DE102024116500A1 - Fiber-reinforced plastic composite component, elastomer bearing and process - Google Patents

Abstract

Proposed fiber-reinforced plastic component (2) which has a wall thickness (D) and an extent (E), wherein either the fibers of the fiber-reinforced plastic component (2) have an average fiber length of at least 10 mm but not more than 60 mm, or the fibers of the fiber-reinforced plastic component (2) are continuous fibers in nonwoven form, wherein the ratio of the wall thickness (D) to the extent (E) is at least 6:150 and at most 20:40.

Description

The invention relates to a fiber-reinforced plastic composite component according to claim 1 and a bearing with the features of claim 5. Furthermore, the invention includes methods according to claims 8, 9 and 10.

Elastomeric bearings designed as bushings are common in practice. To protect highly loaded elastomeric bearings from overload, stop systems or stop devices are regularly used. These stop systems comprise a stop shell, a stop stop, and an elastomeric body connecting the stop shell and the stop stop. In its overall function, such a stop system serves to limit radial travel. These stop systems are positioned between an inner connection geometry, usually a screw-in bearing core, and an outer connection geometry, usually an outer sleeve. Depending on the degree of travel limitation or required free movement, these stop systems must have a corresponding thickness in the radial direction.

The geometry of the stop and the stop shell is largely defined by the requirements, such as strength, clearance, and the connection geometry to the stop. This results in wall thicknesses of up to 8 mm or even more than 10 mm, which correspond to the desired travel limitation. At the same time, these are relatively small and therefore compact, thick components.

The stop block is typically manufactured from plastic using injection molding. This process potentially creates a free jet within the plastic material, which significantly reduces the breaking load of the injection-molded plastic stop block.

Furthermore, voids form in the plastic material during cooling, as the injection-molded plastic stop block has large material accumulations due to its design requirements. These voids also reduce the breaking load.

The stop shells are also typically manufactured from plastic using injection molding. While they are somewhat thinner than the stop blocks, they are still small components. It is also common to find textured surfaces on the side of the injection-molded stop shell facing the outer connection geometry to create damping channels in hydraulic bearings. On the side opposite the channels, the elastomer pad facing the stop block is applied by vulcanization. This surface must be smooth (not ribbed). This necessitates that the stop shell be thick enough to accommodate fluid channels, yet simultaneously smooth. Therefore, stop shells regularly have wall thicknesses exceeding 6 mm, and sometimes even 8 mm.

Plastic components in elastomer bearings for vehicles are relatively small and compact due to the dimensions of the stop block. The maximum dimension of such plastic components is typically less than 150 mm or even less than 100 mm. The combination of a typical wall thickness of 6 mm to sometimes over 8 mm for stop shells, and even well over 10 mm for stop blocks, with a simultaneously very small dimension, is described by experts as a "design not suitable for plastics" and regularly presents manufacturers of such injection-molded components with a major challenge when high-strength, void-free components without weld line-like material weakening due to the risk of free jet formation must be reliably produced.

The object of the invention is therefore to create a fiber-reinforced plastic composite component and an elastomeric bearing, each of which overcomes the aforementioned problems. Furthermore, appropriate manufacturing processes are to be developed.

The main features of the invention are specified in claims 1, 5, 8, 9 and 10. Embodiments are the subject of the dependent claims.

According to the invention, a fiber-reinforced plastic composite component is therefore proposed, which has a wall thickness and an extent, wherein either the fibers of the fiber-reinforced plastic composite component have a mean fiber length of at least 10 mm but at most 60 mm, or the fibers of the fiber-reinforced plastic composite component are present as continuous fibers in nonwoven form, wherein the ratio of the wall thickness to the extent is at least 6:150 and at most 20:40.

The invention eliminates the need for plastic injection molding as a manufacturing process for the component, thereby avoiding its associated disadvantages. The invention thus enables the cost-effective production of a component that can be relatively compact and have wall thicknesses unsuitable for plastics. Free jets are avoided, resulting in high breaking loads and high strength with overall homogeneous component properties. The risk of voids is also eliminated, which further contributes to the high breaking load. Previously necessary ribbing is no longer required. This eliminates the need for weld lines, thus avoiding weld lines in the area of the convergence zones of different flow fronts, which leads to improved compressive and flexural strength. Therefore, the invention enables the production of high-strength, void-free components without weld line-like material weaknesses.

According to the invention, the mean fiber length is selected such that large property gradients within the fiber-reinforced plastic composite component are avoided. This prevents the associated intrinsic notch effect, statistically distributed weak points, and ultimately premature component failure due to low breaking loads.

The wall thickness corresponds to the diameter of the largest possible sphere that can fit inside the fiber-reinforced plastic component, preferably completely. The extent corresponds to the diameter of the smallest possible sphere that can fit inside the fiber-reinforced plastic component, preferably completely. Wall thickness and extent can be considered dimensions of the component. The mean fiber length can be determined, for example, by incinerating the component. It can be ascertained from the fiber-reinforced plastic component.

It is conceivable that the fibers in the fiber-reinforced plastic component or semi-finished product are isotropically oriented, at least in certain areas of the fiber-reinforced plastic component, and preferably throughout the entire component. This allows the isotropically distributed fibers to extend through large portions of the fiber-reinforced plastic component. Isotropic fiber orientations are achieved particularly when using continuous fiber-reinforced semi-finished products, such as GMT semi-finished products with embedded fiber webs. It is also conceivable that the fibers exist as fiber bundles, with the fiber bundles themselves being largely isotropic within the component. Macroscopically isotropic material properties can also be achieved in this way, even if the fiber bundles themselves may exhibit a highly anisotropic orientation.

