DE102011106839A1 - Load-bearing outer module for e.g. door of motor car, has outer shell including outer layer that forms external layer of module, and inner shell including stiffening elements on side that faces away from outer shell - Google Patents

Abstract

The module (1) has a multi-layer structure comprised of fiber reinforced thermoplastic inner shell i.e. covering layer, and an outer shell i.e. outer covering layer, with an outer layer, which forms an external layer (1') of the module. The inner shell includes stiffening elements on a side facing away from the outer shell. The stiffening elements are injected either on the inner covering layer as ribs or directly inserted into the inner covering layer as beads. The outer shell is formed as a sheet molding composite (SMC) outer shell such that a structure core is arranged between the shells. Independent claims are also included for the following: (1) a method for manufacturing an outer module (2) a modular housing component.

Description

The invention relates to a supporting outdoor module with an outer panel for a modular housing component, which is in particular a door or trim component of a motor vehicle, and a method for producing the outer module.

Modular motor vehicle doors or body panels generally have a three-part construction and comprise an inner module to which an outer module outside and inside a door inner lining is attached. The outdoor module may be self-supporting to achieve better handling and easier installation of the module, but usually has no immediate support function of the vehicle door.

If the door interior trim and the exterior module cladding fulfill hardly any structural tasks in the first place, in most cases only the reinforcement areas of the interior module and of the door frame or exterior module serve as crash structures. This may be a diagonal side impact protection, as in the DE 10 2005 009 179 A1 is described. There, a motor vehicle door is disclosed which has a lower weight, is easier to handle in the assembly and also has a higher crash stability. This motor vehicle door has an outer shell corresponding outer module with a Außenbeplankung and an inner shell, which is formed by door narrowing side forming reinforcements. At least one support component for functional components is arranged on the inner side of the inner shell. Here, the door narrow sides of the inner shell and the support member are combined to form a single module module corresponding to the inner module, which is provided with a separate door inner lining.

The DE 10 2004 011 250 B3 deals with the releasable attachment of a plastic outer panel to the door frame by means of rails and hooks. In general, the exterior planking of body components in modern motor vehicle doors is not included in the increase in crash performance and requires because of their low rigidity additional stiffening elements. This is in the DE 10 2008 034 038 A1 a particularly lightweight and rigid reinforcing structure for a side door of a motor vehicle described. This has a door support part for the door outer panel and a reinforcing element for increasing the buckling rigidity of the door in the vertical direction at least over a partial height of the door. However, these stiffening elements are subsequently attached to the frame structure of the outer module. These are necessary, on the one hand to improve the dent resistance to avoid minor damage and to achieve a Class-A surface and also to reduce the vibration sensitivity of the large area to acoustic effects such. B. to prevent droning.

The DE 10 2007 042 418 A1 sets a self-supporting exterior module, which consists of a mounted on a supporting frame planking, represents. The support structure is suitable for easy installation of the modules, but does not contribute as a structural component to increase the crash performance.

Basically, the modular design of motor vehicle doors is a common method to reduce the handling and assembly costs. The outer skin usually comprises only an outer door panel without structural tasks as part of the vehicle body.

Are known from the DE 10 2007 024 163 A1 Modular body parts, in which a planking part made of plastic is mounted on a supporting structure made of steel or light metal. The support structure contributes to a higher rigidity and strength and thereby enables the Class A surface suitability of the plastic skin.

From the DE 202 20 552 U1 is a motor vehicle door with an outer assembly and known with a subframe. The outer module has an outer door skin and forms an outer design surface of the motor vehicle door and the subframe is arranged on the side of the outer subassembly assigned to a vehicle interior and can be connected to the outer subassembly; he wears electrical and / or mechanical functional components of the vehicle door. The outer module has reinforcing regions in the region of its outer edges, so that it has sufficient inherent rigidity and can be handled as a separate door element which is independent of the subframe and which is connected to the subframe for producing the complete vehicle door only in a final assembly step.

In the cited prior art, the planking is not integrated into the body concept as a load-bearing component.

