EP3478470A1 - Motor vehicle composite component and method for the production thereof - Google Patents

Motor vehicle composite component and method for the production thereof

Info

Publication number
EP3478470A1
EP3478470A1 EP17742154.2A EP17742154A EP3478470A1 EP 3478470 A1 EP3478470 A1 EP 3478470A1 EP 17742154 A EP17742154 A EP 17742154A EP 3478470 A1 EP3478470 A1 EP 3478470A1
Authority
EP
European Patent Office
Prior art keywords
mold cavity
composite component
particle foam
motor vehicle
mold
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Withdrawn
Application number
EP17742154.2A
Other languages
German (de)
French (fr)
Inventor
Ingo Brexeler
Thorsten Michel
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Krallmann Kunststoffverarbeitungs GmbH
Original Assignee
Krallmann Kunststoffverarbeitungs GmbH
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 Krallmann Kunststoffverarbeitungs GmbH filed Critical Krallmann Kunststoffverarbeitungs GmbH
Publication of EP3478470A1 publication Critical patent/EP3478470A1/en
Withdrawn legal-status Critical Current

Links

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
    • 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
    • B29C44/08—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 using several expanding or moulding steps
    • B29C44/083—Increasing the size of the cavity after a first part has foamed, e.g. substituting one mould part with another
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/36—Feeding the material to be shaped
    • B29C44/38—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length
    • B29C44/44—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length in solid form
    • B29C44/445—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length in solid form in the form of expandable granules, particles or beads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B29C45/1635—Making multilayered or multicoloured articles using displaceable mould parts, e.g. retractable partition between adjacent mould 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B29C45/1671—Making multilayered or multicoloured articles with an insert
    • B29C2045/1673—Making multilayered or multicoloured articles with an insert injecting the first layer, then feeding the insert, then injecting the second layer
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B29C2045/169—Making multilayered or multicoloured articles injecting electrical circuits, e.g. one layer being made of conductive material
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B29C2045/1696—Making multilayered or multicoloured articles injecting metallic layers and plastic material layers
    • 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
    • B29C44/1266—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being completely encapsulated, e.g. for packaging purposes or as reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/12—Thermoplastic materials
    • 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
    • B29L2031/3002—Superstructures characterized by combining metal and plastics, i.e. hybrid parts
    • 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

Definitions

  • the invention relates to a motor vehicle composite component and a method for its production.
  • the automotive composite part is in particular a visible in the installed state automotive composite component with an integrated electrical connectivity, for example, a car door with integration of functional elements such as windows, door lock, speakers, lamps, switches for mirrors, switches for a roof, Ventilation ducts, airbag etc.,
  • A-pillar or B-pillar a supporting vertical column (A-pillar or B-pillar), or
  • CONFIRMATION COPY a trunk lining or interior lining.
  • a vehicle door of conventional construction has a steel support system, which is covered on the outside by a metal sheet.
  • an aggregate support system is made, which is usually made of metal or synthetic material separately, and in the support system are electrical or electronic elements such as windows, lock, speakers, etc. by screwing, gluing, riveting, clipping etc attached.
  • an inner lining of textile, leather or plastic is applied and fixed.
  • a plastic foam element is mounted, which serves the thermal and acoustic insulation and can be seen on its surface with an additional skin or even with a prefabricated laminate layer.
  • the invention has for its object to provide a method for producing a motor vehicle composite component of the type mentioned, with which a corresponding composite component can be produced in a simplified manner.
  • a corresponding motor vehicle composite component is to be created.
  • This object is achieved with regard to the method in a first alternative by a method having the features of claim 1.
  • first of all plastic particles are introduced into a mold cavity of a molding tool, where they are connected to one another while supplying heat energy to form a particle foam.
  • the mold is adjusted by changing the mold cavity and then injected a thermoplastic material forming at least one support element and / or at least one fastening element in the mold cavity, wherein the thermoplastic material is connected at least in a materially bonded manner with the particle foam.
  • the mold is again adjusted by changing the mold cavity and then a molten metal is injected into the mold cavity, whereby at least one electrical conductor and / or at least one metallic fastener are formed.
