Method for producing a multi-component part of a vehicle

Abstract

A method for producing a multi-component part (200) of a vehicle includes inserting an air-guiding device (10) having at least one contact portion (40) into a cavity (310) of a tool (300). The method then includes heating a composite part (100) having at least one mating contact portion (140) to a melting point of at least one material of the composite part (100), and heating the contact portion (40) of the air-guiding device (10) to a melting point of at least one material of the contact portion (40). The method further includes inserting the heated composite part (100) into the cavity (310) of the tool (300) and pressing the heated composite part (100) into a geometry of the part while simultaneously forming an integrally bonded connection between the mating contact portion (140) of the composite part (100) and the contact portion (40) of the air-guiding device (10).

Claims

1. A method for producing a multi-component part (200) of a vehicle, having the following steps: providing at least one T-shaped air-guiding device (10) having an air-guiding portion (30) with opposite first and second ends and two contact portions (40) extending in opposite directions from the first end of the air-guiding portion (30), a recess (44) being formed in the first end of the air-guiding portion (30), and surface elevations (42) projecting from the surfaces of the contact portions (40) facing away from the second end of the air-guiding portion (30), inserting the air guiding portion (30) of the at least one air-guiding device (10) into a holding portion (312) of a cavity (310) of a tool device (300) so that the air-guiding portion (30) of the air-guiding device (10) is heat insulated by the holding portion (312) of the cavity (310), heating a composite part (100) having at least one continuous mating contact surface (140) for a pressing operation to a melting point of at least one material component of the composite part (100), heating the contact portions (40) of the at least one air-guiding device (10) to a melting point of at least one material component of the contact portions (40) of the air-guiding device (10) while the air-guiding portion (30) is heat-insulated by the holding portion (312) of the cavity (310), inserting the heated composite part (100) into the cavity (310) of the tool device (300), pressing the heated composite part (100) into a specified geometry of the multi-component part (200) with simultaneous formation of an integrally bonded connection between the at least one mating contact surface (140) of the composite part (100) and the contact portions (40) of the air-guiding device (10) so that the surface elevations (42) of the contact portions (40) and surface areas of the contact portions (40) adjacent the surface elevations (42) integrally bond to the at least one mating contact surface (140).

2. The method of claim 1, wherein the heating of the composite part (100) and/or the heating of the contact portions (40) of the air-guiding device (10) are/is carried out by thermal radiation.

3. The method of claim 1, wherein the pressing is carried out to form a complete or substantially complete form-fitting connection between the contact portions (40) of the air-guiding device (10) and the at least one mating contact surface (140) of the composite part (100).

4. The method of claim 1, wherein the step of inserting the air-guiding portion (30) of the at least one air-guiding device (10) into the holding portion (312) of the cavity (310) of the tool device (300) is carried out so that the air-guiding portion (30) of the air-guiding device (10) has a form-fitting reception in the holding portion (312) to achieve both mechanical stabilization and heat dissipation to the holding portion (312) of the tool device (300).

5. The method of claim 1, wherein the surface elevations (42) comprise points projecting partly into the at least one mating contact surface (140).

6. The method of claim 1, wherein the two contact portions (40) define first and second contact portions (40), a projecting distance of the first contact portion (40) from the air-guiding portion (30) is greater than a projecting distance of the second contact portion (40) from the air-guiding portion (30) so that a bonding force between the first contact portion (40) and the mating contact portion (140) is greater than a bonding force between the second contact portion (40) and the mating contact portion (140).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows a first step of a method according to the invention.

(2) FIG. 2 shows a further step of a method according to the invention.

(3) FIG. 3 shows a further step of a method according to the invention.

(4) FIG. 4 shows a further step of a method according to the invention.

(5) FIG. 5 shows a further step of a method according to the invention.

(6) FIG. 6 shows a further step of a method according to the invention.

(7) FIG. 7 shows an embodiment of an air-guiding device according to the invention.

(8) FIG. 8 shows a further embodiment of an air-guiding device according to the invention.

(9) FIG. 9 shows the embodiment of FIG. 8 in another illustration.

(10) FIG. 10 shows an illustration of a tool device for use in a method according to the invention.

(11) FIG. 11 shows another air-guiding device.

(12) FIG. 12 shows another air-guiding device.

DETAILED DESCRIPTION

(13) The method according to the invention will be explained in more detail with reference to FIGS. 1 to 6. It should also be pointed out in particular here that the steps of heating the composite part 100 or the contact portions 40 of the air-guiding device 10 can basically be carried out in parallel or in any desired sequence. It is crucial that, when brought together in the tool device, the two parts, namely the composite part 100 and the contact portions 40 of the air-guiding device 10 have the desired temperature above the melting point of the respective material component.

