Structural member having multiple organic panels and method of manufacturing same

Abstract

In particular, a structural component is proposed, comprising at least two organic panel parts (10A to 10E), which are at least section-wise arranged on top of one another and each have a fiber layer (100), wherein at least one pair of mutually aligned holes (101) is configured in the fiber layers (100) of the organic panel parts (10A to 10E), the organic panel parts (10A to 10E) being connected to one another in a form-locking manner at the at least one pair of mutually aligned holes. Furthermore, a method for producing a structural component is given.

Description

Technical Field

[0001] The present invention relates to a structural component according to claim 1 and a method for manufacturing a structural component according to claim 9. Background Technology

[0002] Structural components, particularly in the automotive field, can serve, for example, supporting and / or structuring functions. Possible applications are diverse; for example, seat frames, doors, and body components.

[0003] Structural components are known to be manufactured from organic panels, as described in DE 10 2013 213 711 A1. Here, the organic panel is thermally modified to manufacture the structural component.

[0004] Sheet-like materials (semi-finished products) made of fiber-reinforced, especially continuous fiber-reinforced, thermoplastics are called organic sheets. The (continuous) fibers can be embedded in the thermoplastic matrix in the form of non-bending fabrics, woven fabrics, or knitted fabrics, for example, made of glass fibers, aramid fibers, carbon fibers, or plastic fibers. Therefore, organic sheets are thermoformable (thermally modifiable) composite materials. For example, polyolefins (especially polypropylene), as well as plexiglass, polycarbonate, polystyrene, and / or polyamides are suitable as matrix materials. When organic sheets are injection molded from plastic materials, the thermoplastic matrix can melt, thereby creating a material-locked bond with the injection-molded plastic material. Therefore, organic sheets are extremely versatile materials, used to manufacture lightweight and highly stable structural components.

[0005] The applicant knows from practice that structural members are manufactured from multiple organic panels. To reliably secure the individual organic panels to each other in the finished structural member, they are typically placed with a relatively large overlap and hot-pressed. A large overlap area is necessary to ensure the panels remain reliably stacked. However, such a large overlap area is generally unnecessary for the stability of the structural member. Due to the complexity of manufacturing organic panels, their effective use in structural members is crucial. Furthermore, it has been shown that the hot pressing of organic panels must be carried out within a relatively small optimal temperature window. Therefore, precise temperature monitoring makes the manufacturing process relatively complex. Summary of the Invention

[0006] The objective of this invention is to provide a structural component that can utilize organic panels most effectively.

[0007] This task is solved by the structural components according to claim 1.

[0008] Such structural members, particularly those for motor vehicles, comprise two or more organic panels that are stacked vertically, at least in sections, and especially flush with each other. Each organic panel has a fiber layer. At least one or more pairs of aligned holes are formed in the fiber layers of the organic panels, at which the organic panels are fastened to each other, specifically by form-locking connections, particularly by form-locking the organic panels to each other. One hole in a pair of aligned holes is formed in one organic panel, while the other hole in the pair is formed in the other organic panel.

[0009] In this way, two or more organic panels (also called organisms) can be fastened to each other in a particularly reliable manner and with a particularly small overlap. This is because fastening the organic panels to their aligning (e.g., arranged to fit together) holes in a shape-locking manner enables a particularly reliable fastening of the organic panels to each other. This allows for a particularly efficient use of the material in the organic panels. The fastening of the organic panels to each other is particularly done in a non-releasable connection manner. For example, one organic panel is fitted from the rear into a section where a hole is formed in it.

[0010] Each organic panel can be constructed, for example, as an organic panel blank, such as by cutting or stamping from a larger organic sheet. When manufacturing the organic panel blanks, it is desirable to generate minimal waste to achieve the most efficient use of the organic panels. The proposed structural members can even incorporate smaller organic panels that were previously discarded as waste.

[0011] Furthermore, the proposed structural members enable the construction of areas of the structural members that withstand greater stress, for example, using organic panels capable of bearing greater loads (e.g., thicker and / or with thicker fiber layers), especially even if these areas are relatively small. This also makes the use of organic panels particularly effective.

