MOTOR VEHICLE COMPOSITE COMPONENT AND METHOD FOR THE PRODUCTION THEREOF

Abstract

To manufacture a motor vehicle composite component, plastic particles are introduced into a mold cavity of a mold and are connected there to one another to form a particle foam. The mold is then adjusted while the mold cavity changes, and a thermoplastic plastic is then injected into the mold cavity while a carrying element and/or at least one fastening element are formed, wherein the thermoplastic plastic is bonded to the particle foam at least by connection in substance. The aforementioned materials may also be introduced in the reverse order. The mold is then adjusted once again while the mold cavity changes, and a metal melt is then injected into the mold cavity, as a result of which an electrical strip conductor and/or at least one metallic fastening element are formed.

Claims

1. A process for manufacturing a motor vehicle composite component, the process comprising the steps of: introducing plastic particles into a mold and bonding the plastic particles to one another in the mold into a particle foam while supplying thermal energy; subsequent to said step of introducing and bonding, adjusting the mold while the mold cavity changes, and injecting a thermoplastic plastic into the mold cavity while at least one carrying element and/or at least one fastening element is formed, wherein the thermoplastic plastic is bonded to the particle foam at least by connection in substance; subsequent to said step of adjusting and injecting, adjusting the mold while the mold cavity changes, and injecting a metal melt into the mold cavity, as a result of which at least one electrical strip conductor and/or at least one metallic fastening element are formed.

2. A process for manufacturing a motor vehicle composite component, the process comprising the steps of: injecting a thermoplastic plastic into a mold cavity of a mold while at least one carrying element and/or at least one fastening element are formed, after which subsequent to said step of injecting, adjusting the mold while the mold cavity changes; subsequent to said step of adjusting, introducing plastic particles into the mold cavity and in the cavity bonding the plastic particles to one another into a particle foam while supplying thermal energy, wherein the thermoplastic plastic is bonded to the particle foam at least by connection in substance; subsequent to said step of introducing and bonding, adjusting the mold while the mold cavity changes; and subsequently injecting a metal melt into the mold cavity, as a result of which at least one electrical strip conductor and/or at least one metallic fastening element are formed.

3. A process for manufacturing a motor vehicle composite component in accordance with claim 2, wherein prefabricated reinforcing elements are inserted into the mold cavity before the introduction of the plastic particles and they are then embedded in the plastic foam.

4. A process for manufacturing a motor vehicle composite component in accordance with claim 3, wherein the reinforcing elements are formed by synthetic fibers and/or natural fibers and/or at least one network or at least one grid consisting of plastic or metal.

5. A process for manufacturing a motor vehicle composite component in accordance with claim 2, wherein prefabricated connection elements are inserted into the mold cavity before the introduction of the plastic particles and are then embedded in the particle foam.

6. A process for manufacturing a motor vehicle composite component in accordance with claim 2, wherein prefabricated connection elements are inserted into the mold cavity before the introduction of the thermoplastic plastic and are then embedded in the thermoplastic plastic.

7. A process for manufacturing a motor vehicle composite component in accordance with claim 5, wherein the connection elements are formed by screws and/or threaded rods and/or clips.

8. A process for manufacturing a motor vehicle composite component in accordance with claim 7, wherein the particle foam is formed with a closed-cell surface.

9. A process in accordance with claim 2, wherein the thermoplastic plastic is additionally bonded to the particle foam in a positive-locking manner.

10. A motor vehicle composite component comprising: a carrier consisting of a plastic particle foam; carrying elements and/or fastening elements consisting of a thermoplastic plastic, wherein the carrier is bonded to carrying elements and/or fastening elements consisting of a thermoplastic plastic by a connection in substance; and at least one electrical strip conductor and/or at least one metallic fastening element.

11. A motor vehicle composite component in accordance with claim 10, wherein the particle foam is formed with a closed-cell surface.

12. A process for manufacturing a motor vehicle composite component in accordance with claim 6, wherein: the connection elements are formed by screws and/or threaded rods and/or clips; and the particle foam is formed with a closed-cell surface.

13. A process for manufacturing a motor vehicle composite component in accordance with claim 1, wherein prefabricated reinforcing elements are inserted into the mold cavity before the introduction of the plastic particles and they are then embedded in the plastic foam.

14. A process for manufacturing a motor vehicle composite component in accordance with claim 13, wherein the reinforcing elements are formed by synthetic fibers and/or natural fibers and/or at least one network or at least one grid consisting of plastic or metal.

15. A process for manufacturing a motor vehicle composite component in accordance with claim 1, wherein prefabricated connection elements are inserted into the mold cavity before the introduction of the plastic particles and are then embedded in the particle foam.

16. A process for manufacturing a motor vehicle composite component in accordance with claim 1, wherein prefabricated connection elements are inserted into the mold cavity before the introduction of the thermoplastic plastic and are then embedded in the thermoplastic plastic.

17. A process for manufacturing a motor vehicle composite component in accordance with claim 16, wherein the connection elements are formed by screws and/or threaded rods and/or clips.

18. A process for manufacturing a motor vehicle composite component in accordance with claim 17, wherein the particle foam is formed with a closed-cell surface.

19. A process in accordance with claim 1, wherein the thermoplastic plastic is additionally bonded to the particle foam in a positive-locking manner.

20. A process for manufacturing a motor vehicle composite component in accordance with claim 15, wherein: the connection elements are formed by screws and/or threaded rods and/or clips; and the particle foam is formed with a closed-cell surface.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0034] In the drawings:

[0035] The only FIGURE is a perspective sectional view showing a motor vehicle composite component in a simplified manner.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0036] Referring to the drawings, a motor vehicle composite component 10 has a carrier 11 made of a plastic particle foam, which is formed at least on a motor vehicle composite component surface with a closed-cell surface 16.

[0037] The carrier 11 is connected in substance to the carrying element and/or fastening element 12 consisting of a thermoplastic plastic.

[0038] At least one strip conductor 13, which interacts with metallic fastening elements 14, 15, is formed on the carrier 11.

[0039] To manufacture the motor vehicle composite component 10, plastic particles are introduced into a mold cavity of a mold and are connected there to one another to form a particle foam. The mold is then adjusted while the mold cavity changes, and a thermoplastic plastic is then injected into the mold cavity while a carrying element and/or the at least one fastening element 12 are formed, wherein the thermoplastic plastic is bonded to the particle foam at least by connection in substance. The aforementioned materials may also be introduced in the reverse order. The mold is then adjusted once again while the mold cavity changes, and a metal melt is then injected into the mold cavity, as a result of which the electrical strip conductor 13 and/or at least one metallic fastening element 14, 15 are formed.

[0040] While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.