DE102014012776A1 - Method for producing a three-dimensional fiber-reinforced plastic composite component and motor vehicle component produced therewith - Google Patents

Abstract

The invention relates to a method for producing a three-dimensional or spatial fiber-plastic composite component (100) with the steps: - producing blanks with different patterns from a UD semi-finished product with a thermoplastic polymer matrix; - Lastgerechtes arranging the blanks, wherein at least a first and at least a second blank stack (10, 20) are formed; - Producing an upper shell and a lower shell, including to the first blank stack (10) and to the second blank stack (20) made of a short fiber reinforced plastic material, a rib structure (161/162) and a peripheral frame (151/152) are molded; - Joining of the upper shell and lower shell, wherein these at their rib structures (161/162) and Umfangszargen (151/152) are joined materially (190) and thereby a circumferentially closed side wall is formed. The invention further relates to a fiber-plastic composite motor vehicle component (100) produced herewith.

Description

The invention relates to a method for producing a three-dimensional fiber-reinforced plastic composite component and to a correspondingly produced three-dimensional fiber-plastic composite motor vehicle component.

A three-dimensional fiber-plastic composite component is understood to mean a component formed from reinforcing fibers and plastic material (s) with a spatial shape, whereby this component is also formed with a larger component thickness (ie with a thickness extension or with a third dimension), at least in sections or regions is. A flat sheet-like fiber-reinforced plastic composite component which has only one shell thickness (such as, for example, a CFRP engine compartment flap or seat pan) is not a three-dimensional fiber-reinforced plastic composite component in the sense of the invention.

The DE 10 2006 040 748 A1 describes a method for the production of three-dimensional motor vehicle components comprising the steps of producing a structural inserter, introducing the structural insert into an injection mold and injecting the structural insert with a thermoplastic, for example in the form of a rib-like structure, wherein the thermoplastic used can be filled with short fibers.

The object of the invention is to provide a novel process for producing a three-dimensional fiber-reinforced plastic composite component which does not have at least one disadvantage associated with the prior art or at least only to a reduced extent.

This object is achieved by an inventive method according to the features of claim 1. Preferred developments and refinements of the method according to the invention will become apparent both from the dependent claims and from the following explanations.

With a sibling claim, the invention also extends to a fiber-plastic composite motor vehicle component produced by the method according to the invention, in particular a motor vehicle structural component. The process characteristics apply analogously also for this fiber-plastic composite motor vehicle component according to the invention.

• – Erzeugen von Zuschnitten mit verschiedenen Schnittmustern aus einem UD-Halbzeug mit thermoplastischer Kunststoffmatrix;
• – lastgerechtes Anordnen der Zuschnitte, wobei wenigstens ein erster und wenigstens ein zweiter Zuschnittstapel gebildet werden (die Zuschnittstapel bestehen aus mindestens zwei Zuschnitten);
• – Erzeugen einer Oberschale und einer Unterschale, wozu sowohl an den ersten Zuschnittstapel (oder an mehrere erste Zuschnittstapel) als auch an den zweiten Zuschnittstapel (oder an mehrere zweite Zuschnittstapel) aus einem mit Kurzfasern verstärkten Kunststoffmaterial eine Rippenstruktur und eine Umfangszarge angespritzt werden;
• – Fügen von Oberschale und Unterschale, wobei diese an ihren Rippenstrukturen und Umfangszargen stoffschlüssig miteinander gefügt werden und eine umlaufend geschlossene Seitenwandung gebildet wird.

The method according to the invention for producing a three-dimensional fiber-reinforced plastic composite component has the following steps:

• - Producing blanks with different patterns from a UD semi-finished with thermoplastic matrix;
• - Load-appropriate arrangement of the blanks, wherein at least a first and at least a second blank stack are formed (the blank stacks consist of at least two blanks);
• - Producing an upper shell and a lower shell, including both the first blank stack (or to a plurality of first blank stacks) and the second blank stack (or to a plurality of second blank stacks) from a short fiber reinforced plastic material, a rib structure and a peripheral frame are molded;
• - Joining of upper shell and lower shell, wherein these are joined to their rib structures and Umfangszargen cohesively with each other and a circumferentially closed side wall is formed.

