a welded group having a cavity, in which the reinforcing layer adheres, at least in regions, to at least one wall delimiting the cavity, analogously to the first exemplary embodiment.
Wie aus Fig. 3 und 4 weiter ersichtlich ist, ist das Verbundbauteil 1 in den dargestellten Ausführungsbeispielen als Karosseriebauteil 1 D, 1 E ausgeführt. Hierbei umfassen die Karosseriebauteile 1 D, 1 E jeweils ein als offene Schale ausgeführtes Hohlprofil 2 als zu verstärkendes vorgeformtes Bauteil. Wie aus Fig. 3 und 4 weiter ersichtlich ist, haftet die jeweilige Verstärkungsschicht 15C, 15D in den dargestellten Ausführungsbeispielen jeweils an der den Hohlraum 7 begrenzenden Wand 2.1 an. Wie aus Fig. 3 und 4 weiter ersichtlich ist, ist der Partikelschaum 16 der Verstärkungsschichten 15C, 15D in den dargestell- ten Ausführungsbeispielen jeweils aus einem Gemisch von nichtmetallischen Hohlkugeln 16A und mindestens einem Matrixmaterial 17 aufgeschäumt. Ana- log zu den bereits beschriebenen Ausführungsbeispielen beinhaltet das Mat- rixmaterial 17 mindestens eine Trigger-Komponente, welche den Zeitpunkt der Aushärtung des Matrixmaterials 17 definiert. Die mindestens eine Trigger- Komponente und die nichtmetallischen Hohlkugeln 16A wurden bereits in Ver- bindung mit dem ersten Ausführungsbeispiel beschrieben. As is further apparent from FIGS. 3 and 4, the composite component 1 in the exemplary embodiments illustrated is designed as a body component 1 D, 1 E. Here, the body components 1 D, 1 E each comprise a designed as an open shell hollow profile 2 as a preformed component to be reinforced. As can also be seen from FIGS. 3 and 4, the respective reinforcing layer 15C, 15D adheres in each case to the wall 2.1 delimiting the cavity 7 in the illustrated exemplary embodiments. As can also be seen from FIGS. 3 and 4, the particle foam 16 of the reinforcing layers 15C, 15D is in each case foamed from a mixture of non-metallic hollow spheres 16A and at least one matrix material 17 in the illustrated exemplary embodiments. Analogous to the exemplary embodiments already described, the matrix material 17 contains at least one trigger component which determines the time of the Curing of the matrix material 17 defined. The at least one trigger component and the non-metallic hollow spheres 16A have already been described in connection with the first exemplary embodiment.
Wie aus Fig. 3 weiter ersichtlich ist, weist die Verstärkungsschicht 15C im dar- gestellten Ausführungsbeispiel eine Versteifungsschicht 18B, welche zwi- schen dem Partikelschaum 16 und der Wand 2.1 des zu verstärkenden Hohl- profils 2 angeordnet ist und die Wand 2.1 verstärkt. Die Versteifungsschicht 18 ist im dargestellten Ausführungsbeispiel als metalltextilverstärkte Schicht 18B mit applizierten nichtmetallischen Hohlkugeln 16A ausgeführt. Hierbei kann das Metalltextil 19 als Gelege und/oder Gewebe und/oder Gestrick aus- geführt werden. Zudem kann die Oberfläche der Wand 2.1 des Hohlprofils 2 im Bereich der Verstärkungsschicht 15C haftoptimiert sein. As can also be seen from FIG. 3, in the exemplary embodiment shown, the reinforcing layer 15C has a stiffening layer 18B, which is arranged between the particle foam 16 and the wall 2.1 of the hollow profile 2 to be reinforced and reinforces the wall 2.1. The stiffening layer 18 is designed in the illustrated embodiment as a metal-textile-reinforced layer 18B with applied non-metallic hollow spheres 16A. In this case, the metal textile 19 can be designed as a scrim and / or fabric and / or knitted fabric. In addition, the surface of the wall 2.1 of the hollow profile 2 in the region of the reinforcing layer 15C may be adhesion-optimized.