The continuous fibers can, for example, have a length of more than 50 mm.

According to a further development of the fiber-reinforced plastic composite component, the wall thickness can be at least 6 mm and/or the extent at most 150 mm.

It is conceivable that the ratio of wall thickness to extent lies between 6:100 and 15:60. These dimensions have proven advantageous for both appropriately dimensioning and manufacturing high-strength components. Such compact components are used particularly as compact stoppers. The more compact the stopper, the fewer bending stresses occur in the component due to reduced leverage.

According to a further development of the fiber-reinforced plastic composite component, it can be manufactured by extrusion, preferably from a thermoplastic fiber-reinforced semi-finished product or a thermoset fiber-reinforced semi-finished product. Semi-finished products with fiber bundles between 10 mm and 60 mm in length, distributed as isotropically as possible within the semi-finished product, are preferably used. It is also possible to layer several semi-finished products in the mold to achieve sufficient wall thickness in the component using thinner semi-finished products.

The fiber-reinforced plastic composite component can therefore be a flow-formed part. This is evident from the component's appearance, as no injection molding marks are visible. Consequently, the component also lacks typical material weaknesses in the gate area. In particular, the surfaces have a homogeneous appearance. Specifically, no structured surfaces are visible, such as those typical of components where free jet formation with subsequent consolidation of the free jet occurs. This avoids the disadvantages associated with injection molding. While components can also be manufactured using long glass fiber injection molding, the fibers break upon injection into a cavity, resulting in fiber lengths of at most 8 mm, and thus an average fiber length of less than 8 mm. Furthermore, the previously described disadvantages of weakening at the gate and the non-homogeneously consolidated free jet are particularly pronounced in long glass fiber injection molding of very thick-walled, compact components – the component according to the invention is also thickly dimensioned. Surprisingly, it turned out that extrusion, which is not usually used for components dimensioned according to the invention, proved to be particularly suitable, even though it initially appears economically unviable. Large, plate-shaped semi-finished products must first be pre-cut into small plates before they can be inserted into the compact cavities in their plasticized state. This pre-cutting, for example by sawing or waterjet cutting, is very cost-intensive and easily exceeds the process costs of extrusion by a factor of 2-4. Therefore, components in the dimensions according to the invention are typically injection-molded and ribbed. However, the high strength, stiffness, and impact resistance requirements for the component cannot be met by injection molding, since, in particular, but the free jet formation leads to significant losses in strength.

The fiber-reinforced plastic composite component can, for example, be a GMT extrusion part (GMT = glass mat reinforced thermoplastic), an SMC extrusion part (SMC = sheet molding compound), or a BMC part (BMC = bulk molding compound). Therefore, the combination of the component dimensions, fiber configuration, and manufacturing process according to the invention offers the surprising advantages of producing very compact components without the formation of a free jet and without the associated weakening in that area.

According to a further development of the fiber-reinforced plastic composite component, it can be formed from a cut-out of a semi-finished product or from a stack of cut-outs of a semi-finished product.

Each blank can have a wall thickness before pressing, also referred to as the individual initial wall thickness. Each stack can also have a wall thickness before pressing, also referred to as the initial wall thickness. By stacking several blanks of suitable wall thickness, components with a significantly reduced defect density (e.g., voids or tightly compressed free-jet clusters) can be produced, which, to the expert, might be considered unsuitable for plastics processing.

According to the invention, a bearing is also proposed comprising a first connecting element, a second connecting element, a stopper means which can be arranged between the first connecting element and the second connecting element, and at least one fiber-reinforced plastic composite component, wherein the at least one fiber-reinforced plastic composite component is part of the stopper means.

The advantages and features described above regarding the fiber-reinforced plastic composite component apply equally to the bearing, to which reference is hereby made.

The bearing can comprise an elastomeric body arranged on the first and/or second connection element, preferably vulcanized on. The stopper can be an assembly and thus advantageously pre-assembled or prefabricated. The first connection element can, for example, be a bearing core or a flange.

The second connection element can be, for example, an outer sleeve or a connecting base. The stopper can be positioned in a load path between the connection elements. This arrangement allows a force applied to one of the connection elements to be transmitted via the stopper to the other connection element. It is also conceivable that the connection elements could be arranged to be adjustable relative to each other.

According to a further development of the bearing, the bearing can be a hydraulic bearing or an elastomeric bearing and/or the stopper means can comprise a stop stop, a stop shell and an elastomeric body connecting the stop stop and the stop shell, preferably consisting of, wherein preferably the stop shell can have a cutout and the stop stop can plunge into the cutout and/or through the cutout under load in the direction of the load path, wherein the stop stop and/or the stop shell is/are designed as the fiber-reinforced plastic composite component.

The stop block and/or the stop shell can (each) be a fiber-reinforced plastic composite component. The advantages of the invention can be particularly realized in the form of the stop block and/or the stop shell as a fiber-reinforced plastic composite component. These components, in particular, are subjected to enormous loads in the load path of highly stressed bearings and are protected from overload by the invention. Depending on how far the adjustment range of the connecting elements relative to each other is to be restricted, the stop block and/or stop shell can have a corresponding wall thickness. This is easily achieved with the invention.

