DE102016211810A1 - Door structure and method for producing a door structure - Google Patents

Abstract

A door structure (10) made of a fiber-plastic composite material for a motor vehicle with a door structure inner part (12) and a door structure outer part (14) is described in which the door structure inner part (12) and the door structure outer part (14) each comprise at least one preform and the door structure inner part (12 ) and the door structure outer part (14) together form an integral unit. In addition, a method for producing a door structure (10) made of a fiber-reinforced plastic composite material for a motor vehicle is described.

Description

The invention relates to a door structure made of a fiber-reinforced plastic composite material for a motor vehicle.

Furthermore, the invention relates to a method for producing a door structure made of a fiber-reinforced plastic composite material for a motor vehicle.

Components made of fiber-reinforced plastic composites are increasingly used in motor vehicles to reduce their weight. A frequently used method for the production of these fiber-reinforced plastic composite components is the so-called Resin Transfer Molding (RTM). In this case, fiber mats, such as scrim, fabric or braids of glass, carbon, aramid, basalt, nylon and / or natural fibers, pressed in a molding process in a defined spatial form. The preformed fiber mats produced in this way are called "preforms" or "preforms". Subsequently, the preforms are placed in a heatable form, in which a matrix for impregnating the fiber mats is injected.

Among others, fiber-reinforced plastic composites are used for body components, in particular load-bearing body parts, flaps and doors of motor vehicles.

In particular, flaps and doors are usually made of several monolithic items or individual shells. This means that a door or a flap must be composed of several such monolithic items. The monolithic items are usually made in a respective associated tool and then glued together.

For this purpose, the surfaces of the monolithic individual parts to be bonded must be prepared for bonding and positioned relative to one another in a subsequent handling step. After that, the actual joining of the individual parts can take place in a joining tool or a joining device.

A door structure of the aforementioned type and a method for producing the same are known from the DE 10 2013 223 519 A1 known. In this case, first a preform is produced, which is impregnated with plastic matrix material. Thereafter, a molding compound of a plastic matrix material and undirected fibers is applied to the preform. Then the preform and the molding compound are pressed.

A flat item made of fiber-reinforced plastic composite material, eg. B. for a vehicle door, and a method for its production are from the DE 10 2012 216 727 A1 known. The fiber-reinforced plastic composite component consists of at least one fiber layer and is formed from fiber mats with different thicknesses.

The object of the present invention is therefore to provide a door structure made of a fiber-reinforced plastic composite, which can be produced easily and inexpensively. In addition, the door structure should have the lowest possible weight and high rigidity.

The object is achieved by a door structure of the aforementioned type, which comprises a door structure inner part and a door structure outer part and in which the door structure inner part and the door structure outer part each comprise at least one preform and the door structure inner part and the door structure outer part together form an integral unit. The door structure is thus formed from a single component. In this case, a door structure, for example, be a supporting part of a side door, a trunk lid or a hood. By integrally forming the door structure eliminates all steps that affect the handling, positioning and joining of items. The associated tools and equipment are no longer necessary. Thus, the door structure is easy to produce. In addition, handling and joining steps usually require additional, reinforced points of attack in the door structure. These can be omitted, resulting in a weight reduction of the door structure and a material saving. The strength and rigidity with regard to the use of the door structure is not limited.

The door structure can, for. B. by means of a RTM, pressing or autoclave process.

One embodiment provides that, at least in sections, a core, preferably a foam core, and / or a cavity is arranged between the door structure inner part and the door structure outer part, wherein the cavity is preferably formed by a blow molding core. By using cores and / or cavities mechanically very stable components can be produced with low weight. Further, portions of the door structure inner part and the door structure outer part can be arranged spaced apart by means of cores. This favors the manufacture of the door structure as a one-piece unit in a single tool. The cores, in particular blow-mold cores, can be removed from them as needed after the component has been manufactured. Alternatively, nuclei generated by nuclei be completely or partially filled with a filler.