Wie aus Fig. 4 weiter ersichtlich ist, weist die Verstärkungsschicht 15D im dar- gestellten Ausführungsbeispiel eine Versteifungsschicht 18C, welche zwi- schen dem Partikelschaum 16 und der Wand 2.1 des zu verstärkenden Hohl- profils 2 angeordnet ist und die Wand 2.1 verstärkt. Die Versteifungsschicht 18 ist im dargestellten Ausführungsbeispiel als Metallkugelschicht 18C ausge- führt. Hierbei kann das Metalltextil 19 als Gelege und/oder Gewebe und/oder Gestrick ausgeführt werden. Zudem sind in den Hohlraum 7 mehrere Stege 14 eingebracht, welche an der Wand 2.1 des Hohlprofils 2 befestigt sind. Da- her haftet die Verstärkungsschicht 15D auch an diesen Stegen 14. Des Wei- teren kann die Oberfläche der Wand 2.1 des Hohlprofils 2 im Bereich der Ver- stärkungsschicht 15C haftoptimiert sein. 4, the reinforcing layer 15D in the exemplary embodiment shown has a stiffening layer 18C, which is arranged between the particle foam 16 and the wall 2.1 of the hollow profile 2 to be reinforced and reinforces the wall 2.1. The stiffening layer 18 is executed in the illustrated embodiment as a metal ball layer 18C. Here, the metal fabric 19 can be performed as a scrim and / or fabric and / or knitted fabric. In addition, a plurality of webs 14 are introduced into the cavity 7, which are attached to the wall 2.1 of the hollow section 2. Therefore, the reinforcing layer 15D also adheres to these webs 14. Furthermore, the surface of the wall 2.1 of the hollow profile 2 can be adhesively optimized in the region of the reinforcing layer 15C.
Das erfindungsgemäße Verfahren zum Herstellen eines Verbundbauteils 1 umfasst die Schritte: Bereitstellen eines vorgeformten Bauteils 2, 3, 10, Einlegen des vorgeformten Bauteils 2, 3, 10 in den Formhohlraum eines Werk- zeugs, Injizieren eines Matrixmaterials 17 in den Formhohlraum, und Aushär- ten des Matrixmaterials 17. Anschließend wird das dadurch entstandene ver- stärkte Verbundbauteil 1 aus dem Formhohlraum entnommen. Erfindungsge- mäß beinhaltet das Matrixmaterial 17 mindestens eine Trigger-Komponente, welche einen Zeitpunkt der Aushärtung des Matrixmaterials 17 definiert. Zu- dem sind aufschäumbare Partikel 16A, 16B vorgesehen, welche von dem Mat- rixmaterial 17 umschlossen werden. The method according to the invention for producing a composite component 1 comprises the steps of providing a preformed component 2, 3, 10, inserting the preformed component 2, 3, 10 into the mold cavity of a tool, injecting a matrix material 17 into the mold cavity, and curing. Then, the resulting reinforced composite component 1 is removed from the mold cavity. According to the invention, the matrix material 17 contains at least one trigger component, which defines a time of curing of the matrix material 17. In addition, foamable particles 16A, 16B are provided, which are enclosed by the matrix material 17.
Wie oben bereits ausgeführt ist, sind die aufschäumbaren Partikel expandier- bare nichtmetallische Hohlkugeln 16A und/oder expandierbare metallische Hohlkugeln 16B. Außerdem kann auch das Matrixmaterial 17 aufgeschäumt werden. Zudem wird zumindest ein Teil der aufschäumbaren Partikel 16A, 16B vor Injektion des Matrixmaterials 17 in dem Formhohlraum des Werkzeugs be- reitgestellt. Des Weiteren wird zumindest ein Teil der aufschäumbaren Partikel 16A, 16B dem Matrixmaterial 17 vor dessen Injektion in den Formhohlraum des Werkzeugs beigemischt. Die mindestens eine Trigger-Komponente wird zum Aushärten des Matrixmaterials 17 mittels energetischer Strahlung und/o- der durch Erhitzen und/oder durch Zugabe von Feuchtigkeit aktiviert. As already explained above, the foamable particles are expandable non-metallic hollow spheres 16A and / or expandable metallic hollow spheres 16B. In addition, the matrix material 17 can also be foamed. In addition, at least a portion of the foamable particles 16A, 16B is provided prior to injection of the matrix material 17 in the mold cavity of the tool. Furthermore, at least a portion of the foamable particles 16A, 16B is added to the matrix material 17 prior to injection into the mold cavity of the tool. The at least one trigger component is activated to harden the matrix material 17 by means of energetic radiation and / or by heating and / or by adding moisture.