[0012] Organic panels can be continuously fiber-reinforced organic panels. The term "continuously fiber-reinforced" should be understood as meaning that the length of the reinforcing fibers is primarily within the dimensional limits of the sheet-like organic panel (at least prior to the modification process). Therefore, it can be specified that the fibers are substantially uninterrupted within the edges of the continuously fiber-reinforced organic panel.

[0013] In particular, form-locking connections can be formed between the fiber layers of organic panels. For example, an organic panel extends with its fiber layers, and is inserted into a hole in another organic panel, for instance, with the edge of one hole, to establish a form-locking connection. The fiber layers in the aligned hole areas can also be at least partially pushed into each other or mixed together to create form-locking between the individual fibers. The form-locking between fiber layers enables particularly reliable connections between organic panels.

[0014] Alternatively or additionally, the filler may extend through at least one pair of aligned holes. The filler may be material-locked to the thermoplastic matrix of one or two organic panels (and thus establish a material-locked connection between the organic panels). The filler achieves a particularly reliable connection between the organic panels. The filler may be made, for example, of an injection molding material, particularly a fiber-reinforced (e.g., long glass fiber reinforced) injection molding material. In other words, the organic panels can be stitched together with the aid of the injection molding material.

[0015] The filler comprises, for example, the same material as or composed of the matrix of at least one of the organic panels. In particular, it may comprise the same material as the matrix and may be additionally reinforced with fibers. This allows for a particularly reliable material-locking (and, if necessary, fiber-reinforced) connection of the organic panels.

[0016] The filler extends through one or more pairs of aligned holes. On the overlapping sides of the organic sheet, the filler can be integrally (particularly made of the same material) with the retainer. The retainer has a diameter larger than the aligned holes. In this way, a particularly reliable form-locking connection of the organic sheet can be achieved.

[0017] In one embodiment, a plurality of pairs of aligned holes are provided, each formed at least in the fiber layer of the organic panel. For example, more than five, ten, or twenty pairs of aligned holes are provided. This allows the organic panels to be secured to each other particularly reliably, even in very small overlapping areas. Furthermore, the individual holes can then be constructed with small diameters.

[0018] Reinforcing ribs can be constructed between at least two pairs of aligned holes, each hole being introduced into at least one fiber layer of an organic panel. Specifically, the reinforcing ribs extend along at least one of the organic panels from one pair to the other. The reinforcing ribs can be integrally constructed with the filler of the at least two pairs of aligned holes. This allows the filler to be secured in place. Furthermore, these holes provide particularly reliable (e.g., material consistency) fastening points for the reinforcing ribs.

[0019] At least one reinforcing rib can be constructed on each side of the overlapping organic plate between at least two pairs of aligned holes. This achieves particularly stable reinforcement of the structural members. The reinforcing ribs can be integrally (particularly with consistent material) connected to each other, for example, by the filling material of the pairs of aligned holes.

[0020] The above-mentioned task is also solved by the method having the features of claim 9.

[0021] Then, a method for manufacturing structural components is proposed, which includes the following steps:

[0022] - Provide two or more organic panels, particularly in the form of organic panel blanks (the provision may include cutting the organic panels to form one or more of the organic panels);

[0023] - The organic panels are arranged such that they are stacked vertically or at least horizontally on top of each other in sections; and

[0024] - Introduce at least one through hole extending through the two organic panels, in particular piercing the organic panels (which are stacked on top of each other), and construct a shape-locking connection of the organic panels at the through hole (in particular by the shape-locking of the organic panels with each other).

[0025] The form-locking connection of organic panels can be achieved by introducing through holes, for example by piercing to interlock the material sections of two organic panels.

[0026] The particularly secure, non-removable fasteners at the through-holes of the acrylic panels enable a highly reliable connection between them, allowing for arrangement with minimal overlap. This facilitates the efficient use of the acrylic material.

[0027] The steps of arranging organic panels, introducing through holes, and fastening the organic panels together can be performed in the same mold, especially in injection molds.

[0028] The acrylic sheet can be shaped before or after the through-hole is introduced. Alternatively, the acrylic sheet can be heated before being introduced into the injection mold or while it is in the injection mold, and shaped when the injection mold is closed. As an alternative or supplement to the shaping, the acrylic sheets can also be pressed together, which enables additional ground-like adhesion between them.

[0029] At least one through-hole extending through two organic sheets can be introduced while the organic sheets are heated. The matrix of each organic sheet can be plastically deformed by heating the organic sheets.

