Method for producing a component and component

Abstract

A component having at least one structural component and one organic sheet, and a method for producing the component, are described. In a first step, a woven-fabric hose is arranged in a contour of a tool and then the tool is closed. In a second step, a plastic, in particular a melt, is injected into the woven-fabric hose arranged in the closed tool. In a third step, a fluid and/or supporting element is introduced into the woven-fabric hose, a cavity thus being formed in the woven-fabric hose. An organic sheet is formed and backmolded with a plastic, and the formed and backmolded organic sheet is bonded to the structural component to produce the component.

Claims

1. A method for producing a component formed at least from a structural component and an organometallic sheet, comprising: forming a hollow structural component by: arranging a woven-fabric tube in a contour of a mold and then closing the mold, injecting an at least partially melted plastic into the closed mold in which the woven-fabric tube is arranged, and introducing a fluid and/or a supporting element into the woven-fabric tube to form a cavity in the woven-fabric tube and embed fibers of the woven-fabric tube in the plastic, such that, after the plastic has cooled down, the hollow structural component is formed with embedded fibers of the woven-fabric tube; and shaping and backmolding an organometallic sheet with a plastic; and bonding the shaped and backmolded organometallic sheet to the hollow structural component to form the component.

2. The method as claimed in claim 1, wherein the fluid and/or the supporting element is introduced at a predeterminable pressure.

3. The method as claimed in claim 1, wherein the fluid and/or the supporting element is introduced into the woven-fabric tube, in such a way that the woven-fabric tube is embedded further into the already injected plastic, at least in certain regions.

4. The method as claimed in claim 1, wherein the organometallic sheet is heated, at least in certain regions.

5. The method as claimed in claim 1, wherein the organometallic sheet is backmolded with a plastic in such a way that a rib structure is formed.

6. The method as claimed in claim 1, wherein, after the plastic, in which the woven-fabric tube is embedded, has cooled down, a continuous fiber-reinforced structural component with a hollow body profile is formed.

Description

(1) The invention is explained in more detail on the basis of the accompanying schematic figures, in which:

(2) FIG. 1 schematically shows a sectional representation of a device according to the invention for producing a structural component after a first, second and third step,

(3) FIGS. 1A, 1B schematically show various supporting elements for making a cavity evolve in the structural component in the third step,

(4) FIG. 2 schematically shows a sectional representation, in particular a longitudinal section, of a structural component,

(5) FIG. 3 schematically shows a further sectional representation, in particular a cross section, of the structural component connected to an organometallic sheet to form a component, and

(6) FIG. 4 schematically shows a perspective view of a vehicle seat with a vehicle occupant positioned on it.

(7) Parts that correspond to one another are provided with the same reference signs in all of the figures.

(8) FIG. 1 schematically shows a sectional representation, in particular a longitudinal section, of a device 1 for producing a structural component 2. FIG. 2 schematically shows a longitudinal section of the structural component 2 and FIG. 3 shows a cross section of the structural component 2, the structural component being connected to an organometallic sheet 4 and forming a component B. An organometallic sheet 4 is a sheet-like semifinished product of a thermoplastic material into which a woven fabric of glass, carbon and/or aramid fibers or a mixed form of these has been introduced in such a way that the fibers are completely wetted with thermoplastic material. Organometallic sheets 4 are consequently continuous fiber-reinforced thermoplastic sheets.

(9) FIG. 1 illustrates the device 1 during a first step S1, a second step S2 and a third step S3 (viewed from top to bottom).

(10) In the present exemplary embodiment, the device 1 comprises a mold 1.1, which is preferably formed as a combination mold comprising a thermoforming mold and an injection mold. For example, the mold 1.1 is formed as a two-part, cavity-forming composite body, which comprises a first mold body and a second mold body. In this case, one of the mold bodies has a shaping profile as a positive contour of the structural component 2 to be produced and the other of the mold bodies has an appropriately corresponding recess. The positive contour and the recess thereby form the cavity of the mold 1.1.

(11) The mold 1.1 is preferably formed from a metal or a metal alloy. Alternatively, the mold 1.1 is formed from a ceramic or a plastic, the mold 1.1 being provided for this purpose with a metal coating, at least in the region of the cavity.

