Method and tool for manufacturing a hollow composite component, as well as hollow composite component

Abstract

A method for producing a hollow composite component comprising the following steps: - an elongated hollow body (12) formed from a fiber-reinforced plastic is formed as a fiber-reinforced plastic semi-finished product in a preheated state using a tool (10) and is subjected to an internal support pressure during this process; - an injection molding process is carried out using the tool (10) by means of which a plastic is injected at least onto a partial area of ​​the hollow body (12); - the tool (10) has two opposing mold parts (14, 16) for forming the hollow body (12); - a first of the mold parts (16) is rigid;and- the second molded part (14) is segmented and thereby divided into segments (18, 20, 22), which are moved successively towards the first molded part (16) and thus successively into contact with the hollow body (12), whereby the hollow body (12) is formed while at least one of the segments (18, 20, 22) is moved towards the first molded part (16), characterized by the further step that- a fluid, which is introduced into the hollow body (12) to effect the support pressure, is selectively temperature-controlled by means of a temperature control device, whereby defined tensile and compressive stresses are introduced into the hollow body (12) during the forming process by introducing the variothermically controlled support pressure.;

Description

[0001] The invention relates to a method and a tool for manufacturing a hollow composite component, as well as such a hollow composite component.

[0002] WO 2013 / 053447 A1 or EP 2 766 248 A1 discloses a front-end module for a motor vehicle, comprising a tubular cross member and injection-molded plastic components which are molded onto the cross member, wherein at least two of the injection-molded components are separately connected to each other in relation to the cross member.

[0003] Furthermore, DE 10 2017 014 538 A1 discloses a cross member for a car body, which comprises a cross member component made at least substantially of a metallic material, supplemented with a plastic to form a hybrid component.

[0004] The object of the present invention is to provide a method and a tool by means of which hollow composite components can be manufactured in a time- and cost-effective manner. A further object of the invention is to provide a hollow component that can be manufactured in a time- and cost-effective manner.

[0005] These problems are solved by the features of claim 1, by a tool with the features of claim 7, and by a hollow composite component with the features of claim 8. Advantageous embodiments with expedient further developments of the invention are specified in the remaining claims.

[0006] In the inventive method for producing a hollow composite component, an elongated hollow body made of fiber-reinforced plastic is formed as a fiber-reinforced plastic semi-finished product (FRP semi-finished product) in a preheated state using a tool and is subjected to internal support pressure during this process. Furthermore, an injection molding process is carried out using the tool, by means of which a plastic is injected at least onto a partial area of ​​the hollow body, particularly after the hollow body has been formed and / or during the forming process. In the inventive method, the tool comprises two opposing mold parts for forming the hollow body.

[0007] A first of the molded parts is rigid and therefore does not comprise any separately formed segments that are movable relative to one another. A second of the molded parts is segmented and thus divided or subdivided into segments, wherein the segments are moved successively in the direction of the first molded part and thus successively into contact with the hollow body, whereby the hollow body is formed while at least one of the segments is moved in the direction of the first molded part. In particular, the hollow body is bent and thereby formed within the framework of the method according to the invention, so that the method according to the invention is a forming concept, in particular a bending concept, within the framework of which the hollow body, for example designed as an FRP profile insert, is formed by a one-shot IHU process.The process is therefore a one-shot IHU injection molding process, in which the hollow body is both formed and injection-molded with plastic within exactly one process step, or in exactly one operation, using the same tool. The resulting composite hollow body, comprising the formed and injection-molded hollow body, can then be ejected or removed. The support pressure is used as a high internal pressure to prevent, for example, undesirable changes to the outer contour of the hollow body during forming.

[0008] The hollow composite component can be used, for example, as a front-end support, as a cross member under an instrument panel, and / or as another component of a motor vehicle, particularly a passenger car, and can be manufactured quickly and cost-effectively using the method according to the invention. In particular, cockpit cross members, crash boxes, front-end adapters, front-end supports, tailgates, lying cross members or bumpers, torsion bars, spool rods, roof frames, vehicle pillars, A-pillars, subframes, steering rack tubes, transmission bridges, outer skirts, battery trays, and / or other components can be manufactured using the method according to the invention. During the injection molding of the plastic onto the hollow body, for example, the plastic forms a metallurgical bond with the hollow body, so that the plastic is a metallurgical injection molded onto the hollow body.Since the tool has segments, it is modular in design, preferably with leading segments. For example, two outer, lateral segments of the second mold part are initially moved into contact with the mold part, while contact between a central segment of the second mold part, located between the lateral segments, and the hollow body is avoided. This fixes the hollow body, particularly its ends, to the mold parts by means of the outer lateral segments. Subsequently, the central segment is moved into contact with the hollow body, thereby forming the hollow body.

