EP2516137A1 - Method for producing continuous-fibre-reinforced moulded parts from thermoplastic plastics and motor vehicle moulded part - Google Patents
Method for producing continuous-fibre-reinforced moulded parts from thermoplastic plastics and motor vehicle moulded partInfo
- Publication number
- EP2516137A1 EP2516137A1 EP10803235A EP10803235A EP2516137A1 EP 2516137 A1 EP2516137 A1 EP 2516137A1 EP 10803235 A EP10803235 A EP 10803235A EP 10803235 A EP10803235 A EP 10803235A EP 2516137 A1 EP2516137 A1 EP 2516137A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- mats
- preform
- molding
- motor vehicle
- molded part
- Prior art date
- Legal status (The legal status 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 status listed.)
- Withdrawn
Links
- 229920001169 thermoplastic Polymers 0.000 title claims abstract description 15
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 10
- 238000000034 method Methods 0.000 claims abstract description 42
- 239000004416 thermosoftening plastic Substances 0.000 claims abstract description 13
- 238000010438 heat treatment Methods 0.000 claims abstract description 12
- 239000011159 matrix material Substances 0.000 claims abstract description 11
- 238000000151 deposition Methods 0.000 claims abstract description 6
- 238000012546 transfer Methods 0.000 claims abstract description 6
- 238000002844 melting Methods 0.000 claims abstract description 4
- 230000008018 melting Effects 0.000 claims abstract description 4
- 238000000465 moulding Methods 0.000 claims description 54
- 239000000835 fiber Substances 0.000 claims description 33
- 238000001746 injection moulding Methods 0.000 claims description 10
- 239000004033 plastic Substances 0.000 claims description 9
- 229920003023 plastic Polymers 0.000 claims description 9
- 238000010276 construction Methods 0.000 claims description 7
- 239000012815 thermoplastic material Substances 0.000 claims description 7
- 238000007596 consolidation process Methods 0.000 claims description 6
- 238000003466 welding Methods 0.000 claims description 5
- 238000003780 insertion Methods 0.000 claims description 4
- 230000037431 insertion Effects 0.000 claims description 4
- 230000002787 reinforcement Effects 0.000 claims description 4
- 238000007789 sealing Methods 0.000 claims description 4
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 3
- 229920002430 Fibre-reinforced plastic Polymers 0.000 claims description 3
- 239000004917 carbon fiber Substances 0.000 claims description 3
- 239000011151 fibre-reinforced plastic Substances 0.000 claims description 3
- 239000003365 glass fiber Substances 0.000 claims description 3
- 239000002557 mineral fiber Substances 0.000 claims description 3
- 230000005855 radiation Effects 0.000 claims description 3
- 239000002994 raw material Substances 0.000 claims description 3
- 239000012209 synthetic fiber Substances 0.000 claims description 3
- 229920002994 synthetic fiber Polymers 0.000 claims description 3
- 239000004760 aramid Substances 0.000 claims description 2
- 229920006231 aramid fiber Polymers 0.000 claims description 2
- 238000005516 engineering process Methods 0.000 claims description 2
- 238000009958 sewing Methods 0.000 claims description 2
- 239000004753 textile Substances 0.000 claims description 2
- 238000002604 ultrasonography Methods 0.000 claims 1
- 238000002360 preparation method Methods 0.000 abstract 1
- 230000000750 progressive effect Effects 0.000 abstract 1
- 239000000463 material Substances 0.000 description 10
- 230000009969 flowable effect Effects 0.000 description 4
- 239000002657 fibrous material Substances 0.000 description 3
- MQFLXLMNOHHPTC-UHFFFAOYSA-N 1-isothiocyanato-9-(methylsulfinyl)nonane Chemical compound CS(=O)CCCCCCCCCN=C=S MQFLXLMNOHHPTC-UHFFFAOYSA-N 0.000 description 2
- 238000004364 calculation method Methods 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 238000005457 optimization Methods 0.000 description 2
- 229920001296 polysiloxane Polymers 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 241001455273 Tetrapoda Species 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 230000000295 complement effect Effects 0.000 description 1
- 238000012790 confirmation Methods 0.000 description 1
- 239000011199 continuous fiber reinforced thermoplastic Substances 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 238000011089 mechanical engineering Methods 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 238000012805 post-processing Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 239000006228 supernatant Substances 0.000 description 1
- 238000003856 thermoforming Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C31/00—Handling, e.g. feeding of the material to be shaped, storage of plastics material before moulding; Automation, i.e. automated handling lines in plastics processing plants, e.g. using manipulators or robots
- B29C31/04—Feeding of the material to be moulded, e.g. into a mould cavity
- B29C31/08—Feeding of the material to be moulded, e.g. into a mould cavity of preforms to be moulded, e.g. tablets, fibre reinforced preforms, extruded ribbons, tubes or profiles; Manipulating means specially adapted for feeding preforms, e.g. supports conveyors
- B29C31/085—Feeding of the material to be moulded, e.g. into a mould cavity of preforms to be moulded, e.g. tablets, fibre reinforced preforms, extruded ribbons, tubes or profiles; Manipulating means specially adapted for feeding preforms, e.g. supports conveyors combined with positioning the preforms according to predetermined patterns, e.g. positioning extruded preforms on conveyors
-
- 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
- B29C70/06—Fibrous reinforcements only
- B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
- B29C70/081—Combinations of fibres of continuous or substantial length and short fibres
-
- 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
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
- B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
- B29C70/205—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres the structure being shaped to form a three-dimensional configuration
- B29C70/207—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres the structure being shaped to form a three-dimensional configuration arranged in parallel planes of fibres crossing at substantial angles
-
- 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
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
- B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
-
- 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
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
-
- 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
-
- 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
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
-
- 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
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
- B29C70/543—Fixing the position or configuration of fibrous reinforcements before or during moulding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
Definitions
- the present invention relates to a process for the production of continuous fiber-reinforced molded parts from thermoplastics and a motor vehicle molding.
- a disadvantage of the prior art is that the pressing process due to necessary material supernatants has an increased material waste result. Furthermore, the 3D structure which arises only during the pressing process, and the associated forced orientation of the continuous fibers during the forming process, merely represents a compromise between the fiber orientation in the third dimension and the necessary flow paths of the material.
- a further disadvantage is that in order to achieve high degrees of deformation increased demand for flowable material, ie is necessary to thermoplastic matrix, which inevitably leads to an increased component weight. In addition, very high degrees of deformation can not be realized because otherwise fiber breaks occur within the continuous-fiber-reinforced molded part.
- the object underlying the present invention is to provide a process for the production of continuous fiber-reinforced molded parts from thermoplastic materials, which overcomes the disadvantages of the prior art.
- the present invention it is advantageously achieved by preforming the unidirectional fiber-reinforced mats into a three-dimensional preform such that in the subsequent consolidation step, the molding substantially does not have to undergo forming or flow processes. Therefore, advantageously less flowable material, ie less thermoplastic matrix is required, as is the case in the prior art. Due to the possibility of fiber orientation according to the invention in the third dimension is also achieved that the forces acting on the molded part produced by the molding according to the invention, and the resulting within the molding load paths can be optimally absorbed by the unidirectional fiber reinforcement.
- the unidirectional fiber reinforced mats are preferably cut from unidirectional films. Compared to the prior art, which discloses only band-shaped structures, the post-processing and the resulting material section can be reduced to a minimum by the targeted cutting of the mats.
- the fiber reinforcement of the mats is preferably formed by mineral fibers, in particular glass fibers, and / or carbon fibers, and / or aramid fibers, and / or polymeric fibers, and / or synthetic fibers and / or from fibers of renewable raw materials. It may be advantageous to perform the fixing of the position of the mats to each other by means of a welding process. Preferably, the position fixing of the mats takes place by an ultrasonic and / or heating element and / or laser welding process. The positional fixing of the blanks of the mats to one another during or after completion of the construction of the preform has the advantage that the preform has a significantly improved handleability.
