WO2019224013A1 - Élément composite pour un véhicule et procédé de fabrication d'un élément composite - Google Patents

Élément composite pour un véhicule et procédé de fabrication d'un élément composite 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)
English (en)
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/fr

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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
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    • 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
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    • 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
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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
    • B29C70/74—Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding
    • B29C70/745—Filling cavities in the preformed part
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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
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    • 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
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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
    • B32B15/04—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
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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
    • B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
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    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
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    • 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
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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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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Structural Engineering (AREA)
  • Architecture (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Textile Engineering (AREA)
  • Body Structure For Vehicles (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un élément composite (1) pour un véhicule, ledit élément composite comprenant un élément (2, 3, 10) préformé à renforcer, ainsi qu'un procédé correspondant pour fabriquer un élément composite (1). Selon l'invention, l'élément préformé (2, 3, 10) présente au moins une couche de renforcement (15) sur des zones partielles de sa surface, laquelle adhère à l'élément préformé (2, 3, 10) et comprend une mousse particulaire (16).
PCT/EP2019/061995 2018-05-25 2019-05-10 Élément composite pour un véhicule et procédé de fabrication d'un élément composite WO2019224013A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102018208244.8A DE102018208244A1 (de) 2018-05-25 2018-05-25 Verbundbauteil für ein Fahrzeug und Verfahren zum Herstellen eines Verbundbauteils
DE102018208244.8 2018-05-25

Publications (1)

Publication Number Publication Date
WO2019224013A1 true WO2019224013A1 (fr) 2019-11-28

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PCT/EP2019/061995 WO2019224013A1 (fr) 2018-05-25 2019-05-10 Élément composite pour un véhicule et procédé de fabrication d'un élément composite

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DE (1) DE102018208244A1 (fr)
WO (1) WO2019224013A1 (fr)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102018222747B3 (de) 2018-12-21 2020-06-04 Audi Ag Karosseriebauteil für ein Fahrzeug
DE102021004335A1 (de) 2021-08-24 2021-10-21 Daimler Ag Seitenschweller für ein Fahrzeug

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090004457A1 (en) * 2007-06-28 2009-01-01 Samsung Electronics Co., Ltd. Polymer foam composite containing hollow particles and process for preparing the same
DE102009034724A1 (de) 2009-07-24 2011-02-03 Daimler Ag Verfahren zur Herstellung eines Bauteils
DE102012024836A1 (de) * 2012-12-18 2014-06-18 Audi Ag Seitenteil für eine Kraftfahrzeugkarosserie und Verfahren zum Herstellen eines Seitenteils für eine Kraftfahrzeugkarosserie
DE102016203444A1 (de) * 2016-03-02 2017-09-07 Volkswagen Aktiengesellschaft Schaumstoffelement sowie Verfahren zur Herstellung eines Schaumstoffelementes
DE102016007913A1 (de) * 2016-06-30 2018-01-04 Krallmann Kunststoffverarbeitung Gmbh Kfz-Verbundbauteil und Verfahren zu seiner Herstellung

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090004457A1 (en) * 2007-06-28 2009-01-01 Samsung Electronics Co., Ltd. Polymer foam composite containing hollow particles and process for preparing the same
DE102009034724A1 (de) 2009-07-24 2011-02-03 Daimler Ag Verfahren zur Herstellung eines Bauteils
DE102012024836A1 (de) * 2012-12-18 2014-06-18 Audi Ag Seitenteil für eine Kraftfahrzeugkarosserie und Verfahren zum Herstellen eines Seitenteils für eine Kraftfahrzeugkarosserie
DE102016203444A1 (de) * 2016-03-02 2017-09-07 Volkswagen Aktiengesellschaft Schaumstoffelement sowie Verfahren zur Herstellung eines Schaumstoffelementes
DE102016007913A1 (de) * 2016-06-30 2018-01-04 Krallmann Kunststoffverarbeitung Gmbh Kfz-Verbundbauteil und Verfahren zu seiner Herstellung

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