Based on this, it is the object of the present invention to provide a supporting outer module having the outer skin, which offers an improvement in crash performance, meets acoustic and optical requirements and contributes to thermal insulation and weight reduction.

This object is achieved by an outdoor module with the features of claim 1.

A further object of the present invention is to improve the process-side sequence and structure in the production of a supporting multilayer outer module which has the outer skin, and to enable shorter cycle times and thus higher quantities.

This object is achieved by a manufacturing method having the features of claim 2. Further developments are set forth in the subclaims.

A modular housing component in which the supporting outer module is used accordingly is disclosed with the features of claim 10.

An outer module according to the invention with outer skin for a modular housing component has a multi-layered construction of a thermoplastic inner lining of FRP and an outer shell with an outer skin arranged thereon, which forms the outer skin. The thermoplastic FRP inner shell has stiffening elements on the side facing away from the outer shell, whereby the outer module is formed as a supporting component. Since the housing component for which the outdoor module is provided may be a modular door or a trim component of a motor vehicle, the outdoor module can be integrated, for example, in a modular body element, thereby enabling not only high design freedom and functional integration, but also the design Adaptation of crash-impacted planking on the vehicle concept.

Although the production of such an outer module in a one-shot process in a single tool is conceivable, since there the output factor is higher, indicating how the effective shot weight, so consumed in a production cycle material, compared to the theoretical shot weight behaves However, the quantity is very limited due to long individual process times. Furthermore, the one-shot process requires a high technological effort.

• – Formen eines thermoplastischen Endlosfaserhalbzeugs, beispielsweise eines Organoblechs, entsprechend einer Innenschalenkontur und Hinterspritzen mit den Versteifungselementen, wobei die thermoplastische FVK-Innenschale erhalten wird,
• – kontinuierlich Herstellen eines SMC-Sheets in einem SMC-Direktverfahren und Fließpressen des SMC-Sheets entsprechend einer Außenschalenkontur, wobei die SMC-Außenschale erhalten wird,
• – Einlegen der thermoplastischen FVK-Innenschale und der SMC-Außenschale in ein Werkzeug und Schließen des Werkzeugs,
• – Erzeugen eines Strukturkerns in einem Hohlraum, der zwischen der thermoplastischen FVK-Innenschale und der SMC-Außenschale gebildet ist, wobei ein Rohaußenmodul erhalten wird,
• – Heißpressen des Rohaußenmoduls,
• – Überfluten der SMC-Außenschale mit einem Polyurethan und Bilden der Außenhaut, wobei das Überfluten der SMC-Außenschale vor oder nach dem Erzeugen des Strukturkerns durchgeführt wird. Das so geschaffene Außenmodul weist eine Class-A-Oberfläche auf. Die Außenhaut kann bereits Farbpigmente aufweisen und damit kann hier bereits ein endfertiges Außenmodul bereitgestellt sein, da jedoch Metallic-Effekte nicht mittels einer solchen IMC-Technik erzeugt werden können, ist das Außenmodul, falls eine Metallic-Lackierung erwünscht ist, noch einem nachfolgenden Lackierprozess zu unterziehen.

A first embodiment of the method for producing the outer module comprises the steps:

• Forming a thermoplastic continuous fiber semi-finished product, for example an organic sheet, corresponding to an inner shell contour and injection-molding with the reinforcing elements, the thermoplastic inner lining of the FRP being obtained,
• Continuously producing an SMC sheet in an SMC direct process and extruding the SMC sheet according to an outer shell contour, whereby the SMC outer shell is obtained,
• Inserting the thermoplastic inner lining of the FVK and the outer shell of the SMC into a tool and closing the tool,
• Producing a structural core in a cavity formed between the thermoplastic inner FRP shell and the outer SMC shell to obtain a rough outer module,
• Hot pressing of the raw outer module,
• Flooding of the SMC outer shell with a polyurethane and forming the outer skin, wherein the flooding of the SMC outer shell is performed before or after the creation of the structural core. The outdoor module thus created has a Class A surface. The outer skin may already have color pigments, and thus a finished outer module may already be provided here, but since metallic effects can not be produced by means of such an IMC technique, if a metallic finish is desired, the outer module is still entitled to a subsequent painting process undergo.