(14) In FIG. 1, the composite part 100, for example in the form of an LWRT preform, is provided in a clamping frame 320. The composite part 100 is already provided here with contact portions 140 which merge into the corresponding basic body of the composite part 100. The optional clamping frame 320 serves for the holding, in particular if, with the aid of the heating device 330 via infrared emitters, the composite part 100 is brought to a temperature which lies above the melting point of the matrix material of the composite part 100. The composite part 100 is thus heated up at this time to such an extent that the matrix material is melted and therefore the composite part 100 is of substantially flexible design.

(15) The insertion of the air-guiding devices 10 takes place previously, afterwards or in parallel in terms of time, as shown in FIG. 3. The basic bodies 20 of the air-guiding devices 10 are inserted with their air-guiding portions 30 into the associated holding portions 312 of the cavity 310 of the tool device 300. FIG. 4 shows the inserted state. In this state, the air-guiding portions 30 are mechanically stabilized by means of the form-fitting reception in the holding portions 312. At the same time, the cavity 310, by means of its form-fitting connection around the air-guiding portions 30, serves for thermal insulation or for dissipating the heat into the tool, and therefore, by means of the heating device 330, only the contact portions 40 and only to a smaller extent, if at all, the air-guiding portions 30 are also brought here by means of the thermal radiation to the corresponding temperature. As soon as the contact portions 40 have likewise reached a temperature which lies above the melting point of a matrix material in said contact portions 40, the composite part 100 which has already been heated up can now be introduced, according to FIG. 5, together with the clamping frame 320 into the cavity 310. The cavity 310 is closed or pushed on from above by means of the tool device 300 with a punch, as shown in FIG. 5. As soon as the cavity 310 is completely closed, the contact portions 40 of the two air-guiding devices 10 are therefore now in direct contact with the associated mating contact portions 140 of the composite part 100. While, by means of the three-dimensional shaping of the cavity 310, firstly pressing and formation of said three-dimensional structure for the composite part 100 is provided, welding and therefore an integrally bonded connection of the heated contact portions 40 and of the heated mating contact portions 140 take place at the same time. Subsequently, an optional cooling step can be carried out which can lead to demolding of a multi-component part 200, as FIG. 6 shows. At this time, the contact portions 40 are therefore connected in an integrally bonded manner to the mating contact portions 140, and a multi-component part 200 has been produced here from a composite part 100 and two air-guiding devices 10.

(16) FIG. 7 shows one possibility of providing an air-guiding device 10. A cross section which is substantially T-shaped here has a basic body 20 which is equipped with a downwardly extending air-guiding portion 30. In a transverse extent, a contact portion 40 is of two-part design here. A first partial contact portion 40a with a smaller width extent B extends to the left on the pressure side D of the air-guiding device 10. A second partial contact portion 40b with a larger width extent B is located on the negative pressure side U of the air-guiding portion 30. It can be seen here in particular in correlation with FIG. 8 that an approach with an air flow takes place on the pressure side D. As soon as this is the case, the associated force from said air flow is then transmitted via tensile forces from the basic body 20 into the composite part 100 via the first partial contact portion 40a and via compressive forces via the second partial contact portion 40b. As a result of the fact that the width extent B on the pressure side D has now been reduced for the first partial contact portion 40a in comparison to the second partial contact portion 40b, the lever arm on this side is reduced, and therefore the portion of tensile forces to be transmitted is reduced and the portion of compressive forces to be transmitted is increased. This asymmetrical distribution of the introduction of pressure leads to an increase in the mechanical stability by means of the loading of an air flow.

(17) As can likewise be gathered from FIG. 7, surface elevations 42 are provided on the upper side of the contact portion 40, here in the form of substantially fin-shaped configurations with a triangular cross section. Said surface elevations lead to a local pressure increase during the pressing operation and at the same time to an improved input of heat during the heating of the contact portion 40. The rear-side depression 44 which can likewise be seen in FIG. 7 and is designed here as a bead leads to a reduction in the material stressing during the pressing operation, and also later on during use of the air-guiding device 10.

(18) FIG. 9 also shows how the beginning of such an air-guiding device 10 having a correspondingly triangular section can be arranged or formed. It can also be seen once again here how the pressure side D and the negative pressure side U differ from each with respect to the contact portion 40. FIGS. 10 to 12 show how a tool device 300 can be used flexibly for different multi-component parts 200. The holding portions 312 here are of such deep design that not only can the normal air-guiding devices 10 be used, as are illustrated in FIG. 10 and also in FIGS. 3 to 6, but so to can particularly long air-guiding portions 30 of other air-guiding devices 10, as FIG. 11, for example, shows. If vehicles having a lower air-guiding functionality are desired, small air-guiding portions 30 of corresponding air-guiding devices 10 according to FIG. 12 can also be inserted into the same deep holding portions 312. The increased flexibility leads to the same tool device 300 being able to be used for a wide variety of desired multi-component parts 200.

(19) The above explanation of the embodiments describes the present invention exclusively within the scope of examples. Individual features of the embodiments, if technically meaningful, can be freely combined with one another here without departing from the scope of the present invention.