Zur Herstellung des in Fig. 1 dargestellten Karosseriebauteils 1A wird zuerst das erste Hohlprofil 2, an dessen Wand 2.1 drei senkrecht abstehende Stege 13 befestigt sind, in den Formhohlraum eingelegt. Anschließend erfolgt die In- jektion von Matrixmaterial 17 mit beigemischten Fasern, so dass zwischen den Stegen 13 die korrespondierenden Abschnitte der faserverstärkten Mat- rixschicht 18A entstehen, welche im fertigen Verbundbauteil 1 zwischen dem Partikelschaum 16 und der Wand 2.1 des ersten Hohlprofils 2 angeordnet sein soll. Anschließend werden die aufschäumbaren Partikel in Form von nichtme- tallischen Hohlkugeln 16A und metallischen Hohlkugeln 16B gemäß der ge- wünschten Verteilung in die zwischen den Stegen 13 und dem ersten Hohl- profil 2 ausgebildeten Zwischenräume eingefüllt. Hierbei können die nichtme- tallischen Hohlkugeln 16A und metallischen Hohlkugeln 16B vor der Injektion des Matrixmaterials 17 mit diesem vermischt werden. Alternativ kann die In- jektion des Matrixmaterials nach dem Einbringen der nichtmetallischen Hohl- kugeln 16A und metallischen Hohlkugeln 16B erfolgen. Anschließend wird der parallel zur Wand 2.1 verlaufende Steg 12, an welchem drei senkrecht abste- henden Stege 13 befestigt sind, aufgesetzt, so dass die Gitterstruktur der Ver- steifungsstruktur 10 entsteht. Anschließend werden die aufschäumbaren Par- tikel in Form von nichtmetallischen Hohlkugeln 16A und metallischen Hohlku- geln 16B gemäß der gewünschten Verteilung in die zwischen den Stegen 13 und dem ersten Hohlprofil 2 ausgebildeten Zwischenräume eingefüllt. Dann erfolgt die Injektion von Matrixmaterial 17 mit beigemischten Fasern, so dass zwischen den Stegen 13 die korrespondierenden Abschnitte der faserverstärk- ten Matrixschicht 18A entstehen, welche im fertigen Verbundbauteil 1 zwi- schen dem Partikelschaum 16 und der Wand 3.1 des zweiten Hohlprofils 3 angeordnet sein soll. Dann wird das zweite Hohlprofil 3 aufgesetzt und mit dem ersten Hohlprofil 2 verbunden. Anschließend erfolgt die Aktivierung der mindestens einen Trigger-Komponente und die Aushärtung des Matrixmateri- als 17. Nach dem Aushärten des Matrixmaterials wird das verstärkte Karosse- riebauteil 1A aus dem Formhohlraum entnommen und weiterverarbeitet bzw. am Fahrzeug verbaut. To produce the bodywork component 1A shown in FIG. 1, first the first hollow profile 2, on the wall 2.1 of which three vertically projecting webs 13 are fastened, is inserted into the mold cavity. Subsequently, the injection of matrix material 17 with admixed fibers takes place so that the corresponding sections of the fiber-reinforced matrix layer 18A are formed between the webs 13, which should be arranged in the finished composite component 1 between the particle foam 16 and the wall 2.1 of the first hollow profile 2 , Subsequently, the foamable particles in the form of non-metallic hollow spheres 16A and metallic hollow spheres 16B are filled according to the desired distribution in the spaces formed between the webs 13 and the first hollow profile 2. In this case, the non-metallic hollow spheres 16A and metallic hollow spheres 16B can be mixed with the latter prior to the injection of the matrix material 17. Alternatively, the injection of the matrix material can take place after introduction of the non-metallic hollow spheres 16A and metallic hollow spheres 16B. Subsequently, the web 12, which runs parallel to the wall 2.1 and to which three webs 13 projecting perpendicularly, are attached, so that the lattice structure of the reinforcing structure 10 is formed. Subsequently, the foamable particles In the form of non-metallic hollow spheres 16A and metallic hollow spheres 16B according to the desired distribution, the intermediate spaces formed between the webs 13 and the first hollow profile 2 are filled. Then the injection of matrix material 17 with admixed fibers takes place, so that the corresponding sections of the fiber-reinforced matrix layer 18A are formed between the webs 13, which should be arranged in the finished composite component 1 between the particle foam 16 and the wall 3.1 of the second hollow profile 3 , Then, the second hollow section 3 is placed and connected to the first hollow section 2. Subsequently, the activation of the at least one trigger component and the hardening of the matrix material 17 takes place. After hardening of the matrix material, the reinforced body component 1A is removed from the mold cavity and further processed or installed on the vehicle.
