WO2019162125A1 - Method for producing a plastics component, and plastics component - Google Patents

Abstract

A method for producing a plastics component (1) has the method steps: producing a component blank (2) from a foamed plastic, extruding an endless filament, which forms an extrudate (3), onto the component blank (2), applying the extrudate (3), which is at a temperature of at least 85 degrees Celsius, to the component blank (2), whereby a part of the foamed plastic and/or a surface of the component blank (2) are/is melted, whereby the extrudate (3) is connected to the component blank (2). A plastics component (1) can be obtained by means of the method.

Description

 Diehl Aviation Laupheim GmbH, 88471 Laupheim

Process for producing a plastic component and plastic component

The invention relates to a method for producing a plastic component. Furthermore, the invention relates to a plastic component, producible in particular with the method.

Many components are nowadays used as foam components, in particular

Particle foam parts, manufactured. Such components withstand limited mechanical loads and tend to permanent deformation.

The document DE 10 06 29 98 A1 describes a plastic profile bar with a foam core and an outer skin, wherein a reinforcement extends in the outer skin and the reinforcement forms a strand with high strength.

From US 8,389,425 B2 a bonded mat is known which contains a spiral fabric which is bonded to a carrier. The spiral fabric comprises continuous spiral fibers, at least some of which contain expanded polymeric microspheres. The carrier comprises a porous material. Methods of making the spiral fabric and the carrier and methods of joining the spiral fabric and the carrier are disclosed.

The object of the invention is to provide a method for producing a plastic component and a plastic component, which can withstand mechanical loads.

The object is achieved by a method for producing a plastic component with the features of claim 1. Further, the object is achieved by the plastic component having the features of claim 15. Preferred and / or advantageous embodiments will become apparent from the dependent claims and the description below.

A method for producing a plastic component is proposed. The plastic component is in particular a fiber-reinforced plastic component, in particular an endless fiber reinforced plastic component. The plastic component is, for example, a composite component. The plastic component may form a flat plate or a shaped body. The plastic component can carry increased mechanical loads and is in particular resistant to deformation and / or bending.

According to the invention, a component blank is produced from a foamed plastic. In particular, the foamed plastic comprises polypropylene, polyethylene, polystyrene, polybutylene terephthalate, polyethylene terephthalate, polycarbonates or a biopolymer. The foam plastic can be produced for example by foam extrusion. Furthermore, it can be provided that the foam plastic from a

Plastic granules is generated and, for example, foamed physically or mechanically. In particular, the foam plastic is produced in a mold, for example a negative mold. The component blank is in particular dimensionally stable after cooling. Furthermore, the foamed plastic may comprise foam particles and / or be made of foam particles.

In a further process step, an endless filament is extruded. The extruded continuous filament forms an extrudate. The extrudate comprises in particular a

Plastic matrix and the reinforcing fiber, wherein the reinforcing fiber is preferably completely embedded in the plastic matrix. The continuous filament may comprise an endless fiber and in particular comprise an endless fiber bundle.

For example, the fiber bundle forming the continuous filament comprises more than three individual fibers, and more particularly more than five individual fibers. The continuous filament and / or extrudate preferably has a length of more than one meter and in particular more than ten meters. In particular, the extrudate is formed from the continuous filament in a continuous extrusion process. The formation of the extrudate is preferably carried out with the aid of an extrusion die. The extrudate forms in particular an endless extrudate. The continuous filament is extruded onto the component blank. For example, the extrusion die is guided over the component blank, alternatively, the component blank can be guided past the extrusion die. When extruding the continuous filament onto the component blank, the extrudate is deposited on the component blank.

The extrudate may in particular be honeycombed, reticulated and / or otherwise two-dimensional or three-dimensional and / or deposited. When extruded onto the component blank, the extrudate has an extrudate temperature that is greater than the softening temperature of the foamed plastic. Preferably, the Extrusion temperature greater than 85 degrees Celsius and especially greater than 150 degrees Celsius.

In a further method step, the extrudate with the extrudate temperature, which is greater than the softening temperature of the foam plastic and preferably greater than 85 or 150 degrees Celsius, connected to the component blank, in particular let sink into the component blank and / or pressed and / or pressed , The filament temperature extrudate contacts a surface of the component blank. In this case, a part of the foam plastic and / or the surface of the component blank is melted, whereby the extrudate is connected to the component blank or its surface. In particular, a part of the collapses

Schaumkunststoffes, so that forms a notch and / or the extrudate in the

Surface and / or the component blank sinks. Preferably, the sinking is accelerated and / or assisted by the application of force or pressure to the extrudate. After sinking and / or pressing the extrudate is cohesively, positively and / or non-positively disposed in the component blank. The

Component blank together with the sunken and / or pressed-in extrudate forms in particular the plastic component. The extrudate can preferably sink completely into the component blank and / or be pressed in, alternatively the extrudate closes in a form-fitting manner with a surface of the component blank or the extrudate partially protrudes out of the component blank.

