Method for producing a structural component with integrated functional element, structural assembly and vehicle

Abstract

Method for producing a structural component (10) with an integrated functional element (22), in which a cutout (18) is produced in a fiber composite semi-finished product (12) and a scrim (20) is formed, wherein the functional element (22) is introduced at least partially into the cutout (18); the scrim (20) is bonded in a joining step with pressure and temperature conditions (p;is acted upon, under which the functional element (22) is integrally connected to a matrix material (14) of the fiber composite semi-finished product (12), characterized in that a plurality of fiber composite semi-finished products (12) are provided with cutouts (18) and the fiber composite semi-finished products (12) are stacked during the production of the laminate (20) with at least partial overlap of the cutouts (18), and in the production of the laminate (20) a multi-part functional element (22) is used, the components (32) of which are each introduced into at least one of the cutouts (18), to generate the pressure and temperature conditions (p;T) a tool (24) is used which comprises an embossed structure (36), and a component (34) of the functional element (22) is applied to a surface (30) of the fiber composite semi-finished product (12) facing the embossed structure (36) of the tool (24), which component is arranged at least in sections next to the cutout (18), and a structure is embossed onto the component (34) of the functional element (22) by the embossed structure (36) of the tool (24);

Description

[0001] The invention relates to a method for producing a structural component according to the preamble of patent claim 1. Furthermore, the invention relates to a structural assembly and a vehicle.

[0002] In various fields of technology, for example in the automotive sector, it is common practice to combine structural components with other functional elements, such as lights. Typically, the structural components and the other functional elements are first manufactured separately and then assembled together.

[0003] However, this approach involves a high level of effort and limits the design freedom with regard to the structural component and the other functional carrier.

[0004] From EP 3 049 236 B1 a multi-layer structural component is known which comprises a first and a second fiber composite layer between which a foam layer is arranged.

[0005] Furthermore, DE 10 2013 202 223 A1 discloses a method for producing a decorative composite. A decorative layer with an opening is provided, and a film is placed over the opening on the decorative layer. In a forming step, the film is then inserted into the opening.

[0006] DE 10 2017 208 097 B3 discloses a method for producing a joint component with an outer joint part and an inner joint part. The outer joint part is inserted into a fiber composite semi-finished product and connected to it in a form-fitting manner.

[0007] DE 10 2016 222 467 A1 discloses a method for producing a fiber structure in which a positioning device is introduced into a fiber composite semi-finished product and these are positively connected to one another by applying pressure and / or temperature.

[0008] DE 10 2015 219 719 A1 discloses a fiber composite component with an integrated connection system for add-on parts. The connection system is incorporated into a fiber composite semi-finished product and bonded to it by applying pressure and temperature.

[0009] The invention is based on the object of providing a novel method for producing a structural component with an integrated functional element. In particular, the method should avoid conflicts in meeting structural requirements and requirements related to the additional functional element, thus ensuring a high degree of design freedom. At the same time, the method should be feasible with minimal effort.

[0010] The object is solved by the subject matter of independent claims 1, 3 and 6. Further preferred embodiments of the invention emerge from the remaining features mentioned in the subclaims.

[0011] A first aspect of the invention relates to a method for producing a structural component with an integrated functional element, in which a cutout is produced in a fiber composite semi-finished product and a fabric is formed, wherein the functional element is introduced into the cutout at least in sections.

[0012] According to the invention, it is provided that a plurality of fiber composite semi-finished products are provided with cutouts and the fiber composite semi-finished products are layered during the production of the scrim with the cutouts overlapping at least in sections, and during the production of the scrim, a multi-part functional element is used, the components of which are each introduced into at least one of the cutouts, a tool is used to generate the pressure and temperature conditions, which tool comprises an embossed structure, and a component of the functional element is applied to a surface of the fiber composite semi-finished product facing the embossed structure of the tool, which component is arranged at least in sections next to the cutout and a structure is embossed onto the component of the functional element by the embossed structure of the tool.