[0030] Alternatively, through-holes are introduced into the organic sheets (stacked one on top of the other) using at least one punch, for example, in the form of a needle. The punch may be attached to an injection mold. By punching into the preheated organic sheet, holes can be introduced without cutting the fibers. For example, the fibers of the fiber layers of the organic sheet can be pushed apart. In this case, the fiber layers can interlock and / or form-locked from the rear. Thus, the organic sheets can be sewn together using a punch or a needle.

[0031] Optionally, injection molding material is injected into the organic sheet (in an injection mold), wherein at least one through-hole extending through the organic sheet is filled with filler formed of injection molding material and / or injection molded with reinforcing ribs or other functional elements. The reinforcing ribs and filler may be injection molded into the organic sheet as continuous injection molding segments.

[0032] Preferably, at least two, and in particular more, through-holes extending through the organic panel are introduced into the organic panel, which enables a particularly reliable fastening.

[0033] Therefore, at least one reinforcing rib can be injection molded onto the organic sheet, thereby connecting at least two through holes (and in particular, the filler introduced therein) to each other.

[0034] This method can be particularly used to construct structural members for manufacturing any construction scheme described herein. For the respective advantages of each embodiment, refer to the corresponding description in the context. Attached Figure Description

[0035] The concept upon which this invention is based will now be further explained with reference to exemplary embodiments shown in the accompanying drawings. Wherein:

[0036] Figures 1A to 1C A schematic cross-sectional view of two organic panels is shown, which are connected to each other by punching holes.

[0037] Figures 2A to 2D A schematic top view showing two organic panels at different stages of manufacturing the structural components;

[0038] Figure 3 A perspective view of three organic panels used to manufacture the structural components of the car door is shown;

[0039] Figure 4A and Figure 4B Showing according to Figure 3 Top view of the two sides of the three organic panels arranged one on top of the other;

[0040] Figure 5A and 5B Shown according to Figure 4A and4B Top views of both sides of the structural components manufactured according to the arrangement;

[0041] Figure 5C and 5D Showing according to Figure 5A and 5B A three-dimensional view of both sides of the structural components; and

[0042] Figure 6A and 6B Showing according to Figure 6A and 6B Top view of both sides of the inner door panel of the structural components. Detailed Implementation

[0043] Figure 1A Two organic panels, 10A and 10B, are shown, which are in Figure 1A The areas shown are stacked one on top of the other and are currently abutting each other surface-to-surface. Organic panels 10A and 10B each include a fiber layer 100 in the form of a non-crimping or woven fabric, in the form of a fiber pad. The fiber layers 100 are respectively embedded in a matrix 102 made of thermoplastic plastic. Organic panels 10A and 10B are particularly made of thermoplastic glass fiber woven fabric or non-crimping fabric.

[0044] Figure 1A A punch 2 is also shown, having a tip 20 adjacent to the organic sheets 10A and 10B. For example, the organic sheets 10A and 10B are clamped in a mold (e.g., an injection mold). The punch 2 can be supported on the injection mold, for example, in a movably supported manner. The punch 2 has a diameter of, for example, 3 mm to 4 mm.

[0045] Figure 1B The diagram illustrates the following after the punch 2 moves perpendicularly to the surfaces of the organic plates 10A and 10B, thus causing the hole 101 (with the diameter of the punch 2) to pierce into the organic plates 10A and 10B. Figure 1A Organic panels 10A and 10B. Organic panels 10A and 10B are therefore punctured or punched by means of a punch (especially commonly).

[0046] Holes 101 of the two organic panels 10A and 10B are aligned coaxially with each other. Holes 101 overlap each other, that is, they are arranged aligned with each other. The holes together form a through hole DL passing through the two organic panels 10A and 10B.

[0047] The piercing of organic panels 10A and 10B can be performed after heating the organic panels 10A and 10B. In the region of hole 101, the fibers of the fiber layer 100 of organic panels 10A and 10B are pushed laterally by the tip 20 of punch 2. Through the punching of hole 101, organic panels 10A and 10B are interlocked in the region of hole 101. A shape lock exists between the (punctured) organic panels 10A and 10B, by which organic panels 10A and 10B are fastened to each other.