It is a consideration of the invention to provide a method in which mechanical characteristics of the plastic component are locally increased significantly where necessary. Further, it is a consideration to provide a method in which only a tool is required for the production of the blank, for example a mold, wherein no further form is necessary for reinforcing with the filament. The method also makes it possible to allow increased geometric freedom in the production of the plastic component, for example, undercuts are possible that would not be possible in non-generative method. It can also be provided that the steps of extruding the continuous filaments onto the component blank and pressing in and / or sinking in the extrudate are carried out and / or performed a number of times, in particular successively, so that a repeated application of the reinforcement is possible.

The foam plastic is designed in particular as a particle foam.

For example, the particle foam is formed from EPS, EPE or EPP. The

Particulate foam preferably comprises foam beads of one thermoplastic. The particle foam preferably has a density between 15 and 80 kilograms per cubic meter. This embodiment is based on the consideration to provide a plastic component, which is particularly light, but is characterized by a high mechanical stability.

Optionally, the continuous filament is formed as a commingled yarn and / or the extrudate is extruded from and / or consists of the commingled yarn. The commingled yarn is formed by a fiber bundle, wherein the fiber bundle comprises a reinforcing fiber. The reinforcing fiber is in particular a fiber made of a thermoset or as a carbon fiber or silicon fiber. The reinforcing fiber may also be formed as a thermoplastic having a higher melting point than enveloping fibers. The reinforcing fiber is enveloped by a plurality of further, in particular thermoplastic, fibers. In particular, the thermoplastic fibers and the reinforcing fiber are juxtaposed. For example, the commingled yarn is first melted to form the extrudate, the melting, for example, resulting in a rod-shaped and / or cord-shaped intermediate structure. The rod-shaped and / or cord-shaped

Intermediate structure is then re-melted and injected into the extrudate and / or extruded and, in particular, discharged as an extrudate. The fibers and / or components used in the commingled yarn have similar mechanical properties, such as strength, elasticity and / or stiffness. This embodiment is based on the consideration to provide a method for producing a plastic component with improved mechanical strength properties.

An embodiment of the invention provides that the extrudate is heated before and / or during the application, in particular during the sinking and / or during the pressing and / or during the pressing with a heat source. For example, for this purpose, the extrudate is selectively, locally or globally heated and / or heated. Alternatively and / or additionally, the surface of the component blank can be heated. As a heat source, for example, a hot air source, such as a hair dryer, serve. Alternatively, the heat source is formed by a radiation source for emitting infrared and / or thermal radiation. This embodiment is based on the consideration to heat the extrudate and / or the surface so far that the sinking and / or pressing into the component blank as efficiently as possible, fast and good.

In particular, the process of sinking in and / or the method can take place in a tempered process chamber. In particular, provision is made for the component blank to be cooled and / or allowed to cool before extruding the continuous filament onto the component blank.

For example, the component blank has sprung from a thermal treatment or a thermal production process.

It is particularly preferred for the extrudate to be extruded or deposited with exact position, position accuracy and / or to a predetermined location. For example,

especially with a web planning module, determines a path along which the continuous filament is extruded onto the component blank. In particular, the

Path planning in a world coordinate system, alternatively, the path planning takes place in an object coordinate system, for example, that of the component blank. Preferably, the continuous filament is extruded onto the component blank based on CAD data.

The continuous filament is in particular in a two-dimensional or

extruded three-dimensional pattern on the component blank and / or the extrudate is deposited according to the pattern. For example, the continuous filament is extruded helical, polygonal and / or along a joint or seam on the component blank. In particular, the path along which the continuous filament is extruded may be a closed path or an open path. In particular, that will

Endless filament extruded onto the component blank so that the mechanical

Properties, such as stiffness or flexural strength, the subsequent use of the plastic component concern. Furthermore, it can be provided that the

Extrusion temperature is chosen so that the extrudate sinks to a desired depth in the component blank.

An embodiment of the invention provides that the extrudate is positioned by means of a robot. In this case, for example, a nozzle for extruding the

Endless filaments are moved over the component blank. Further, the continuous filament may be extruded onto an end effector or robotic arm with the end effector or robotic arm depositing the extrudate onto the component blank.

