Hollow profile compounding technology

Abstract

The invention relates to a method for producing a composite part having at least one functional element from at least one cylindrical hollow profile and from at least one plastic which can be introduced into the hollow profile by means of a specific injection molding method. The method for producing a composite part is carried out by: a) providing an injection mould, the invention relates to an injection mold having at least one openable cavity and a mold dimension (A) in the closing direction and a mold dimension (B) at right angles to the closing direction of the mold and a cavity circumference (UW) corresponding to the circumference of the cavity in the region of the mold dimensions (A) and (B), and having at least one auxiliary cavity, b) providing at least one hollow profile in the form of a hollow cylinder having i) a circumferential hollow profile dimension (UH), a wall thickness (S), an outer diameter (C) and a longitudinal axis (L), ii) at least one bend having an angle (W), and iii) at least one perforation (2, 3) along the longitudinal axis (L) thereof and in the region of the hollow profile without bending, iv) has a ratio of the outer diameter (C) to the wall thickness (S) in the range of from 5: 1 to 300: 1, the outer diameter (C) in the region of the mould contact surface (K) being greater than the mould dimension (A) by 0.1% to 5% and less than the mould dimension (B) by 0.1% to 5%, and v) the specification of the outer diameter (C) being based on 90 DEG in the direction of the longitudinal axis (L) of the hollow profile, and vi) the circumferential hollow profile dimension UH = C * TT corresponds to the circumferential cavity dimension (UW) of the at least one injection mold cavity in the closed state, and vii) the sealing surface of the mold with the hollow profile in the closed state is referred to as a mold contact surface, c) placing the at least one hollow profile in the at least one cavity of the injection mold, d) closing at least one cavity of the injection mold and compressing the hollow profile at the mold contact surface thereof in the closing direction of the at least one cavity, e) injecting plastic into the interior of the hollow profile and simultaneously filling the at least one auxiliary cavity via the at least one perforation 2 in the hollow profile, f) extruding excess plastic through at least one of the two lateral openings in the hollow profile by injecting a gas or a fluid or a combination of both, g) cooling the molten plastic introduced into the hollow profile and the auxiliary cavity in e), and h) removing the finished composite part from the injection mold, and removing any runners that may be present, with the proviso that the specifications of the mold size (A), the mold size (B) and the circumferential cavity size (UW) in method step a) are based on the area of the injection mold in which the unbent area of the hollow profile is located and the hollow profile is metal-based or composite material-based.

Description

technical field [0001] The invention relates to a process for producing a composite part with at least one functional element consisting of at least one cylindrical hollow profile and at least one to be introduced into the hollow profile by means of a specific injection moulding method composed of plastics. Background technique [0002] Even now, there are many instances in which composite components are used in motor vehicle construction. Composite parts are usually produced from metal closed hollow profiles joined to at least one separately produced plastic element. The production of two separate parts and finally the joining of these at least two parts leads to an increased level of manufacturing and assembly complexity. Furthermore, in order to join the hollow profile to the plastic element(s), additional joining means in the form of screws, nuts, rivets etc. are required, which in turn usually requires more construction space and results in a higher weight of the comp...

AI Technical Summary

Problems solved by technology

Additionally, a disadvantage of the process of EP 3369544 A1 is the upstream step for producing suitable support elements which have to be individually matched and prefabricated with respect to the hollow profile to be used in each case

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