Also, a core can serve as a receptacle for an insert, a so-called insert, which is usually made of metal. The core then includes investment geometries for unique positioning of the insert.

Insert parts, such as Anschraubelemente for hinges are preferably placed on three sides in contact with the fiber composite component, so the fiber layers themselves. Thus, a high load acting on the insert, be included in the fiber composite component. Any existing geometric tolerances of the insert can be compensated by fiber layers in the investment area, which in comparison to the other fiber layers have a lower fiber volume content and thus can be over-pressed.

Preferably, a one-part or multi-part foam core is arranged essentially running along a door lower edge and / or a door lock edge and / or a window lower edge and / or a window leading edge and / or a door hinge edge. Thus, the desired mechanical properties, in particular strength and stiffness, of the door structure can be achieved at those points where they are necessary. At the same time the weight of the door structure is kept low.

According to a variant, the cavity, which is preferably formed by a single-part or multi-part blow molding core, can be arranged running along a front edge of the window and / or along a door hinge edge. Thus, a portion of the door structure along the door hinge edge and / or the window leading edge is very stiff. At the same time, the weight of the door structure is low. Optionally, the cavity can be completely or partially filled with a filling material.

In a design variant, the door structure inner part and / or the door structure outer part can respectively comprise at least two preforms. In this way it is also possible to produce complex geometries of the door structure inner part and / or outer door structure part by assembling them from a plurality of preforms. Using the various preforms, the fiber directions and the number of fiber layers can be set locally.

Preferably, the door structure inner part and / or the door structure outer part each comprise 3 to 6 preforms.

Advantageously, the preforms of the door structure inner part and / or the door structure outer part are arranged overlapping at least in sections. This results in a permanently fixed connection of the preforms, which results in a mechanically stable door structure. In addition, the door structure becomes mechanically particularly stable at the points of overlap.

According to an embodiment, the door structure inner part and / or the door structure outer part comprise a lock-side preform, a sill-side preform, a hinge-side preform and a window-front edge-side preform. Thus, a door structure with complex geometry can be produced in a simple manner. This door structure is stiff and has a low weight.

The sill-side preform preferably extends to a lower edge of the window. This preform thus extends in height over the entire door body, d. H. from the sill edge to the lower edge of the window. It is thus a large part of the door structure formed from only one preform.

In addition, the door structure inner part and / or the door structure outer part can comprise a window lower edge-side preform. Thus, the desired geometry, together with the desired mechanical properties, can be implemented in a specific preform.

In one embodiment variant, at least one insert part made of metal is arranged in the door structure inner part and / or in the door structure outer part, and the insert part preferably forms a fastening part for attaching other parts. For example, a part of the hinge mechanism or the lock mechanism may be attached to this insert. In addition, the insert can be used for attachment of components of the door inner and / or outer door trim. Crash elements can also be fastened via the inserts. In summary, the inserts are used to attach the door equipment. For example, the inserts may include threads. The inserts can be made of aluminum or stainless steel.

In addition, a glass fiber layer for galvanic isolation can be arranged between the insert part and the door structure inner part or the door structure outer part. Such insulation is particularly necessary to galvanically separate steel materials and carbon fibers. This prevents corrosion of the steel materials. As an alternative to glass fibers, other, electrically non-conductive fibers can be used.

Furthermore, the door structure inner part and / or the door structure outer part may comprise at least one reinforcing insert, preferably of a unidirectional fiber band. Such reinforcing insert serve to absorb forces that act on the door structure.

Another object of the invention is to provide a method with which a door structure made of a fiber-reinforced plastic composite material can be produced simply and inexpensively.

• a) Einlegen mindestens eines Preforms eines Türstrukturinnenteils in ein Werkzeug,
• b) Einlegen mindestens eines Kerns, vorzugsweise eines Schaumkerns und/oder Blasformkerns, in das Werkzeug,
• c) Einlegen mindestens eines Preforms eines Türstrukturaußenteils in das Werkzeug,
• d) Schließen des Werkzeugs,
• e) Einbringen von Harz in das geschlossene Werkzeug und
• f) Aushärten des Harzes.