It is particularly preferred that the component blank is formed at least in two parts. In this case, the component blank is formed, for example, from two component blank parts. For example, the component blank parts form shell halves, which can be assembled into a formwork. Further, the component blank parts may be formed as plates, wherein the plastic component then forms, for example, a plate composite. The component blank parts are formed as foam parts. Preferably, the continuous filament connects at least two parts of the component blank and / or at least two component blank parts. For example, this is the

Continuous filament extruded between the two component blank parts, and then compressed the component blank parts and / or brought together so that the extrudate sinks into both. The extrudate can be partially between the

Component blank parts may be arranged, alternatively, the extrudate is disposed in an entire contact area of the component blank parts. In this case, the extrudate is sunk into the at least two parts and / or both component blank parts and, in particular, connects them in particular to one another in a materially bonded manner. The extrudate between the component blank parts forms a seam in particular.

A particularly preferred embodiment provides that the extrudate is clamp-shaped, wherein the extrudate clamp-shaped at least two parts of the

Component blanks connects. For example, the extrudate forms a staple with a center piece and two legs, the legs forming two piece blank parts

connect non-positively. The legs preferably sink into each of the

Surfaces of the component blanks, which are remote from a contact region of the component blanks.

In particular, it is envisaged that the extrudate containing the two parts of the

Connecting component blanks together, sealing the joint between the two parts. In particular, the extrudate extends over the entire joint of the component blank. In particular, the extrudate closes the joint in one

Circumferential direction. In this case, the extrudate close the joint against dust, dirt and / or moisture, wherein the extrudate is formed in particular even water-repellent and / or media repellent.

For example, the component blank parts form two halves and / or shells of a channel and / or a conduit, in particular a ventilation channel, wherein the extrudate connects the halves and / or shells at the joints and further ingress of dirt and / or moisture into or out of the Channel prevented. This embodiment is based on the consideration to provide a method for producing a plastic component, in which the reinforcing structure, here the extrudate, in addition to the improvement of the mechanical stability and a further effect, for example, the sealing fulfilled.

An embodiment of the method provides that a notch is introduced into the surface of the component blank. For example, the notch becomes thermal or introduced with a cutting tool. In particular, it can also be provided that the notch is introduced by means of a laser in the surface of the component blank. The notch has a depth, the depth

is preferably less than or equal to the diameter of the extrudate. The width and / or the diameter of the notch is preferably less than or equal to the diameter of the extrudate. The continuous filament is extruded into and / or on the indentation.

In particular, after extruding the continuous filament into and / or on the indentation, the extrudate is pressed into the indentation and / or allowed to sink into the indentation and / or pressed onto the indentation.

Optionally, it is provided that the component blank has a cover layer on a surface. The cover layer is in particular directly connected to the foam plastic of the component blank. The cover layer is for example sprayed onto the component blank, applied or poured. Alternatively, it can be provided that the component blank is applied to the cover layer. Furthermore, it can be provided that the cover layer and the component blank are glued together. The cover layer is preferably formed from a thermoset. The continuous filament can be extruded onto the cover layer, wherein the extrudate sinks, for example, through the cover layer into the foam plastic of the component blank. Preferably, the cover layer is at least partially perforated and / or has a notch, wherein exposed in the notch, the foam plastic, wherein the continuous filament is extruded into the notch or the perforated section and can sink there into the foam plastic.

Another object of the invention is a plastic component, wherein the

Plastic component from the method as previously described is available. The

Plastic component preferably forms a fiber-reinforced plastic component.

For example, the plastic component is a flat plate. The flat plate can consist of two partial plates. The two partial plates can form, for example, the two parts of the component blank or the component blank parts. The extrudate is applied between the two plates, with the still-hot extrudate partially sunk into the plates and, after cooling, joining the two sub-plates to the plate.

It is particularly preferred that the plastic component forms a molded part. In this case, for example, the component blank is formed by means of a mold, for example a negative mold. The extrudate as stiffening is according to the application of the

Molded parts arranged. The extrudate is in the molded part and especially in the Component blank according to the shape of the mold component and / or arranged arbitrarily three or two-dimensional and / or embedded.

Optionally, it is provided that the plastic component of two or more

Component blanks or component blank parts, wherein the extrudate the two

Component blanks interconnected by being connected to each of the component blanks, in particular directly with the respective plastic foam. The extrudate is partially sunk in particular in the two component blanks and / or pressed and / or pressed. The endless filament connects the two component blanks preferably cohesively.