Zur Herstellung des in Fig. 2 dargestellten Verstärkungsbauteils 1 B wird zuerst die Verstärkungsstruktur 10 mit den Stegen 12 und 13 in den Formhohlraum eingelegt. Hierbei ist der Formhohlraum so ausgeführt, dass zwischen den Wänden des Formhohlraums und den Stegen 12 und 13 der Verstärkungs- Struktur 10 Hohlräume ausgebildet sind, in welche das Gemisch zum Erzeu- gen des Partikelschaums 16 eingebracht werden können. Im dargestellten Ausführungsbeispiel umfasst der Partikelschaum 16 metallische Hohlkugeln 16B und Matrixmaterial 17. Hierbei können die metallischen Hohlkugeln 16B vor der Injektion des Matrixmaterials 17 mit diesem vermischt werden. Alter- nativ kann die Injektion des Matrixmaterials 17 nach dem Einbringen der me- tallischen Hohlkugeln 16B erfolgen. Anschließend erfolgt die Aktivierung der mindestens einen Trigger-Komponente und die Aushärtung des Matrixmateri- als 17. Nach dem Aushärten des Matrixmaterials wird das fertige Verstär- kungsbauteil 1 B aus dem Formhohlraum entnommen und weiterverarbeitet bzw. in den Hohlraum 7 des Karosseriebauteils 1 C eingeführt. For the production of the reinforcing member 1 B shown in Fig. 2, first, the reinforcing structure 10 is inserted with the webs 12 and 13 in the mold cavity. Here, the mold cavity is designed so that between the walls of the mold cavity and the webs 12 and 13 of the reinforcing structure 10 cavities are formed, in which the mixture for generating the particle foam 16 can be introduced. In the illustrated embodiment, the particle foam 16 comprises metallic hollow spheres 16B and matrix material 17. In this case, the metallic hollow spheres 16B can be mixed with the matrix material 17 before the matrix material is injected. Alternatively, the injection of the matrix material 17 may take place after the introduction of the metallic hollow spheres 16B. After activation of the matrix material, the finished reinforcing component 1B is removed from the mold cavity and further processed or introduced into the cavity 7 of the body component 1C.
Zur Herstellung des in Fig. 3 dargestellten Karosseriebauteils 1 D wird zuerst das Hohlprofil 2 in den Formhohlraum eingelegt. Anschließend wird die als metalltextilverstärkte Schicht 18B mit applizierten nichtmetallischen Hohlku- geln 16A ausgeführte Versteifungsschicht 18 entlang der Wand 2.1 des Hohl- profils 2 eingelegt. Anschließend werden die aufschäumbaren Partikel in Form von nichtmetallischen Hohlkugeln 16A in den Hohlraum 7 des Hohlprofils 2 eingefüllt. Hierbei können die nichtmetallischen Hohlkugeln 16A vor der Injek- tion des Matrixmaterials 17 mit diesem vermischt werden. Alternativ kann die Injektion des Matrixmaterials nach dem Einbringen der nichtmetallischen Hohl- kugeln 16A erfolgen. Anschließend erfolgt die Aktivierung der mindestens ei- nen Trigger-Komponente und die Aushärtung des Matrixmaterials 17. Nach dem Aushärten des Matrixmaterials wird das verstärkte Karosseriebauteil 1A aus dem Formhohlraum entnommen und weiterverarbeitet bzw. am Fahrzeug verbaut. To produce the bodywork component 1 D shown in FIG. 3, the hollow profile 2 is first inserted into the mold cavity. Subsequently, the metal-textile-reinforced layer 18B with applied non-metallic hollow core is removed. 16A performed stiffening layer 18 along the wall 2.1 of the hollow profile 2 inserted. Subsequently, the foamable particles in the form of non-metallic hollow spheres 16 A are filled into the cavity 7 of the hollow section 2. In this case, the non-metallic hollow spheres 16A can be mixed with the matrix material 17 prior to injection of the matrix material 17. Alternatively, the injection of the matrix material can take place after introduction of the non-metallic hollow spheres 16A. Subsequently, the activation of the at least one trigger component and the hardening of the matrix material 17 takes place. After hardening of the matrix material, the reinforced body component 1A is removed from the mold cavity and further processed or installed on the vehicle.