[0009] Furthermore, the tool can include following axial punches and semi-finished product transfer elements. The segments are preferably individually movable and adaptable to different forming radii. Using the inventive method, which is designed as a heat-based one-shot process, a cycle time of less than 60 seconds can be achieved, within which the hollow composite component can be produced.

[0010] The invention also includes a tool designed for carrying out a method according to the invention. Advantages and advantageous embodiments of the method according to the invention are to be regarded as advantages and advantageous embodiments of the tool according to the invention, and vice versa.

[0011] Furthermore, the invention includes a hollow composite component which is produced by means of a method and / or a tool according to the invention. Advantages and advantageous embodiments of the method and the tool according to the invention are to be regarded as advantages and advantageous embodiments of the hollow composite component according to the invention, and vice versa.

[0012] Further advantages, features, and details of the invention will become apparent from the following description of a preferred embodiment and from the drawings. The features and combinations of features mentioned above in the description, as well as those mentioned below in the figure description and / or shown in the figures alone, can be used not only in the combinations specified, but also in other combinations or individually, without departing from the scope of the invention.

[0013] The drawing shows in: Fig. 1 a schematic perspective view of a tool according to the invention; Fig. 2 a schematic side view of a movable axial sealing plunger of the tool; Fig. 3 a schematic front view of the tool; Fig. 4 another schematic front view of the tool; Fig. 5 another schematic front view of the tool; Fig. 6. A schematic perspective view of the tool (in part); Fig. 7. A further schematic perspective view of the tool (in part); Fig. 8. A further schematic perspective view of the tool (in part); Fig. 9. A further schematic perspective view of the tool (in part); Fig. 10. A schematic and cutaway perspective view of the tool; Fig. 11. A further cutaway front view of the tool; Fig. 12 another cutaway front view of the tool; Fig. 13 schematic sectional views of the tool, each showing a partial section; Fig. 14. A schematic sectional view of the tool; and Fig. 15. A schematic front view of the tool (in part).

[0014] In the figures, identical or functionally equivalent elements are provided with the same reference symbols.

[0015] Fig. Figure 1 shows a tool in a schematic perspective view. 10 for manufacturing a hollow composite component. This means that the tool 10 is trained to manufacture the hollow composite component. In the process, for example, a component made of Fig. 4 recognizable, elongated hollow bodies formed from a fiber-reinforced plastic 12 as a fiber composite semi-finished product (FRP semi-finished product) in a preheated state using the tool 10 It is reshaped and, during this process, subjected to internal support pressure. Furthermore, the tool is used to... 10 an injection molding process was carried out, by means of which a plastic is applied to at least a partial area of ​​the hollow body.12 is injected. This creates the hollow body. 12 added to the hollow composite component.

[0016] Looks especially good Fig. 3. It is evident that the tool 10 two opposing molded parts 14 and 16 exhibits the molded part 16 It is rigid and therefore has no segments that can move relative to each other. In contrast, the second molded part is 14 segmented and thus into segments 18 , 20 and 22 subdivided. As will be explained in more detail below, the segments are 18 and 20 for example so-called leading segments, where the segment 22 For example, a lagging bending head. Within the framework of the process, and thus by means of the tool. 10 will the hollow body 12 bent, that is, reshaped by bending, so that the tool 10It is designed as an internal high-pressure bending and injection molding tool. As will be explained in more detail below, the segments are 18 , 20 and 22 one after the other in the direction of the molded part 16 and thereby in contact with the hollow body 12 moved, causing the hollow body 12 is reshaped while at least one of the segments 18 , 20 and 22 in the direction of the first molded part 16 is moved. In Fig. 1. The respective arrows illustrate 24 the movements of the segments 18 , 20 and 22 .

[0017] Out of Fig. 15 it is evident that the tool 10 at least one axial sealing piston 26 exhibits which, relative to the molded parts 14 and 16 , especially in the axial direction of the hollow body 12 is moved in order to thereby expand the hollow body 12in particular, to seal its interior and to fix at least one of its legs. Specifically, each leg or each end must have an axial sealing plug. 26 designed to connect the two ends of the hollow body 12 to seal and fix. This allows a fluid, especially a gas, which is used to create the supporting pressure, to enter the hollow body. 12 The fluid, especially when introduced into its interior, should not escape undesirably from the ends of the hollow body. In particular, the fluid should be sealed via one of the axial sealing pistons. 26 into the hollow body 12 initiated. In Fig. 2 illustrates a double arrow 28 which are particularly in the axial direction of the hollow body 12 progressive movement of the respective axial sealing piston 26 The movable axial sealing piston 26 This occurs simultaneously with sealing the hollow body. 12 and used for thigh fixation.