Further advantages and / or effects will be apparent from the attached figures and their description. Showing:

Figures 1 a and 1 b a first embodiment of a plastic component;

Figure 2 shows an embodiment of a formed as a molded component plastic component; Figure 3 is a plastic component of two half-shells;

Figure 4 shows another embodiment of a plastic component of two half-shells;

Figure 5 shows an embodiment of a plastic component with a cover layer;

Figure 6 shows an embodiment of a plastic component with two cover layers;

Figure 7 shows an embodiment of a plastic component with sealed joints.

FIG. 1 a shows a plastic component 1 during the method for producing the plastic component 1. The plastic component 1 has a component blank 2 made of a foamed plastic. In particular, the component blank 2 is constructed from a particle foam. For example, expanded polyethylene, expanded polypropylene or expanded polystyrene. The component blank 2 is foamed in a mold. After foaming of the component blank 2 in the form of this is allowed to cool and removed after cooling. Furthermore, it can be provided that the

Component blank 2 is post-processed after cooling, for example, ground or provided with a cover layer. In particular, the component blank 2 may also be formed as a sandwich material with a core of foam plastic. On the cooled component blank extrudate 3 is extruded from a continuous filament. The extrudate 3 is extruded onto the surface of the component blank at an extrudate temperature. The extrudate temperature is greater than that

Softening temperature of the particle foam and / or foam plastic. The extrudate 3 is introduced locally into the component blank 2. The extrudate 3 with the extrudate temperature melts the surface of the component blank 2 and / or the

Foam plastic on. As a result, the foam plastic collapses in this area, so that the extrudate 3 sinks into the foam plastic and the component blank 2. The sinking can be done by taking advantage of the gravitational force, alternatively and / or additionally the extrudate 3 is pressed with a Eindrückkraft 4 in the component blank 2.

In particular, the continuous filament forms a commingled yarn, the commingled yarn representing a fiber bundle. The fiber bundle of the commingled yarn comprises a glass fiber or C fiber as reinforcing fiber and additionally thermoplastic fibers, wherein the reinforcing fiber is coated with the thermoplastic. The commingled yarn has been extruded into the continuous filament 3 in a pultrusion process followed by an extrusion process.

FIG. 1 b shows a finished plastic component 1 produced by the method. The extrudate 3 is flush with the surface of the component blank 2 and / or pressed. The extrudate 3 is cohesively and / or partially positively and / or non-positively connected to the component blank 2. The extrudate 3 forms a

mechanical reinforcement for the plastic component 1 and / or for the component blank 2. The extrudate 3 realizes higher mechanical characteristics, such as stiffness and flexural strength, of the plastic component 1. Furthermore, only one tool for producing the component blank 2 is necessary for applying and introducing the extrudate 3 No special tools are needed.

FIG. 2 shows a plastic component 1, which is designed as a molded component. The plastic component 1 forms in this example a half-shell of an air outlet channel. The plastic component 1 has a three-dimensional shape and is in a

Lengthwise L extends. The plastic component 1 would tilt in the longitudinal direction L without reinforcement for bending, kinking and / or breaking. To prevent this, the plastic component 1 has the continuous filament 3 as a reinforcement. The extrudate 3 is applied in the longitudinal direction L. Furthermore, it may also be possible that the extrudate 3 in any two-dimensional or three-dimensional Extension and / or shape is integrated in the plastic component 1. After the plastic component 1 in this embodiment tends to bend mainly in the longitudinal direction, the extension of the continuous filament is in this

Embodiment in the longitudinal direction.

FIG. 3 shows a plastic component 1 which is formed by two half-shells 5a and 5b. The half-shells 5a and 5b in particular form the component blank 2. The two half-shells 5a and 5b are connected by means of the extrudate 3 in a material-locking, force-locking and / or form-fitting manner. The extrudate 3 is here formed like a clamp and clamps the two half-shells 5a and 5b together. The extrudate 3 is sunk and / or pressed in both the half-shell 5a and the half-shell 5b. For the production, the two half shells 5a and 5b, which also as

Component blank parts can be understood, brought together and then connected to the extrudate 3, wherein the extrudate 3 is extruded onto both half-shells 5a and 5b.

Figure 4 shows another embodiment of the plastic component 1. Das

Plastic component 1 is formed as shown in Figure 3 from two half-shells 5a and 5b. The half-shells 5a and 5b can again be regarded as component blank parts. The half-shells 5a and 5b are made of the foamed plastic, for example, foamed in a mold. After cooling, the half-shells 5a and 5b are removed from the mold and brought together, wherein at the seams and / or

Joint between the half-shells 5a and 5b, the continuous filament is extruded, so that the joints between the half-shells 5a and 5b are closed by the extrudate 3. Furthermore, the extrudate 3 partially sinks into the two half shells 5a and 5b, the two half shells 5a and 5b being thus joined at the abutment points by means of the extrudate 3. The extrudate 3 seals the joint between the half-shells 5a and 5b.