The SMC direct process includes the steps of mixing matrix components with reinforcing fibers, pressing and portioning the fiber matrix mass to the SMC sheet, and performing an accelerated aging of the SMC sheet by subjecting it to microwave treatment. By eliminating the otherwise lasting several days of maturation of SMC semi-finished products, the processing time of the raw materials to the finished outer shell can be reduced to a few minutes. Furthermore, a variation of each individual formulation component, including the fillers and reinforcing fibers, can be realized during the ongoing process. In addition to the reduction of cycle times and costs, a maximum of flexibility during component production can be achieved.

To create the structural core, a foam material may be introduced into the cavity, which may be, for example, a honeycomb structure or a cellular foam structure of injection molded polyamide, but preferably the introduction of the foam material may be accomplished by injecting a foamable polymer material into the cavity. For this purpose, physically or chemically foamable polyurethanes are suitable.

All paths between the individual tools can be bridged automatically, so that the SMC sheet is transferred by the SMC direct method by means of a gripper device for extrusion. Accordingly, the thermoplastic continuous fiber semi-finished product can be spent by means of a gripper device to a molding and injection mold. The formed SMC Outer shell and inner shell can also be transferred by means of gripping means to the tool, in which the production of the structural core takes place.

This tool can advantageously be a cube tool with two closing planes, wherein in a first closing plane of the structural core, in particular by injecting the foamable material and thus the Rohaußenmodul is generated and in a second closing level simultaneously the hot pressing a Rohaussenmoduls generated in a previous closing cycle he follows. This allows short cycle times and large quantities to be realized.

When using such a die tool, the flooding may occur prior to injecting the foamable material in the first sealing plane of the tool or after injecting the foamable material in the second sealing plane of the tool. Alternatively, the flooding may be performed prior to injecting the foamable material into another tool.

When inserting into the tool, at least the SMC outer shell can be held by a device for generating negative pressure. Furthermore, at least one tool surface of the tool, which performs the hot pressing, can be tempered inductively variothermally, in particular with a nitrogen cooling.

A modular housing component according to the invention consists of an outer module, which forms an outer panel for the housing component, and of an inner module connected to the outer module. In the modular housing component may be a modular door or a trim component of a motor vehicle or other device, in particular a household appliance.

These and other advantages are set forth by the following description with reference to the accompanying figures.

The reference to the figures in the description is to aid in the description and understanding of the subject matter. Articles or parts of objects which are substantially the same or similar may be given the same reference numerals. The figures are merely a schematic representation of an embodiment of the invention.

Showing:

1 a perspective view of a modular vehicle door with exterior module, interior module and interior trim,

2 an interior view of an outer module according to the prior art,

3 schematic side sectional views through two vehicle doors of connected outer and inner modules,

4 a partial cross-sectional view through an outdoor module,

5 a schematic cross-sectional view through a layer structure of the outer module according to the invention,

6 an interior perspective view of the outer module,

7 a schematic cross-sectional view through a vehicle door from the connected outer and inner module,

8th a process diagram for the production of SMC in the direct processing method,

9 schematically ondulationfreie and undulating continuous fibers in comparison,

10 a flow chart of the process steps of a manufacturing method according to the invention.

The present invention relates to the manufacture of an outer module for a modular housing component such as a supporting body outer panel. An exterior body panel according to the invention particularly relates to modular driver, passenger, rear side and / or rear doors, roof panels, bumpers, fenders, tailgates, engine hoods, engine covers, compressor / engine covers; Furthermore, the outdoor modules of the invention are generally suitable for modular housing, such as household appliances such as vacuum cleaners.