[0048] Organic panels 10A and 10B, fastened together, form structural member 1. Structural member 1 is, for example, a decorative part or body part of an automobile.

[0049] After punch 2 punctures the organic sheets 10A and 10B, punch 2 is pulled out again from the through hole DL. Then, filler is introduced into the through hole DL, for example, by injection molding.

[0050] Through-hole DL is used as a flow channel for injection molding materials.

[0051] Figure 1C The diagram shows organic panels 10A and 10B after filler 11 has been introduced into the through-holes DL (i.e., the two holes 101 of organic panels 10A and 10B). The filler 11 secures organic panels 10A and 10B in a form-locked position in the region of the holes 101.

[0052] Furthermore, not only is the interior of the through-hole DL filled with filler 11, but the material of filler 11 is also extended to both sides of the vertically placed organic panels 10A and 10B, in addition to the edges of the hole 101. Therefore, retainers 13 are constructed on both sides of the organic panels 10A and 10B, which provide a particularly reliable form-locking connection for the organic panels 10A and 10B at the through-hole DL.

[0053] Figure 1C Also schematically shown is an (open) injection mold 4, which is used for injection molding of injection molding materials and optionally for modifying organic sheet parts 10A, 10B, with punches 2 movably supported on the injection mold.

[0054] refer to Figures 2A to 2D The method for manufacturing structural components 1' that are repeatedly punctured will now be further described.

[0055] In the first step, two organic boards 10A and 10B (also referred to as the organism) are provided, see [link / reference]. Figure 2AThis may include, for example, cut pieces (e.g., punched pieces) from larger organic sheets. Both organic sheets 10A and 10B are flat and planar, but non-planar organic sheets can also be joined in the manner described herein. Punching, shaping, and injection molding are preferably performed in the same mold.

[0056] In another step, organic panels 10A and 10B are arranged in such a way that they are stacked one on top of the other in sections, see [reference needed]. Figure 2B In this case, organic panels 10A and 10B overlap each other vertically in the overlapping area UB, particularly in a surface-to-surface manner. The segmental overlapping arrangement of organic panels 10A and 10B can be achieved, in particular, by placing organic panels 10A and 10B in a mold (e.g., an injection mold).

[0057] In another step, several through holes DL are introduced through the two organic plate components 10A and 10B, see Figure 2C The introduction of each via DL can be combined as for a single via DL. Figure 1A and 1B Proceed as detailed in the instructions.

[0058] Here, on the one hand, multiple or all through holes DL can be introduced (one after another) using the same punch 2. On the other hand, a separate punch 2 can be provided for each through hole DL to be punctured, so that all through holes DL can be punctured at the same time.

[0059] According to Figure 2C In the example, a mesh, or more precisely a matrix, of multi-row and multi-column through-holes (DL) is introduced into organic panels 10A and 10B.

[0060] By punching or piercing the organic panels 10A and 10B, these organic panels are fastened together to form structural member 1'.

[0061] In the next step, ribs, namely reinforcing ribs 11, are injected through the needle-punched through-holes DL. Specifically, this is achieved by injection molding using an injection mold. See [link to relevant documentation]. Figure 2D .

[0062] As an injection molding material, for example, long fiber reinforced materials are used, especially long glass fiber reinforced injection molding materials.

[0063] according to Figure 2D Reinforcing rib 11 serves as a retainer (similar to that according to...) Figure 1C (The retainer 13). In addition, the reinforcing rib 11 strengthens the structural member 1', for example, to resist torsion.

[0064] According to Figure 2DIn the example, each through-hole DL is connected to at least two adjacent through-hole DLs by means of reinforcing ribs 11. In the current case, a set of mutually parallel reinforcing ribs 11 extends over the plurality of through-hole DLs. Another set of mutually parallel reinforcing ribs 11 extends perpendicular to the aforementioned set of reinforcing ribs 11.

[0065] By injecting through the through-hole DL, the injection-molded reinforcing rib 11 has particularly good stability.

[0066] Reinforcing ribs 11 can be optionally constructed (injection molded) on both sides of the interconnected organic plates 10A and 10B, which can further improve the stability of the structural member 1'.