Zur Herstellung des in Fig. 4 dargestellten Karosseriebauteils 1 D wird zuerst das Hohlprofil 2 in den Formhohlraum eingelegt. Anschließend wird die als Metallkugelschicht 18C ausgeführte Versteifungsschicht 18 entlang der Wand 2.1 des Hohlprofils 2 eingebracht. Anschließend werden die aufschäumbaren Partikel in Form von nichtmetallischen Hohlkugeln 16A in den Hohlraum 7 des Hohlprofils 2 eingefüllt. Hierbei können die nichtmetallischen Hohlkugeln 16A vor der Injektion des Matrixmaterials 17 mit diesem vermischt werden. Alter- nativ kann die Injektion des Matrixmaterials nach dem Einbringen der nichtme- tallischen Hohlkugeln 16A erfolgen. Anschließend erfolgt die Aktivierung der mindestens einen Trigger-Komponente und die Aushärtung des Matrixmateri- als 17. Nach dem Aushärten des Matrixmaterials wird das verstärkte Karosse- riebauteil 1A aus dem Formhohlraum entnommen und weiterverarbeitet bzw. am Fahrzeug verbaut. For the production of the body component 1 D shown in Fig. 4, the hollow section 2 is first inserted into the mold cavity. Subsequently, the stiffening layer 18 embodied as a metal ball layer 18C is introduced along the wall 2.1 of the hollow profile 2. Subsequently, the foamable particles in the form of non-metallic hollow spheres 16 A are filled into the cavity 7 of the hollow section 2. Here, the non-metallic hollow spheres 16A may be mixed with the matrix material 17 prior to injection. Alternatively, the injection of the matrix material can take place after introduction of the non-metallic hollow spheres 16A. Subsequently, the activation of the at least one trigger component and the hardening of the matrix material 17 takes place. After hardening of the matrix material, the reinforced body component 1A is removed from the mold cavity and further processed or installed on the vehicle.
BEZUGSZEICHENLISTE LIST OF REFERENCE NUMBERS
1 Verbundbauteil 1 composite component
1A, 1C, 1 D, 1 E Karosseriebauteil  1A, 1C, 1 D, 1 E body component
1 B Verstärkungsbauteil 1 B reinforcing member
2, 3 Hohl profil  2, 3 hollow profile
2.1 , 3.1 Wand 2.1, 3.1 wall
4 Strebe 4 strut
5, 6, 7 Hohlraum  5, 6, 7 cavity
8 Verbindungsstelle 8 connection point
10 Versteifungsstruktur 10 stiffening structure
12, 13, 14 Steg  12, 13, 14 footbridge
15, 15A, 15B, 15C, 15D Verstärkungsschicht  15, 15A, 15B, 15C, 15D reinforcing layer
16 Partikel schäum 16 particles of foam
16A nichtmetallische Hohlkugel16A non-metallic hollow sphere
16B metallische Hohlkugel16B metallic hollow sphere
17 Matrixmaterial 17 matrix material
18 Versteifungsschicht  18 stiffening layer
18A faserverstärkte Matrixschicht 18B metalltextilverstärkte Schicht18A fiber reinforced matrix layer 18B metal textile reinforced layer
18C Metallkugelschicht 18C metal ball layer
19 Metallgewebe 19 metal mesh

Claims

PATENTANSPRÜCHE: CLAIMS:
1. Verbundbauteil (1 ) für ein Fahrzeug, mit einem vorgeformten Bauteil (2, 3, 10), A composite component (1) for a vehicle, comprising a preformed component (2, 3, 10),
dadurch gekennzeichnet, dass  characterized in that
das vorgeformte Bauteil (2, 3, 10) zumindest an Teilbereichen seiner Oberfläche eine Verstärkungsschicht (15) aufweist, welche an dem vor- geformten Bauteil (2, 3, 10) haftet und einen Partikelschaum (16) um- fasst.  the preformed component (2, 3, 10) has a reinforcing layer (15) at least at partial areas of its surface, which adheres to the preformed component (2, 3, 10) and encloses a particle foam (16).