The outer module described for this purpose, by way of example in the figures, a vehicle door exterior module 1 , has a multi-layered construction of thermoplastic and thermosetting FRP cover layers, stiffening elements that can either be molded onto the inner FRP cover layer as ribs or introduced directly into it as corrugations, from a core structure and a tool-made surface preparation for an open class A or surface coating of the used for the thermosetting FRP cover layer SMC sheets. The thermoplastic FRP cover layer is formed from an organic sheet.

The term "SMC sheet" here refers to a fiber-matrix semifinished product from a plate-like dough-like molding compound which comprises thermosetting reaction resins and reinforcing fibers, which are usually in matt form, more rarely in fabric form with typical fiber lengths of 25 to 50 mm. In addition, SMC molding compositions contain additives for reducing the shrinkage, such as polyethylene, styrene and / or other thermoplastic constituents. In addition to reaction resin, reinforcing fibers and the additives for shrinkage reduction, SMC compositions usually contain fillers, in particular mineral fillers, and may also contain other additives such as reaction accelerators, inhibitors, release agents, color pastes, flame retardants, etc. The SMC compound is pressed in foil form and can then be cut to size and further processed by extrusion. In this case, fastening elements can already be inserted into the mold. This makes SMC particularly economical. The fillers serve to reduce weight and costs. Advantageously, with a SMC semi-finished product comprising appropriate shrinkage reduction additives to achieve a shrinkage of less than -0.05%, Class A surfaces can be produced.

The term "organic sheet" is understood to mean plate-shaped continuous fiber reinforced thermoplastic pulleys used for components with high strength and low weight. Organic sheets can be thermoformed and enable short process cycles and are also easy to weld. Available organic sheets, for example from TPone, Zeesen, Germany, have glass, carbon and aramid fibers as reinforcing fibers, PA6, PA12, PPS, PEEK, PET, PBT, HDPE are offered as matrix systems there.

Organic sheets may consist of special fiber arrangements having fibers in defined orientations embedded in the thermoplastic matrix. For example, the fiber arrangements can be fabrics, scrims, knits, etc. In addition to the mentioned reinforcing fibers and matrix systems, of course, all other common types of reinforcing fibers, for. As ceramic fiber, metal fibers, natural fibers and other polymer fibers in question; Also, various reinforcing fibers may be combined in a fiber array. The matrix systems mentioned are to be understood as exemplary only and in no way limiting.

Thus, the organic sheet used to form a cover layer may comprise aramid fibers and a network of steel fibers in the thermoplastic matrix.

The core structure provided between the cover layers may have a cellular structure of a polyurethane foam, a foam injection-molded polyamide or a honeycomb structure.

The surface preparation performed in the tool is a hot pressing and flooding of the SMC sheet to obtain a coatable Class A surface of the outer module topcoat.

The structure of the outer module made of thermoplastic and thermosetting cover layers with structural core and stiffening elements allows, for example, the adaptation of the crashbeaufschlagten planking on the vehicle concept by the configuration of materials, semi-finished products and geometries due to the high degree of design freedom and functional integration. The planking can be optimally integrated as a load-bearing component in a modular body element; this can be like 1 shows to be a vehicle door and an interior trim 3 , an outdoor module 1 (Planking module) and an indoor module 2 (Door carrier) be constructed. The door carrier 2 takes in addition to the outdoor module 1 and the interior trim 3 Functional units, such as windows, speakers, etc. on.

The outdoor module 1 or the planking is due to its structure acoustic and optical requirements in terms of a Class A surface and the freedom of design. The sandwich construction of the planking also contributes significantly to the importance of thermal insulation and weight reduction in the course of electromobility. Furthermore, the structure offers excellent NVH characteristics, with NVH (Noise, Vibration, Harshness) which are referred to as vibration audible and / or vibration in motor vehicles.

Since in a side impact and side crash (eg, Federal Motor Vehicle Safety Standard Side Impact, FMVSS, 214), the planking as the first vehicle element is in contact with the impact body, the bearing outer panel of the present invention provides 1 as an energy absorbing element an improvement of the crash performance.