[0013] In other words, the structural component with the integrated functional element is manufactured in just one work step, in which the still unjoined composite is pressed under temperature control, resulting in a materially joined composite component.

[0014] Because the functional element and the fiber composite semi-finished product merge thermoplastically at their interfaces, the functional element becomes an integral part of the structural component, allowing for complete freedom of design. This creates a seamless structure that eliminates the need for conventionally required sealing between the functional element and the structural component. This seamless structure also makes conventionally required tolerance compensation elements redundant and advantageously increases the aerodynamic properties of the structural component. All of this also reduces the required installation space and saves mass. Furthermore, a structural component manufactured using the process according to the invention is particularly durable, resilient, and therefore safe.Since the functional element is integrally integrated into the structural component, the structural component can be loaded and deformed across the area of ​​the functional element, which opens up completely new design freedoms for the placement of lights, for example, particularly in the automotive sector.

[0015] The functional element can also be multi-part before the joining step and integrated into the structural component in different areas after the joining step. Components of the functional element can include plates, sleeves, granules, films, or even pre-assembled assemblies, such as light guides, OLEDs, LCDs, or EL films, including passive and active lighting elements. These components can also be combined with other components, such as light guides.

[0016] A matrix material of the fiber composite semi-finished product and a material of at least one component of the functional element are preferably identical. Particularly preferably, the material of the entire functional element is identical to the matrix material. This can preferably be an amorphous injection-molded material, such as a thermoplastic. The matrix material can also be mixed with color particles or painted in a process step following the joining step.

[0017] Possible filler fibers include carbon fibers, glass fibers, natural fibers, or other reinforcing fibers. These can be used as long or short fibers, or even in random form. In principle, other semi-finished materials are also conceivable.

[0018] The structural component is preferably a vehicle structural component. This can be part of the exterior or interior of a vehicle. The functional element can preferably comprise a radiation-related element, for example, an optically functional element such as a light-guiding element or an element for conducting ultrasound or radar radiation. Furthermore, the functional element can preferably also comprise a mechanical connecting element, such as a contact surface, a locking element, a clip element, a screw receptacle, or an adhesive flange.

[0019] With a suitable tool for generating the pressure conditions, all of these elements can be integrated particularly easily onto a surface of the structural component, for example, by pressing or pressing them in. Preferably, the functional element is designed to complement the cutout at least in sections before the joining step and is capable of completely filling it. Thus, the tool can be used to create a uniform shape on the surface, even in the area of ​​the functional element, with respect to the structural component.

[0020] The invention offers the advantage that the functional element can have a variable geometry across the various fiber composite semi-finished products.

[0021] When layering the fiber composite semi-finished products, one fiber direction is preferably arranged alternately in order to make the mechanical properties of the structural component more homogeneous.

[0022] The cutout of a fiber composite semi-finished product arranged between two fiber composite semi-finished products is preferably selected to be larger than the cutouts of the surrounding fiber composite semi-finished products.

[0023] In this way, a particularly secure placement and integration of the functional element in the cutouts is achieved, since the functional element is also located in sections between different fiber composite semi-finished products.

[0024] Since the components of the functional element are also connected to each other in the joining step, even a complex geometry of the functional element can be manufactured particularly easily.

[0025] If, for example, layered fiber composite semi-finished products and plate-like components of the functional element are used, a larger plate can be inserted into a larger cutout in the middle of the layering, in other words in a layered structure (“stacking”), than in smaller cutouts that are located above and below.

[0026] According to the invention, a tool comprising an embossed structure is used to generate the pressure and temperature conditions.

[0027] Thus, in just one joining step, radiation technology elements such as a light coupling surface or mechanical connecting elements such as a contact surface can be produced.

[0028] The embossed structure can comprise a positive or negative embossed structure. A negative embossed structure can, for example, also accommodate additional components that are pressed against the surface of the fiber composite semi-finished product under pressure conditions and thermoplastically fused with them under temperature conditions.