FIG. 5 shows a plastic component 1 in one exemplary embodiment with a cover layer 6. The cover layer 6 is disposed on a surface of the component blank 2 and / or of the

Plastic component 1 is arranged. The cover layer 6 is formed from a thermosetting plastic. The cover layer 6 is arranged in this embodiment only on one side. The extrudate is in the component blank 2, in particular the foam core or the

Foamed plastic, penetrated. The sinking and / or impressions of the extrudate 3 in the component blank 2 in the production of the plastic component 1 is stopped by the cover layer 6. After the cover layer 6 has a softening temperature greater than the extrudate temperature, the extrudate 3 can not melt this and remains so positioned. After cooling the extrudate 3, the extrudate 3 with the

Component blank 2, in particular with the foamed plastic, connected.

Figure 6 shows an embodiment of the plastic component 1, wherein the

Plastic component 1 has two cover layers 6 in this embodiment. The

Cover layers 6 are on different, opposite sides of the

Component blanks 2 arranged. In order to allow the extrudate 3 to sink into the component blank 2, the cover layer 6 is notched on one side. The notching can be done mechanically, for example with a saw, furthermore, the notch can be introduced by means of a laser. The continuous filament is extruded into the indentation.

Thus, the extrudate 3 comes into contact with the foam plastic of the component blank 2, can melt it and into the foam plastic or the

Component blank 2 sink in. The extrudate temperature of the extrudate 3 is chosen so that the extrudate 3 is flush with the cover layer 6.

FIG. 7 shows an exemplary embodiment in which two component blanks 2 are joined together by means of the extrudate 3 to form a common plastic component 1. In this case, the component blanks 2 are arranged so that between the component blanks 2, the continuous filament can be extruded. The hot extrudate 3 sinks into both component blanks 2 and connects to them in each case materially. The extrudate 3 then holds the two component blanks 2 together in the plastic component 1.

LIST OF REFERENCE NUMBERS

1 plastic component 2 component blank

3 extrudate

4 indentation force

5a, 5b half shell 6 top layer

Claims

1. A method for producing a plastic component (1), with the Steps: - Production of a component blank (2) made of a foam plastic, - Extruding an endless filament, which forms an extrudate (3), on the component blank (2) - Applying the extrudate (3) on the component blank (2) having an extrudate temperature which is greater than the softening temperature of the foamed plastic, whereby a part of the foamed plastic and / or a surface of the component blank (2) is melted, whereby the extrudate (3) is connected to the component blank (2). 2. The method according to claim 1, characterized in that the extrudate (3) is thereby applied to the component blank (2) that it is allowed to sink into the component blank (2) and / or is pressed and / or on the component blank (2 ) is pressed. 3. The method according to any one of the preceding claims, characterized in that the component blank (2) is made of a particle foam as a foam plastic. 4. The method according to any one of the preceding claims, characterized in that as extrudate (3) the continuous filament is extruded from a Commingled Yarn. 5. The method according to any one of the preceding claims, characterized in that the extrudate (3) is heated before and / or during application with a heat source. 6. The method according to any one of the preceding claims, characterized in that prior to extruding the continuous filament of the component blank (2) is cooled. 7. The method according to any one of the preceding claims, characterized in that the continuous filament is extruded along a pre-planned path on the component blank (2). 8. The method according to claim 7, characterized in that the extrudate (3) is positioned by means of a robot. 9. The method according to any one of the preceding claims, characterized in that the component blank (2) is formed at least in two parts, wherein the extrudate (3) connects at least two parts of the component blank (2). 10. The method according to claim 9, characterized in that the extrudate (3) between the parts of the component blank (2) is arranged. 11. The method according to claim 9 or 10, characterized in that with the  Extrudate (3) a joint between at least two parts of the component blank (2) is sealed. 12. The method according to any one of the preceding claims, characterized in that in a surface of the component blank (2) a notch is introduced, wherein the Extrudate (3) is extruded into and / or on the notch. 13. The method according to any one of the preceding claims, characterized in that on a surface of the component blank (2) a cover layer is applied. 14. The method according to any one of the preceding claims, characterized in that the extrudate (3) without tools in the component blank (2) is introduced. 15. plastic component (1) obtainable by the method according to one of the preceding claims. 16. plastic component (1) according to claim 15, characterized in that two component blanks (2) through the extrudate (3) are connected by the extrudate (3) with two component blanks (2) is connected.