[0018] The fluid is selectively temperature-controlled, i.e., cooled and / or heated, for example, by means of a temperature control unit. This is achieved by introducing the variothermally controlled support pressure into the hollow body. 12 During forming, defined tensile and compressive stresses can be introduced to prevent wrinkling and / or damage. Furthermore, the interaction of the leading elements (segments) can... 18 and 20 ) with respect to force and distance tensile forces in the hollow body preferably designed as a tube 12 be initiated, particularly in a forming or bending zone in which the hollow body 12 is transformed.

[0019] For example, the segments 18 and 20 (Leader) simultaneously relative to the segment 22 moved and in the direction of the molded part 16moved, causing, for example, the leading edges to come into contact with the pipe (hollow body), especially simultaneously. 12 ) are moved while the segment is still in contact 22 with the pipe. The leading edges are therefore external tool parts that move simultaneously downwards or in the direction of the molded part. 16 to be moved. This causes the ends of the pipe to be moved by the advancing segments. 18 and 20 first fixed, whereupon the pipe was moved using the segment 22 is formed. Since the tube is fixed at its ends by means of the guides, unwanted relative movements between the tube and the tool are prevented. 10 be avoided.

[0020] Preferably, the rigid molded part has 16 Spray nozzles are used to inject the plastic onto the pipe. The movable molded part 14 directs the transformation of the hollow body 12 one, whereby the bending of the hollow body12 This occurs while the molded parts are being formed. 14 and 16 moving towards each other. During the forming process, the hollow body is in a position where 12 on a shelf, which is for example formed by the molded part 16 is formed. Alternatively or additionally, the tray includes, for example, pens arranged at intervals of, for example, 80 mm. A desired reshaping or deformation of the hollow body. 12 can be achieved by selectively targeting bending surfaces on the hollow body to be bent 12 can be achieved. The hollow body, also known as a bending body, is also referred to as a bending body. 12 For example, during forming, it is filled with the fluid and thus subjected to the internal support pressure, also known as gas support pressure, in order to achieve, for example, a desired round outer contour of the hollow body. 12to maintain and prevent excessive creases and dents, or to stretch continuous reinforcing fibers. Furthermore, it is conceivable that the axial sealing stamps 26 , which are also referred to as axial cylinders, on the rigid molded part 16 are arranged. The molded part 14 For example, a movable side is where ejectors are used to eject the hollow composite component from the tool. 10 are provided. Preferably, a gas is used as the fluid to generate the support pressure.

[0021] As from Fig. 3 is recognizable, for example the segment 22 a length L of approximately 60 mm. Furthermore, it is made of Fig. 3. It is evident that the molded part, which functions, for example, as a bending tool, 16 in three components in the form of segments 18 , 20 and 22It is divided to allow for targeted control. The segments serve this purpose. 18 and 20 the thigh fixation, while the segment 22 as a bending head for bending and thus shaping the hollow body 12 The core pulls and controls are adapted accordingly to the segmented tool. 10 .

[0022] Fig. 4 shows the tool 10 in a starting position. Here, the tool is 10 opened, the axial sealing piston is in a zero position, there is no pressure in the system and the hollow body designed as an FVK profile 12 It gets warm, that is, as a result of the heated state in a processing area 29 of the tool 10 between the molded parts 14 and 16 transported and / or heated on site. Thus, it shows Fig. 4 the tool 10 in a starting position.

[0023] Fig. 5 shows the tool 10 during a handover where the tool is open and a support or fixation of the hollow body, also simply referred to as semi-finished product, is required. 12 This is planned. There is no pressure in the system and a handling device is moving away from the processing area, also referred to as the work area. 29 .

[0024] Fig. 6 shows the molded part 16 during the transfer of the pre-formed warm hollow body 12 , which is also simply referred to as a profile. As in connection with Fig. As can be seen in section 7, for example, the first supports are via pins or sliders. 30 Realized. Second supports not shown are represented, for example, by an offset tool division. Fig. 8 and Fig. 9 show the molded part 16 during the handover of the extended warm profile. Fig. 10 shows the tool10 partially shown in a schematic and cutaway perspective view.

[0025] Fig. 11 shows the tool 10 when bending the profile (hollow body) 12 The axial sealing plungers move to the respective ends and, controlled by force, apply slight support pressure to the interior of the profile. The tool 10 It is finally closed sequentially. As in Fig. As illustrated by arrows in Figure 11, the legs or ends of the profile are first fixed using the leading edges, which are moved simultaneously or sequentially towards the molded part. 16 and thereby being moved into contact with the profile in order to attach the ends of the profile and thus the profile as a whole to the molded parts 14 and 16 to fix while there is contact between the bending head (segment) 22 ) and the hollow body 12 still does not happen.

