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WO2020038659A1 - Vehicle component reinforced by means of deposition technology and device and method for producing same - Google Patents

Vehicle component reinforced by means of deposition technology and device and method for producing same Download PDF

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Publication number
WO2020038659A1
WO2020038659A1 PCT/EP2019/069128 EP2019069128W WO2020038659A1 WO 2020038659 A1 WO2020038659 A1 WO 2020038659A1 EP 2019069128 W EP2019069128 W EP 2019069128W WO 2020038659 A1 WO2020038659 A1 WO 2020038659A1
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WO
WIPO (PCT)
Prior art keywords
strand
component
resin
reinforcement
vehicle component
Prior art date
Application number
PCT/EP2019/069128
Other languages
German (de)
French (fr)
Inventor
Anja JÄSCHKE
Original Assignee
Audi Ag
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Audi Ag filed Critical Audi Ag
Publication of WO2020038659A1 publication Critical patent/WO2020038659A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
    • B29C70/382—Automated fiber placement [AFP]
    • B29C70/384—Fiber placement heads, e.g. component parts, details or accessories
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
    • B62D29/043—Superstructures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0827—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using UV radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for

Definitions

  • the invention relates to a reinforced vehicle component according to the preamble of claim 1.
  • the invention further relates to a device and a method for producing such a vehicle component.
  • Components, in particular flat components can be reinforced by applying a fiber-plastic composite (FKV) or a fiber-reinforced plastic (FRP), as described, for example, in DE 101 34 372 A1.
  • FKV fiber-plastic composite
  • FRP fiber-reinforced plastic
  • DE 10 2013 021 672 A1 describes a method for producing a hybrid component, which is provided as a composite of a carrier profile part, in particular sheet metal part, and a fiber-reinforced plastic.
  • a hybrid component which is provided as a composite of a carrier profile part, in particular sheet metal part, and a fiber-reinforced plastic.
  • at least one semi-finished fiber product pre-impregnated with a matrix material is placed as a band under pressure and heat in a common process step on the carrier professional part and irreversibly connected to it.
  • Thermal curing requires a heating and / or cooling device and precise temperature control, for which a temperature control unit is required. Nevertheless, temperature fluctuations can occur (for example due to heat accumulation or uneven heat dissipation), which results in a lack of reproducibility and high reject rates. In addition, especially when materials or materials with different coefficients of thermal expansion are connected or joined, stresses can occur during cooling that affect the properties of the component and can lead to component distortion or even delamination.
  • the invention is intended to at least avoid or at least reduce a disadvantage associated with the prior art.
  • the vehicle component according to the invention comprises a basic component, which is in particular flat or as a profile part, and at least one reinforcement made of a fiber-plastic composite material applied thereon.
  • the reinforcement has at least one (with UV-curable flarz) resin-impregnated strand, deposited on the base component to be reinforced and then pressed on and UV-hardened.
  • the reinforcement is preferably a local reinforcement that reinforces the basic component in regions or in places.
  • Several such local reinforcements can be provided, which can also be applied to both sides of a flat basic component.
  • the vehicle component according to the invention is light and stable and can be manufactured cheaply, as explained in more detail below.
  • the vehicle component according to the invention can be produced without the introduction of heat, since the flarz is cured by means of UV light (ie by means of ultraviolet radiation), so that the above-mentioned disadvantages do not occur.
  • the invention also favors new load path-optimized design concepts.
  • the vehicle component according to the invention is in particular a body component, by which both a structural component and an outer skin component can be meant. Through the reinforcement z. B. specifically improve the crash behavior of front flaps, bumpers, side wall pillars, sills and the like. Furthermore, such vehicle components can also replace expensive waisted blank parts.
  • the vehicle component according to the invention can also be an installation part, such as, for example, a flood shelf or a rear seat backrest.
  • the basic component to be reinforced can be made from a metal sheet (e.g. a steel sheet), in particular from a light sheet (e.g. an aluminum sheet), from an organic sheet, from a plastic, in particular from an injection-molded or blow-molded plastic, from a Fiber-plastic composite (FKV) or fiber-reinforced plastic (FVK), be made of a foamed material or structure (both plastic and metal) or from a metal casting.
  • a metal sheet e.g. a steel sheet
  • a light sheet e.g. an aluminum sheet
  • an organic sheet e.g. an organic sheet
  • a plastic in particular from an injection-molded or blow-molded plastic, from a Fiber-plastic composite (FKV) or fiber-reinforced plastic (FVK)
  • FKV Fiber-plastic composite
  • FVK fiber-reinforced plastic
  • a strand is generally understood to mean a band-like, cord-like or hose-like structure made of a material containing reinforcing fibers.
  • a strand in the sense of the invention is, in particular, a tape (tape) containing reinforcing fibers or a cord (roving) or the like containing reinforcing fibers, wherein tubular designs are also possible.
  • the reinforcing fibers can be carbon fibers, glass fibers, synthetic fibers or metal fibers, whereby fiber mixtures are also possible. They are preferably continuous fibers, and staple fibers (of limited length) can also be used.
  • the reinforcing fibers can be present in the strand as a UD layer (s) with unidirectionally oriented fibers, as a braid or as a knitted fabric.
  • the strand is preferably textile-like.
  • the at least one strand for the reinforcement is preferably provided that the at least one strand for the reinforcement
  • - Made of a material containing reinforcing fibers; - from a textile containing reinforcing fibers, in particular metal fibers, which is provided with additives (e.g. fillers or other auxiliaries) which improve the adhesion or the material connection to / to the basic component and / or improve the adhesion between the reinforcing fibers and / or adapt the coefficient of thermal expansion or linear expansion of the reinforcement to the basic component;