While 1 a modular structure of a motor vehicle door with an indoor module 2 , an outdoor module 1 with planking 1' and a door lining 3 shows is in 2 an outdoor module 1 represented according to the prior art. As in the prior art, the door inner lining 3 and the planking 1' in the first place hardly perform any structural tasks, in most cases serve exclusively the reinforcement areas of the inner module and the Türrahmes 2 ' as part of the exterior module 1 as crash structures. These crash-relevant structures are protected by an approximately diagonal side impact protection 3 ' strengthened. To increase the dent resistance of the outer skin 1' the outdoor module here additionally has a stiffening element 4 ' on.

The planking module which can be produced by the method according to the invention 1 Can be integrated as a load-bearing structure in the vehicle body.

The disclosed manufacturing method reduces both the investment and the manufacturing costs, since the decoupling of the number of components in the tool from the clamping force is made possible with the floor technology used or reversing plate technology, there is no linear course. Furthermore, the manufacturing method according to the invention guarantees small dimensional tolerances and enables short cycle times by using a thermoplastic matrix system. The painting is done in a separate, subsequent step, so that metallic effects are feasible.

The production of the outdoor module 1 with the FRP sandwich structure takes place in a plant 20 with two closing levels I, II as in 10 shown. In order to keep the cycle times, investment costs and beyond the dimensional tolerances low, a tool cube / insert combines 21 the two processing stations I, II with each other. Since metallic coatings can not be applied in closed molds, for example by in-mold coating, offline painting is outside the mold 20 unavoidable. This takes place according to the production process according to the invention.

The sandwich construction of the outer module 1 combines a high weight-specific stiffness in both crash and vibration behavior with good thermal and acoustic insulation. Electromobility plays a key role in increasing range, ride comfort and cost reduction. In addition, the listed layer structure additionally isolates the interior by reducing the sound radiation of the large-area planking due to the high rigidity and absorbing the ambient noise through the foam core.

The outdoor module according to the invention 1 is particularly suitable for use in modular body elements, these can according to the in 1 be constructed shown motor vehicle door. The structure and the number of individual components in the body element can vary according to the requirement profile. Due to the simple handling and the quick installation of the planking module according to the invention 1 Furthermore, the manufacturing cost of the body member are significantly reduced. The planking module 1 protrudes in the mounted state over the contour of the carrier module 2 out to cover the dividing plane between them. In this parting line, as in 3 shown, for mounting the planking module 1 to the carrier 2 a circumferential adhesive bond 9 be applied in the edge regions, such as with a Sikaflex ^® adhesive, Sika Germany GmbH, Stuttgart. This adhesive connection 9 can be removed with a necessary repair of the internal units. To the planking 1 after repair again to the carrier 2 to add again an adhesive edge 9 be applied.

The one from the SMC topcoat 4a formed outer half shell 4a represents the planking 1' of the outdoor module 1 ready, while from the organic sheet the inner half-shell 4b is formed, which the stiffening elements such as reinforcing ribs 7 having.

Because of the good formability of the organic sheet in the warm state and the shape independence of the inner cover layer 4b in the case of sandwich components and the outer cover layer which can be produced by extrusion from the SMC sheet 4a a high design freedom can be guaranteed and the transition area between the planking module 1 and carriers 2 be designed in different ways. So can the inner cover layer 4b the planking 1 as a kind of inset 2 B in the door carrier 2 be inserted ( 3 , left), with the bond 9 done in the border area. Alternatively, a weld in the injection mold on heating cartridges done.

The introduction of the through the planking module 1 absorbed power in the door carrier 2 can also by a tongue and groove principle 9 ' . 9 '' be improved ( 3 , right), where here the inner cover layer 4b the planking 1 in the edge area as a spring 9 ' is formed, which in a corresponding groove 9 '' in the edge area of the interior module 2 intervenes. The circulating adhesive connection 9 can be integrated into the tongue and groove connection, wherein for mounting the adhesive 9 in the groove 9 '' or on the spring 9 ' can be applied.