- the mats are at least partially preheated prior to depositing on the workpiece carrier with the aim of increasing the flexibility of the mats. Due to the increased flexibility of the mats is advantageously achieved that they can adapt better when placed on the workpiece carrier of the three-dimensional rough contour. It is preferably provided to heat the workpiece carrier in order to be able to maintain the flexibility of the mats.
- the heating of the preform or the preheating of the mats is preferably carried out by convection heating and / or infrared radiation. Further preferably within a convection and / or infrared continuous furnace. The heating by infrared radiation or by convection heating represents for a component which already has a dreidimensionale coarse contour, an optimal method for uniform heating of the entire preform.
- a robot system For the transfer of the mats and / or for the introduction of the preform, a robot system can be used.
- a tetrapod system for example a so-called FlexPicker TM from ABB
- an alternative software-based camera monitoring and control unit image recognition
- the use of rotober systems achieves a favorable reduction in the duration of the process compared to a manual process.
- a high reproducibility of the method can be achieved through the use of robots. This is particularly advantageous with regard to a reproducible alignment of the mats to each other, and the associated fiber orientation within the molding.
- the setting of the homogeneous inner mold pressure is preferably carried out by an edge-side injection molding of a circumferential plastic welt in the injection molding process within the mold.
- the adjustment of the homogeneous inner mold pressure can also be done by additional insertion of GMT pieces (glass mat reinforced thermoplastic), more preferably by a shot-pot technique or by inserting sealing cords in the mold or by inserting a sealing film in the mold.
- GMT pieces glass mat reinforced thermoplastic
- the abovementioned possibilities can be used in any combination.
- a uniform consolidation of the preform or of the molded part is achieved by the homogeneous inner mold pressure.
- the edge region is also closed in an advantageous manner, so that no fiber material can escape from the edge region or there is no splicing of the fiber material used. Due to the edge gating only little additional material is needed, which in particular does not significantly increase the weight of the molding.
- complementary functions such as clips, recordings or attachment points can be formed.
- the workpiece carrier is moved on a conveying path, whereby the individual process steps take place along this conveying path.
- the workpiece carrier can thus be moved along a plurality of stations, in particular a plurality of robot stations, in order to further minimize the process time until the completion of the molding.
- the molding is preferably produced within a time interval of 20 to 120 seconds, more preferably within a time interval of 40 to 90 seconds, and even more preferably within a time interval of 55 to 65 seconds.
- the specified time intervals represent normal production times for molded parts of the automotive industry, so that the inventive method can also be integrated within the production line of a motor vehicle.
- part of the invention is a motor vehicle molding, wherein the molding is three-dimensionally constructed of at least two unidirectional fiber-reinforced mats in a manner such that the fiber orientation is matched to the attacking in the later use of the molding forces and thereby resulting within the molding load paths.
- the motor vehicle molding on a plastic piping.
- the Kunststoffke- is preferably integrally formed peripherally on the molding.
- the molding of the plastic bead on the motor vehicle molding by an injection molding process within an injection molding or injection molding process.
- the plastic piping is formed from a fiber-reinforced, more preferably short-fiber-reinforced plastic.
- the peripheral edge of the plastic piping preferably forms a closed structure. Particularly advantageous thus increases the structural rigidity of the molding.
- the molded part has a cavity with at least one closed cross section.
- the at least one closed cross section can in particular be produced by an expansion body arranged within the preform.
- the expansion body is pressurized by means of a fluid so that it forms the cavity within the motor vehicle molding in conjunction with the walls of the molding tool.
- an elastic bladder in particular a silicone bladder, is used as the expansion body. It is also conceivable to work with a lost core, which forms the cavity within the molding. Further alternatives are gas and / or water injection methods.
- the fiber reinforcement of the mats or of the molded part prefferably be formed by mineral fibers, in particular glass fibers and / or carbon fibers and / or arabin fibers and / or polymeric fibers and / or synthetic fibers and / or from fibers of renewable raw materials is or are.
- the motor vehicle molding is designed as a supporting structure of an opening of the vehicle closing flap or door, or as a structural part of the body. Further preferably, the molded part may be formed as part of the underbody of the vehicle or as a battery case or as a battery carrier. Furthermore, in the context of the invention is that the molding is used in an aircraft as a structural profile.
- a motor vehicle according to the invention includes any land, water or air vehicle.
- Fig. 2 is a detail view of a motor vehicle molding according to the invention with a
- Kunststoffkeder Fig. 3 shows another inventive automotive molding with a cavity
- FIG. 1 shows a system for implementing the method according to the invention for producing continuous fiber-reinforced molded parts 1 made of thermoplastic materials.
- cut-to-size, substantially flat, unidirectionally fiber-reinforced mats 2 with a thermoplastic matrix at least partially surrounding the fibers are provided on a plurality of conveyor units 3.
- the mats 2 are removed from the conveyor unit 3 from a magazine and provided at a predetermined position.
- the provision of the mats 2 via a rolling and / or cutting unit done (not shown here).
- the mats 2 are at least partially preheated before depositing on a workpiece carrier 5 with the aim of increasing the flexibility of the mats 2.
- the mats 2 are transferred to a workpiece carrier 5 which predetermines the rough contour 4 of the molded part 1.
- the workpiece carrier 5 itself is moved on a conveyor line 13.
- the cut mats 2 are deposited and continuously to a three-dimensional preform 6 constructed in such a way that the fiber orientation of the mats 2 on the forces acting in the subsequent use of the molding 1 forces, and the resulting within the molding 1 load paths, is tuned ,
- the transfer, the depositing and the construction of the preform 6 take over a plurality of robot stations or robot systems 14, which are arranged along the conveyor line 13. After completion of the construction of the preform 6, the mats 2 are fixed in position relative to each other.
- the position fixation by means of a laser welding system 7, wherein a laser optics (not shown in detail) is arranged at a further robot station 17.
- a positional fixation of the mats 2 to each other can take place by means of textile technology.
- the preform 6 is then heated in an infrared continuous furnace 8 above the melting temperature of the thermoplastic matrix of the preform 6.
- the heating can also take place within a convection continuous furnace or in a molding tool 10 itself.
- an injection molding unit 15 which provides correspondingly plasticized material, preferably a fiber-reinforced thermoplastic material, and injects it with pressure into the molding tool 10.
- the consolidated molded part 1 is also removed from the mold 10 by means of the robot station 9 and fed to a storage unit 16.
- FIG. 2 shows a detailed view of a motor vehicle molding 1 according to the invention with an integrally formed plastic piping 18.
- the molding 1 is built up in three dimensions from at least two unidirectionally fiber-reinforced mats 2 in a manner such that the fiber orientation is based on the later engagement of the molding 1 Forces, and thereby resulting within the molding 1 load paths, is tuned.
- the plastic piping 18 is peripherally molded on the molded part at the edge. The molding of the
- Kunststoffkeders 18 on the motor vehicle molding 1 is effected by a Anspritzvorgang within an injection molding process in the mold 10 of the motor vehicle molding 1.
- the Kunststoffkeder 1 is formed from a short fiber reinforced plastic.
- FIG. 3 shows a motor vehicle molding 1 according to the invention with a cavity 20 which has at least one closed cross-section.
- the at least one closed cross section is produced by an expansion body 19 arranged within the preform 6.
- the expansion body 19 is pressurized by means of a fluid (indicated by arrows), so that this forms in connection with the walls of the mold (not shown here) the cavity 20 within the motor vehicle molding 1.