[0067] Injection molding of organic sheets 10A and 10B through needle-punched through-holes DL can also be called "injection stitching" because it has an effect similar to sewing, for example, using thread. The injection material injected through the through-holes DL extends uniformly through the through-holes DL and through the reinforcing ribs 11. This achieves a particularly reliable connection between the two organic sheets 10A and 10B.

[0068] Because the organic panels 10A and 10B are securely fastened to each other with exceptional reliability, the overlapping area UB can be constructed to a relatively small size. This saves a significant amount of organic panels. Furthermore, the stability of structural member 1' can be improved and adjusted based on requirements with minimal weight.

[0069] Optionally, the organic panels 10A and 10B (e.g., simultaneously with injection stitching) are hot-pressed (especially in the molten state) to achieve further improved fastening between the organic panels 10A and 10B.

[0070] exist Figures 1A to 2D The diagram shows the connection of two organic panels 10A and 10B. However, it is also possible to connect two or more organic panels 10A and 10B to each other in the same manner. Furthermore, through-holes can be drilled through organic panels that are stacked one on top of the other, such as through three or more stacked organic panels.

[0071] Figure 3 Another embodiment of multiple organic panels is shown, in this case three organic panels 10C to 10E.

[0072] Organic board parts 10C~10E have been based on Figure 3 Pre-forming was carried out, that is, by modification (especially thermoforming) from flat organic sheets.

[0073] Organic panels 10C to 10E are configured to jointly construct structural member 1" in the form of a component for a vehicle door inner panel. Organic panels 10C to 10E have different characteristics from each other. Here, each organic panel 10C to 10E meets the requirements of structural member 1" in the area constructed by its respective organic panel 10C to 10E.

[0074] The first organic panel 10C forms a planar segment in the completed structural member 1”, for example, part of a component support, and is made of a (thin) organic panel, which in this case has a thickness of 0.6 mm. The second organic panel 10D forms part of a horizontal support for the inner door panel in the completed structural member 1”. The second organic panel 10D is made of a medium-thickness organic panel, which in this case has a thickness of 1.0 mm. The third organic metal panel 10E forms part of a longitudinal beam for the inner door panel in the completed structural member 1”. The longitudinal beam must bear a particularly heavy load. Therefore, the first organic panel 10C is made of a thick organic panel, which in this example has a thickness of 1.5 mm.

[0075] Figure 4A and Figure 4B The diagram shows organic panels 10C to 10E arranged one on top of the other. The first organic panel 10C and the (smaller) second organic panel 10D overlap the entire surface of the second organic panel 10D. Therefore, the second organic panel 10D reinforces the first organic panel 10C. The first organic panel 10C and the (smaller) third organic panel 10E partially overlap. The second organic panel 10D and the third organic panel 10E do not overlap.

[0076] Figures 5A to 5D The completed structural member 1” is shown. The three organic panels 10C to 10E are fastened to each other by injection stitching. Several through holes DL connect the first and second organic panels 10C, 10D and the first and third organic panels 10C, 10E.

[0077] A mesh of reinforcing ribs 11 is constructed on both sides of structural member 1".

[0078] The edges of the organic panels 10C to 10E are encapsulated with injection-molded material. This protects the fiber layers of the organic panels 10C to 10E. Optional eyelets or other connecting elements are injection-molded on the structural member 1". All injection-molded sections can be constructed without undercut, thus simplifying manufacturing.

[0079] Furthermore, in the current example, a surface-coated injection area 14 is constructed on the externally visible portion of structural member 1, in this case, on the longitudinal beam. Another surface-coated injection area is constructed in the form of at least a portion of the guide rail of a window adjuster. In particular, the externally visible surface can be provided with a surface structure, such as granulation, through appropriate injection molding.

[0080] Figure 6A and 6B The inner door panel 3 for the vehicle door is shown, wherein, according to Figures 5A-5D Structural component 1 forms the component of the inner door panel 3. The structural component provides structural functions (and also provides support functions in the example shown).

[0081] exist Figure 6A and 6B In the example shown, structural member 1 is connected, for example, by screwing, to a metal plate that forms the rest of the door inner panel 3. Alternatively, the remaining components of the door inner panel 3 may be manufactured in the form of the structural member described herein.

[0082] according to Figures 5A-5D The construction of structural member 1 shown is merely exemplary. For example, the structural member could be constructed as an entire inner door panel. To do this, several organic panels could be interconnected by injection stitching.