The UD semifinished product (or UD tape) has plane-parallel or unidirectionally arranged continuous fibers or long fibers and a thermoplastic polymer matrix material. The fibers or reinforcing fibers are, in particular, carbon or glass fibers, although in principle other fiber materials are also possible. The particular strip-like blanks can be made from the same UD semi-finished or from different UD semi-finished products. The particularly automated production or production of the blanks can take place, for example, with a mechanical cutting device (that is to say with knives or the like) or with a laser cutting machine.

A load-oriented arrangement of the blanks is understood to mean that the previously produced different blanks with respect to the forces and moments acting in the subsequent use of the component to be produced and the resulting within the component load paths, especially taking into account the fiber orientation, one above the other and / or side by side to be ordered. Particularly preferred is z. B. provided that in high-load areas or sections (eg. At force application points) more blanks are arranged as in other areas that are less heavily loaded. As a result, only as much long fibers or continuous fibers are introduced, as is necessary with regard to the component load (that is, no oversizing). By using different blanks is also very little waste.

The different blanks are arranged according to specification to blank stacks (stacked tape blanks or patches), typically with the same fiber orientation, wherein at least one layer also offset one Fiber orientation (ie an angle other than 0 °). The blank stacks may (depending on the load paths), for example, have a thickness of up to 7 mm. (The UD semi-finished products or tapes themselves have a thickness of, for example, 0.15 mm to 0.3 mm.) The stacking of the blanks can, in particular automatically (for example with the help of at least one high-speed picking robot), on at least one storage table, in particular with Vakuumansaugung done. In this case, the blanks can also be thermally stapled, for which purpose the plastic matrix material contained in the UD semifinished product is melted at points. A blank stack can also consist of several individual sub-stacks or individual patches (ie at least two patches).

To produce an upper shell and a lower shell, the previously formed blank stacks are inserted into injection molds, in which the blank stacks are then overmolded or at least back-injected with a thermoplastic material mixed with short fibers and rib structures and peripheral frames are injection-molded. Previously, the blank stacks are heated, which can be done outside the injection molds or directly in the injection molds. The frames serve to form a circumferential side wall on the component to be produced and the rib structures serve on the manufactured component of the stabilization or increase in strength as well as the spacing between a component top and a component bottom (as explained in more detail below). The fiber reinforcement with short fibers, which may be carbon or glass fibers, in particular in agreement with the UD fibers, leads to a high mechanical strength of the sprayed component areas. The short fibers preferably have a length of 0.4 mm to 12.0 mm (optionally also up to 25 mm). In order to add the upper shell and lower shell later, it is preferably provided that the rib structures and frames are mirror-symmetrical to each other. In injection molding, functional elements (such as, for example, support and fastening elements, holders and the like) can also be formed or cast on and / or inlays (for example metallic threaded bushes or the like) can be molded or cast.

For joining the upper shell and lower shell, these previously produced component components (after removal from the injection molds) are correspondingly positioned and aligned and, in particular with a defined force and / or defined path, pressed against each other, so that they face each other at their mutually facing rib structures and Umfangszargen be joined together cohesively. The cohesive joining can be done by gluing. However, it is preferably provided that the integral joining takes place by welding, for which the corresponding joints at the rib structures and peripheral frames either still have residual heat from the injection molding process and / or by means of a heating device (eg an infrared emitter, a hot gas emitter, an ultrasound Probe and / or the like) are deliberately heated in advance and melted.

With the method steps explained above, a three-dimensional fiber-plastic composite component, which is in particular a motor vehicle component, is produced which is formed from a materially interconnected upper shell and lower shell. The one-piece fiber-reinforced plastic composite component is thus made of several pieces. The upper shell has a (possibly also spatially shaped) top with a peripheral frame and the lower shell a (possibly spatially shaped) underside with a peripheral frame, wherein the upper shell and lower shell are joined together at their Umfangszargen cohesively, so that a closed, in particular Dirt and moisture density, side wall is formed, which peripherally joins the top and bottom. The side wall is thus formed from a reinforced with short fibers thermoplastic. The endless or long fibers originating from the UD semi-finished product are only in the upper side and lower side and in particular extend in a belt-like manner through the upper side and lower side (upper and lower belt). Further, the upper shell and the lower shell are formed with (inner) rib structures and also joined to these rib structures, wherein the rib structures are completely enclosed by the circumferential side wall. A rib structure is understood to mean, in particular, the entirety of rib elements which are arranged in accordance with load and production.