In 4 and 5 is the layer structure of an outer module according to the invention 1 , which is present as a fiber composite sandwich component shown. This consists of two cover layers 4a and 4b , wherein for the outer cover layer 4a a SMC sheet is used and the inner cover layer 4b consists of a crash-resistant organic sheet, for example, embedded in a thermoplastic resin matrix Carbon fibers, steel threads and aramid fibers consists. Furthermore, the merh layer structure of the outer module comprises 1 a structural core 5 , z. B. of a polyurethane or polyamide foam, an outer skin 6 which is obtained, for example, by flooding with a polyurethane varnish, and stiffening ribs 7 or beads with locally foamed spaces 8th and the already mentioned adhesive bond 9 , which may also be a primer.

In the in 4 The example shown may be that between the cover layers 4a and 4b sandwiched foam core 5 from a maximum thickness of, for example, 15 mm to 5 mm, with no foam core material between the cover layers in the edge region 4a . 4b is present. The outer cover layer 4a is here formed from a SMC sheet on which the outer skin 6 forming paint layer is applied. The organic sheet for the inner cover layer 4b here is 1.2 mm thick.

Depending on the mechanical, optical and acoustic requirements, the described layer structure of the planking module can vary. So z. B. the density of the foam core 5 be varied or the core 5 can be completely eliminated (eg for wheel arches).

The stiffening elements on the inner organo sheet 4b in the form of beads 10 and ribs 7 (please refer 6 ) can additionally stiffen the sandwich structure. The shaping of z. B. wavy areas 11 , sketched in 7 , and the use of a flexible adhesive 9 are possibilities to achieve a certain compliance in the event of a crash (necessary for the force absorption over the entire Eindrückweg of about 445 mm in the door resistance test FMVSS 214) and to maintain the structural integrity, without sacrificing the design freedom of the outer skin 1' to influence negatively. In the event of a side crash, the load-bearing paneling, in contrast to conventional side impact protection elements (which direct the force selectively into the side walls), enables the surface force transmission via the inner module, the door carrier module 2 to the side walls (A / B / C columns). The wavy areas 11 , which have a suitable deformation structure geometry, represent deformable areas that in the outer module 1 are integrated.

Another key issue in large plastic parts is the adjustment of thermal expansion and the associated gap size. The anisotropic behavior of fiber composites may be present in the present planking 1 be balanced constructively by suitable material combinations and corresponding ply structures and so small tolerances are annoyed.

Around the SMC sheet with Class A surface quality to form the outer shell 4a of the outdoor module 1 For example, the in 8th presented direct method for SMC (D-SMC), which enables continuous production of SMC compounds with direct subsequent processing to the component in the extrusion molding process. First, in a mixing unit 43 the liquid components 44 and the fillers 45 blended before the reinforcing fibers in the Schnittfaserdosierung 42 be mixed. The SMC mass thus obtained is formed into plates and according to the intended use for the outer shell 4a by means of a cutting device 41 portioned before they are in the microwave maturing unit 40 subjected to accelerated aging, so that the obtained SMC sheet by means of a suitable gripper device 30 in the extrusion tool 50 The SMC sheet can be transferred to the outer shell 4a pressed. This one-step process eliminates the need for several days of ripening and thus the processing time of the raw materials to the finished outer shell 4a reduced to a few minutes. By eliminating the intermediary intermediate step, a variation of each individual formulation component, including the fillers and reinforcing fibers, can be realized simultaneously during the ongoing process. In addition to the reduction of cycle times and costs, a maximum of flexibility during component production can be achieved. 9 Fig. 2 shows the different fiber structure of a non-tangled random fiber, as present in the SMC sheet, whose individual fibers or fiber bundles have no preferential orientation, compared to an undulating fabric, as it can be used for the organic sheet.