The object is achieved by a method of the type mentioned above with the following steps:

• a) inserting at least one preform of a door structure inner part into a tool,
• b) inserting at least one core, preferably a foam core and / or blow molding core, into the tool,
• c) inserting at least one preform of a door structure outer part into the tool,
• d) closing the tool,
• e) introducing resin into the closed mold and
• f) curing the resin.

It can be made as a one-piece unit "in one shot" as a door structure part. Preferably, we use an RTM method for this purpose, more preferably a low-pressure RTM method. A composition of the door structure made of individual parts to be bonded is eliminated.

In a preferred embodiment, at least two preforms are inserted into the tool in step a) and / or in step c). Thus, door structures with complex geometries can be produced.

The invention will be explained below with reference to various embodiments, which are shown in the accompanying drawings. Show it:

1 a first embodiment of the door structure according to the invention in an exploded view,

2 A second embodiment of the door structure according to the invention in an exploded view,

3 A third embodiment of the door structure according to the invention, wherein a door structure inner part is omitted for clarity,

4 1 schematically a construction of a door structure inner part of the door structure according to the invention made of preforms,

5 schematically a to 4 alternative embodiment of a structure of a door structure inner part of the door structure of preforms according to the invention,

6 1 schematically a construction of a door structure outer part of the door structure according to the invention made of preforms,

7 a detail of the door structure according to the invention and

8th two embodiments of an overlap of preforms of a door structure according to the invention.

1 shows a first embodiment of a door structure 10 , This comprises a door structure inner part 12 and a door structure exterior 14 , In between is a foam core 16 arranged.

At the foam core 16 are four inserts 18a - 18d made of metal, for mounting of door equipment and / or for mounting the door structure 10 serve in a body of a vehicle.

The inserts 18a and 18b For example, they can be used to mount a hinge mechanism that locks the door structure 10 is pivotally mounted in a body of a vehicle.

With the help of the inserts 18c and 18d can elements of a door interior or door outer panel on the door structure 10 be fixed.

The door structure 10 is through a door lower edge 20 , a door lock edge 22 , a window lower edge 24 , a window leading edge 26 and a door hinge edge 28 limited. These edges are shared by the door structure interior part 12 and from the door structure exterior 14 educated.

In the illustrated embodiment, the foam core is 16 executed in one piece.

As in 1 can be seen, run portions of the foam core 16 along the window leading edge 26 , the door hinge edge 28 , the lower door edge 20 , the door lock edge 22 and the lower edge of the window 24 , In addition, the foam core includes 16 a stiffening section 30 ,

A second embodiment of the door structure 10 is in 2 to see. This embodiment differs from the embodiment of 1 by the construction of the core between the door structure inner part 12 and the door structure exterior 14 ,

The core here includes a foam core 16 that runs along the lower door edge 20 , the door lock edge 22 and the lower edge of the window 24 runs. As in the embodiment of 1 this foam core has 16 via a stiffening section 30 ,

In addition, in this second embodiment, a blow mold core 32 provided, consisting of two sections 34 . 36 consists. A first section 34 of the blow mold core 32 runs along the door hinge edge 28 , A second section 36 of the blow mold core 32 runs along the front edge of the window 26 ,

In the finished door structure 10 leaves the blow mold core 32 a cavity that runs along the window leading edge 26 and the door hinge edge 28 runs.

In the first part 34 of the blow mold core 32 that goes along the door hinge edge 28 runs, is the insert 18a arranged and in the second section 36 of the blow mold core 32 that is along the window front edge 26 runs, is the insert 18b attached.

The blow mold core 32 can after curing the door structure 10 be removed from this, with the inserts 18a . 18b in the door structure 10 remain.