The fiber-reinforced plastic composite component produced according to the invention has, in cross-section, a closed contour (formed by upper side, lower side and side wall) which completely surrounds the ribs of the (inner) rib structures. The rib structures are also formed from a thermoplastic reinforced with short fibers. Due to the interconnected rib structures, the upper side and the lower side are spaced apart from each other (which according to Steiner's theorem also increases the area moment of inertia and bending / torsional moment of resistance) and supported against each other, so that the fiber-reinforced plastic composite component produced according to the invention has a component thickness ( third dimension) and is mechanically very resilient. The frames and the rib structures are exclusively injection molding or casting elements, which are produced by injection molding (with a short fibers containing thermoplastic material). The top and bottom are formed from formed and pressed and possibly (with a short fibers containing thermoplastic material) back-injected and / or overmoulded blanks or blank stacks of a UD semi-finished. In an analogous manner, a fiber composite component according to the invention may also be formed from a plurality of upper shells and / or lower shells, which are joined accordingly.

In other words, a three-dimensional fiber-plastic composite component produced according to the invention has an upper side and a lower side and a circumferential side wall connecting the upper side and the lower side, wherein the component is formed from the upper shell and lower shell which are connected to one another in a material-locking manner and (at least one) the upper shell and the lower shell cohesively joining joining seam which extends circumferentially through the side wall has. Blanks, in particular strip blanks, are preferably processed from a UD semifinished product only in the upper side and in the lower side, more blanks being arranged locally in highly loaded component regions (for example at force introduction and / or attachment points) than in other, less stressed component regions , Developments arise as previously and explained below.

An advantage of the invention lies in the fact that the sub-processes of manufacture and in particular also the overall manufacturing process can be automated, so that a partial automation or even full automation is possible. This is associated with the fact that the processing of semi-finished thermoplastic products in any case allows short cycle times (in particular compared to thermoset semi-finished products, which are processed, for example. In RTM process, which brings cycle times of several minutes). The inventive method is thus particularly suitable for continuous production or series production with a short cycle time (the cycle time during injection molding, optionally including a previous forming, to produce the upper shell and / or lower shell may, for example, be only 1 to 2 minutes). Injection molding also offers many design degrees of freedom and has a good cost balance with regard to tool life and materials or raw materials.

Furthermore, there are cost saving potentials, in particular due to the reduction of the cut. The invention thus makes possible the comparatively cost-effective and large-scale production of three-dimensional fiber-reinforced plastic composite components (according to the preceding definition) and in particular motor vehicle components, wherein the fiber-reinforced plastic composite components produced according to the invention are also lightweight (ie have a low weight) and yet highly resilient or mechanically stressable are. This is not an exhaustive list of advantages associated with the invention.

• – dass (zum Erzeugen von Oberschale und Unterschale) der erste Zuschnittstapel in die Kavität eines ersten Spritzgießwerkzeugs und der zweite Zuschnittstapel in die Kavität eines zweiten Spritzgießwerkzeugs eingelegt werden, danach die Spritzgießwerkzeuge geschlossen und das mit Kurzfasern verstärkte Kunststoffmaterial in die Kavitäten eingespritzt wird; und
• – dass (zum Fügen von Oberschale und Unterschale) die erzeugte Oberschale und die erzeugte Unterschale nach dem Öffnen der Spritzgießwerkzeuge in den Kavitäten verbleiben und daraufhin die betreffenden Werkzeugteile (d. h. die die Oberschale und Unterschale aufnehmenden bzw. tragenden Werkzeugteile bzw. -hälften) durch Bewegen (d. h. insbesondere durch Verschieben, Verdrehen, und/oder Verschwenken) wenigstens eines dieser Werkzeugteile derart umpositioniert werden, dass sich schließlich die Oberschale und die Unterschale (spiegelsymmetrisch) gegenüberliegen, wonach die betreffenden Werkzeugteile zusammengefahren und hierbei Ober- und Unterschale gefügt werden.

