Bonding of thermoplastic components to a thermoset component

Abstract

A process for producing a component from a fiber-reinforced plastic with a thermoset matrix. The process includes the steps providing a first and second thermoset prepreg layer, producing a cutout in the first thermoset prepreg layer, providing a thermoplastic layer in the semifinished product between the first and the second thermoset prepreg layer in the region of the cutout, and manufacturing the component with a first and second thermoset layer and a thermoplastic layer in the region of the cutout, where the thermoplastic layer is locked between the two thermoset layers. The component may be used in a vehicle, where the component has been produced from a fiber-reinforced plastic with a thermoset matrix by the abovementioned process.

Claims

1. A process for producing a component from a fiber-reinforced plastic with a thermoset matrix, the process comprising the steps of: forming a cutout in a first thermoset prepreg layer, positioning a thermoplastic layer between the first thermoset prepreg layer and a second thermoset prepreg layer in the region of the cutout in the first thermoset prepreg layer, and processing the component so that the thermoplastic layer is fixed between the first thermoset prepreg layer and the second thermoset prepreg layer, wherein the thermoplastic layer has a bottom surface, top surface and side surfaces, and wherein the bottom and side surfaces are covered by either one or both of the thermoset prepreg layers.

2. The process as claimed in claim 1, wherein the process further comprises attaching a thermoplastic structure on the thermoplastic layer at the cutout.

3. The process as claimed in claim 2, wherein the step of attaching the thermoplastic structure on the thermoplastic layer at the cutout comprises injection molding a thermoplastic injection-molding material in the region of the cutout.

4. The process as claimed in claim 2, wherein the step of attaching the thermoplastic structure on the thermoplastic layer via the cutout comprises attaching the thermoplastic structure by welding.

5. The process as claimed in claim 1, wherein, prior to the processing step, the thermoplastic layer comprises a thermoplastic organopanel of either a thermoplastic film or a thermoplastic sheet.

6. The process as claimed in claim 1, wherein either the first or second thermoset prepreg layer comprises a plurality of mutually superposed prepregs.

7. The process as claimed in claim 1, wherein the first and second thermoset prepreg layers each comprises a fiber material composed of glass, aramid, carbon or Kevlar in a thermoset matrix.

8. The process as claimed in claim 1, wherein, prior to the processing step, the thermoplastic layer comprises a thermoplastic layer including a fiber material composed of glass, aramid, carbon or Kevlar in a thermoplastic matrix.

9. The process as claimed in claim 2, further comprising attaching the thermoplastic structure to the thermoplastic layer through the cutout after the processing step is complete.

10. The process as claimed in claim 1, wherein the thermoplastic layer is accessible through only the cutout.

Description

BRIEF DESCRIPTION OF THE DRAWING

(1) The invention is explained via examples below, with reference to the attached drawings, on the basis of preferred embodiments, where the features described below can respectively represent an aspect of the invention either individually or in combination.

(2) FIG. 1 is a diagrammatic sectional view of a thermoset component with hole and, fixed at said hole, a thermoplastic structure as in the prior art,

(3) FIG. 2 is a diagrammatic perspective view of an arrangement of a first and second thermoset prepreg layer, where the first thermoset prepreg layer has a cutout, and of a thermoplastic layer in the semifinished product, for the production of a thermoset component in a first, preferred embodiment of the invention,

(4) FIG. 3 is a diagrammatic Perspective view of a component, manufactured from the arrangement in FIG. 2, with a first and second thermoset layer and a thermoplastic layer, and also a thermoplastic structure secured thereon in accordance with the first embodiment,

(5) FIG. 4 is a sectional view of the component of FIG. 3 with the thermoplastic structure secured thereon in accordance with the first embodiment, and

(6) FIG. 5 is a low diagram for the production of the component of FIGS. 3 and 4 with the thermoplastic structure secured thereon in accordance with the first embodiment.

DETAILED DESCRIPTION OF THE INVENTION

(7) FIG. 5 shows a process for the production of a component produced from a fiber-reinforced plastic with a thermoset matrix, for use in a vehicle, in accordance with a first, preferred embodiment of the invention. The process of FIG. 5 is described below with additional reference to FIGS. 2 to 4.

(8) The process begins with step S100. Step S100 begins provision of an arrangement 20 for the production of a component 22. FIG. 2 shows the arrangement 20, where step S100 begins by providing a first and a second thermoset prepreg layer 24, 26.

(9) The thermoset prepreg layers 24, 26 relate to layers with fibers which have been preimpregnated with reactive resins. The reactive resins consist of a thermoset plastics matrix which is typically of high viscosity but has not yet been polymerized. The fibers present can take the form of simple unidirectional layer, woven fabric, or laid scrim. The prepregs for the formation of the thermoset prepreg layers 24, 26 are provided here in the form of webs wound onto rollers. The prepregs relate to unidirectionally reinforced or sheet-like semifinished products, or else other preforms of, in principle, any desired shape. The prepreg layers 24, 26 are configured here as continuous-fiber-reinforced semifinished thermoset product based on a fiber material made of glass, aramid, carbon or Kevlar in a thermoset matrix. The matrix here is in the partially crosslinked state known as B-state, with paste-like to solid consistency, but can be returned to the liquid state by warming.

(10) Step S110 produces a cutout 28 in the first thermoset prepreg layer 24. The shape of the cutout 28 here is rectangular. The cutout 28 can by way of example be produced by use of a cutter or punch.

(11) Step S120 relates to provision of a thermoplastic layer 30 in the semifinished product between the first and the second thermoset prepreg layer 24, 26 in the region of the cutout 28. The thermoplastic layer 30 in the semifinished product here has been formed locally in the region of the cutout 28, and the thermoplastic layer 30 in the semifinished product here extends across the cutout 28 and additionally an adjacent region 32.

(12) The thermoplastic layer 30 in the semifinished product relates to a layer made of a semifinished fiber product with thermoplastic matrix. The semifinished thermoplastic product here can be configured as long-fiber-reinforced thermoplastic (LFT), glass-mat-reinforced thermoplastic (GMT) or thermoplastic prepreg.

(13) The thermoplastic layer 30 in the semifinished product here is configured as thermoplastic organopanel, i.e. as semifinished fiber-matrix product with a woven fiber fabric or with a laid fiber scrim, these having been embedded into a thermoplastic matrix. The thermoplastic layer 30 provided here in the semifinished product is based on a fiber material made of glass, aramid, carbon or Kevlar in a thermoplastic matrix.

(14) In step S130, the component 22 is manufactured. For this, the arrangement 20 depicted in FIG. 2 is hardened with exposure to heat and pressure. The thermoplastic layer 30 here in the semifinished product also undergoes warming and shaping.

(15) The component 22 depicted in FIGS. 3 and 4, with a first and second thermoset layer 34, 36 and a thermoplastic layer 38 in the region of the cutout 28, is formed from the arrangement 20 with the two thermoset prepreg layers 24, 26 and, between these in the semifinished product, the thermoplastic layer 30. As can clearly be seen in particular in FIG. 4, the thermoplastic layer 38 is locked between the two thermoset layers 34, 36 in the finished component 22.

(16) Step S140 fixes a thermoplastic structure 40 on the thermoplastic layer 38 via the cutout 28 by means of ultrasound welding. The thermoplastic structure 40 here, also termed thermoplastic component, is a standard part for use in automobile construction, in particular a screw dome or a fixing clip. Appropriate processes for automated ultrasound welding are known per se in the prior art.