In 3 is a third embodiment of the door structure 10 shown. For reasons of clarity, here is the door structure inner part 12 omitted.

In the door structure 10 According to the third embodiment, the foam core runs 16 along the lower edge of the window 24 , the door lock edge 22 and essentially along the bottom door edge 20 ,

In addition to this foam core 16 is a one-piece blow mold core 37 provided along the window leading edge 26 and the door hinge edge 28 runs. In addition, a section of the blow mold core runs 37 along the lower door edge 20 ,

The door structure interior part 12 is composed of several preforms in all embodiments.

As in 4 can be seen, includes the door structure interior part 12 a door lock-side preform 40 , a sill-side preform 42 , a hinge-side preform 44 , a window front edge side preform 46 and a lower window-side preform 48 ,

For further reinforcement is a reinforcing insert 50 in the door structure interior part 12 arranged. The reinforcement insert 50 is here designed as a unidirectional sliver.

Alternatively to the in 4 shown configuration, the door structure inner part 12 also according to 5 be constructed. In this configuration is the reinforcement insert 50 omitted. In addition, the individual preforms are geometrically modified. In particular, the lower window-side preform 48 otherwise, for example, it does not include an opening.

According to the 4 and 5 includes the door structure inner part 12 five preforms, with the reinforcing insert 50 was not counted as a preform. Of course it is also possible, the door structure inner part 12 build from more or less preforms. The door structure interior part 12 can z. B. comprise three, four or six preforms.

In particular, starting from the in 4 and 5 shown configurations of the sill-side preform 42 and the lower edge-side preform 48 be designed as a single, one-piece preform. This results in a structure of the door structure inner part 12 from four preforms, wherein the reinforcing insert was not counted as a preform again.

In 6 is the structure of the door structure outer part 14 to see. This is composed in the embodiment shown of five preforms.

Also the door structure outer part 14 includes a door lock-side preform 52 , a sill-side preform 54 , a hinge-side preform 56 , a window front edge side preform 58 and a lower window-side preform 60 , Optionally, the door structure outer part 14 with a reinforcement insert 62 be equipped.

As with the door structure interior part 12 mentioned, can also the door structure outer part 14 out of more or less, the door structure exterior may be constructed of three, four or preforms. For example, the six preforms include.

Since carbon fibers are electrically conductive, they must be galvanic of metal parts, eg. B. the inserts 18a - 18d to be isolated. Otherwise, corrosion of the metal parts can occur.

One way to realize this isolation is in 7 shown schematically. Here is in a preform 64 which consists of carbon fibers, a glass fiber layer 66 inserted, so that no direct contact between the carbon fibers and a metal part, not shown, formed. Since glass fibers are not electrically conductive, so the corrosion of metallic components is prevented.

The door structure interior part 12 forming preforms 40 . 42 . 46 . 44 and 48 and / or the door structure exterior 14 forming preforms 52 . 54 . 56 . 58 and 60 may be arranged relative to each other so that they overlap at least partially geometrically. The two in. Can 8th schematically illustrated types of overlap are used.

In the 8a ) are schematically a first preform 100 , the two fiber layers 101 and 102 includes, and a second preform 200 , the two fiber layers 201 . 202 includes shown.

At the overlapping outer contours are the fiber layers 101 and 102 and the fiber layers 201 and 202 arranged staggered in pairs and matched so that the fiber layers 101 and 201 such as 102 and 202 each "on impact" lie.