  • thermoplastic material is injected to form at least one support element and / or at least one fastener in a mold cavity of a mold. Thereafter, the mold is adjusted under the end of the mold cavity and then plastic particles are introduced into the mold cavity and there, with the supply of heat energy to a particle foam connected to each other, wherein the thermoplastic material is connected at least in a material-locking manner with the particle foam. Subsequently, the mold under changes of
  • thermoplastic resin is first injected into the mold cavity and then the plastic particles are introduced into the mold cavity and it becomes a Particle foam formed, which is connected to the thermoplastic material.
  • cohesive connection is a
  • stiffening elements are introduced into the mold cavity before the introduction of the plastic particles and then embedded in the particle foam.
  • the stiffening elements may be, for example, plastic fibers and / or natural fibers and / or at least one net of plastic or metal or at least one lattice of plastic or metal.
  • prefabricated fasteners are introduced before the introduction of the plastic particles in the mold cavity and then embedded in the particle foam.
  • prefabricated connecting elements are introduced into the mold cavity before the introduction of the thermoplastic material and then embedded in the thermoplastic material.
  • the connecting elements may be, for example, screws and / or threaded rods and / or clips.
  • the particle foam is formed with a closed-pored surface.
  • the vehicle composite component is produced in an integrated particle foam metal injection method, wherein a particle foam, a thermoplastic material, a molten metal and optionally
  • the method combines the previously separate and temporally spaced steps in a single operation. Separate fasteners made of different materials are no longer required and the connection functions are integrated into the composite component, whereby the subsequent assembly processes are shortened and simplified. In addition, assembly errors are avoided, resulting in significant cost savings.
  • the composite component has a low weight and at the same time a high absorption capacity against noise and against the action of external forces and additionally has a very good thermal insulation.
  • the particle foam not only fulfills a filling function, but also represents an elementary component of the composite component, which fulfills supporting and filling functions, serves for fastening, has a temperature and sound absorbing effect and also fulfills protective, covering, decoration and haptic functions.
  • the particle foam serves as an electrical insulator.
  • all electrical conductors and necessary metal fasteners are introduced by the metal injection process in the particle foam and / or the thermoplastic material, so that the subsequent retraction of power cables or the equipment of the Ver Bundbauteils with clips, screws, etc. is no longer necessary.
  • thermoplastic material By injecting the thermoplastic material can form functional elements, controls or frame structures.
  • the introduced stiffening elements serve to reinforce the composite component, wherein fibers or fiber composites can also be injected simultaneously with the thermoplastic material.
  • the automotive composite component for achieving the above object has a carrier made of plastic particle foam, which is materially connected to support elements and / or fasteners made of a thermoplastic material, and at least one electrical conductor track and / or at least one metallic fastener.
  • a motor vehicle composite component 10 has a carrier 11 made of a plastic particle foam, which is formed at least on its upper side with a closed-pored surface 16.
  • the carrier 11 is materially connected to support elements and / or fastening elements 12 made of a thermoplastic material. On the carrier 11, at least one conductor track 13 is formed, which cooperates with metallic fastening elements 14, 15.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Molding Of Porous Articles (AREA)

Abstract

In order to produce a motor vehicle composite component, plastics particles are introduced into a mould cavity of a mould and, by thermal energy being supplied, are connected to one another there to form a particle foam. Furthermore, the mould is adjusted by changing the mould cavity and then a thermoplastic is injected into the mould cavity forming a supporting element and/or at least one fastening element, wherein the thermoplastic is connected to the particle foam at least in an integrally bonded manner. The above-mentioned materials can also be introduced in the reverse sequence. The mould is subsequently adjusted once again by changing the mould cavity and then a molten metal is injected into the mould cavity, as a result of which at least one electric strip conductor and/or at least one metallic fastening element are/is formed.