10 illustrates the manufacture of the outer module 1 with the SMC / Organboblech sandwich structure in a cube tool 20 , Here is the closing level I on the stamp page 21 of the tool cube 20 the already finished and with the stiffening elements injected inside half shell 4b by means of gripper 30 and a linear unit 30 inserted. The outer SMC half shell 4a is also in its final form by means of gripper 30 and a linear unit 30 ' into the die side 22 the shooting level I of the tool 20 inserted. In the closing level I is the foaming of the gap between the half-shells 4a . 4b instead of. The stamp page is located in the tool cube 21 and the die side, the later the planking 1' of the outdoor module 1 by flooding with a PUR varnish to form the outer skin 6 trains, on the closing side 22 , The flooding of the outer shell 4a before foaming, in the closing plane I of the cube tool 20 or in another tool. That to the outer shell 4a Shaped SMC sheet is contoured into the die of the closing side 22 inserted, there by means of vacuum suction 26 fixed in his position. After closing the tool 20 Will the between the outer shell 4a and the inner shell 4b formed cavity foamed and so a Rohaußenmodul 1'' from inner shell 4b , Structural core 5 and outer shell 4a (and possibly the outer skin 6 ) receive. In the clasp plane II is on the stamp side 21 an already filled out in a previous cycle Rohaussenmodul 1'' , Alternatively to the flooding of the outer shell 4a before foaming in closing level I, the outer shell can also be filled with foam 4a of the raw outer module 1'' be flooded in the closing level II.

In the top picture of the 10 is the outer skin formed by flooding 6 shown in both closing levels I, II, however, only one of the two alternative process variants will be selected.

The foaming of the gap between the outer shell 4a and the inner shell 4b by means of an injection device 24 for a foamable material such as a polyurethane then takes place in a closed mold 20 , shown in the middle picture of the 10 instead, while at the same time in the second closing plane II of the tool 20 the hot pressing of the raw outer module 1'' to the finished outdoor module 1 he follows. For this purpose has the closing side 23 the second closing plane of the tool 20 a temperature control, which tempered the tool surface inductive or with nitrogen.

Of course, the other tool surfaces of the tool can 20 be equipped with tempering, and the tempering can in addition to nitrogen also have a water or oil cooling.

After completion of the closing cycle of the tool 20 can in it, as in the bottom picture of the 10 indicated by the dashed arrows, the finished outdoor module 1 from the closing level II by means of a linear unit 30 ' and a final finish, such as for metallic effects, the planking side 1' be supplied.

That in the closing plane I by the foaming of the space between the outer and inner half-shell 4a . 4b generated raw external module 1'' remains on the stamp side 21 of the tool 20 so that it turns after the tool cube 21 180 ° in the closing plane II (top picture of the 10 ), in which then the - if not yet done, flooding and - hot pressing is performed, while in the closing level I again half-shells 4a . 4b be inserted.

With the method according to the invention, assembly, functional and manufacturing costs can be reduced, wherein the self-supporting outer module can be manufactured with low manufacturing tolerances by in-mold assembly, while various processing steps are connected by a tool cube, so that the outer module produced quasi in a machine can be. The sandwich construction of the lightweight core outer module contributes to weight reduction, and the outer module can be used as a structural member to enhance crash performance by distributing the energy widely to the outside of the support. The modular design of the housing module manufactured with the outer module such as a motor vehicle door requires only a small handling effort. Due to the low vibration sensitivity / NVH or the increase in stiffness, a gain in comfort is achieved, and at the same time the layer construction not only gives a high degree of design freedom, but also a Class A surface. Functional elements such as strain waves can be structurally integrated into the inner cover layer because of the design independence. Thus, the course of the indentation resistance is specifically defined via the Eindrückweg by material selection, layer structure, functional elements. The functional integration holds further cost saving potential. The connection of the modules by gluing prays a simple repair concept.

It is particularly important for use in motor vehicle construction that short cycle times and higher quantities can be realized by the method according to the invention, so that the outdoor module can also be mass produced. The planking provided by the outdoor module is of high quality, not yielding, and has a very good thermal insulation and a very good acoustic behavior.