A preferred development of the method according to the invention provides

• - That (for generating upper shell and lower shell) of the first blank stack in the cavity of a first injection mold and the second blank stack in the cavity of a second injection mold are inserted, then closed the injection molds and the short fiber reinforced plastic material is injected into the cavities; and
• - That (for joining upper shell and lower shell), the generated upper shell and the lower shell produced remain after opening the injection molds in the cavities and then the respective tool parts (ie, the upper shell and lower shell receiving or supporting tool parts or halves) by moving (ie in particular by shifting, twisting, and / or pivoting) at least one of these tool parts are repositioned such that finally the upper shell and the lower shell (mirror-symmetrical) are opposite, after which the respective tool parts moved together and this upper and lower shell are joined.

From this preferred development, further time and cost savings, as well as improved automation result.

Particularly preferably, it is provided that the upper shell and the lower shell are produced substantially simultaneously or simultaneously in the injection molds, wherein in principle a time-staggered production of upper shell and lower shell is possible. The joining of the upper shell and lower shell takes place virtually without reaction, for which purpose these previously produced component components or component components remain in the cavity-forming tool parts (for example in the matrix or in the male part) and, after the repositioning of these tool parts, are mirror-symmetrical, then that by closing the tool parts, the cohesive joining of upper shell and lower shell can be done on the mutually facing rib structures and Umfangszargen. For this purpose, the joining regions on the rib structures and ribs of the upper shell and / or lower shell can project out of the cavity. The concrete design of the injection molding tools is within the skill of the art and knowledge. Closing the tool parts for joining Upper shell and lower shell is preferably force and in particular controlled path.

The first and the second injection mold belong in particular to an injection molding system which is designed such that the repositioning (and repositioning) of the tool parts for positioning and alignment of the upper shell and lower shell for the joining process and the subsequent closing for joining the upper shell and lower shell, in particular automated , is accomplishable.

After cooling, the tool parts can be opened and the finished fiber-plastic composite component can be removed, in particular automatically (for example by means of a robot and gripper). Thereafter, the tool parts for producing a further upper shell and lower shell can be repositioned or repositioned again.

It is preferably provided that the joints at the rib structures and peripheral frames of the upper shell and / or the lower shell before joining by means of at least one heating or heating device (eg an infrared radiator, a hot gas radiator, an ultrasonic probe and / or The like) are melted, in particular, it is provided that only the joints are melted locally. This melting can take place during the repositioning and / or before the collapse or closing of the tool parts. For example. can be moved automatically into the tool gap before closing a suitably trained heating device. The Schmelzerwärmung can also be done externally, for example. By means of a fan or a Strahlenumlenkspiegels.

Regardless of a specific variant of the method, it can be provided that at least one of the blank stacks is deformed prior to insertion or introduction into the cavity of the injection mold in order to give this blank stack a planar spatial shape (preform). This forming can take place in a correspondingly formed forming tool. It is preferably provided that the blank stack is heated beforehand, in particular up to the melting temperature of the thermoplastic matrix material, for example in an oven (for example infrared or circulating air oven) or by means of another heating or heating device (for example a radiant heater or a heat radiator) Contact heating) can take place. After removal from the forming tool, the shell-like Fasergelege a dimensionally stable shape and can be placed in the injection mold, where then (optionally after renewed heating) the injection molding. Alternatively it can be provided that at least one of the blank stacks is deformed directly (ie without preforms in a forming tool) during closing of the injection mold, for which purpose the injection mold is designed accordingly. Here, too, it is preferably provided that the blank stack is previously heated (if appropriate also only after insertion). Likewise, the injection mold can be heated (especially since injection molds typically have a heater anyway). After the blank stack has been reshaped, the injection process can begin immediately or immediately (that is to say without the blank stack being converted, and in particular also without renewed heating).