- a fluid indicated by arrows
- an elastic bladder in particular a silicone bladder is used.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Textile Engineering (AREA)
- Robotics (AREA)
- Reinforced Plastic Materials (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
The invention relates to a method for producing continuous-fibre-reinforced moulded parts (1) from thermoplastic plastics, the method comprising the following steps: preparation of cut-to-size, substantially flat, unidirectionally fibre-reinforced mats (2) with a thermoplastic matrix which at least partially surrounds the fibres; transfer of the mats (2) to a workpiece carrier (5) which predetermines the rough contour (4) of the moulded part (1); depositing and progressive build-up of the mats (2) on the workpiece carrier (5) to form a three-dimensional preform (6) such that the orientation of the fibres in the mats (2) is adapted to the forces applied when the moulded part (1) is subsequently in use and to the load paths resulting therefrom within the moulded part (1); securing the mats (2) in place relative to each other during or after build-up of the preform (6); heating of the preform (6) up to or above the melting temperature of the thermoplastic matrix of the preform (6); introduction of the three-dimensional preform (6) into a mould tool (10) forming the final contour of the moulded part (1); setting of a homogeneous pressure within the mould tool in order to ensure that the preform (6) consolidates whilst simultaneously retaining the orientation of the fibres within the preform (6); and removal of the consolidated moulded part (1) from the mould tool (10).
Description
Verfahren zur Herstellung von endlosfaserverstärkten Formteilen aus thermoplastischem Kunststoff sowie Kraftfahrzeugformteil Process for producing continuous fiber-reinforced molded parts made of thermoplastic material and motor vehicle molding
Die vorliegende Erfindung bezieht sich auf ein Verfahren zur Herstellung von endlosfaserverstärkten Formteilen aus thermoplastischen Kunststoffen sowie ein Kraftfahrzeugformteil. The present invention relates to a process for the production of continuous fiber-reinforced molded parts from thermoplastics and a motor vehicle molding.
Die Druckschrift US 7,235,149 B2 beschreibt ein Verfahren zur Herstellung von Kraftfahr- zeugformteilen aus endlosfaserverstärkten thermoplastischen Kunststoffen. Hierbei werden die bandförmigen endlosfaserverstärkten Vorformstücke auf einer ebenen Fläche in verschiedenen Winkeln zueinander abgelegt. Das dabei entstehende flache Gelege wird im Anschluss vorgewärmt und durch Thermoformen umgeformt. Je nach Wanddicke des Bauteils erfolgt die Konsolidierung in einem getrennten oder im gleichen Thermoformwerkzeug. The document US Pat. No. 7,235,149 B2 describes a method for the production of motor vehicle moldings from continuous fiber-reinforced thermoplastics. Here, the band-shaped continuous fiber-reinforced preform pieces are placed on a flat surface at different angles to each other. The resulting flat scrim is then preheated and thermoformed. Depending on the wall thickness of the component, the consolidation takes place in a separate or in the same thermoforming tool.
Nachteilig am Stand der Technik ist, dass der Pressvorgang aufgrund von notwendigen Materialüberständen einen erhöhten Materialverschnitt zur Folge hat. Des Weiteren stellt die erst beim Pressvorgang entstehende 3D-Struktur, und die damit verbundene Zwangsorientierung der Endlosfasern beim Umformvorgang, lediglich einen Kompromiss zwischen der Faserausrichtung in der dritten Dimension und den nötigen Fließwegen des Materials dar. Nachteilig ist ferner, dass zur Erzielung hoher Umformgrade ein erhöhter Bedarf an fließfähigem Material, d.h. an thermoplastischer Matrix notwendig ist, was zwangsläufig zu einem erhöhten Bauteilgewicht führt. Zudem lassen sich sehr hohe Umformgrade nicht realisieren, da es ansonsten zu Faserbrüchen innerhalb des endlosfaserverstärkten Form- teils kommt. A disadvantage of the prior art is that the pressing process due to necessary material supernatants has an increased material waste result. Furthermore, the 3D structure which arises only during the pressing process, and the associated forced orientation of the continuous fibers during the forming process, merely represents a compromise between the fiber orientation in the third dimension and the necessary flow paths of the material. A further disadvantage is that in order to achieve high degrees of deformation increased demand for flowable material, ie is necessary to thermoplastic matrix, which inevitably leads to an increased component weight. In addition, very high degrees of deformation can not be realized because otherwise fiber breaks occur within the continuous-fiber-reinforced molded part.
Damit liegt die der vorliegenden Erfindung zugrunde liegende Aufgabe in der Bereitstellung eines Verfahrens zur Herstellung von endlosfaserverstärkten Formteilen aus thermoplastischen Kunststoffen, welche die Nachteile des Stands der Technik überwindet. Thus, the object underlying the present invention is to provide a process for the production of continuous fiber-reinforced molded parts from thermoplastic materials, which overcomes the disadvantages of the prior art.
Diese Aufgabe ist erfindungsgemäß durch ein Verfahren zur Herstellung von endlosfaserverstärkten Formteilen aus thermoplastischen Kunststoffen gemäß Patentanspruch 1 gelöst. Bevorzugte Ausführungsform des erfindungsgemäßen Verfahrens sind in den davon abhängigen Patentansprüchen beschrieben. This object is achieved by a method for producing continuous fiber reinforced molded parts made of thermoplastic materials according to claim 1. Preferred embodiments of the method according to the invention are described in the dependent claims.
BESTÄTIGUNGSKOPIE
Das erfindungsgemäße Verfahren umfasst die folgenden Schritte: CONFIRMATION COPY The method according to the invention comprises the following steps:
- Bereitstellen von zugeschnittenen, im Wesentlichen flächig ausgebildeten, unidirek- tional-faserverstärkten Matten mit einer die Fasern zumindest teilweise umgebenden thermoplastischen Matrix, Provision of cut, essentially flat, unidirectionally fiber-reinforced mats with a thermoplastic matrix at least partially surrounding the fibers,
- Transfer der Matten zu einem die Grobkontur des Formteils vorgebenden Werkstückträger, Transfer of the mats to a workpiece carrier which predetermines the rough contour of the molded part,
- Ablegen und fortlaufendes Aufbauen der Matten auf dem Werkstückträger zu einem dreidimensionalen Vorformling derart, dass die Faserorientierung der Matten auf die im späteren Einsatz des Formteils angreifenden Kräfte, und die daraus innerhalb des Formteils resultierenden Lastpfade, abgestimmt wird, Depositing and continuously building the mats on the workpiece carrier into a three-dimensional preform such that the fiber orientation of the mats is matched to the forces acting in the subsequent use of the shaped part, and the load paths resulting therefrom within the molded part,
- Lagefixierung der Matten zueinander während oder nach Abschluss des Aufbaus des Vorformlings, Fixing the mats to one another during or after completion of the construction of the preform,
- Erwärmung des Vorformlings bis an oder über die Schmelztemperatur der thermoplastischen Matrix des Vorformlings, Heating the preform to or above the melting temperature of the thermoplastic matrix of the preform,
- Einbringung des dreidimensionalen Vorformlings in ein die endgültige Kontur des Formteils formendes Formwerkzeug, Introduction of the three-dimensional preform into a molding tool which forms the final contour of the molding,
- Einstellen eines homogenen Formwerkzeuginnendrucks mit dem Ziel der Gewähr- leistung der Konsolidierung des Vorformlings bei gleichzeitigem Erhalt der Faserorientierung innerhalb des Vorformlings, Setting a homogeneous inner mold pressure with the aim of guaranteeing the consolidation of the preform while at the same time maintaining the fiber orientation within the preform,
- Entnahme des konsolidierten Formteils aus dem Formwerkzeug. - Removal of the consolidated molding from the mold.