[0029] According to the invention, a component of the functional element is applied to a surface of the fiber composite semi-finished product facing the embossed structure of the tool, which component is arranged at least in sections next to the cutout.

[0030] The component can, for example, be applied during the production of the scrim and then formed and molded during the joining step. However, it is also possible to apply the component during the joining step itself, for example, by placing it in a negative embossing structure of the tool and pressing it on during the joining step.

[0031] All this is particularly advantageous for producing, for example, mechanical fasteners next to the cutout.

[0032] In a further preferred embodiment of the method of the invention, it is provided that a light guide is used as a component of the functional element, which is placed at least in sections in or above the cutout.

[0033] Here, too, the component can be placed during the fabrication of the scrim and / or during the joining step itself. The light guide can, for example, be a transparent element inserted into the cutout or a separate light guide that is pressed into place during the joining step. In the latter case, the light guide is preferably a pre-assembled component in which the light guide preferably has a protective sleeve that bonds to the matrix material or the material of the remaining functional element.

[0034] Particularly preferably, the tool has a negative embossed structure that can accommodate the optical fiber during the pressing process in the joining step in order to limit the pressure acting on the optical fiber. Alternatively, in a separate step, after consolidation, a temperature- and pressure-sensitive insert part can be locally bonded to the structural component, for example, by induction hardening.

[0035] In a further preferred embodiment of the method of the invention, it is provided that the functional element, after the joining step, comprises a transparent region which fills the cutout and has a contact surface, and that the functional element comprises a mechanical connecting element which is arranged on a surface of the fiber composite semi-finished product next to the contact surface.

[0036] The transparent area can, for example, be transmissive to light, radar radiation, or even ultrasound. The contact surface can, for example, be designed to accommodate a vehicle module, such as a vehicle light or a parking distance sensor.

[0037] The mechanical connecting element can, for example, comprise an adhesive flange or a threaded bushing.

[0038] A further aspect of the present invention relates to a structural assembly comprising at least one structural component, produced in a method according to the invention as described above.

[0039] Preferably, the structural assembly may comprise a vehicle module that rests against a contact surface of a functional element integrated into the structural component and is provided with a cover element that is fastened to a mechanical connecting element of the functional element.

[0040] The vehicle module can, for example, include a vehicle light, a parking distance sensor, or components of such or other devices. The functional element is always tailored to the requirements of the vehicle module used, for example, by being designed transparently.

[0041] The cover element can, for example, be a fastening or a cover.

[0042] A further aspect of the invention relates to a vehicle comprising a structural component produced by a method according to the invention as described above and / or a structural assembly according to the invention as described above.

[0043] The vehicle may preferably be a motor vehicle, such as a land vehicle, water vehicle, or aircraft. An automobile is particularly suitable, since the advantages of the structural component produced using the method according to the invention are particularly evident there.

[0044] For example, the vehicle module can be a daytime running light, brake light, tail light or headlight.

[0045] Since such lighting devices can be integrated very flexibly into the structural component, completely new possibilities for visual communication between the vehicle and its surroundings become possible.

[0046] For example, the vehicle can provide warning or notification messages particularly efficiently. In addition to displaying the vehicle status, for example, in the area of ​​car-sharing or taxi services, charging or fuel status can also be displayed.

[0047] Since the functional element can be part of the supporting structure, warning messages can also be displayed in previously inaccessible areas of the vehicle. For example, a flashing signal can be displayed all around if a vehicle is involved in an accident. This is possible because the functional element can even be located in the area of ​​a crumple zone. All of this significantly increases vehicle safety.

[0048] The advantages mentioned also apply to ships, rail vehicles, motorcycles, commercial vehicles and agricultural machinery.

[0049] The various embodiments of the invention mentioned in this application can be advantageously combined with one another, unless stated otherwise in the individual case.

[0050] The invention is explained below in exemplary embodiments with reference to the accompanying drawings. They show: Fig. 1 a method not according to the invention; Fig. 2 a method according to the invention in a further embodiment; Fig. 3 a structural assembly according to the invention; Fig. 4 a structural assembly according to the invention under deformation; and Fig. 5 a vehicle according to the invention.