Description

KFZ-Verbundbau-teil und Verfahren zu seiner Herstellung  Automotive composite component and method for its production
Die Erfindung betrifft ein Kfz-Verbundbauteil sowie ein Verfahren zu seiner Herstellung. Bei dem Kfz-Verbundteil handelt es sich insbesondere um ein im eingebauten Zustand sichtbares Kfz-Verbundbauteil mit einer integrierten elektrischen Konnektivität, beispielsweise um eine Autotür mit Integration von Funktionselementen wie Fensterheber, Türschloss, Lautsprecher, Lampen, Schalter für Spiegel, Schalter für ein Dach, Lüftungskanäle, Airbag etc., The invention relates to a motor vehicle composite component and a method for its production. The automotive composite part is in particular a visible in the installed state automotive composite component with an integrated electrical connectivity, for example, a car door with integration of functional elements such as windows, door lock, speakers, lamps, switches for mirrors, switches for a roof, Ventilation ducts, airbag etc.,
einen Stoßfänger mit Integration von Sensoren für eine a bumper with integration of sensors for one
Einparkhilfe, von Crash-Sensoren oder Sensoren für dieParking assistance, from crash sensors or sensors for the
Airbag-Auslösung, Airbag deployment,
- eine Schwellerleiste,  - a sill strip,
einen Spoiler mit Integration von Antennen, Sensorik oder Beleuchtung,  a spoiler with integration of antennas, sensors or lighting,
eine Mittelkonsole,  a center console,
eine Armauflage,  an armrest,
- eine Sonnenblende,  - a sun visor,
ein Armaturenbrett,  a dashboard,
einen Dachhimmel,  a headliner,
eine tragende vertikale Säule (A-Säule oder B-Säule) , oder  a supporting vertical column (A-pillar or B-pillar), or
BESTÄTIGUNGSKOPIE eine Kofferraumverkleidung oder eine Innenraumverklei- dung . CONFIRMATION COPY a trunk lining or interior lining.
Im Folgenden wird beispielshaft von einem Bauteil zum Aus- bau einer tragenden Struktur einer Fahrzeugtür ausgegangen. Eine Fahrzeugtür herkömmlichen Aufbaus besitzt ein stählernes Tragsystem, das außenseitig von einem Blech abgedeckt ist. Für den Innenausbau der Fahrzeugtür wird ein Aggregat- Trägersystem gefertigt, das meist aus Metall oder Kunst- Stoff separat hergestellt wird, und in dem Trägersystem werden elektrische oder elektronische Elemente wie Fensterheber, Schloss, Lautsprecher etc. durch Schrauben, Kleben, Nieten, Einclipsen etc. befestigt. In einem weiteren Arbeitsschritt wird eine Innenverkleidung aus Textil, Leder oder Kunststoff aufgebracht und befestigt. In vielen Fällen wird zusätzlich auf das Aggregat-Trägersystem ein Kunststoffschaum-Element montiert, das der Wärme- und Schalldämmung dient und an seiner Oberfläche mit einer zusätzlichen Haut oder auch mit einer vorgefertigten Laminatschicht ver- sehen sein kann. In the following example, it is assumed that a component for expanding a supporting structure of a vehicle door. A vehicle door of conventional construction has a steel support system, which is covered on the outside by a metal sheet. For the interior of the vehicle door, an aggregate support system is made, which is usually made of metal or synthetic material separately, and in the support system are electrical or electronic elements such as windows, lock, speakers, etc. by screwing, gluing, riveting, clipping etc attached. In a further step, an inner lining of textile, leather or plastic is applied and fixed. In many cases, in addition to the aggregate support system, a plastic foam element is mounted, which serves the thermal and acoustic insulation and can be seen on its surface with an additional skin or even with a prefabricated laminate layer.
Die Herstellung eines entsprechenden Kfz-Verbundbauteils benötigt eine Vielzahl unterschiedlicher Arbeitsschritte und ist damit sowohl sehr zeitaufwendig als auch kostenin- tensiv. The production of a corresponding automotive composite component requires a large number of different work steps and is thus both very time-consuming and cost-intensive.