Gemäß der vorliegenden Erfindung wird in vorteilhafter Weise durch das Vorabformen der unidirektional-faserverstärkten Matten zu einem dreidimensionalen Vorformling erreicht, dass in dem darauf folgenden Konsolidierungsschritt das Formteil im Wesentlichen keine Umform- bzw. Fließvorgänge durchlaufen muss. Daher ist in vorteilhafter Weise weniger fließfähiges Material, d.h. weniger thermoplastische Matrix nötig, als dies beim Stand der Technik der Fall ist. Aufgrund der Möglichkeit der erfindungsgemäßen Faserorientierung auch in der dritten Dimension wird zudem erreicht, dass die an das mittels des erfindungsgemäßen Verfahrens hergestellten Formteils angreifenden Kräfte, und die daraus innerhalb des Formteils resultierenden Lastpfade, optimal durch die unidirektionale Faserverstärkung aufgenommen werden können.
Aufgrund der Optimierung der Faserorientierung und der Verringerung des Anteils an fließfähigem Material ergibt sich somit ein Formteil mit einem geringen Gewicht und im Vergleich zu Formteilen des Standes der Technik geringerer Wandstärke, was insbesondere auch im Hinblick auf den in Fahrzeugen begrenzten Bauraum große Vorteile bietet. Durch die Verringerung an fließfähigem Material erhöht sich zudem der Fasergehalt, was ebenfalls zur Gewichtsreduzierung und Optimierung der Kraftaufnahme beiträgt. Die unidirektio- nalen faserverstärkten Matten werden vorzugsweise aus unidirektionalen Folien zugeschnitten. Im Vergleich zum Stand der Technik, der lediglich bandförmige Strukturen offenbart, kann durch den gezielten Zuschnitt der Matten die Nachbearbeitung und der dabei anfallende Materialabschnitt auf ein Minimum reduziert werden. Die Faserverstärkung der Matten wird vorzugsweise durch Mineralfasern, insbesondere Glasfasern, und/oder Carbonfasern, und/oder Aramidfasern, und/oder polymeren Fasern, und/oder synthetischen Fasern und/oder aus Fasern von nachwachsenden Rohstoffen gebildet. Es kann vorteilhaft sein, die Lagefixierung der Matten zueinander mittels eines Schweißverfahrens durchzuführen. Vorzugsweise erfolgt die Lagefixierung der Matten dabei durch ein Ultraschall- und/oder Heizelement- und/oder Laserschweißverfahren. Die Lagefixierung der Zuschnitte der Matten zueinander während oder nach Abschluss des Aufbaus des Vorform- lings bietet den Vorteil, dass der Vorformling eine deutlich verbesserte Handhabbarkeit aufweist. According to the present invention, it is advantageously achieved by preforming the unidirectional fiber-reinforced mats into a three-dimensional preform such that in the subsequent consolidation step, the molding substantially does not have to undergo forming or flow processes. Therefore, advantageously less flowable material, ie less thermoplastic matrix is required, as is the case in the prior art. Due to the possibility of fiber orientation according to the invention in the third dimension is also achieved that the forces acting on the molded part produced by the molding according to the invention, and the resulting within the molding load paths can be optimally absorbed by the unidirectional fiber reinforcement. Due to the optimization of the fiber orientation and the reduction of the proportion of flowable material thus results in a molding with a low weight and compared to molded parts of the prior art lower wall thickness, which offers great advantages especially in view of the space limited in vehicles. By reducing the flowable material also increases the fiber content, which also contributes to weight reduction and optimization of power consumption. The unidirectional fiber reinforced mats are preferably cut from unidirectional films. Compared to the prior art, which discloses only band-shaped structures, the post-processing and the resulting material section can be reduced to a minimum by the targeted cutting of the mats. The fiber reinforcement of the mats is preferably formed by mineral fibers, in particular glass fibers, and / or carbon fibers, and / or aramid fibers, and / or polymeric fibers, and / or synthetic fibers and / or from fibers of renewable raw materials. It may be advantageous to perform the fixing of the position of the mats to each other by means of a welding process. Preferably, the position fixing of the mats takes place by an ultrasonic and / or heating element and / or laser welding process. The positional fixing of the blanks of the mats to one another during or after completion of the construction of the preform has the advantage that the preform has a significantly improved handleability.
Zur Lagefixierung der Matten zueinander können zudem textiltechnische Verfahren, vorzugsweise Vernadeln und/oder Vernähen eingesetzt werden. Vorzugsweise werden die Matten vor dem Ablegen auf dem Werkstückträger zumindest teilweise vorgewärmt mit dem Ziel die Flexibilität der Matten zu erhöhen. Durch die erhöhte Flexibilität der Matten wird vorteilhaft erreicht, dass diese sich beim Ablegen auf dem Werkstückträger der dreidimensionalen Grobkontur besser anpassen können. Vorzugsweise ist vorgesehen den Werkstückträger zu beheizen, um die Flexibilität der Matten aufrecht erhalten zu können.
Die Erwärmung des Vorformlings oder die Vorwärmung der Matten erfolgt vorzugsweise durch Konvektionserwärmung und/oder Infrarotstrahlung. Weiter vorzugsweise innerhalb eines Konvektions- und/oder Infrarot-Durchlaufofens. Die Erwärmung durch Infrarotstrahlung oder durch Konvektionserwärmung stellt für ein Bauteil, welches bereits eine dreidi- mensionale Grobkontur aufweist, ein optimales Verfahren zur gleichmäßigen Erwärmung des gesamten Vorformlings dar. For fixing the position of the mats to one another, it is also possible to use textile-technical methods, preferably needling and / or sewing. Preferably, the mats are at least partially preheated prior to depositing on the workpiece carrier with the aim of increasing the flexibility of the mats. Due to the increased flexibility of the mats is advantageously achieved that they can adapt better when placed on the workpiece carrier of the three-dimensional rough contour. It is preferably provided to heat the workpiece carrier in order to be able to maintain the flexibility of the mats. The heating of the preform or the preheating of the mats is preferably carried out by convection heating and / or infrared radiation. Further preferably within a convection and / or infrared continuous furnace. The heating by infrared radiation or by convection heating represents for a component which already has a dreidimensionale coarse contour, an optimal method for uniform heating of the entire preform.
Zum Transfer der Matten und/oder zur Einbringung des Vorformlings kann ein Robotersystem genutzt werden. Insbesondere kann dabei ein Tetrapodensystem (beispielsweise ein sogenannter FlexPicker™ der Firma ABB) mit einer alternativen softwaregestützten Kame- raüberwachungs- und Steuereinheit (Bilderkennung) genutzt werden. Durch den Einsatz von Rotobersystemen wird eine vorteilhafte Verringerung der Verfahrensdauer gegenüber einem manuellen Verfahren erreicht. Zusätzlich ist durch den Einsatz von Robotern eine hohe Reproduzierbarkeit des Verfahrens erzielbar. Dies ist insbesondere im Hinblick auf eine reproduzierbare Ausrichtung der Matten zueinander, und der damit verknüpften Faserorientierung innerhalb des Formteils, von großem Vorteil. For the transfer of the mats and / or for the introduction of the preform, a robot system can be used. In particular, a tetrapod system (for example a so-called FlexPicker ™ from ABB) can be used with an alternative software-based camera monitoring and control unit (image recognition). The use of rotober systems achieves a favorable reduction in the duration of the process compared to a manual process. In addition, a high reproducibility of the method can be achieved through the use of robots. This is particularly advantageous with regard to a reproducible alignment of the mats to each other, and the associated fiber orientation within the molding.