It is preferably provided that the short fiber reinforced plastic material for injection molding is at least partially recycled material, which may be recycled material both in the short fibers and in the thermoplastic plastic material. Particularly preferably, it is provided that the recycled material used is obtained at least partially from the waste waste produced during the production of the blanks (of the UD semi-finished product), for which purpose this waste waste is processed in a suitable manner. Preferably, therefore, the blend of UD tapes is incorporated. Advantageously, the short fibers are then formed of the same material as the long or continuous fibers (i.e., in particular carbon fiber or glass fiber). The at least partial use of recycled material, which is obtained in particular from pre-processing, leads to an improved cost and environmental balance. The recycling material accumulates in the preliminary processes and is therefore available free of charge. The recycled material can also come from other in-house processes, for example, from a thermoset process, where a lot of dry fibers incurred, which can be processed into injection molding material.

The invention will be explained in more detail by way of example and not by way of limitation with reference to the schematic figures. The features shown in the figures and / or explained below may also be general features of the invention, even detached from certain combinations of features.

1 shows in perspective views an inventively produced strut bar and located in the interior of this strut brace structure.

2 shows in several sectional views chronologically the inventive method for producing a three-dimensional fiber-reinforced plastic composite component.

1a shows in installation position a strut manufactured by a method according to the invention 100 for installation in a motor vehicle body, with two forked Domanbindungen 110A and 110B and a front wall connection 120 , The one-piece strut bar 100 has a top 130 , a bottom 140 and a circumferential side wall 150 on. The component thickness H (third dimension) can be more than 10 mm and in particular more than 20 mm and vary in sections. At the strut bar 100 So it is a voluminous (not area-blechartiges) three-dimensional fiber composite component, the deviating also have a non-planar shape and, for example, can also be curved.

In the top 130 and in the bottom 140 Strip-cut strips of a UD semifinished product are incorporated in a belt-like manner, whereby the contained endless fibers or long fibers are inserted between the Domanbindungen 110A and 110B as well as between the Domanbindungen 110A / 110B and the end wall connection 120 extend as illustrated by the lines. In the field of connection forks 110A and 110B more cuts are placed to locally strengthen these high-stress areas. About 90% of the UD semi-finished blanks are formed as continuous strip blanks and about 10% of the UD semi-finished blanks serve the local reinforcement, for example. At force application points, this ratio is only exemplary and therefore z. B. may be 50% to 50%. The side wall 150 as well as the functional elements, namely the end wall connection 120 and the connection surfaces 115A and 115B at the connection forks 110A and 110B , are formed by injection molding of a short fiber reinforced plastic material.

Inside the strut bar 100 is located as a ribbed structure 160 trained core, such as in 1b shown. The rib structure 160 gets along with the functional elements and the side wall 150 produced by injection molding of a plastic material reinforced with short fibers, wherein preferably equal wall thicknesses are desired.

According to the invention, the strut brace 100 from an upper shell (or upper component half) and a lower shell (or lower component half) formed, which are joined together. The visible and revolving through the side wall 150 extending joint seam is with 190 referred to, wherein the joint seam on which the upper shell and the lower shell are integrally connected to each other, in the example shown, virtually horizontal (or possibly also slightly curved) through the entire strut 100 including the rib structure 160 , extends. In the 1 b shown rib structure 160 So is by an upper shell belonging to the upper rib structure 161 and by a lower rib structure associated with the lower shell 162 educated. The same applies to the side wall 150 , which consists of an upper shell belonging to the upper peripheral frame 151 and from a lower shell belonging to the lower shell 152 is formed.

At the strut bar 100 It is, so to speak, a lightweight strut brace made of short fiber reinforced thermoplastic with partial reinforcements from long fibers or continuous fibers (not cover the entire component geometry according to the invention), the long fibers or continuous fibers in the form of UD semi-finished or UD tapes with thermoplastic Plastic matrix (not to be confused with organo sheets) are provided. Different fiber materials (ie different UD semi-finished products) can also be used. It should be noted that the mechanical characteristics of UD tapes are clearly superior to those of short fiber reinforced injection molding. Thus, very high lightweight grades can be achieved.

The production of the strut brace 100 is hereinafter generally based on the 2 explained, for comparison or similar component components for simplicity, the same reference numerals are used.