Der Erfindung liegt die Aufgabe zugrunde, ein Verfahren zur Herstellung eines Kfz-Verbundbauteils der genannten Art zu schaffen, mit dem sich ein entsprechendes Verbundbauteil in vereinfachter Weise herstellen lässt. Darüber hinaus soll ein entsprechendes Kfz-Verbundbauteil geschaffen werden. Diese Aufgabe wird hinsichtlich des Verfahrens in einer ersten Alternative durch ein Verfahren mit den Merkmalen des Anspruchs 1 gelöst. Dabei werden zunächst Kunststoff- Partikel in einen Formhohlraum eines Formwerkzeugs einge- bracht und dort unter Zuführung von Wärmeenergie zu einem Partikelschaum miteinander verbunden. Daraufhin wird das Formwerkzeug unter Änderung des Formhohlraums verstellt und anschließend ein thermoplastischer Kunststoff unter Bildung zumindest eines Tragelementes und/oder zumindest eines Be- festigungselementes in den Formhohlraum eingespritzt, wobei der thermoplastische Kunststoff zumindest in Stoffschlüssiger Weise mit dem Partikelschaum verbunden wird. Anschließend wird das Formwerkzeug unter Änderung des Formhohlraums nochmals verstellt und es wird dann eine Metallschmelze in den Formhohlraum eingespritzt, wodurch zumindest eine elektrische Leiterbahn und/oder zumindest ein metallisches Befestigungselement gebildet werden. The invention has for its object to provide a method for producing a motor vehicle composite component of the type mentioned, with which a corresponding composite component can be produced in a simplified manner. In addition, a corresponding motor vehicle composite component is to be created. This object is achieved with regard to the method in a first alternative by a method having the features of claim 1. In the process, first of all plastic particles are introduced into a mold cavity of a molding tool, where they are connected to one another while supplying heat energy to form a particle foam. Thereafter, the mold is adjusted by changing the mold cavity and then injected a thermoplastic material forming at least one support element and / or at least one fastening element in the mold cavity, wherein the thermoplastic material is connected at least in a materially bonded manner with the particle foam. Subsequently, the mold is again adjusted by changing the mold cavity and then a molten metal is injected into the mold cavity, whereby at least one electrical conductor and / or at least one metallic fastener are formed.
In einer alternativen Ausgestaltung des Verfahrens gemäß Anspruch 2 ist vorgesehen, dass zunächst ein thermoplastischer Kunststoff unter Bildung zumindest eines Tragelementes und/oder zumindest eines Befestigungselementes in einen Formhohlraum eines Formwerkzeugs eingespritzt wird. Daraufhin wird das Formwerkzeug unter Endung des Formhohlraums verstellt und anschließend werden Kunststoff-Partikel in den Formhohlraum eingebracht und dort unter Zuführung von Wärmeenergie zu einem Partikelschaum miteinander verbunden, wobei der thermoplastische Kunststoff zumindest in stoffschlüssiger Weise mit dem Partikelschaum verbunden wird. Anschließend wird das Formwerkzeug unter Änderungen desIn an alternative embodiment of the method according to claim 2 is provided that initially a thermoplastic material is injected to form at least one support element and / or at least one fastener in a mold cavity of a mold. Thereafter, the mold is adjusted under the end of the mold cavity and then plastic particles are introduced into the mold cavity and there, with the supply of heat energy to a particle foam connected to each other, wherein the thermoplastic material is connected at least in a material-locking manner with the particle foam. Subsequently, the mold under changes of
Formhohlraums nochmals verstellt und anschließend eine Metallschmelze in den Formhohlraum eingespritzt, wodurch zu- mindest eine elektrische Leiterbahn und/oder zumindest ein metallisches Befestigungselement gebildet werden. Re-adjusted mold cavity and then injected a molten metal into the mold cavity, whereby at least one electrical conductor track and / or at least one metallic fastening element are formed.
Die beiden vorgenannten Verfahren unterscheiden sich auf diese Weise im Wesentlichen durch die Reihenfolge der Einbringung der Materialien. Während bei dem zuerst genannten Verfahren zunächst der Partikelschaum gebildet und auf diesen dann der thermoplastische Kunststoff aufgespritzt wird, wird bei dem zweiten Verfahren zunächst der thermoplasti- sehe Kunststoff in den Formhohlraum eingespritzt und anschließend werden die Kunststoff-Partikel in den Formhohlraum eingebracht und es wird ein Partikelschaum gebildet, der mit dem thermoplastischen Kunststoff verbunden wird. Unter dem Begriff "stoffschlüssige Verbindung" wird eineThe two aforementioned methods differ in this way essentially by the order of introduction of the materials. While in the first-mentioned method, first the particle foam is formed and then the thermoplastic material is sprayed onto it, in the second method the thermoplastic resin is first injected into the mold cavity and then the plastic particles are introduced into the mold cavity and it becomes a Particle foam formed, which is connected to the thermoplastic material. The term "cohesive connection" is a
Verbindung verstanden, bei der die zu verbindenden Bauteile durch atomare oder molekulare Kräfte zusammengehalten werden . Vorzugsweise kann vorgesehen sein, dass vorgefertige Versteifungselemente vor dem Einbringen der Kunststoff- Partikel in den Formhohlraum eingebracht und dann in den Partikelschaum eingebettet werden. Bei den Versteifungselementen kann es sich beispielsweise um Kunststofffasern und/oder Naturfasern und/oder zumindest ein Netz aus Kunststoff oder Metall oder zumindest ein Gitter aus Kunststoff oder Metall handeln. Compound understood in which the components to be connected by atomic or molecular forces are held together. Preferably, it can be provided that prefabricated stiffening elements are introduced into the mold cavity before the introduction of the plastic particles and then embedded in the particle foam. The stiffening elements may be, for example, plastic fibers and / or natural fibers and / or at least one net of plastic or metal or at least one lattice of plastic or metal.