[0051] Fig. 1 schematically shows a method for producing a structural component 10. The structural component 10 itself is described in more detail in the other figures.

[0052] In the process, several fiber composite semi-finished products 12 are provided, the matrix material 14 of which consists of a thermoplastic. The fibers 16 contained in the fiber composite semi-finished products 12 are predominantly carbon fibers or customized semi-finished products.

[0053] The fiber composite semi-finished products 12 are each provided with a cutout 18.

[0054] The fiber composite semi-finished products 12 provided with the cutout 18 are layered to form a fabric 20, with the cutouts 18 overlapping one another.

[0055] In addition, a functional element 22 is provided, which is complementary to the cutouts 18 and is inserted into the cutouts 18 during the formation of the scrim 20. In this case, the functional element 22 is an insert made of the matrix material 14, which is also used for the fiber composite semi-finished product 12. The functional element 22 and the matrix material 14 consist, for example, of a clear, i.e., translucent, thermoplastic.

[0056] The fabric 20 is inserted into a tool 24 comprising a punch 26 and a die 28. Defined pressure conditions p and temperature conditions T can be generated with the tool 24 and transferred to the fabric 20.

[0057] By subjecting the fabric 20 to the pressure and temperature conditions p, T, the functional element 22 is bonded in the process to the matrix material 14 of the fiber composite semi-finished product 12. Since several fiber composite semi-finished products 12 are used in the present example, these also bond to one another accordingly.

[0058] As a result, after completion of the procedure, the Fig. 1, the components of the fabric 20, which are still shown individually, are joined to the structural component 10 in only one work step, wherein surfaces 30 of the structural component 10 are defined in their shape by the tool 24.

[0059] Fig. 2 shows a method according to the invention, wherein Fig. 2a shows the clutch 20 before the joining step and Fig. 2b shows the structural component 10 after the joining step. In other words, in Fig. 2b shows how the fabric 20 has already bonded together and the surfaces 30 have already been formed with the tool 24.

[0060] In Fig. 2a, i.e., before the joining step, it can be seen that the functional element 22 used in the manufacture of the scrim 20 is multi-part. It comprises components 32, in this case in the form of plates, each of which is inserted into a cutout 18.

[0061] Furthermore, a component 34 of the functional element 22 is applied to a surface 30 of the fiber composite semi-finished product 12, which faces the punch 26 of the tool 24. This component 34, here also in the form of a plate, overlies the cutout 18 and is also located in sections adjacent to the cutout 18.

[0062] It can be seen that the punch 26 of the tool 24 is provided with an embossed structure 36.

[0063] If the tool 24 now applies the pressure and temperature conditions p, T to the non-woven fabric 20, the components 32, 34 and the fiber composite semi-finished products 12 of the non-woven fabric 20 melt into each other at their interfaces and bond together. At the same time, the components 32, 34 are formed on the surface 30, which is exposed to the embossed structure 36.

[0064] The fabric 20 is thus formed and joined into the structural component 10 or the Fig. 2b shown state.

[0065] There it is shown that the structural component 10 has, on its surface 30 facing the embossed structure 36, a contact surface 38 formed on the functional element 22.

[0066] To the left and right of the contact surface 38, mechanical connecting elements 40 can be seen, which have been produced from the component 34 with the embossed structure 36.

[0067] For further information, please refer to Fig. 3. There, a structural assembly 42 according to the invention is shown, which comprises a structural component 10 manufactured using the method according to the invention.

[0068] The structural assembly 42 further comprises a vehicle module 44, which in this case comprises a lamp body. The lamp body of the vehicle module 44 is positioned on the contact surface 38 of the structural component 10. The contact surface 38 is designed to complement the adjacent surface of the lamp body of the vehicle module 44. The functional element 22 is designed here as a light guide 46, so that the structural component 10 with the vehicle module 44 can be illuminated.