In the variant according to 8b ) is the outer contour of a preform 300 straight, ie executed without a step. On the other hand, the outer contour of a preform 400 altogether formed as a stage. That means all of the preform 400 forming fiber layers are formed into a step.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102013223519 A1 [0007]
• DE 102012216727 A1 [0008]

Claims (14)

Door structure ( 10 ) of a fiber-reinforced plastic composite material for a motor vehicle, having a door structure inner part ( 12 ) and a door structure outer part ( 14 ), wherein the door structure inner part ( 12 ) and the door structure outer part ( 14 ) at least one preform ( 40 . 42 . 44 . 46 . 48 . 52 . 54 . 56 . 58 . 60 ) and the door structure inner part ( 12 ) and the door structure outer part ( 14 ) together form an integral unit. Door structure ( 10 ) according to claim 1, characterized in that at least in sections between the door structure inner part ( 12 ) and the door structure outer part ( 14 ) a core, preferably a foam core ( 16 ), and / or a cavity is or are arranged, wherein the cavity preferably by a blow mold core ( 32 . 37 ) is formed. Door structure ( 10 ) according to claim 2, characterized in that a one- or multi-part foam core ( 16 ) substantially along a lower door edge ( 20 ) and / or a door lock edge ( 22 ) and / or a lower edge of the window ( 24 ) and / or a window leading edge ( 26 ) and / or a door hinge edge ( 28 ) is arranged running. Door structure ( 10 ) According to claim 2 or 3, characterized in that the cavity, which is preferably (by a one or multi-part Blasformkern 32 . 37 ) is formed along a window leading edge ( 26 ) and / or along a door hinge edge ( 28 ) is arranged running. Door structure ( 10 ) according to one of the preceding claims, characterized in that the door structure inner part ( 12 ) and / or the door structure outer part ( 14 ) at least two preforms ( 40 . 42 . 44 . 46 . 48 . 52 . 54 . 56 . 58 . 60 ). Door structure ( 10 ) according to claim 5, characterized in that the preforms ( 40 . 42 . 44 . 46 . 48 . 52 . 54 . 56 . 58 . 60 ) of the door structure inner part ( 12 ) and / or the door structure outer part ( 14 ) are arranged overlapping at least in sections. Door structure ( 10 ) according to one of the preceding claims, characterized in that the door structure inner part ( 12 ) and / or the door structure outer part ( 14 ) a lock-side preform ( 40 . 52 ), a sill-side preform ( 42 . 54 ), a hinge-side preform ( 44 . 56 ) and a window front edge-side preform ( 46 . 58 ). Door structure ( 10 ) according to claim 7, characterized in that the swelling-side preform ( 42 . 54 ) to a lower edge of the window ( 24 ). Door structure ( 10 ) according to claim 7, characterized in that the door structure inner part ( 12 ) and / or the door structure outer part ( 14 ) a window lower edge side preform ( 48 . 60 ). Door structure ( 10 ) according to one of the preceding claims, characterized in that in the door structure inner part ( 12 ) and / or in the door structure outer part ( 14 ) at least one insert ( 18 ) is arranged from metal and the insert ( 18 ) preferably forms a fastening part for attaching other parts. Door structure ( 10 ) according to claim 10, characterized in that between the insert part ( 18 ) and the door structure inner part ( 12 ) or the door structure outer part ( 14 ) a glass fiber layer ( 66 ) is arranged for galvanic isolation. Door structure ( 10 ) according to one of the preceding claims, characterized in that the door structure inner part ( 12 ) and / or the door structure outer part ( 14 ) at least one reinforcing insert ( 50 . 62 ), preferably from a unidirectional sliver. Method for producing a door structure ( 10 ) of a fiber-plastic composite material for a motor vehicle, having the following steps: a) placing at least one preform ( 40 . 42 . 44 . 46 . 48 ) of a door structure inner part ( 12 ) in a tool, b) inserting at least one core, preferably a foam core ( 16 ) and / or blow molding core ( 32 . 37 ), into the tool, c) inserting at least one preform ( 52 . 54 . 56 . 58 . 60 ) of a door structure outer part ( 14 ) in the tool, d) closing the tool, e) introducing resin into the closed tool and f) curing the resin. A method according to claim 13, characterized in that in step a) and / or in step c) at least two preforms ( 40 . 42 . 44 . 46 . 48 . 52 . 54 . 56 . 58 . 60 ) are inserted into the tool.

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