In Weiterbildung der Erfindung kann vorgesehen sein, dass vorgefertigte Verbindungselemente vor dem Einbringen der Kunststoff-Partikel in den Formhohlraum eingebracht und dann in den Partikelschaum eingebettet werden. Alternativ oder zusätzlich dazu kann vorgesehen sein, dass vorgefertigte Verbindungselemente vor dem Einbringen des thermoplastischen Kunststoffs in den Formhohlraum eingebracht und dann in den thermoplastischen Kunststoff einge- bettet werden. In a further development of the invention can be provided that prefabricated fasteners are introduced before the introduction of the plastic particles in the mold cavity and then embedded in the particle foam. Alternatively or additionally, it can be provided that prefabricated connecting elements are introduced into the mold cavity before the introduction of the thermoplastic material and then embedded in the thermoplastic material.
Bei den Verbindungselementen kann es sich beispielsweise um Schrauben und/oder Gewindestangen und/oder Clips handeln. In besonders bevorzugter Ausgestaltung der Erfindung ist vorgesehen, dass der Partikelschaum mit einer geschlossenporigen Oberfläche ausgebildet wird. Durch entsprechende Wahl der Verfahrensparameter kann die Art und Oberflächenstruktur der geschlossenporigen Oberfläche eingestellt wer- den. Auf diese Weise lassen sich wahlweise glatte oder strukturierte oder weiche Oberflächen erzielen, die den ästhetischen Ansprüchen der Automobilhersteller genügen, so dass auf aufwendige Nachverarbeitungen verzichtet werden kann . The connecting elements may be, for example, screws and / or threaded rods and / or clips. In a particularly preferred embodiment of the invention, it is provided that the particle foam is formed with a closed-pored surface. By appropriate choice of the process parameters, the type and surface structure of the closed-pored surface can be adjusted. In this way, either smooth or textured or soft surfaces can be achieved that meet the aesthetic requirements of car manufacturers, so that can be dispensed with expensive post-processing.
Zusätzlich zu der Stoffschlüssigen Verbindung zwischen dem Partikelschaum und dem thermoplastischen Kunststoff kann zwischen diesen Materialien auch eine formschlüssige Verbindung beispielsweise durch Hinterschnitte oder Durchdrin- gungen gegeben sein. In addition to the cohesive connection between the particle foam and the thermoplastic material, there can also be a positive connection between these materials, for example by undercuts or penetrations.
Wie bereits erläutert wurde, wird das Kfz-Verbundbauteil in einem integrierten Partikelschaum-Metall-Spritzverfahren hergestellt, wobei ein Partikelschaum, ein thermoplasti- scher Kunststoff, eine Metallschmelze und gegebenenfallsAs already explained, the vehicle composite component is produced in an integrated particle foam metal injection method, wherein a particle foam, a thermoplastic material, a molten metal and optionally
Verstärkungsfasern, Faserverbünde und Befestigungselemente in ein einziges Formwerkzeug eingebracht und miteinander verbunden . werden, wobei gleichzeitig insbesondere der Par- tikelschäum eine gewünschte Oberflächengestaltung erhält. Ein nachträgliches Zusammenfügen, Montieren oder Verschweißen kann dadurch weitestgehend oder vollständig entfallen. Auf diese Weise ist ein kombiniertes Fertigbauteil mit in- tegrierter elektrischer und elektronischer Anschlussmöglichkeit herstellbar. Reinforcing fibers, fiber composites and fasteners introduced into a single mold and connected together. at the same time as the par- foamed plastic receives a desired surface design. Subsequent assembly, assembly or welding can be eliminated as far as possible or completely. In this way, a combined prefabricated component with integrated electrical and electronic connection possibility can be produced.