In an elastomeric bearing or hydraulic bearing, a (further) elastomer body can connect the first connection element, for example, an outer sleeve, to the second connection element, for example, a bearing core, and bond it there. Support elements, such as a cage in a hydraulic bearing, can be embedded in the (further) elastomer body. It is conceivable that the (further) elastomer body and/or at least one support element defines a channel with the first connection element. It is also conceivable that the bearing has at least two chambers that can be filled with fluid and are fluidically connected via the channel.

According to a further development of the bearing, the bearing can be an elastomeric bearing or a hydraulic bearing, and the stopper means can comprise or be a stop shell, wherein the first connection element, when the bearing is subjected to a load, preferably a radial load, in a direct load path, preferably by direct or directly elastomer-buffered contact, with the The stop shell can be accessed. It is conceivable that the stop element is designed without a radial opening for a stop. Since the stop shell now serves for contact with the first connection element, an opening for receiving a stop can be omitted.

The stop shell can be a fiber-reinforced plastic composite component. The advantages of the invention are particularly evident in the form of a stop shell made of fiber-reinforced plastic. This component, in particular, is subjected to enormous loads in the load path of heavily loaded bearings and is protected from overload by the invention. Depending on how far the adjustment range of the connecting elements relative to each other is to be restricted, the stop shell can have a corresponding wall thickness. This is easily achieved with the invention.

In an elastomeric bearing or hydraulic bearing, an elastomer body can connect the first connection element, for example, an outer sleeve, to the second connection element, for example, a bearing core, and bond it there. Support elements, such as a cage in a hydraulic bearing, can be embedded in the elastomeric body. It is conceivable that the elastomeric body and/or at least one support element, together with the first connection element, define a channel. It is also conceivable that the bearing has at least two chambers that can be filled with fluid and are fluidically connected via the channel.

It is conceivable that the first connecting element is equipped with an elastomeric stop, an elastomer-coated stopper projection, a stopper projection supporting the elastomeric stop, and/or an elastomer-free stopper projection. The stopper projection can extend along the central longitudinal axis A and form a rib. Alternatively, the stopper projection can form a stop geometry or bulge, preferably centrally located, projecting from the first connecting element. The elastomeric stop and/or the stopper projection extend radially from the first connecting element. This allows the adjustment range between the elastomeric stop and/or stopper projection and the stopper element to be limited and adjusted. The stopper projection can be formed by the first connecting element, preferably in one piece and/or of a single material. Alternatively, the stopper projection can be positively and/or force-fit connected to the connecting element, for example, by injection molding it onto a continuously extruded connecting element.

The elastomer stop can have a radial thickness of 0.6 mm to 20 mm. It can achieve direct elastomer-buffered contact. Therefore, only the elastomer stop is located between the stopper projection and/or first connecting element and the stopper element during contact.

It is conceivable that the elastomer-free stopper projection defines a hard stop. It can achieve direct contact between the stopper projection and the stopper mechanism.

Furthermore, it is conceivable that the elastomer-coated stopper projection is provided with a thin elastomer skin. This skin can have a radial thickness of 0.6 mm to 3 mm. It can achieve direct elastomer-buffered contact.

• - Bereitstellen eines thermoplastischen faserverstärkten Halbzeugs,
• - Zuschneiden des faserverstärkten Halbzeugs zur Erzeugung zumindest eines Einlegers,
• - Erhitzen des Einlegers,
• - Einbringen des erhitzten Einlegers in eine Kavität eines Fließpresswerkzeugs,
• - wobei das Fließpresswerkzeug mindestens eine Tauchkante aufweist,
• - Schließen des Fließpresswerkzeugs,
• - Umformen des Einlegers mittels Aufbringen eines Pressdrucks, so dass der Einleger in der Kavität fließt, zur Erzeugung des Faser-Kunststoff-Verbundbauteils und
• - Entformen des Faser-Kunststoff-Verbundbauteils.

According to the invention, a method is also proposed for producing a fiber-reinforced plastic composite component as disclosed, which has a wall thickness and an extent, wherein either the fibers of the fiber-reinforced plastic composite component are present as fiber bundles and have an average fiber length of at least 10 mm but at most an average fiber length of 60 mm, or wherein the fibers of the fiber-reinforced plastic composite component are present as continuous fibers in nonwoven form, wherein the ratio of the wall thickness to the extent is at least 6:150 and at most 20:40, comprising the following steps:

• - Providing a thermoplastic fiber-reinforced semi-finished product,
• - Cutting the fiber-reinforced semi-finished product to produce at least one insert,
• - Heating the insert,
• - Inserting the heated insert into a cavity of a flow-forming tool,
• - wherein the extrusion tool has at least one immersion edge,
• - Closing the extrusion tool,
• - Shaping the insert by applying pressure so that the insert flows in the cavity, to produce the fiber-reinforced plastic composite component and
• - Demolding of the fiber-reinforced plastic composite component.

The advantages and features described above regarding the fiber-reinforced plastic composite component and the bearing apply equally to the process to which reference is hereby made. The steps indicated can be found in the The specified order must be present. The procedure can be a GMT procedure.

This process is suitable, for example, for manufacturing a fiber-reinforced plastic composite component as a GMT extrusion part. Cutting the fiber-reinforced semi-finished product creates one or more blanks. Instead of a single insert, several inserts or even a stack of inserts can be used. Another possible process step is to create a stack of inserts after cutting. The use of the extrusion process allows for the use of appropriately long fibers. The fiber length in the insert is largely maintained during processing in the extrusion die, so that the average fiber length in the pressed part or fiber-reinforced plastic composite component corresponds almost exactly to the average fiber length of the insert.