[0083] List of reference numerals

[0084] 1, 1', 1" Structural components

[0085] 10A~10E Organic Panels

[0086] 100 fiber layers

[0087] 101 holes

[0088] 102 Matrix

[0089] 11. Filler

[0090] 12 Reinforcing Ribs

[0091] 13 Retaining components

[0092] 14-sided coverage injection area

[0093] 2 punches

[0094] 3. Inner door panel

[0095] 4 Injection molds

[0096] 20 cutting-edge

[0097] DL through hole

[0098] UB overlapping region

Claims

1. A structural member (1, 1', 1"), said structural member comprising at least two organic panels (10A~10E), said organic panels being stacked vertically on top of each other at least in sections and said organic panels each having a fiber layer (100), wherein, At least one pair of aligned holes (101) are formed in the fiber layer (100) of the organic panels (10A~10E), and the organic panels (10A~10E) are connected to each other in a form-locking manner at the at least one pair of aligned holes. A shape-locking connection is constructed between the fiber layers (100) of the organic panels (10A~10E).

2. The structural components (1, 1', 1") according to claim 1, characterized in that, A filler (11) extends through the at least one pair of holes (101) aligned with each other.

3. The structural components (1, 1', 1") according to claim 2, characterized in that, The filler (11) comprises the same material as the matrix (102) of at least one of the organic panels (10A~10E) or is composed of the same material as the matrix of at least one of the organic panels.

4. The structural components (1, 1', 1") according to claim 2, characterized in that, The filler (11) extends through a pair of aligned holes (101) and is integrally connected to retainers (13) on both sides of the overlapping organic plates (10A~10E), the retainers having a larger diameter than the aligned holes (101).

5. The structural components (1, 1', 1") according to claim 1, characterized in that, The organic plate (10A~10E) is provided with a plurality of holes (101) aligned with each other and each hole is formed at least in the fiber layer (100).

6. The structural components (1, 1', 1") according to claim 1, characterized in that, Reinforcing ribs (12) are constructed between at least two pairs of aligned holes (101).

7. The structural components (1, 1', 1") according to claim 1, characterized in that, At least one reinforcing rib (12) is constructed on each side of an organic plate (10A~10E) that is stacked on top of each other between at least two pairs of aligned holes (101).

8. A method for manufacturing structural members (1, 1', 1"), the method comprising the following steps: - Provide at least two organic boards (10A~10E); - The organic panels (10A~10E) are arranged such that the organic panels are at least segmentally stacked on top of each other; and - At least one through-hole (DL) extending through the at least two organic panels (10A~10E) is introduced into the organic panels (10A~10E) to form a shape-locking connection of the organic panels (10A~10E) at the through-hole (DL). The organic panels (10A~10E) each have a fiber layer (100), and the through-holes (DL) are formed at least in the fiber layer (100). A shape-locking connection is constructed between the fiber layers (100) of the organic panels (10A~10E).

9. The method according to claim 8, characterized in that, At least one through hole (DL) extending through both organic panels (10A~10E) is introduced while the organic panels (10A~10E) are in a heated state.

10. The method according to claim 8, characterized in that, Using a punch (2), at least one extension is pierced into the organic plates (10A~10E) through the through holes (DL) of the two organic plates (10A~10E).

11. The method according to claim 8, characterized in that, Injection molding material is injected into the organic sheet (10A~10E), wherein at least one through hole (DL) extending through the organic sheet (10A~10E) is filled with a filler (11) formed of injection molding material.

12. The method according to claim 8, characterized in that, At least two through holes (DL) extending through the organic panels (10A~10E) are introduced into the organic panels (10A~10E).

13. The method according to claim 12, characterized in that, At least one reinforcing rib (12) is injection molded onto the organic sheet (10A~10E), the reinforcing rib connecting the two through holes (DL) to each other.

14. The method of claim 8, wherein the method is configured for manufacturing a structural member comprising at least two organic panels (10A~10E), the organic panels being at least segmentally stacked on top of each other and each organic panel having a fiber layer (100), wherein, At least one pair of aligned holes (101) are formed in the fiber layer (100) of the organic panels (10A~10E), and the organic panels (10A~10E) are connected to each other in a form-locking manner at the at least one pair of aligned holes.

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