Die Einstellung des homogenen Formwerkzeuginnendrucks erfolgt vorzugsweise durch ein randseitiges Anspritzen eines umlaufenden Kunststoffkeders im Spritzgussverfahren inner- halb des Formwerkzeugs. Die Einstellung des homogenen Formwerkzeuginnendrucks kann zudem durch zusätzliches Einlegen von GMT-Stücken (glasmattenverstärkter Thermoplast), weiter vorzugsweise durch eine Shot-Pot-Technik oder durch das Einlegen von Dichtschnüren in das Formwerkzeug oder durch das Einlegen einer Dichtfolie in das Formwerkzeug erfolgen. Weiterhin im Rahmen der Erfindung können die vorgenannten Möglich- keiten in beliebiger Kombination eingesetzt werden. Durch die Einstellung eines homogenen Formwerkzeuginnendrucks durch die vorgenannten Möglichkeiten wird erreicht, dass es zu keinen unkontrollierten Fließvorgängen des thermoplastischen Materials der Matten innerhalb des Formwerkzeugs kommt, die zu einer ungewollten Verlagerung des in die thermoplastische Matrix eingebetteten Fasermaterials führt. Zudem wird durch den homo- genen Formwerkzeuginnendruck eine gleichmäßige Konsolidierung des Vorformlings bzw. des Formteils erreicht. Insbesondere durch das randseitige Einspritzen eines umlaufenden Kunststoffkeders im Spritzgussverfahren wird in vorteilhafter Weise der Randbereich zudem verschlossen, sodass kein Fasermaterial aus dem Randbereich austreten kann bzw. es zu keinem Aufspleißen des eingesetzten Fasermaterials kommt.
Durch die randseitige Anspritzung wird zudem nur wenig zusätzliches Material benötigt, was insbesondere das Formteilgewicht nicht wesentlich erhöht. Weiterhin können bei Einsatz eines Spritzgussverfahrens an dem Formteil ergänzende Funktionen wie z.B. Clipse, Aufnahmen oder Befestigungsstellen angeformt werden. The setting of the homogeneous inner mold pressure is preferably carried out by an edge-side injection molding of a circumferential plastic welt in the injection molding process within the mold. The adjustment of the homogeneous inner mold pressure can also be done by additional insertion of GMT pieces (glass mat reinforced thermoplastic), more preferably by a shot-pot technique or by inserting sealing cords in the mold or by inserting a sealing film in the mold. Furthermore, in the context of the invention, the abovementioned possibilities can be used in any combination. By setting a homogeneous internal pressure of the mold by the aforementioned possibilities is achieved that there is no uncontrolled flow processes of the thermoplastic material of the mats within the mold, which leads to an unwanted displacement of embedded in the thermoplastic matrix fiber material. In addition, a uniform consolidation of the preform or of the molded part is achieved by the homogeneous inner mold pressure. In particular, by the edge-side injection of a circumferential plastic welt in the injection molding process, the edge region is also closed in an advantageous manner, so that no fiber material can escape from the edge region or there is no splicing of the fiber material used. Due to the edge gating only little additional material is needed, which in particular does not significantly increase the weight of the molding. Furthermore, when using an injection molding process on the molded part complementary functions such as clips, recordings or attachment points can be formed.
Vorzugsweise wird der Werkstückträger auf einer Förderstrecke bewegt, wobei die einzelnen Verfahrensschritte entlang dieser Förderstrecke erfolgen. In vorteilhafter Weise kann so der Werkstückträger entlang einer Vielzahl von Stationen, insbesondere einer Vielzahl von Roboterstationen bewegt werden, um die Verfahrenszeit bis zur Fertigstellung des Formteils weiter zu minimieren. Preferably, the workpiece carrier is moved on a conveying path, whereby the individual process steps take place along this conveying path. Advantageously, the workpiece carrier can thus be moved along a plurality of stations, in particular a plurality of robot stations, in order to further minimize the process time until the completion of the molding.
Die Herstellung des Formteils erfolgt vorzugsweise innerhalb eines Zeitintervalls von 20 bis 120 Sekunden, weiter vorzugsweise innerhalb eines Zeitintervalls von 40 bis 90 Sekunden und noch weiter vorzugsweise innerhalb eines Zeitintervalls von 55 bis 65 Sekunden. Die angegebenen Zeitintervalle stellen übliche Produktionszeiten für Formteile der Automobilindustrie dar, sodass das erfindungsgemäße Verfahren auch innerhalb der Produktionslinie eines Kraftfahrzeugs integriert werden kann. The molding is preferably produced within a time interval of 20 to 120 seconds, more preferably within a time interval of 40 to 90 seconds, and even more preferably within a time interval of 55 to 65 seconds. The specified time intervals represent normal production times for molded parts of the automotive industry, so that the inventive method can also be integrated within the production line of a motor vehicle.
Vorzugsweise erfolgt das Ablegen der Matten auf Basis von durch Finite-Elementberech- nung des Formteils ermittelten Lastpfaden innerhalb des Bauteils. Die Finite-Elementbe- rechnung des Formteils erlaubt es die Faserorientierungen auf diese Lastpfade gezielt anzupassen. Die Anpassung kann dabei durch das erfindungsgemäße Verfahren in vorteilhafter Weise auch in der räumlichen Ausrichtung des Bauteils erfolgen. Weiterhin Teil der Erfindung ist ein Kraftfahrzeugformteil, wobei das Formteil dreidimensional aus mindestens zwei unidirektional-faserverstärkten Matten schichtweise aufgebaut ist in der Art, dass die Faserorientierung auf die im späteren Einsatz des Formteils angreifenden Kräfte und die dabei innerhalb des Formteils entstehenden Lastpfade abgestimmt ist. Vorzugsweise weist das Kraftfahrzeugformteil einen Kunststoffkeder auf. Der Kunststoffke- der ist vorzugsweise randseitig umlaufend an dem Formteil angeformt. In vorteilhafter Weise erfolgt das Anformen des Kunststoffkeders an dem Kraftfahrzeugformteil durch einen Anspritzvorgang innerhalb eines Spritzgussverfahrens bzw. Spritzgussvorgangs.
Vorteilhaft ist der Kunststoffkeder aus einem faserverstärkten, weiter vorzugsweise kurzfaserverstärkten Kunststoff gebildet. Vorzugsweise bildet der randseitig umlaufende Kunststoffkeder dabei eine geschlossen Struktur. Besonders vorteilhaft erhöht sich somit die Struktursteifigkeit des Formteils. The laying down of the mats preferably takes place on the basis of load paths within the component determined by finite element calculation of the molded part. The finite element calculation of the molded part allows the fiber orientations to be specifically adapted to these load paths. The adaptation can be carried out by the inventive method in an advantageous manner in the spatial orientation of the component. Furthermore, part of the invention is a motor vehicle molding, wherein the molding is three-dimensionally constructed of at least two unidirectional fiber-reinforced mats in a manner such that the fiber orientation is matched to the attacking in the later use of the molding forces and thereby resulting within the molding load paths. Preferably, the motor vehicle molding on a plastic piping. The Kunststoffke- is preferably integrally formed peripherally on the molding. Advantageously, the molding of the plastic bead on the motor vehicle molding by an injection molding process within an injection molding or injection molding process. Advantageously, the plastic piping is formed from a fiber-reinforced, more preferably short-fiber-reinforced plastic. In this case, the peripheral edge of the plastic piping preferably forms a closed structure. Particularly advantageous thus increases the structural rigidity of the molding.
In einer vorteilhaften Ausführungsform weist das Formteil einen Hohlraum mit mindestens einem geschlossenen Querschnitt auf. Der mindestens eine geschlossene Querschnitt kann insbesondere durch einen innerhalb des Vorformlings angeordneten Expansionskörpers hergestellt werden. Innerhalb des Vorformlings wird der Expansionskörper mittels ei- nes Fluids mit Druck beaufschlagt, sodass dieser in Verbindung mit den Wandungen des Formwerkzeugs den Hohlraum innerhalb des Kraftfahrzeugformteils bildet. Vorzugsweise wird als Expansionskörper eine elastische Blase, insbesondere eine Silikonblase eingesetzt. Denkbar ist hierbei auch mit einem verlorenen Kern zu arbeiten, welcher den Hohlraum innerhalb des Formteils bildet. Weitere Alternativen sind Gas- und/oder Wasserinjek- tionsverfahren. In an advantageous embodiment, the molded part has a cavity with at least one closed cross section. The at least one closed cross section can in particular be produced by an expansion body arranged within the preform. Within the preform, the expansion body is pressurized by means of a fluid so that it forms the cavity within the motor vehicle molding in conjunction with the walls of the molding tool. Preferably, an elastic bladder, in particular a silicone bladder, is used as the expansion body. It is also conceivable to work with a lost core, which forms the cavity within the molding. Further alternatives are gas and / or water injection methods.