2 shows two to an injection molding machine or machine 200 belonging injection molding tools 210 and 220 (First and second injection mold) for producing an upper shell and a lower shell. In the injection molds 210 and 220 By way of example, these are horizontal tools that are actuated by horizontal clamping units, not shown. Likewise, vertical tools can also be used. In both cases, low-cost injection molding standard technology can be used. The right-sided tool halves 212 and 224 are stationary or fixed on a common first base plate 231 arranged. The left-sided tool halves 214 and 222 are also on a common second base plate 232 arranged and together with respect to the right-side mold halves 212 and 224 movable relative.

In the cavities 215 and 225 the tool halves 214 and 224 be previously made of a UD semi-finished with thermoplastic resin matrix blank stacks or insert elements 10 and 20 inserted (which can be inserted per cavity also several stacks or patches) and recorded in a suitable manner, as in 2a shown. With these insert elements 10 and 20 becomes the component to be manufactured 100 right there in the top 130 and bottom 140 amplifies where the forces are, with the insert elements 10 and 20 adapted to the power flow.

Subsequently, the blank stacks are 10 and 20 by a heating device 300 containing multiple infrared emitters 311 . 312 and 313 has heated at the same time, including the heating or heating 300 is moved into the tool gap, as in 2 B shown. For heating the inserted blank stacks 10 and 20 only the infrared emitters 313 and 311 activated. It can also be provided a temperature control. If necessary, local heating is sufficient. (Alternatively, the UD depositors 10 and 20 even before inserting into the tools 210 / 220 to be heated.)

After heating, the injection molds 210 and 220 closed, with the heated blank stacks 10 and 20 can be reshaped simultaneously within the tool cavities. (Alternatively, the UD depositors 10 and 20 also be converted in advance, as explained above, in which case, if necessary, can be dispensed with the heating, since the preformed depositors 10 and 20 Immediately thereafter, a plastic material reinforced with short fibers is simultaneously injected into both cavities, with the inserted heated (or still warm) blank stacks 10 and 20 overmoulded or at least back-injected, and wherein the blank stack 10 an upper peripheral frame 151 and an upper rib structure 161 and to the blank stack 20 a lower peripheral frame 152 and a lower rib structure 162 be sprayed. Furthermore, functional elements (such as, for example, the end wall connection 120 and / or the bonding surfaces 115A / 115B ) are injected. This is in 2c shown. Thus, an upper shell and a lower shell are generated simultaneously or simultaneously. The injection molding is essentially only the formation of ribs, frames and functional elements. The rib structures 161 / 162 and the sides 151 / 152 are mirror-symmetrical to each other. The plastic material used for injection molding is preferably the same plastic material as in the UD semifinished product or at least a similar plastic material. The plastic material used for injection molding and / or the short fibers contained therein may at least partially be recycled material, as explained above.

After injection molding, the injection molds 210 and 220 opened, wherein the generated upper shell and the lower shell produced are not removed from the mold, but in the cavities 215 and 225 the first and second injection mold 210 / 220 remain. The left-side tool parts or halves 214 and 222 then become relative to the right side tool parts or halves 212 and 224 shifted and thereby repositioned so that the upper shell is finally opposite to the lower shell. The left tool half 214 of the first injection mold 210 is now opposite the right half of the tool 224 of the second injection mold 220 , After that, with the help of the heating device 300 at the same time only the mutually facing rib structures 161 / 162 and peripheral frames 151 / 152 (At their faces) targeted locally melted, including the heating or heating 300 is moved back into the tool gap, as in 2d shown. To melt on now the infrared emitters 311 and 312 activated (ie instead of the infrared emitters 313 now become the infrared emitters 312 activated; Furthermore, the infrared emitters are again 311 activated, but preferably with a different temperature profile), whereby a temperature control can also be provided here.

After the tool parts and halves carrying the upper shell and lower shell 214 and 224 aligned with each other and the joints are melted to the upper and lower shell (the melting can optionally also coincide with the repositioning of the tool parts 214 / 222 done), these are tool parts 214 and 224 force and / or path controlled together. Suitable tool guiding elements may be provided (not shown) around the left mold half 214 of the first injection mold 210 exactly to the right tool half 224 of the second injection mold 220 to move. Here, the upper shell and the lower shell with a force F by a few tenths of a millimeter pressed against each other and by welding to the protruding and facing rib structures 161 / 162 and peripheral frames 151 / 152 cohesively joined, as in 2e shown, creating a three-dimensional fiber-reinforced plastic composite component 100 with a circumferentially closed side wall 150 (such as in 1a shown) is formed.