[0026] Fig. 12 shows the tool 10 when bending the hollow body 12 In this process, the hollow body 12 Bent by die bending, in particular into a profile end geometry. The bending, especially die bending, is carried out by the bending head, which is also referred to as a trailing die.

[0027] For example, the tool's inserts are interchangeable to create a bend-resistant design for a rib cavity. The segments 18 , 20 and 22 are, for example, by means of respective, in Fig. 15 actuators, labeled 32, are moved. The actuators 32 The integrated actuators with force-displacement sensing define the required forming forces as a function of displacement and time. A connection is also provided to apply the support pressure. The axial sealing pistons, also known as axial cylinders, are in Fig. 5 is recognizable and labelled there as 26. Furthermore, in Fig. 15 sealing segments 1 , hold-down segments with 2, a radius forming section with 4, a head area with 5 and receiving structures with 6.

[0028] Fig. Figure 13 shows a cavity of the tool. 10 , present with aluminium inlays, wherein in Fig. Thirteen sectional views, each running along the respective cutting planes A and B, are shown. A desired bending shape during the flow process is supported in the area of ​​injection-molded ribs. Furthermore, it follows from Fig. 14. A rib shape suitable for forming the FRP semi-finished product is particularly evident, especially in comparison to the aluminum inserts. Inclined transverse ribs and / or continuous inclined longitudinal ribs are conceivable. In particular, the method and the tool can be used to achieve this. 10 The following advantages can be realized: - Bending and injection molding to create a front-end carrier or cross member within a single operation in a complete tool in the shape of the tool. 10 , without multiple subsequent rework or pre-processing steps - Ribbing for material-bonded injection molding is not required to the same extent as in 2-stage processes. - Injection molding material is saved, resulting in a weight reduction. - Savings on additional bending machines and separate upstream forming processes, thus cost savings in machine hour rates, labor, and hall usage. - Reduced cycle time, increased overall output - The use of gas has a positive impact on the biotope, upkeep, maintenance, and is a significantly cleaner application compared to the use of water. - Additionally, gas causes less wear and tear on surrounding tools compared to water. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] WO 2013 / 053447 A1

[0002] EP 2766248 A1

[0002] DE 102017014538 A1

[0003]

Claims

[1] Method for producing a hollow composite component, characterized by , that: - an elongated hollow body (12) formed from a fiber-reinforced plastic as a fiber composite semi-finished product in a preheated state by means of a tool (10) and during which time a support pressure is applied to the inside; - an injection molding process is carried out using the tool (10), by means of which a plastic is injected at least onto a partial area of ​​the hollow body (12); - the tool (10) has two opposing mold parts (14, 16) for forming the hollow body (12); - one of the molded parts (16) is rigid; and - the second molded part (14) is segmented and thereby divided into segments (18, 20, 22), which are moved one after the other in the direction of the first molded part (16) and thus come into contact with the hollow body (12) one after the other, whereby the hollow body (12) is reshaped, while at least one of the segments (18, 20, 22) is moved in the direction of the first molded part (16). [2] Method according to claim 1, characterized by , that at least one axial sealing plunger (26) is moved relative to the molded parts (14, 16) in the axial direction of the hollow body (12) in order to seal the hollow body (12) and to fix at least one of its legs. [3] Method according to claim 1 or 2, characterized by , that a fluid which is introduced into the hollow body (12) to effect the support pressure is selectively tempered by means of a tempering device. [4] Method according to any one of the preceding claims, characterized by, that first two lateral segments (18, 20, 22), which connect to a central segment (18, 20, 22) on both sides, are moved into contact with the hollow body (12), while contact between the central segment (22) and the hollow body (12) is omitted in order to fix the hollow body (12), in particular its ends, to the molded parts (14, 16), whereupon the central segment (22) is moved into contact with the hollow body (12), thereby reshaping the hollow body (12). [5] Method according to claim 4, characterized by , that the hollow body (12) is reshaped by means of the lateral segments (18, 20) or that a reshaping of the hollow body (12) caused by the lateral segments (18, 20) does not take place. [6] Method according to any one of the preceding claims, characterized by , that the hollow body (12) is bent and thereby reshaped by means of the tool (10). [7] Tool (10) which is designed to carry out a method according to one of the preceding claims. [8] Hollow composite component manufactured by a method according to any one of claims 1 to 6 and / or by a tool (10) according to claim 7.

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