2. Verbundbauteil (1 ) nach Anspruch 1 , 2. Composite component (1) according to claim 1,
dadurch gekennzeichnet, dass  characterized in that
das vorgeformte Bauteil eine Versteifungsstruktur (10) ist, an welcher die Verstärkungsschicht (15) zumindest bereichsweise anhaftet.  the preformed component is a stiffening structure (10) to which the reinforcing layer (15) at least partially adheres.
3. Verbundbauteil (1 ) nach Anspruch 1 , 3. composite component (1) according to claim 1,
dadurch gekennzeichnet, dass  characterized in that
das vorgeformte Bauteil ein Hohlprofil (2, 3) ist, an dessen Wand (2.1 , 3.1 ) die Verstärkungsschicht (15) zumindest bereichsweise anhaftet.  the preformed component is a hollow profile (2, 3), on the wall (2.1, 3.1) of which the reinforcing layer (15) adheres at least in regions.
4. Verbundbauteil (1 ) nach Anspruch 1 , 4. composite component (1) according to claim 1,
dadurch gekennzeichnet, dass  characterized in that
das vorgeformte Bauteil eine Schweißgruppe mit Hohlraum (7) ist, bei welchem an mindestens einer Wand die Verstärkungsschicht (15) zumin- dest bereichsweise anhaftet.  the preformed component is a welding group with a cavity (7) in which the reinforcing layer (15) adheres to at least one wall at least in certain areas.
5. Verbundbauteil (1 ) nach einem der Ansprüche 1 bis 4, 5. Composite component (1) according to one of claims 1 to 4,
dadurch gekennzeichnet, dass  characterized in that
der Partikelschaum (16) aus einem Gemisch von nichtmetallischen Hohl- kugeln (16A) und/oder einem Metallwerkstoff und mindestens einem the particle foam (16) made of a mixture of non-metallic hollow spheres (16A) and / or a metal material and at least one
Matrixmaterial (17) aufgeschäumt ist. Foamed matrix material (17).
6. Verbundbauteil (1 ) nach Anspruch 5, 6. composite component (1) according to claim 5,
dadurch gekennzeichnet, dass der Metallwerkstoff in Form von metallischen Hohlkugeln (16B) oder Me- talltextil (19) vorliegt. characterized in that the metal material is present in the form of metallic hollow spheres (16B) or metal textile (19).
7. Verbundbauteil (1 ) nach Anspruch 6, 7. composite component (1) according to claim 6,
dadurch gekennzeichnet, dass  characterized in that
das Metalltextil (19) als Gelege und/oder Gewebe und/oder Gestrick aus- geführt ist.  the metal textile (19) is designed as a scrim and / or fabric and / or knitted fabric.
8. Verbundbauteil (1 ) nach einem der Ansprüche 5 bis 7, 8. Composite component (1) according to one of claims 5 to 7,
dadurch gekennzeichnet, dass  characterized in that
die nichtmetallischen Hohlkugeln (16A) unter Temperatureinwirkung und/oder Druckeinwirkung aufschäumbar sind.  the non-metallic hollow spheres (16A) can be foamed under the effect of temperature and / or pressure.
9. Verbundbauteil (1 ) nach einem der Ansprüche 5 bis 8, 9. composite component (1) according to one of claims 5 to 8,
dadurch gekennzeichnet, dass  characterized in that
die nichtmetallischen Hohlkugeln (16A) als Thermoplastkugeln und/oder Keramikkugeln und/oder Glaskugeln ausgeführt sind.  the non-metallic hollow spheres (16A) are designed as thermoplastic spheres and / or ceramic spheres and / or glass spheres.
10. Verbundbauteil (1 ) nach einem der Ansprüche 5 bis 9, 10. composite component (1) according to one of claims 5 to 9,
dadurch gekennzeichnet, dass  characterized in that
die nichtmetallischen Hohlkugeln (16A) mit Thermoplast beschichtete Blähstoffe sind.  the non-metallic hollow spheres (16A) are thermoplastically coated blown fabrics.