It is preferably provided that the rib structure 161 the upper shell and / or the rib structure 162 the lower shell with respect to the surrounding frame 151 respectively. 152 formed with excess length (for example, in the range of a few tenths of a millimeter to a few millimeters) and that when joining the mold half 214 so far against the fixed tool half 224 is moved until the side wall 150 forming peripheral frames 151 / 152 touch while keeping the side wall 150 arises, with the frames 151 / 152 be circumferentially cohesively joined together, so that the outer joint seam 190 Dirt and moisture proof even under load.

After cooling, the produced fiber composite component 100 with help of a robot-controlled gripper 400 demolded and removed, as in 2f shown. The essentially produced in a single operation or run component 100 has a closed cross-section or a closed profile.

The injection molding plant 200 can also be designed differently. For example. For example, the cavity for the upper shell and / or lower shell may be formed on a cube die, which merely has to be pivoted for repositioning.

QUOTES INCLUDE IN THE DESCRIPTION

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Cited patent literature

• DE 102006040748 A1 [0003]

Claims (9)

Method for producing a three-dimensional fiber-reinforced plastic composite component ( 100 ) comprising the steps of: - producing blanks having different patterns from a UD semi-finished product with thermoplastic matrix; Load-appropriate arrangement of the blanks, wherein at least one first and at least one second blank stack ( 10 . 20 ) are formed; Producing an upper shell and a lower shell, to which end the first blank stack ( 10 ) and to the second blank stack ( 20 ) of a short fiber reinforced plastic material a rib structure ( 161 / 162 ) and a peripheral frame ( 151 / 152 ) are injected; - joining of upper shell and lower shell, whereby these at their rib structures ( 161 / 162 ) and peripheral frames ( 151 / 152 ) are joined cohesively and thereby a circumferentially closed side wall ( 150 ) is formed. Method according to claim 1, characterized in that - the first blank stack ( 10 ) into the cavity ( 215 ) of a first injection molding tool ( 210 ) and the second blank stack ( 20 ) into the cavity ( 225 ) of a second injection molding tool ( 220 ) is inserted, then the injection molding tools ( 210 . 220 ) is closed and injected with short fiber reinforced plastic material; and that - the upper shell produced and the lower shell produced after opening the injection molds ( 210 . 220 ) in the cavities ( 215 . 225 ) and the relevant tool parts ( 214 . 224 ) are repositioned such that the upper shell and lower shell are opposite, after which the respective tool parts ( 214 . 224 ) and in this case upper shell and lower shell are joined. Method according to claim 2, characterized in that the joints at the rib structures ( 161 ; 162 ) and peripheral frames ( 151 ; 152 ) of the upper shell and / or the lower shell before joining by means of a heating device ( 300 ) are melted. Method according to claim 2 or 3, characterized in that at least one of the blank stacks ( 10 ; 20 ) when closing the injection mold ( 210 ; 220 ) is deformed. Method according to one of the preceding claims, characterized in that it at least partially involves the reinforced with short fibers plastic material to recycled material. A method according to claim 5, characterized in that the recycled material used is obtained at least partially from the waste generated during the production of the blanks wastes. Fiber-reinforced plastic composite vehicle component ( 100 ), produced by a method according to one of the preceding claims, comprising a top side ( 130 ), a bottom ( 140 ) and a circumferential, the top ( 130 ) and underside ( 140 ) connecting, side wall ( 150 ), wherein the component ( 100 ) is formed from cohesively interconnected upper shell and lower shell, with a cohesively connecting the upper shell and the lower shell joining seam ( 190 ) passing through the side wall ( 150 ) runs. Fiber-reinforced plastic composite vehicle component ( 100 ) according to claim 7, characterized in that only in the top ( 130 ) and in the bottom ( 140 ) Blanks are processed from a UD semifinished product, wherein more blanks are arranged locally in highly loaded component areas than in other, less loaded component areas. Fiber-reinforced plastic composite vehicle component ( 100 ) according to claim 7 or 8, characterized in that this is designed as a strut brace.

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