Es hat sich als vorteilhaft erwiesen, dass die Faserverstärkung der Matten bzw. des Formteils durch Mineralfasern, insbesondere Glasfasern und/oder Carbonfasern und/oder Ara- midfasern und/oder polymeren Fasern und/oder synthetischen Fasern und/oder aus Fasern von nachwachsenden Rohstoffen gebildet ist bzw. sind. It has proved to be advantageous for the fiber reinforcement of the mats or of the molded part to be formed by mineral fibers, in particular glass fibers and / or carbon fibers and / or arabin fibers and / or polymeric fibers and / or synthetic fibers and / or from fibers of renewable raw materials is or are.
Vorzugsweise ist das Kraftfahrzeugformteil als Tragstruktur einer eine Öffnung des Fahrzeugs verschließenden Klappe oder Tür, oder als Strukturteil der Karosserie ausgebildet. Weiter vorzugsweise kann das Formteil als Teil der Bodengruppe des Fahrzeugs oder als Batteriegehäuse oder als Batterieträger ausgebildet sein. Weiterhin im Rahmen der Erfindung ist, dass das Formteil in einem Flugzeug als Strukturprofil eingesetzt ist. Ein Kraftfahrzeug schließt erfindungsgemäß jedwedes Land-, Wasser-, oder Luftfahrzeug mit ein. Preferably, the motor vehicle molding is designed as a supporting structure of an opening of the vehicle closing flap or door, or as a structural part of the body. Further preferably, the molded part may be formed as part of the underbody of the vehicle or as a battery case or as a battery carrier. Furthermore, in the context of the invention is that the molding is used in an aircraft as a structural profile. A motor vehicle according to the invention includes any land, water or air vehicle.
Andere mögliche Anwendungen der erfindungsgemäßen Technik ergeben sich bei der Herstellung von Leichtbauteilen und Hohlkörperbauteilen im Automobilbereich, für industrielle Anwendungen, im Maschinenbau, für Sportgeräte und im Baubereich.
Ausführungsbeispiele Other possible applications of the technique according to the invention result in the production of lightweight components and hollow body components in the automotive sector, for industrial applications, in mechanical engineering, for sports equipment and in the construction sector. embodiments
Im Folgenden wird die Erfindung anhand einer lediglich ein Ausführungsbeispiel darstellenden Zeichnung erläutert. Es zeigen schematisch: Fig. 1 eine Anlage zur Durchführung des erfindungsgemäßen Verfahrens In the following the invention will be explained with reference to a drawing showing only one embodiment. 1 shows a plant for carrying out the method according to the invention
Fig. 2 eine Detailansicht eines erfindungsgemäßen Kraftfahrzeugformteil mit einem Fig. 2 is a detail view of a motor vehicle molding according to the invention with a
Kunststoffkeder Fig. 3 ein weiteres erfindungsgemäßes Kraftfahrzeugformteil mit einem Hohlraum Kunststoffkeder Fig. 3 shows another inventive automotive molding with a cavity
In den Figuren werden gleiche oder funktionsgleiche Elemente mit den gleichen Bezugszeichen versehen. In the figures, identical or functionally identical elements are provided with the same reference numerals.
Die Figur 1 zeigt eine Anlage zur Umsetzung des erfindungsgemäßen Verfahrens zur Her- Stellung von endlosfaserverstärkten Formteilen 1 aus thermoplastischen Kunststoffen. Auf mehreren Fördereinheiten 3 werden dabei zugeschnittene, im Wesentlichen flächig ausgebildete, unidirektional-faserverstärkte Matten 2 mit einer die Fasern zumindest teilweise umgebenden thermoplastischen Matrix bereitgestellt. In diesem Ausführungsbeispiel werden die Matten 2 von der Fördereinheit 3 aus einem Magazin entnommen und auf einer vorbe- stimmten Position bereitgestellt. Alternativ kann die Bereitstellung der Matten 2 über eine Abroll- und/oder Schneideinheit erfolgen (hier nicht näher dargestellt). Die Matten 2 werden vor dem Ablegen auf einem Werkstückträger 5 zumindest teilweise vorgewärmt mit dem Ziel die Flexibilität der Matten 2 zu erhöhen. Im Anschluss erfolgt ein Transfer der Matten 2 zu einem die Grobkontur 4 des Formteils 1 vorgebenden Werkstückträger 5. Der Werk- stückträger 5 selbst wird auf einer Förderstrecke 13 bewegt. Auf dem Werkstückträger 5 werden die zugeschnittenen Matten 2 abgelegt und fortlaufend zu einem dreidimensionalen Vorformling 6 aufgebaut in derart, dass die Faserorientierung der Matten 2 auf die im späteren Einsatz des Formteils 1 angreifenden Kräfte, und die daraus innerhalb des Formteils 1 resultierenden Lastpfade, abgestimmt wird. Den Transfer, das Ablegen und das Auf- bauen des Vorformlings 6 übernehmen mehrere Roboterstationen oder Robotersysteme 14, die entlang der Förderstrecke 13 angeordnet sind. Nach Abschluss des Aufbaus des Vorformlings 6 werden die Matten 2 zueinander lagefixiert. Dabei erfolgt die Lagefixierung mittels einer Laserschweißanlage 7, wobei eine Laseroptik (nicht näher dargestellt) an einer weiteren Roboterstation 17 angeordnet ist.