By using a dipping edge, circumferential trimming of the pressed part or fiber-reinforced composite component is unnecessary. Instead, the insert only flows up to the dipping edge during forming and pressing. This results in significantly less waste compared to a pressing process where flat semi-finished products protrude beyond the final component dimensions or even the cavity and are squeezed off circumferentially during the pressing process. Therefore, the use of a dipping edge is particularly sustainable and advantageous for the components dimensioned according to the invention. Due to the insert's compact size, it can also be inserted and positioned with sufficient precision within the cavity to make the process more sustainable and less prone to waste compared to larger pressed parts.

The plunge edge can be part of the extrusion tool. When the tool closes, it can plunge into the cavity, thus forming a yield point on the outer circumference (relative to the insert).

The relatively small insert can be positioned with sufficient precision within the similarly small cavity so that it does not protrude beyond its outer circumference. This is possible because the insert can be sufficiently thick relative to the dimensions of the compact or fiber-reinforced composite component to press material from the (thicker) center to the outer edge of the cavity, or vice versa, since the plunge edge in the mold prevents lateral flow. Compared to its thickness or wall thickness, the lateral flow paths of the compact insert according to the invention are small. Due to the inventive design, the insert exhibits little to no sag when placed in the cavity. This allows for the use of simple devices for transporting the plasticized, finished semi-finished products; the use of large robots with needle pickers for handling conventional, large GMT semi-finished products is unnecessary. This reduces manufacturing costs and significantly increases production quality.

The fiber-reinforced plastic component can be cooled. This cooling can occur, for example, before demolding, at least partially. Partial cooling can continue until the fiber-reinforced plastic composite component reaches dimensional stability. It can then be demolded to cool completely elsewhere without risking deformation.

• - Bereitstellen eines faserverstärkten Halbzeugs mit einer Imprägnierung aus einem duroplastischen Harzsystem,
• - Zuschneiden des faserverstärkten Halbzeugs zur Erzeugung eines Einlegers,
• - Einbringen des Einlegers in eine Kavität eines Fließpresswerkzeugs,
• - wobei das Fließpresswerkzeug mindestens eine Tauchkante aufweist,
• - Schließen des Fließpresswerkzeugs,
• - Umformen des Einlegers mittels Aufbringen eines Pressdrucks, so dass der Einleger in der Kavität fließt,
• - Aushärten des Einlegers zur Erzeugung des Faser-Kunststoff-Verbundbauteils und
• - Entformen des Faser-Kunststoff-Verbundbauteils.

According to the invention, a further method is proposed for producing a fiber-reinforced plastic composite component as disclosed, which has a wall thickness and an extent, wherein the fibers of the fiber-reinforced plastic composite component have an average fiber length of at least 10 mm but at most an average fiber length of 60 mm, and/or the fibers of the fiber-reinforced plastic composite component are continuous fibers and/or long fiber bundles, wherein the ratio of the wall thickness to the extent is at least 6:150 and at most 20:40, comprising the following steps:

• - Providing a fiber-reinforced semi-finished product with an impregnation made from a thermosetting resin system,
• - Cutting the fiber-reinforced semi-finished product to create an insert,
• - Inserting the insert into a cavity of an extrusion tool,
• - wherein the extrusion tool has at least one immersion edge,
• - Closing the extrusion tool,
• - Shaping the insert by applying pressure so that the insert flows into the cavity,
• - Curing of the insert to produce the fiber-reinforced plastic composite component and
• - Demolding of the fiber-reinforced plastic composite component.

The advantages and features described above regarding the fiber-reinforced plastic composite component, the bearing, and the process apply equally to the further process, to which reference is hereby made. The steps indicated can be found in the aforementioned series. The sequence is present. The procedure may be an SMC procedure.

The impregnation of the supplied semi-finished product may consist of or comprise a (still) uncured thermosetting resin system. An "uncured thermosetting resin system" can be a resin system before it has cured.

The fibers can be present in a largely isotropically distributed manner as fiber bundles or in the form of a continuous fiber-reinforced nonwoven fabric. While the fibers are in any case also cut and thus shortened by the pre-processing/cutting, in the case of a nonwoven fabric with continuous fibers as the starting form, the invention intends to continue referring to continuous fibers after pre-processing/cutting, even though these are cut all around the insert.

The process is suitable, for example, for producing a fiber-reinforced plastic composite component as an SMC extrusion part. If the resin-impregnated starting material is not sheet-shaped, it can be pre-assembled in a different way instead of being cut to size, so that the volume of the insert corresponds to the volume of the finished component. The invention, with its further method, allows the use of a resin-impregnated, curable semi-finished product, which can be consolidated by extrusion and subsequently cured. This method is also not known for compact, thick-walled components corresponding to the dimensions according to the invention.

• - Bereitstellen eines faserverstärkten Halbzeugs mit einer Imprägnierung aus einem duroplastischen Harzsystem,
• - Einbringen des faserverstärkten Halbzeugs in eine Kavität eines Fließpresswerkzeugs,
• - wobei das Fließpresswerkzeug mindestens eine Tauchkante aufweist,
• - Schließen des Fließpresswerkzeugs,
• - Umformen des eingebrachten Halbzeugs mittels Aufbringen eines Pressdrucks, so dass eingebrachte Halbzeug in der Kavität fließt,
• - Aushärten des eingebrachten Halbzeugs zur Erzeugung des Faser-Kunststoff-Verbundbauteils,
• - Entformen des Faser-Kunststoff-Verbundbauteils.