Das Verfahren verbindet die bisher separat und in zeitlichem Abstand auszuführenden Schritte in einem Arbeitsgang. Separate Befestigungselemente aus unterschiedlichen Materialien werden nicht mehr benötigt und die Verbindungsfunktionen sind in das Verbundbauteil integriert, wodurch die nachfolgenden Montageprozesse verkürzt und vereinfacht sind. Darüber hinaus sind Montagefehler vermieden, was zu deutlichen Kosteneinsparungen führt. Das Verbundbauteil hat ein niedriges Gewicht und gleichzeitig eine hohe Absorptionsfähigkeit gegen Geräusche und gegen die Einwirkung äußerer Kräfte und besitzt zusätzlich eine sehr gute Temperaturdämmung . The method combines the previously separate and temporally spaced steps in a single operation. Separate fasteners made of different materials are no longer required and the connection functions are integrated into the composite component, whereby the subsequent assembly processes are shortened and simplified. In addition, assembly errors are avoided, resulting in significant cost savings. The composite component has a low weight and at the same time a high absorption capacity against noise and against the action of external forces and additionally has a very good thermal insulation.
Der Partikelschaum erfüllt nicht nur eine Füllfunktion, sondern stellt einen elementaren Bestandteil des Verbundbauteils dar, der Trag- und Füllfunktionen erfüllt, der Befestigung dient, temperatur- und schallabsorbierend wirkt und zusätzlich auch Schutz-, Verkleidungs- , Dekorationsund Haptikfunktionen erfüllt. Darüber hinaus dient der Partikelschaum als elektrischer Isolator. The particle foam not only fulfills a filling function, but also represents an elementary component of the composite component, which fulfills supporting and filling functions, serves for fastening, has a temperature and sound absorbing effect and also fulfills protective, covering, decoration and haptic functions. In addition, the particle foam serves as an electrical insulator.
Vorzugsweise werden alle elektrische Leiterbahnen sowie notwendige metallische Befestigungselemente mit dem Metallspritzverfahren in den Partikelschaum und/oder den thermoplastischen Kunststoff eingebracht, so dass das nachträgliche Einziehen von Stromkabeln oder die Ausstattung des Ver- bundbauteils mit Clips, Schrauben etc. nicht mehr notwendig ist . Preferably, all electrical conductors and necessary metal fasteners are introduced by the metal injection process in the particle foam and / or the thermoplastic material, so that the subsequent retraction of power cables or the equipment of the Ver Bundbauteils with clips, screws, etc. is no longer necessary.
Durch das Einspritzen des thermoplastischen Kunststoffs lassen sich Funktionselemente, Bedienelemente oder Rahmenkonstruktionen ausbilden. Die eingebrachten Versteifungselemente dienen der Verstärkung des Verbundbauteils, wobei Fasern oder Fasernverbunde auch gleichzeitig mit dem thermoplastischen Kunststoff eingespritzt werden können. By injecting the thermoplastic material can form functional elements, controls or frame structures. The introduced stiffening elements serve to reinforce the composite component, wherein fibers or fiber composites can also be injected simultaneously with the thermoplastic material.
Das Kfz-Verbundbauteil zur Lösung der obenstehenden Aufgabe besitzt einen Träger aus Kunststoff-Partikelschaum, der Stoffschlüssig mit Tragelementen und/oder Befestigungselementen aus einem thermoplastischen Kunststoff verbunden ist, sowie zumindest eine elektrische Leiterbahn und/oder zumindest ein metallisches Befestigungselement. The automotive composite component for achieving the above object has a carrier made of plastic particle foam, which is materially connected to support elements and / or fasteners made of a thermoplastic material, and at least one electrical conductor track and / or at least one metallic fastener.
Weitere Merkmale des Kfz-Verbundbauteils ergeben sich aus der vorstehenden Beschreibung des Verfahrens. .· Other features of the automotive composite component will be apparent from the foregoing description of the method. . ·
In der einzigen Figur ist ein KFZ-Verbundbauteil in vereinfachter Weise dargestellt. In the single figure, a motor vehicle composite component is shown in a simplified manner.