1 1 . Verbundbauteil (1 ) nach einem der Ansprüche 1 bis 10, 1 1. Composite component (1) according to one of claims 1 to 10,
dadurch gekennzeichnet, dass  characterized in that
die Materialdichte im Partikelschaum (16) lokal unterschiedlich ist, so dass unterschiedliche Eigenschaften erzielt werden.  the material density in the particle foam (16) is locally different, so that different properties are achieved.
12. Verbundbauteil (1 ) nach einem der Ansprüche 1 bis 1 1 , 12. Composite component (1) according to one of claims 1 to 1 1,
dadurch gekennzeichnet, dass  characterized in that
die Verstärkungsschicht (15) gezielte Schwachstellen aufweist, wobei im Crashfall eine gezielte Energieabsorption über den Partikelschaum (16) erfolgt. the reinforcing layer (15) has targeted weak points, wherein in the event of a crash, a targeted energy absorption takes place via the particle foam (16).
13. Verbundbauteil (1 ) nach einem der Ansprüche 3 bis 9, dadurch gekennzeichnet, dass 13. Composite component (1) according to one of claims 3 to 9, characterized in that
die Verstärkungsschicht (15) eine Versteifungsschicht (18) aufweist, wel- che zwischen dem Partikelschaum (16) und der Wand (2.1 , 3.1 ) des zu verstärkenden Hohlprofils (2, 3) oder der zu verstärkenden Schweiß- gruppe angeordnet ist.  the reinforcing layer (15) has a stiffening layer (18) which is arranged between the particle foam (16) and the wall (2.1, 3.1) of the hollow profile (2, 3) to be reinforced or the welding group to be reinforced.
14. Verbundbauteil (1 ) nach Anspruch 13, 14. Composite component (1) according to claim 13,
dadurch gekennzeichnet, dass  characterized in that
die Versteifungsschicht (18) als faserverstärkte Matrixschicht (18A) oder als metalltextilverstärkte Matrixschicht oder als metalltextilverstärkte Schicht (18B) mit applizierten nichtmetallischen Hohlkugeln (16A) oder als Metallkugelschicht (18C) ausgeführt ist.  the stiffening layer (18) is designed as a fiber-reinforced matrix layer (18A) or as a metal-textile-reinforced matrix layer or as a metal-textile-reinforced layer (18B) with applied non-metallic hollow spheres (16A) or as a metal ball layer (18C).
15. Verfahren zum Herstellen eines Verbundbauteils (1 ) mit den Schritten: 15. A method for producing a composite component (1) with the steps:
Bereitstellen eines vorgeformten Bauteils (2, 3, 10),  Providing a preformed component (2, 3, 10),
Einlegen des vorgeformten Bauteils (2, 3, 10) in den Formhohlraum eines Werkzeugs,  Inserting the preformed component (2, 3, 10) into the mold cavity of a tool,
Injizieren eines Matrixmaterials (17) in den Formhohlraum,  Injecting a matrix material (17) into the mold cavity,
Aushärten des Matrixmaterials (17),  Curing the matrix material (17),
Entnahme des dadurch entstandenen verstärkten Verbundbauteils (1 ), dadurch gekennzeichnet, dass  Removal of the resulting reinforced composite component (1), characterized in that
das Matrixmaterial (17) mindestens eine Trigger-Komponente beinhaltet, welche einen Zeitpunkt der Aushärtung des Matrixmaterials (17) definiert und  the matrix material (17) contains at least one trigger component which defines a time of curing of the matrix material (17) and
dass aufschäumbare Partikel (16A, 16B) vorgesehen sind, welche von dem Matrixmaterial (17) umschlossen werden.  that foamable particles (16A, 16B) are provided, which are enclosed by the matrix material (17).
PCT/EP2019/061995 2018-05-25 2019-05-10 Composite component for a vehicle and method for producing a composite component WO2019224013A1 (en)

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DE102009034724A1 (en) 2009-07-24 2011-02-03 Daimler Ag Method for manufacturing e.g. operating element of switch in inner area of motor vehicle, involves filling cavity with casting material by filling molding tool before or after insertion of substrate, and positioning substrate by cavity
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