According to the invention, a further method is proposed for the production of a fiber-reinforced plastic composite component, which has a wall thickness and an extent, wherein the fibers of the fiber-reinforced plastic composite component have an average fiber length of at least 10 mm but at most 60 mm, and/or the fibers of the fiber-reinforced plastic composite component are in the form of continuous fibers and/or long fiber bundles, wherein the ratio of the wall thickness to the extent is at least 6:150 and at most 20:40, comprising the following steps:

• - Providing a fiber-reinforced semi-finished product with an impregnation made from a thermosetting resin system,
• - Inserting the fiber-reinforced semi-finished product into a cavity of an extrusion tool,
• - wherein the extrusion tool has at least one immersion edge,
• - Closing the extrusion tool,
• - Shaping the inserted semi-finished product by applying a pressing pressure, so that the inserted semi-finished product flows in the cavity,
• - Curing of the introduced semi-finished product to produce the fiber-reinforced plastic composite component,
• - Demolding of the fiber-reinforced plastic composite component.

The advantages and features described above regarding the fiber-reinforced plastic component, the bearing, and the process can equally apply to the process described above, to which reference is hereby made. The steps indicated can be performed in the stated order. The process can be a BMC process.

The impregnation of the provided semi-finished product can consist of or comprise a (still) uncured thermosetting resin system. An "uncured thermosetting resin system" can be a resin system in its curing state. The semi-finished product can be an amorphous mass. The semi-finished product can be placed in the preferably heated extrusion die, where it distributes itself within the cavity upon closing of the die.

The process is suitable, for example, for producing a fiber-reinforced plastic composite component as a BMC extrusion part. The invention, with its further method, allows the use of a resin-impregnated, curable semi-finished product, which can be consolidated by extrusion and subsequently cured. This method is also not known for compact, thick-walled components of the dimensions according to the invention.

According to a possible further development of the process, for example the further process (SMC or BMC), curing can take place under vacuum. The vacuum serves to prevent bubble formation during curing.

• - materialentfernende Bearbeitung des Faser-Kunststoff-Verbundbauteils zum Einbringen eines Durchbruchs und/oder eines Hinterschnitts oder
• - das Volumen des Einlegers oder des in die Kavität eingebrachten Halbzeugs kann dem Volumen des gefertigten Faser-Kunststoff-Verbundbauteils entsprechen.

According to a further development of a disclosed procedure, this can include:

• - material removal machining of the fiber-reinforced plastic composite component to create a through-hole and/or an undercut or
• - the volume of the insert or the semi-finished product placed in the cavity can correspond to the volume of the manufactured fiber-reinforced plastic composite component.

The advantage of material removal processing in the context of fiber-reinforced plastic composite components is that complex geometries can be created.

The advantage of volume matching is the avoidance of waste and rework, such as material removal. This volume matching can be advantageously achieved by utilizing the diving edge. The focus here is on the finished fiber-reinforced plastic component as a complete, manufactured item. An intermediate product is not considered a finished fiber-reinforced plastic component within the meaning of this claim.

According to a further development of a disclosed method, the insert can be formed from a stack of blanks and/or the ratio of the initial wall thickness of the insert to the maximum initial extent of the insert can be at least 6:120, preferably at least 8:80. These ratios advantageously contribute to compactness. This method is therefore particularly advantageous in direct comparison to injection-molded components, the more compact the components are.

"Initial" is defined as the state before forming. The initial wall thickness corresponds to the diameter of the largest possible sphere that fits within the insert, preferably completely. The initial extent corresponds to the diameter of the smallest possible sphere within which the insert fits, preferably completely.

It is conceivable that the insert or stack of blanks has an initial wall thickness of at least 12 mm. It is also conceivable that the insert or stack of blanks has an initial extent of no more than 120 mm. This ensures that the insert has sufficient clearance on its outer circumference from the cavity wall and/or the immersion edge for secure placement without pinching. In particular, with regard to the heated insert containing fibers of the specified average length, it remains sufficiently rigid to guarantee sufficiently accurate placement of the insert within the cavity.

According to a further development of a method as disclosed, the ratio of an individual initial wall thickness of a blank to the maximum individual initial extent of the blank can be at least 0.03, preferably at least 0.08.

"Single" shall be understood to refer to a single blank. The initial wall thickness of the single blank corresponds to the diameter of the largest possible sphere that can fit within the blank, preferably completely. The initial extent of the single blank corresponds to the diameter of the smallest possible sphere within which the blank can fit, preferably completely.

According to a possible further development of a disclosed process, the flow-forming tool can be a multi-cavity tool. This is only made possible by the dimensions of the inserts. It is advantageous to use a multi-cavity plunge-edge tool to simultaneously produce several fiber-reinforced plastic composite components without external trimming. This is particularly feasible because the compact inserts sag little or not at all, thus allowing several inserts to be easily accommodated and placed in the various cavities at the same time.

According to a possible further development of a disclosed method, the insert or stack of blanks in the cavity can have a distance on the outer circumference from the cavity wall and/or immersion edge. This prevents crushing.