Ein KFZ-Verbundbauteil 10 besitzt einen Träger 11 aus einem Kunststoff-Partikelschaum, der zumindest auf seiner Oberseite mit einer geschlossenporigen Oberfläche 16 ausgebildet ist. A motor vehicle composite component 10 has a carrier 11 made of a plastic particle foam, which is formed at least on its upper side with a closed-pored surface 16.
Der Träger 11 ist Stoffschlüssig mit Tragelementen und/oder Befestigungselementen 12 aus einem thermoplastischen Kunststoff verbunden. An dem Träger 11 ist zumindest eine Leiterbahn 13 ausgebildet, die mit metallischen Befestigungselementen 14, 15 zusammenwirkt . The carrier 11 is materially connected to support elements and / or fastening elements 12 made of a thermoplastic material. On the carrier 11, at least one conductor track 13 is formed, which cooperates with metallic fastening elements 14, 15.

Claims

Patentansprüche claims
Verfahren zur Herstellung eines Kfz-Verbundbauteils , wobei Kunststoff-Partikel in einen Formhohlraum eines Formwerkzeugs eingebracht und dort unter Zuführung von Wärmeenergie zu einem Partikelschaum miteinander verbunden werden, woraufhin das Formwerkzeug unter Änderung des Formhohlraums verstellt und anschließend ein thermoplastischer Kunststoff unter Bildung zumindest eines Tragelementes und/oder zumindest eines Befestigungselementes in den Formhohlraum eingespritzt wird, wobei der thermoplastische Kunststoff zumindest in Stoffschlüssiger Weise mit dem Partikelschaum verbunden wird, woraufhin das Formwerkzeug unter Änderung des Formhohlraums verstellt und anschließend eine Metallschmelze in den Formhohlraum eingespritzt wird, wodurch zumindest eine elektrische Leiterbahn und/oder zumindest ein metallisches Befestigungselement gebildet werden . A method for producing a motor vehicle composite component, wherein plastic particles are introduced into a mold cavity of a mold and joined together with the supply of heat energy to a particle foam, whereupon the mold adjusted by changing the mold cavity and then a thermoplastic material to form at least one support element and / or at least one fastener is injected into the mold cavity, wherein the thermoplastic material is connected at least in a material-locking manner with the particle foam, after which the mold is adjusted changing the mold cavity and then a molten metal is injected into the mold cavity, whereby at least one electrical conductor and / or or at least one metallic fastener is formed.
Verfahren zur Herstellung eines Kfz-Verbundbauteils , wobei ein thermoplastischer Kunststoff unter Bildung zumindest eines Tragelementes und/oder zumindest eines Befestigungselementes in einen Formhohlraum eines Formwerkzeugs eingespritzt wird, woraufhin das Formwerkzeug unter Änderung des Formhohlraums verstellt wird und anschließend Kunststoff-Partikel in den Formhohlraum ein- gebracht und dort unter Zuführung von Wärmeenergie zu einem Partikelschaum miteinander verbunden werden, wobei der thermoplastische Kunststoff zumindest in stoffschlüssiger Weise mit dem Partikelschaum verbunden wird, woraufhin das Formwerkzeug unter Änderung des Formhohlraums verstellt und anschließend eine Metallschmelze in den Formhohlraum eingespritzt wird, wodurch zumindest eine elektrische Leiterbahn und/oder zumindest ein metallisches Befestigungselement gebildet werden . Method for producing a motor vehicle composite component, wherein a thermoplastic material is injected into a mold cavity of a mold to form at least one support element and / or at least one fastener, after which the mold is adjusted while changing the mold cavity and then plastic particles are introduced into the mold cavity brought there and with the supply of heat energy to a particle foam are joined together, wherein the thermoplastic material is at least in a materially connected to the particle foam, whereupon the mold adjusted by changing the mold cavity and then a molten metal is injected into the mold cavity, whereby at least one electrical Conductor and / or formed at least one metallic fastener.