Alternativ kann schon während des Aufbaus des Vorformlings 6 eine Lagefixierung der Matten 2 zueinander durch textiltechnische Verfahren erfolgen. Der Vorformling 6 wird anschließend in einem Infrarot-Durchlaufofen 8 über die Schmelztemperatur der thermoplastischen Matrix des Vorformlings 6 erwärmt. Alternativ kann die Erwärmung auch innerhalb eines Konvektionsdurchlaufofens oder in einem Formwerkzeug 10 selbst erfolgen. Mittels einer weiteren Roboterstation 9 erfolgt die Einbringung des dreidimensionalen Vorformlings 6 in das die endgültige Kontur des Formteils 1 formendes Formwerkzeug 10. Das Einstellen eines homogenen Formwerkzeuginnendrucks, mit dem Ziel der Gewährleistung der Konsolidierung des Vorformlings 6 bei gleichzeitigem Erhalt der Faserorientierung innerhalb des Vorformlings 6, erfolgt durch ein randseitiges Anspritzen eines umlaufenden Kunst- stoffkeders 18 (vergl. Fig. 2) an den Vorformling 6. Hierfür ist eine Spritzgießeinheit 15 vorgesehen, die entsprechend plastifiziertes Material, vorzugsweise ein faserverstärktes Thermoplastmaterial, bereitstellt und mit Druck in das Formwerkzeug 10 einspritzt. Das konsolidierte Formteil 1 wird ebenfalls mittels der Roboterstation 9 aus dem Formwerk- zeug 10 entnommen und einer Lagereinheit 16 zugeführt. FIG. 1 shows a system for implementing the method according to the invention for producing continuous fiber-reinforced molded parts 1 made of thermoplastic materials. In this case, cut-to-size, substantially flat, unidirectionally fiber-reinforced mats 2 with a thermoplastic matrix at least partially surrounding the fibers are provided on a plurality of conveyor units 3. In this embodiment, the mats 2 are removed from the conveyor unit 3 from a magazine and provided at a predetermined position. Alternatively, the provision of the mats 2 via a rolling and / or cutting unit done (not shown here). The mats 2 are at least partially preheated before depositing on a workpiece carrier 5 with the aim of increasing the flexibility of the mats 2. Subsequently, the mats 2 are transferred to a workpiece carrier 5 which predetermines the rough contour 4 of the molded part 1. The workpiece carrier 5 itself is moved on a conveyor line 13. On the workpiece carrier 5, the cut mats 2 are deposited and continuously to a three-dimensional preform 6 constructed in such a way that the fiber orientation of the mats 2 on the forces acting in the subsequent use of the molding 1 forces, and the resulting within the molding 1 load paths, is tuned , The transfer, the depositing and the construction of the preform 6 take over a plurality of robot stations or robot systems 14, which are arranged along the conveyor line 13. After completion of the construction of the preform 6, the mats 2 are fixed in position relative to each other. In this case, the position fixation by means of a laser welding system 7, wherein a laser optics (not shown in detail) is arranged at a further robot station 17. Alternatively, even during the construction of the preform 6, a positional fixation of the mats 2 to each other can take place by means of textile technology. The preform 6 is then heated in an infrared continuous furnace 8 above the melting temperature of the thermoplastic matrix of the preform 6. Alternatively, the heating can also take place within a convection continuous furnace or in a molding tool 10 itself. By means of a further robot station 9, the introduction of the three-dimensional preform 6 in the final contour of the molding 1-forming mold 10. The setting of a homogeneous internal mold pressure, with the aim of ensuring the consolidation of the preform 6 while maintaining the fiber orientation within the preform 6, 2) on the preform 6. For this purpose, an injection molding unit 15 is provided, which provides correspondingly plasticized material, preferably a fiber-reinforced thermoplastic material, and injects it with pressure into the molding tool 10. The consolidated molded part 1 is also removed from the mold 10 by means of the robot station 9 and fed to a storage unit 16.
Fig 2. zeigt eine Detailansicht eines erfindungsgemäßen Kraftfahrzeugformteils 1 mit einem angeformten Kunststoffkeder 18. Das Formteil 1 ist dreidimensional aus mindestens zwei unidirektional-faserverstärkten Matten 2 schichtweise aufgebaut ist in der Art, dass die Fa- serorientierung auf die im späteren Einsatz des Formteils 1 angreifenden Kräfte, und die dabei innerhalb des Formteils 1 entstehenden Lastpfade, abgestimmt ist. Der Kunststoffkeder 18 ist randseitig umlaufend an dem Formteil langeformt. Das Anformen des FIG. 2 shows a detailed view of a motor vehicle molding 1 according to the invention with an integrally formed plastic piping 18. The molding 1 is built up in three dimensions from at least two unidirectionally fiber-reinforced mats 2 in a manner such that the fiber orientation is based on the later engagement of the molding 1 Forces, and thereby resulting within the molding 1 load paths, is tuned. The plastic piping 18 is peripherally molded on the molded part at the edge. The molding of the
Kunststoffkeders 18 an dem Kraftfahrzeugformteil 1 erfolgt durch einen Anspritzvorgang innerhalb eines Spritzgussverfahrens in dem Formwerkzeug 10 des Kraftfahrzeugformteils 1. Der Kunststoffkeder 1 ist aus einem kurzfaserverstärkten Kunststoff gebildet. Kunststoffkeders 18 on the motor vehicle molding 1 is effected by a Anspritzvorgang within an injection molding process in the mold 10 of the motor vehicle molding 1. The Kunststoffkeder 1 is formed from a short fiber reinforced plastic.
Fig. 3 zeigt ein erfindungsgemäßes Kraftfahrzeugformteil 1 mit einem Hohlraum 20 der mindestens einen geschlossenen Querschnitt aufweist. Der mindestens eine geschlossene Querschnitt wird durch einen innerhalb des Vorformlings 6 angeordneten Expansionskör- pers 19 hergestellt. Innerhalb des Vorformlings 6 wird der Expansionskörper 19 mittels eines Fluids mit Druck beaufschlagt (durch Pfeile angedeutet), sodass dieser in Verbindung mit den Wandungen des Formwerkzeugs (hier nicht näher dargestellt) den Hohlraum 20 innerhalb des Kraftfahrzeugformteils 1 bildet.
Als Expansionskörper 19 wird eine elastische Blase, insbesondere eine Silikonblase eingesetzt. Alternativ kann mit einem verlorenen Kern gearbeitet werden, welcher den Hohlraum 20 innerhalb des Formteils 1 bildet.
FIG. 3 shows a motor vehicle molding 1 according to the invention with a cavity 20 which has at least one closed cross-section. The at least one closed cross section is produced by an expansion body 19 arranged within the preform 6. Within the preform 6, the expansion body 19 is pressurized by means of a fluid (indicated by arrows), so that this forms in connection with the walls of the mold (not shown here) the cavity 20 within the motor vehicle molding 1. As expansion body 19, an elastic bladder, in particular a silicone bladder is used. Alternatively, you can work with a lost core, which forms the cavity 20 within the molded part 1.
Claims
Patentansprüche claims
Verfahren zur Herstellung von endlosfaserverstärkten Formteilen (1) aus thermoplastischen Kunststoffen, umfassend die folgenden Schritte: Process for producing continuous fiber-reinforced molded parts (1) from thermoplastic materials, comprising the following steps:
- Bereitstellen von zugeschnittenen, im Wesentlichen flächig ausgebildeten, unidi- rektional-faserverstärkten Matten (2) mit einer die Fasern zumindest teilweise umgebenden thermoplastischen Matrix, Provision of cut, substantially flat, unidirectionally fiber-reinforced mats (2) with a thermoplastic matrix at least partially surrounding the fibers,
- Transfer der Matten (2) zu einem die Grobkontur (4) des Formteils (1) vorgebenden Werkstückträger (5), Transfer of the mats (2) to a workpiece carrier (5) which predetermines the rough contour (4) of the molded part (1),
Ablegen und fortlaufendes Aufbauen der Matten (2) auf dem Werkstückträger (5) zu einem dreidimensionalen Vorformling (6) derart, dass die Faserorientierung der Matten (2) auf die im späteren Einsatz des Formteils (1) angreifenden Kräfte, und die daraus innerhalb des Formteils (1) resultierenden Lastpfade, abgestimmt wird, Depositing and continuously constructing the mats (2) on the workpiece carrier (5) into a three-dimensional preform (6) such that the fiber orientation of the mats (2) affects the forces acting on the subsequent use of the molded part (1) and the inside thereof Molded part (1) resulting load paths, is tuned,
- Lagefixierung der Matten (2) zueinander während oder nach Abschluss des Aufbaus des Vorformlings (6), - fixing the position of the mats (2) to one another during or after completion of the construction of the preform (6),
- Erwärmung des Vorformlings (6) bis an oder über die Schmelztemperatur der thermoplastischen Matrix des Vorformlings (6), Heating the preform (6) up to or above the melting temperature of the thermoplastic matrix of the preform (6),
- Einbringung des dreidimensionalen Vorformlings (6) in ein die endgültige Kontur des Formteils (1) formendes Formwerkzeug (10), - introduction of the three-dimensional preform (6) in a final contour of the molding (1) forming mold (10),
- Einstellen eines homogenen Formwerkzeuginnendrucks mit dem Ziel der Gewährleistung der Konsolidierung des Vorformlings (6) bei gleichzeitigem Erhalt der Faserorientierung innerhalb des Vorformlings (6), - setting a homogeneous inner mold pressure with the aim of ensuring the consolidation of the preform (6) while maintaining the fiber orientation within the preform (6),
- Entnahme des konsolidierten Formteils (1) aus dem Formwerkzeug (10). - Removal of the consolidated molding (1) from the mold (10).