According to a possible further development of a disclosed process, the tool or extrusion die can be a multi-cavity die, wherein the semi-finished product extends over or covers several, preferably all, cavities. In this case, the die does not need to have plunge edges. Furthermore, no pre-cut inserts are placed into the cavities, which is cost-effective since waterjet cutting and/or machining of the semi-finished product can be dispensed with. Instead, the individual components are punched or milled from the dimensionally stable, formed semi-finished product after compression molding. In this way, several components can be manufactured simultaneously, all of which can be separated together in a single or multiple punching operations. In this case, the additional costs for material waste must be weighed against the savings from pre-cutting, taking into account the subsequent punching operation, in order to assess the economic viability. Thus, in one or more of the processes described above, the step of cutting the fiber-reinforced semi-finished product to create an insert can be omitted, since cavity-specific singulation of the semi-finished product is no longer necessary. Therefore, in one or more of the processes described above, the step of inserting the insert into a cavity of an extrusion die can be omitted and replaced by inserting the semi-finished product, preferably uncut, into the extrusion die. A process step involving covering several cavities with a single semi-finished product is conceivable. This process step can be achieved by inserting the the semi-finished product is inserted into the tool. A dipping edge is also unnecessary. Furthermore, the term "insert" can be replaced by "semi-finished product" in one or more of the processes described above.

• 1 einen Querschnitt durch ein Lager,
• 2 eine Perspektivansicht eines Anschlagstoppers als Faser-Kunststoff-Verbundbauteil
• 3 einen Querschnitt durch eine Anschlagplatte als Faser-Kunststoff-Verbundbauteil,
• 4a bis 4c ein Ablaufschema eines Herstellungsverfahrens und
• 5 einen Querschnitt durch ein weiteres Lager.

Further features, details and advantages of the invention will become apparent from the wording of the claims and from the following description of exemplary embodiments with reference to the drawings. The drawings show:

• 1 a cross-section through a bearing,
• 2 A perspective view of a stop block made of fiber-reinforced plastic composite material.
• 3 a cross-section through a stop plate as a fiber-reinforced plastic composite component,
• 4a to 4c a flowchart of a manufacturing process and
• 5 a cross-section through another bearing.

In the figures, identical or corresponding elements are designated with the same reference numerals and are therefore not described again unless expedient. Features already described are not described again to avoid repetition and are applicable to all elements with the same or corresponding reference numerals, unless explicitly excluded. The disclosures contained in the entire description are transferable analogously to identical parts with the same reference numerals or component designations. Furthermore, the positional designations chosen in the description, such as top, bottom, side, etc., refer to the directly described and illustrated figure and are to be applied analogously to the new position if the position changes. Individual features or combinations of features from the different embodiments shown and described can also represent independent, inventive, or inventive solutions.

1 Figure 1 shows a cross-section through a bearing (200) as a hydraulic bearing. The hydraulic bearing is depicted as a bushing and is penetrated by a central longitudinal axis A. It comprises a first connection element 202, which is shown as an example bearing core. The bearing core is a hollow cylinder and can be penetrated by a screw. The hydraulic bearing also comprises a second connection element 204, which is shown as an outer sleeve. The hydraulic bearing further comprises two stop means 206, each of which represents an assembly and is arranged between the first connection element 202 and the second connection element 204 in a load path L. The first connection element 202 is supported by two elastomer pads 226 in which support elements 228 are embedded.

Each assembly consists of a stop 208, an elastomer body 210, and a stop shell 212. The elastomer body 210 elastically connects the stop 208 to the stop shell 212. The stop shell 212 has an opening 214. Each stop shell 212 forms a section of a concealed but dashed-line channel 216 with an inlet 218 in one stop shell 212 and an outlet 220 in the other stop shell 212. The hydraulic bearing comprises a first fluid-filled working chamber 222 and a second fluid-filled working chamber 224. The working chambers 222 and 224 are fluidically connected to each other via the channel 216. The channel 216 extends between the inlet 218 and the outlet 220 through a stop shell 212, between the support element 228 and the second connection element 204, into the opposite stop shell 212, in order to exit into the second working chamber 224. Under load, the stop 208 can then, upon contact with the first connection element 202, plunge into and/or pass through the opening 214 in the direction of the load path L.

The hydraulic bearing also includes at least one fiber-reinforced plastic composite component 2, which is part of the stop element 206. The stop element 208 and/or the stop shell 212 can be designed as the fiber-reinforced plastic composite component 2.

2 shows a perspective view of a stop block 208, for example according to 1 , in isolation. The stop block 208 is a compression-molded part and is designed as a fiber-reinforced plastic composite component 2. The fiber-reinforced plastic composite component 2 has a maximum wall thickness D and a maximum extent E, where E and D are sphere diameters. The largest possible sphere with wall thickness D fits completely inside the fiber-reinforced plastic composite component 2, for which contact lines K are shown for illustrative purposes, following the surface of the stop block 208. The fiber-reinforced plastic composite component 2 fits completely inside the smallest possible sphere with extent E.

3 shows a cross-section through a stop shell 212, for example according to 1 , in a unique position. The stop shell 212 is a flow-formed part and designed as a fiber-reinforced plastic composite component 2. The fiber-reinforced plastic composite component 2 has a maximum wall thickness D and a maximum extent E, where E and D are sphere diameters. The largest possible sphere with wall thickness D lies completely within the Fiber-reinforced plastic component space. The fiber-reinforced plastic component 2 fits completely inside the smallest possible sphere of extent E.