(12) In the first step S1, a woven-fabric tube 3 is placed into the positive contour of the mold 1.1. Then the mold 1.1 is closed. The closing of the mold 1.1 may in this case take place manually or preferably in an automated manner.

(13) In the second step S2, a liquid plastic, for example in the form of a melt 5, is injected into the woven-fabric tube 3 arranged in the closed mold 1.1. For this purpose, the device 1 comprises an injection machine (not represented any more specifically), which can be manually actuated or operates in an automated manner.

(14) The melt 5 is for example a liquid plastic, at a temperature lying appropriately above its melting point, for example between 100 degrees Celsius and 200 degrees Celsius. Particularly suitable for this are single-phase, non-water-soluble thermoplastics, for example polyamide, polyolefin, polypropylene, or thermosets, for example polyurethane.

(15) In the third step S3, a fluid 6, for example water, is introduced into the woven-fabric tube 3 at an appropriately low temperature and appropriately high pressure, so that the already injected melt 5 distributes itself, preferably uniformly, on the and/or into the woven-fabric tube 3 on the outer and/or inner wall of the woven-fabric tube 3. After introduction of the fluid 6 into an open end of the woven-fabric tube 3 to make a cavity H evolve, the fibers of the woven-fabric tube 3 lie embedded in the cooled-down melt 5. This produces a continuous fiber-reinforced, thermoplastic structural component 2 with a hollow body profile along the positive contour of the mold 1.1.

(16) FIGS. 1A and 1B show alternative embodiments for the evolution of the cavity H by means of a supporting element S. The supporting element S according to FIG. 1A is formed as an inflatable enveloping element E, for example a balloon.

(17) The enveloping element E is introduced into an open end of the woven-fabric tube 3 already surrounded with melt 5 and is inflated under a predetermined pressure with a fluid 6, for example air, water or gas, so that a cavity H is made to evolve in the woven-fabric tube 3 along its longitudinal extent. After the melt 5 with the embedded woven-fabric tube 3 has cooled down, the enveloping element E can be removed, or if appropriate may remain, and then forms for example an inner wall of the hollow structural component 2.

(18) In FIG. 1B, a supporting material M, for example a foam material, can be introduced into an open end of the woven-fabric tube 3 as an alternative supporting element S.

(19) In a further step (not represented any more specifically), the organometallic sheet 4 is shaped and a surface of the organometallic sheet 4 is backmolded with a reinforcing structure, preferably a rib structure. The rib structure is preferably formed from the same thermoplastic material as the organometallic sheet 4. Consequently, an integrated, and consequently one-piece, component is formed from the organometallic sheet 4 and the rib structure.

(20) The bonding of the organometallic sheet 4 to the structural component 2 preferably takes place by way of the thermoplastic matrix of the organometallic sheet 4 and/or the thermoplastically reinforced surface of the structural component 2 that is facing the organometallic sheet 4, the thermoplastic matrix being appropriately heated, so that the structural component 2 enters into a material-bonded connection with the organometallic sheet 4. In other words, a superficial fusion takes place between the structural component 2 and the organometallic sheet 4.

(21) The closed hollow profile gives the structural component 2 a comparatively high torsional rigidity. Consequently, the structural component 2 is reduced in weight and flexurally particularly rigid in comparison with structural component 2 with open profiles. For example, the structural component 2 is consequently suitable for the production of a seat-back rear wall for a vehicle seat 7.

(22) FIG. 4 shows in a perspective view a vehicle seat 7, given by way of example, with a vehicle occupant 8 positioned on it.

(23) For example, a seat-back rear wall of the vehicle seat 7 can be produced by means of the structural component 2 and the organometallic sheet 4, it being possible for headrest sleeves, belt deflectors and/or a mounting for a belt retractor device to be formed in the molded-in rib structure of the organometallic sheet 4.

(24) Alternatively or in addition, it is possible to arrange the structural component 2 in a channel 9 arranged in the vehicle seat cover, known as a trim channel.

LIST OF REFERENCE SIGNS

(25) 1 device 1.1 mold 2 structural component 3 woven-fabric tube 4 organometallic sheet 5 melt 6 fluid 7 vehicle seat 8 vehicle occupant 9 channel B component E enveloping element H cavity M supporting material S supporting element S1 first step S2 second step S3 third step