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 102005009179 A1 [0003]
• DE 102004011250 B3 [0004]
• DE 102008034038 A1 [0004]
• DE 102007042418 A1 [0005]
• DE 102007024163 A1 [0007]
• DE 20220552 U1 [0008]

Claims (10)

Outdoor module ( 1 ) with an outer skin ( 1' ) for a modular housing component, characterized in that the outer module ( 1 ) a multilayer structure of a thermoplastic FRP inner shell ( 4b ) and an outer shell ( 4a ) with an outer skin ( 6 ), the outer skin ( 1' ), wherein the thermoplastic FRP inner shell ( 4b ) on the outer shell ( 4a ) side facing stiffeners ( 7 . 10 . 11 ) having. Method for producing an outer module ( 1 ) according to claim 1, wherein the outer shell ( 4a ) an SMC outer shell ( 4a ) and between the thermoplastic FRP inner shell ( 4b ) and the SMC outer shell ( 4a ) a structural core ( 5 ), comprising the steps of: - providing the thermoplastic FRP inner shell ( 4b ) by molding a thermoplastic continuous fiber semi-finished product according to an inner shell contour and injection molding with the stiffening elements ( 7 . 10 . 11 ), - providing the SMC outer shell ( 4a ) by continuously producing an SMC sheet in an SMC direct process and extruding the SMC sheet according to an outer shell contour, - inserting the thermoplastic FRP inner shell ( 4b ) and the SMC outer shell ( 4a ) into a tool ( 20 ) and closing the tool ( 20 ), - generating the structural core ( 5 ) in one between the thermoplastic FRP inner shell ( 4b ) and the SMC outer shell ( 4a ), thereby obtaining a Rohaußenmoduls ( 1'' ), - hot pressing of the raw outer module ( 1'' ), - flood the SMC outer shell ( 4a ) with a polyurethane and forming the outer skin ( 6 ). Method according to claim 2, in which the SMC direct method comprises the steps: Mixing of matrix components with reinforcing fibers, Pressing and portioning the fiber matrix mass to the SMC sheet, - Perform an accelerated maturation by means of microwaves. Method according to claim 2 or 3, wherein the flooding of the SMC outer shell ( 4a ) before or after the creation of the structure kernel ( 5 ) is carried out. Method according to at least one of claims 2 to 4, wherein the generation of the structural core ( 5 ) comprises introducing a foam material and in particular by injecting a foamable polymer material into the cavity, wherein the structural core ( 5 ) comprises a honeycomb structure and / or the foam material is an injection molded polyamide foam and / or the foamable material is a polyurethane. Method according to at least one of claims 2 to 5, comprising the step of: - automatically transferring the SMC sheet according to the SMC direct method for extruding, the thermoplastic continuous fiber semi-finished product into a molding and injection mold, the outer shell ( 4a ) from extrusion to the tool ( 20 ) and the inner shell ( 4b ) from the mold and injection mold to the tool ( 20 ) by means of one or more gripper devices ( 30 ). Method according to at least one of claims 2 to 6, wherein the tool ( 20 ) a tool cube ( 20 ) with two closure planes (I, II), wherein the creation of the structural core ( 5 ) in a first closing plane (I) of the tool ( 20 ) and the hot pressing of the raw outer module ( 1'' ) in a second closing plane (II) of the tool ( 20 ) he follows. The method of claim 7, wherein the flooding prior to injection of the foamable material in the first sealing plane (I) of the tool ( 20 ) or in another tool and the flooding after injection of the foamable material in the second closing plane (II) of the tool ( 20 ) he follows. Method according to at least one of claims 1 to 8, wherein at least the SMC outer shell ( 4a ) by a device for generating negative pressure ( 26 ) in the tool ( 20 ) is maintained and at least one tool surface for hot pressing inductively variotherm, in particular with a nitrogen cooling is tempered. Modular housing component with an outdoor module ( 1 ) with outer skin ( 1' ) and an indoor module ( 2 ), characterized in that the outer module ( 1 ) an outdoor module ( 1 ) according to claim 1, which can be produced by a method according to at least one of claims 2 to 9, and with the inner module ( 2 ) connected is.

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