The wall thickness D of the fiber-reinforced plastic component 2 (stop stop 208, stop shell 212) is at least 6 mm and/or the extent E is at most 150 mm. Their ratio is at least 6:150 but at most 20:40. The fiber-reinforced plastic component 2 (stop stop 208, stop shell 212) can be made from a thermoplastic fiber-reinforced semi-finished product or a thermoset fiber-reinforced semi-finished product, and can be formed from a blank 103 of a semi-finished product 100 or from a stack of blanks 103 of a semi-finished product 100. The fibers of the fiber-reinforced plastic component 2 (stop stop 208, stop shell 212) are present as fiber bundles and have an average fiber length of at least 10 mm and at most 60 mm. Alternatively, they can be in the form of a continuous fiber fleece with isotropic orientation.

Figure sequence 4a to 4c shows, in three sequences, parts of a manufacturing process for a fiber-reinforced plastic composite component 2.

In 4a A thermoplastic or thermoset semi-finished product 100 is provided. The fibers in the semi-finished product 100 are isotropically oriented. The thermoset semi-finished product 100 is impregnated with a thermoset resin system. The semi-finished product 100 is cut to size, resulting in one or more blanks 103. The cutting process serves to produce an insert 102. The insert 102 can be formed from a single blank 103 or a stack of blanks 103.

In 4b The thermoplastic insert 102, for example formed from blanks 103, is heated by means of a heat source 110, whereby this only applies to thermoplastic semi-finished products 100. Heating is omitted for thermoset semi-finished products 100.

Then, as 4c Figure 1 shows the insert 102 being placed into a cavity 106 of an extrusion die 104. The extrusion die 104 can comprise a die 112 and a male die 114. The die 112 and male die 114 define the cavity 106, the shape of which corresponds to the desired shape of the fiber-reinforced plastic component 2. The cavity 106 is bounded by a plunge edge 108 formed on the male die 114.

The extrusion die 104 is then closed and the insert 102 is formed by applying pressure to it, causing the insert 102 to flow into the cavity 106. This creates a fiber-reinforced plastic component 2, which still needs to cure from a thermosetting semi-finished product 100. The fiber-reinforced plastic component 2 is then demolded.

4c Figure 1 also shows a maximum initial extent EIE of a single blank 103, as well as a maximum initial wall thickness EID of this blank 103, wherein the shown initial wall thickness EID or "height" of the blank 103 corresponds lengthwise to the diameter of a sphere in the blank 103. Figure 1 also shows a maximum initial wall thickness ID of the insert 102, wherein the shown initial wall thickness ID or "height" of the blank 103 corresponds lengthwise to the diameter of a sphere in the insert 102, and a maximum initial extent IE of this insert 102.

5 Figure 2 shows a cross-section through another bearing (200) as an elastomeric bearing. To avoid repetition, only the differences to the previous bearing will be discussed. 1 The stop means 206 is a stop shell 212. The stop shell 212 is a fiber-reinforced plastic composite component. It has no opening 214 and does not carry a stop stop 208. Under radial load, the first connection element 202 and the stop shell 212 can contact each other, thus placing them in direct force flow. An elastomeric stop 230 is arranged on the first connection element 202. The elastomeric stop 230 is supported by a stop projection 232 of the first connection element 202. The stop projection 232 can extend along the central longitudinal axis A and form a rib, particularly if the first connection element 202 is manufactured by extrusion. Preferably, however, the stopper projection 232 forms only a stop geometry, preferably arranged centrally on the first connecting element 202, wherein in both cases the stopper projection 232 extends radially away from the rest of the connecting element 232.

The invention is not limited to one of the embodiments described above, but can be modified in a variety of ways. All features and advantages arising from the claims, the description, and the drawings, including design details, spatial arrangements, and process steps, can be essential to the invention both individually and in various combinations.

The invention encompasses all combinations of at least two of the features disclosed in the description, the claims and/or the figures.

To avoid repetition, features disclosed by the device itself shall also be deemed disclosed by the process and be claimable. Likewise, features disclosed by the process shall be deemed disclosed by the device itself and be claimable.

Reference symbol list

2

Fiber-reinforced plastic composite component

100

semi-finished product

102

insert

103

Cut

104

Extrusion tool

106

cavity

108

Diving edge

110

heat source

112

die

114

die

200

Storage

202

first connection element

204

second connection element

206

Stopper

208

Stop stop

210

Elastomeric body

212

Stop shell

214

breakthrough

216

channel

218

inlet

220

Outlet

222

Chamber of Labour

224

Chamber of Labour

226

Elastomer padding

228

Support element

230

Elastomeric stop

232

Stopper advantage

A

central longitudinal axis

D

maximum wall thickness

E

maximum extension

OATH

Individual initial wall thickness

EIE

Single initial extension

ID

Initial wall thickness

IE

Initial extension

K

Contact line

L

Load path

Claims (13)