Verfahren nach Anspruch 1 , dadurch gekennzeichnet, dass die Lagefixierung der Matten (2) zueinander mittels eines Schweißverfahrens, vorzugsweise Ultraschall-, und/oder Heizelement-, und/oder Laserschweißverfahren erfolgt. A method according to claim 1, characterized in that the position fixing of the mats (2) to each other by means of a welding process, preferably ultrasound, and / or Heizelement-, and / or laser welding process takes place.
Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass die Lagefixierung der Matten (2) zueinander durch textiltechnische Verfahren, vorzugsweise Vernadeln und/oder Vernähen erfolgt.
A method according to claim 1 or 2, characterized in that the fixing of the position of the mats (2) to each other by textile technology method, preferably needling and / or sewing takes place.
4. Verfahren nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass die Matten (2) vor dem Ablegen auf dem Werkstückträger (5) zumindest teilweise vorgewärmt werden mit dem Ziel die Flexibilität der Matten (2) zu erhöhen. 4. The method according to any one of the preceding claims, characterized in that the mats (2) before being deposited on the workpiece carrier (5) are at least partially preheated with the aim of increasing the flexibility of the mats (2).
Verfahren nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass die Erwärmung des Vorformlings (6) oder die Vorwärmung der Matten (2) durch Kon- vektionserwärmung und/oder Infrarotstrahlung erfolgt, vorzugsweise innerhalb eines Konvektions- und/oder innerhalb eines Infrarot-Durchlaufofens. Method according to one of the preceding claims, characterized in that the heating of the preform (6) or the preheating of the mats (2) by convection heating and / or infrared radiation takes place, preferably within a convection and / or within an infrared continuous furnace.
Verfahren nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass zum Transfer der Matten (2) und/oder zur Einbringung des Vorformlings (6) ein Robotersystem (9, 14) genutzt wird. Method according to one of the preceding claims, characterized in that for the transfer of the mats (2) and / or for the introduction of the preform (6), a robot system (9, 14) is used.
Verfahren nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass die Einstellung des homogenen Formwerkzeuginnendrucks durch randseitiges Anspritzen eines umlaufenden Kunststoffkeders (18) im Spritzgussverfahren innerhalb des Formwerkzeugs (10) und/oder durch das zusätzliche Einlegen von GMT-Stücken in das Formwerkzeug (10) und/oder durch eine Shot-Pot-Technik und/oder durch das Einlegen von Dichtschnüre in das Formwerkzeug (10) und/oder durch das Einlegen einer Dichtfolie in das Formwerkzeug (10) erfolgt. Method according to one of the preceding claims, characterized in that the adjustment of the homogeneous inner mold pressure by edge-side molding of a circumferential plastic Keders (18) by injection molding within the mold (10) and / or by the additional insertion of GMT pieces in the mold (10) and / or by a shot-pot technique and / or by the insertion of sealing cords in the mold (10) and / or by the insertion of a sealing film in the mold (10).
Verfahren nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass der Werkstückträger (5) auf einer Förderstrecke (3) bewegt wird und die einzelnen Verfahrensschritte entlang der Förderstrecke (3) erfolgen. Method according to one of the preceding claims, characterized in that the workpiece carrier (5) is moved on a conveying path (3) and the individual process steps take place along the conveying path (3).
Verfahren nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass die Herstellung des Formteils (1) innerhalb eines Zeitintervalls von 20 bis 120 Sekunden, vorzugsweise 40 bis 90 Sekunden, weiter vorzugsweise 55 bis 65 Sekunden erfolgt. Method according to one of the preceding claims, characterized in that the production of the molded part (1) takes place within a time interval of 20 to 120 seconds, preferably 40 to 90 seconds, more preferably 55 to 65 seconds.
Kraftfahrzeugformteil (1), dadurch gekennzeichnet, dass das Formteil (1) dreidimensional aus mindestens zwei unidirektional-faserverstärkten Matten (2) schichtweise aufgebaut ist in der Art, dass die Faserorientierung auf die im späteren Einsatz des Formteils (1) angreifenden Kräfte und die dabei innerhalb des Formteils (1) entstehenden Lastfade abgestimmt ist.
Motor vehicle molding (1), characterized in that the molded part (1) in three dimensions from at least two unidirectional fiber-reinforced mats (2) is constructed in layers such that the fiber orientation on the subsequent use of the molding (1) acting forces and the case within the molded part (1) resulting load paths is tuned.
11. Kraftfahrzeugformteil (1) nach Anspruch 10, dadurch gekennzeichnet, dass ein Kunststoffkeder (18), vorzugsweise randseitig umlaufend an dem Formteil (1) angeformt, vorzugsweise angespritzt ist. 11. Motor vehicle molding (1) according to claim 10, characterized in that a Kunststoffkeder (18), preferably peripherally integrally formed on the molded part (1), preferably molded.
12. Kraftfahrzeugformteil nach Anspruch 11 , dadurch gekennzeichnet, dass der Kunststoffkeder (18) aus einem faserverstärkten Kunststoff gebildet ist. 12. Motor vehicle molding according to claim 11, characterized in that the Kunststoffkeder (18) is formed of a fiber-reinforced plastic.
13. Kraftfahrzeugformteil (1) nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass das Formteil (1) einen Hohlraum (20) mit mindestens einem geschlossenen Querschnitt aufweist. 13. Motor vehicle molding (1) according to one of the preceding claims, characterized in that the molded part (1) has a cavity (20) with at least one closed cross-section.
14. Kraftfahrzeugformteil (1) nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass die Faserverstärkung durch Mineralfasern, insbesondere Glasfasern, und/oder Carbonfasern, und/oder Aramidfasern, und/oder polymeren Fasern, und/oder synthetischen Fasern und/oder aus Fasern von nachwachsenden Rohstoffen gebildet ist/sind. 14. Motor vehicle molding (1) according to any one of the preceding claims, characterized in that the fiber reinforcement by mineral fibers, in particular glass fibers, and / or carbon fibers, and / or aramid fibers, and / or polymeric fibers, and / or synthetic fibers and / or fibers of renewable raw materials is / are.
15. Kraftfahrzeugformteil (1) nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass das Formteil (1) als Tragstruktur einer eine Öffnung des Fahrzeugs verschließenden Klappe oder Tür, oder als Strukturteil der Karosserie ausgebildet ist.
15. Motor vehicle molding (1) according to one of the preceding claims, characterized in that the molded part (1) is designed as a support structure of an opening of the vehicle closing flap or door, or as a structural part of the body.
Applications Claiming Priority (3)
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DE102009060027 | 2009-12-21 | ||
DE102010013131A DE102010013131A1 (en) | 2009-12-21 | 2010-03-26 | Process for producing continuous fiber-reinforced molded parts made of thermoplastic material and motor vehicle molding |
PCT/EP2010/007827 WO2011085792A1 (en) | 2009-12-21 | 2010-12-21 | Method for producing continuous-fibre-reinforced moulded parts from thermoplastic plastics and motor vehicle moulded part |
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EP2516137A1 true EP2516137A1 (en) | 2012-10-31 |
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EP10803235A Withdrawn EP2516137A1 (en) | 2009-12-21 | 2010-12-21 | Method for producing continuous-fibre-reinforced moulded parts from thermoplastic plastics and motor vehicle moulded part |
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EP (1) | EP2516137A1 (en) |
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WO2011085792A1 (en) | 2011-07-21 |
US20120269999A1 (en) | 2012-10-25 |
CN102762360A (en) | 2012-10-31 |
CN102762360B (en) | 2015-04-01 |
KR20120123350A (en) | 2012-11-08 |
DE102010013131A1 (en) | 2011-06-22 |
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