3. Verfahren zur Herstellung eines Kfz-Verbundbauteils 3. A method for producing a motor vehicle composite component
nach einem der Ansprüche 1 oder 2, dadurch gekennzeichnet, dass vorgefertigte Versteifungselemente vor dem Einbringen der Kunststoff-Partikel in den Formhohlraum eingebracht und dann in den Partikelschaum eingebettet werden.  according to one of claims 1 or 2, characterized in that prefabricated stiffening elements are introduced before the introduction of the plastic particles in the mold cavity and then embedded in the particle foam.
4. Verfahren zur Herstellung eines Kfz-Verbundbauteils 4. A method for producing a motor vehicle composite component
nach Anspruch 3, dadurch gekennzeichnet, dass die Versteifungselemente von KunstStofffasern und/oder von Naturfasern und/oder von zumindest einem Netz oder zumindest einem Gitter aus Kunststoff oder Metall gebildet sind.  according to claim 3, characterized in that the stiffening elements of Kunststofffasern and / or natural fibers and / or of at least one network or at least a grid made of plastic or metal are formed.
5. Verfahren zur Herstellung eines Kfz-Verbundbauteils ' nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass vorgefertigte Verbindungselemente vor dem Einbringen der Kunststoff-Partikel in den Formhohlraum eingebracht und dann in den Partikelschaum eingebettet werden. 5. A process for producing an automotive composite component 'according to one of claims 1 to 4, characterized in that prefabricated connecting elements inserted prior to introducing the plastics particles into the mold cavity and then be embedded in the particle foam.
6. Verfahren zur Herstellung eines Kfz-Verbundbauteils nach einem der Ansprüche 1 bis 5, dadurch gekennzeich net, dass vorgefertigte Verbindungselemente vor dem Einbringen des thermoplastischen Kunststoffs in den Formhohlraum eingebracht und dann in den thermoplasti sehen Kunststoff eingebettet werden. 6. A method for producing a motor vehicle composite component according to one of claims 1 to 5, characterized in that prefabricated connecting elements are introduced prior to introduction of the thermoplastic material into the mold cavity and then seen in the thermoplastic see plastic.
7. Verfahren zur Herstellung eines Kfz-Verbundbauteils nach Anspruch 5 oder 6, dadurch gekennzeichnet, dass die Verbindungselemente von Schrauben und/oder Gewindestangen und/oder Clips gebildet sind. 7. A method for producing a composite automotive component according to claim 5 or 6, characterized in that the connecting elements of screws and / or threaded rods and / or clips are formed.
8. Verfahren zur Herstellung eines Kfz-Verbundbauteils nach Anspruch 7, dadurch gekennzeichnet, dass der Par tikelschaum mit einer geschlossenporigen Oberfläche ausgebildet wird. 8. A method for producing a motor vehicle composite component according to claim 7, characterized in that the Par tikelschaum is formed with a closed-pore surface.
9. Verfahren nach einem der Ansprüche 1 bis 8, dadurch g kennzeichnet, dass der thermoplastische Kunststoff zu sätzlich in formschlüssiger Weise mit dem Partikelschaum verbunden wird. 9. The method according to any one of claims 1 to 8, characterized g indicates that the thermoplastic material is additionally connected in a positive manner with the particle foam.
10. Kfz-Verbundbauteil (10), mit einem Träger (11) aus ei nem Kunststoff-Partikelschaum, der stoffschlüssig mit Tragelementen und/oder Befestigungselementen (12) aus einem thermoplastischen Kunststoff verbunden ist, und mit zumindest einer elektrischen Leiterbahn (13) und/oder zumindest einem metallischen Befestigungsele ment (14, 15) . 10. automotive composite component (10), with a carrier (11) from egg nem plastic particle foam, which is materially connected to support elements and / or fastening elements (12) made of a thermoplastic material, and with at least one electrical conductor track (13) and / or at least one metallic Befestigungsele element (14, 15).
11. Kfz-Verbundbauteil nach Anspruch 10, dadurch gekennzeichnet, dass der Partikelschaum mit einer geschlossenporigen Oberfläche (16) ausgebildet ist. 11. Motor vehicle composite component according to claim 10, characterized in that the particle foam is formed with a closed-pored surface (16).
EP17742154.2A 2016-06-30 2017-06-27 Motor vehicle composite component and method for the production thereof Withdrawn EP3478470A1 (en)

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DE102016007913.4A DE102016007913B4 (en) 2016-06-30 2016-06-30 Automobile composite component and method for its production
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