Fiber-reinforced plastic component (2), which has a wall thickness (D) and an extent (E), whereby - either the fibers of the fiber-reinforced plastic component (2) have an average fiber length of at least 10 mm but not more than 60 mm, - or the fibers of the fiber-reinforced plastic component (2) are in continuous form as nonwoven fibers, whereby the ratio of the wall thickness (D) to the extent (E) is at least 6:150 and at most 20:40. Fiber-reinforced plastic composite component (2) according to Claim 1 , characterized in that the wall thickness (D) is at least 6 mm and/or the extent (E) is at most 150 mm. Fiber-reinforced plastic composite component (2) according to one of the preceding claims, characterized in that it is produced by means of extrusion, preferably from a thermoplastic fiber-reinforced semi-finished product or a thermosetting fiber-reinforced semi-finished product. Fiber-reinforced plastic composite component (2) according to one of the preceding claims, characterized in that it is formed from a blank (103) of a semi-finished product (100) or from a stack of blanks (103) of a semi-finished product (100). Bearing (200) comprising a first connection element (202), a second connection element (204), a stopper means (206) which is arranged between the first connection element (202) and the second connection element (204), and at least one fiber-reinforced plastic composite component (2), wherein the at least one fiber-reinforced plastic composite component (2) is part of the stopper means (206). Storage (200) after Claim 5 , characterized in that the bearing (200) is an elastomeric bearing or a hydraulic bearing and/or the stopper means (206) comprises a stop stop (208), a stop shell (212) and an elastomeric body (210) connecting the stop stop (208) and the stop shell (212), preferably consisting of, wherein the stop shell (212) has a cutout (214) and the stop stop (208) can, under load, plunge into and/or pass through the cutout (214) in the direction of a load path (L), wherein the stop stop (208) and/or the stop shell (212) is/are designed as a fiber-reinforced plastic composite component (2). Storage (200) after Claim 5 , characterized in that the bearing (200) is an elastomeric bearing or a hydraulic bearing and the stopper means (206) comprises or is a stop shell (212), wherein the first connecting element (202) can come into direct contact with the stop shell (212) when the bearing (200) is subjected to a load, preferably radial load, preferably by direct or directly elastomer-buffered contact. Method for producing a fiber-reinforced plastic component (2), which has a wall thickness (D) and an extent (E), whereby either the fibers of the fiber-reinforced plastic component (2) are present as fiber bundles and have an average fiber length of at least 10 mm but not more than 60 mm, or the fibers of the fiber-reinforced plastic component (2) are present as continuous fibers in nonwoven form, wherein the ratio of the wall thickness (D) to the extent (E) is at least 6:150 and at most 20:40, comprising the following steps: - Providing a thermoplastic, fiber-reinforced semi-finished product (100), - Cutting the fiber-reinforced semi-finished product (100) to produce at least one insert (102), - Heating the insert (102), - Inserting the heated insert (102) into a cavity (106) of a Extrusion tool (104), - wherein the extrusion tool (104) has at least one plunge edge (108), - closing the extrusion tool (104), - forming the insert (102) by applying a pressing pressure so that the insert (102) flows in the cavity (106), to produce the fiber-reinforced plastic component (2), - demolding the fiber-reinforced plastic component (2). Method for producing a fiber-reinforced plastic component (2), which has a wall thickness (D) and an extent (E), whereby the fibers of the fiber-reinforced plastic component (2) have an average fiber length of at least 10 mm but not more than 60 mm, and/or the fibers of the fiber-reinforced plastic component (2) are continuous fibers and/or long fiber bundles, wherein the ratio of the wall thickness (D) to the extent (E) is at least 6:150 and at most 20:40, comprising the following steps: - Providing a fiber-reinforced semi-finished product (100) impregnated with a thermosetting resin system, - Cutting the fiber-reinforced semi-finished product (100) to produce an insert (102), - Inserting the insert (102) into a cavity (106) of an extrusion die (104), - wherein the extrusion tool (104) has at least one plunge edge (108), - closing the extrusion tool (104), - forming the insert (102) by applying pressure so that the insert (102) flows into the cavity (106), - curing the insert (102) to produce the fiber-reinforced plastic component (2), - demolding the fiber-reinforced plastic component (2). Method for producing a fiber-reinforced plastic component (2), which has a wall thickness (D) and an extent (E), whereby the fibers of the fiber-reinforced plastic component (2) have an average fiber length of at least 10 mm but not more than 60 mm, and/or the fibers of the fiber-reinforced plastic component (2) are continuous fibers and/or long fiber bundles, wherein the ratio of the wall thickness (D) to the extent (E) is at least 6:150 and at most 20:40, comprising the following steps: - Providing a fiber-reinforced semi-finished product (100) with an impregnation of a thermosetting resin system, - Inserting the fiber-reinforced semi-finished product (100) into a cavity (106) of an extrusion die (104), - wherein the extrusion die (104) has at least one plunge edge (108), - Closing the extrusion die (104), - Forming the inserted semi-finished product (100) by applying pressure so that the inserted semi-finished product (100) flows in the cavity (106), - Curing the inserted semi-finished product (100) to produce the fiber-reinforced plastic component (2), - Demolding the fiber-reinforced plastic component (2). Procedure according to Claim 8 , 9 or 10 , characterized by - material removal processing of the fiber-reinforced plastic component (2) to create a through-hole (214) and/or an undercut or by the fact that - the volume of the insert (102) or of the semi-finished product (100) placed into the cavity (106) corresponds to the volume of the manufactured fiber-reinforced plastic component (2). Procedure according to one of the Claims 8 until 11 , characterized in that the insert (102) is formed from a stack of blanks (103) and/or the ratio of the initial wall thickness The (ID) of the inserter (102) to the maximum initial extension (IE) of the inserter (102) is at least 6:120, preferably at least 8:80. Procedure according to Claim 12 , characterized in that the ratio of a single initial wall thickness (EID) of a blank (103) to the maximum single initial extent (EIE) of the blank (103) is at least 0.03, preferably at least 0.08.