[0069] Furthermore, the structural assembly 42 comprises a cover element 48. The cover element 48 is positioned on the structural component 10 via molded-on mechanical connecting elements 40. For example, the cover element 48 is glued to the left mechanical connecting element 40 and screwed into the right mechanical connecting element 40. The mechanical connecting elements 40 can be flexibly connected to the embossed structure 36, as for example in Fig. 2b, adapted to the desired connection principle.

[0070] Fig. 4 shows a structural assembly 42 according to the invention, which is subjected to a deforming force F.

[0071] In the upper part of the Fig. 4, the structural assembly 42 is shown without force applied and in the lower part with force applied. It can be seen that a deformation and thus a deflection x of the structural component 10 occurs as a result of the force F. Due to the method according to the invention and the special type of integration of the functional element 22 into the structural component 10 implemented therein, the structural component 10 can, as in Fig. 4, lie in the middle of the area subjected to the force F. The structural properties of the structural component 10 are advantageously retained.

[0072] Fig. 5 finally shows a vehicle 50 according to the invention, which in this case is a motor vehicle.

[0073] The vehicle 50 comprises structural assemblies 42 according to the invention, in which different functions are integrated into the structure of the vehicle 50 with the functional elements 22 and respective associated vehicle modules 44.

[0074] These include, purely by way of example, a parking distance sensor 52, a brake light 54 and a circumferential signal light 56. List of reference symbols 10 Structural component 12 Fiber composite semi-finished products 14 Matrix material 16 fiber 18 Excerpt 20 clutches 22 Functional element 24 tools 26 stamps 28 die 30 Surface 32 components 34 component 36 embossed structure 38 system surface 40 connecting element 42 Structural assembly 44 Vehicle module 46 light guides 48 Cover element 50 vehicles 52 Parking distance sensor 54 Brake light 56 Signal lighting F Force x deflection

Claims

[1] A method for producing a structural component (10) with an integrated functional element (22), in which a cutout (18) is produced in a fiber composite semi-finished product (12) and a scrim (20) is formed, wherein the functional element (22) is introduced at least partially into the cutout (18); the scrim (20) is subjected to pressure and temperature conditions (p; T) in a joining step, under which the functional element (22) is bonded to a matrix material (14) of the fiber composite semi-finished product (12), characterized bythat several fiber composite semi-finished products (12) are provided with cutouts (18), and the fiber composite semi-finished products (12) are layered during the production of the fabric (20) with at least partial overlap of the cutouts (18), and during the production of the fabric (20), a multi-part functional element (22) is used, the components (32) of which are each introduced into at least one of the cutouts (18), a tool (24) comprising an embossed structure (36) is used to generate the pressure and temperature conditions (p; T), and a component (34) of the functional element (22) is applied to a surface (30) of the fiber composite semi-finished product (12) facing the embossed structure (36) of the tool (24), which component is arranged at least partially next to the cutout (18), and a structure is applied to the component (34) by the embossed structure (36) of the tool (24). of the functional element (22). [2] Method according to claim 1, characterized bythat a light guide (46) is used as a component (32; 34) of the functional element (22), which is placed at least in sections in or above the cutout (18). [3] Structural assembly (42) comprising at least one structural component (10) manufactured by a method according to one of the preceding claims. [4] Structural assembly (42) according to claim 3, characterized by that a vehicle module (44) rests against a contact surface (18) of a functional element (22) integrated into the structural component (10) and is provided with a cover element (48) which is fastened to a mechanical connecting element (40) of the functional element (22). [5] Structural assembly (42) according to claim 3, characterized bythat the functional element (22) comprises, after the joining step, a transparent region which fills the cutout (18) and has a contact surface (38), and that the functional element (22) comprises a mechanical connecting element (40) which is arranged on a surface (30) of the fiber composite semi-finished product (12) next to the contact surface (38). [6] Vehicle (50) comprising a structural component (10) manufactured by a method according to one of claims 1 or 2 or a structural assembly (42) according to one of claims 3 to 5.

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