  • additives e.g. fillers or other auxiliaries
  • reinforcing fibers and other reinforcing materials such as hollow spheres, expanded glass, clay, which can be used to break down energy, particularly in the event of a crash, whereby these reinforcing materials can preferably be located inside a tube-like strand);
  • the device according to the invention is intended to press at least one resin-impregnated strand onto a base component to be reinforced therewith and to illuminate the resin-impregnated strand with UV light at least in some areas.
  • the device according to the invention has a pressing device with which the resin-impregnated strand (when laying down and / or after laying down) can be pressed onto the basic component to be reinforced, and at least one UV lamp, with which the deposited and pressed-on strand is at least partially included UV light can be illuminated and can therefore be cured or UV-cured.
  • the pressure device is a pressure roller or roller, which is at least partially formed from a transparent or translucent material, and that the UV lamp is integrated in the pressure roller, so that UV curing takes place simultaneously with the pressure can.
  • the pressure roller is literally flooded with UV light when the UV lamp is switched on.
  • the method according to the invention is preferably carried out automatically on a device according to the invention and comprises at least the following steps:
  • UV curing of the pressed strand preferably directly after pressing on or immediately upon pressing, in particular by means of a UV lamp arranged in the pressing roller (see above).
  • Geometric elements can also be formed, which then function as spacers, for example.
  • This process or procedure does not require temperature control and is therefore very stable and reproducible as well as inexpensive.
  • the method according to the invention can also be used to produce sandwich components with a foam core.
  • a UV-curing thermoset is used as the plastic matrix.
  • the strand which is initially still dry (ie not pre-impregnated), can be passed through a resin bath with the liquid matrix material (synthetic resin) for impregnation (as described in DE 10 2013 021 672 A1).
  • the strand so impregnated with resin can then be deposited on the base component in the wet state, pressed on and cured by UV lighting or by means of UV light.
  • the reinforcement fibers are embedded in the plastic matrix so that a fiber-plastic composite is created.
  • the matrix material can contain an adhesion promoter.
  • the resin with which the strand is impregnated or is impregnated can be a foaming resin which then foams, in particular after being deposited, before or during UV curing or during UV curing, so that the reinforcement at least in sections has a foamed plastic matrix.
  • the reinforcement can additionally take on a sealing function, sound insulation or heat protection function and / or energy absorption function. It can be physical foaming or chemical foaming. The foaming process is preferably only activated by the UV light.
  • the basic component When the resin-impregnated strand is put down, the basic component can be wrapped around the strand at least at the point to be reinforced.
  • the strand can therefore be deposited in a winding-like process.
  • so-called cast knots so-called cast knots (knot elements), which are used in a so-called space frame body, can be strengthened.
  • FIG. 1 illustrates a vehicle component according to the invention.
  • FIG. 2 schematically shows a device according to the invention with which the vehicle component shown in FIG. 1 can be produced.
  • the vehicle component 100 shown in FIG. 1 is merely an example of a rear seat back reinforcement.
  • the rear seat back reinforcement 100 has a basic component 110 made of sheet metal, in particular aluminum sheet, and formed like a frame.
  • the basic component 110 can, however, also be made of another material, as described above.
  • This basic component 110 is, for example, a deep-drawn / stamped part and can therefore be ne spatial shape.
  • the struts 130 which extend between recesses or punched-out portions 120 are reinforced or stiffened in a targeted manner by means of reinforcements 140 made of a fiber plastic composite material in order to optimize load paths and / or to achieve greater crash safety.
  • these strip-like reinforcements 140 act like tension bands and, particularly under point load, bring about a load distribution.
  • the reinforcements 140 have at least one resin-impregnated strand, which is deposited on the base component 110 to be reinforced and then pressed on and UV-hardened, or are formed therefrom.
  • the device 200 illustrates the production of the vehicle component 100 with the aid of a device 200 according to the invention.
  • the device 200 is designed, for example, as a depositing head and can be fastened to a robot arm and can thus be moved with the robot, as illustrated by the arrow F. (A similar device is known from the patent DE 10 2013 021 672 A1 already cited above).
  • the device 200 has a winding spool 210, from which a band-like strand (also referred to as tape) containing reinforcing fibers is continuously unwound.
  • the strand 220 can have a thickness in the range from 0.1 mm to 2.0 mm, but can also be thinner or thicker.
  • the unwound strand 220 is soaked in a resin bath 230 (or a functionally equivalent device) with liquid, UV-curable resin material and then placed on the base component 110, which is supported by a table 300 or the like.
  • the limp strand 220 can be placed very well on the contour of the basic component 110.
  • the wet deposited strand 220 is then pressed onto the base component 110 with a predetermined contact pressure using a pressure roller 240 and is cured during and / or immediately thereafter by UV light, for which purpose in the pressure roller 240 and / or next to the pressure roller 240 (ie the pressure roller 240 downstream) at least one UV lamp 250 is arranged.
  • the basic component 110 can be pretreated at least at the relevant points (for example by sand or plasma blasting).
  • the strand 220 can then be cut off using a cutting device 260.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Composite Materials (AREA)
  • Robotics (AREA)
  • Textile Engineering (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

The invention relates to a vehicle component (100), having a base component (110) and at least one reinforcement (140) made of a fiber-plastic composite material and applied thereon, wherein the reinforcement (140) has at least one resin-impregnated strand (220) which is deposited on the base component (110) to be reinforced and is subsequently pressed thereon and UV-cured. The invention also relates to a device (200) and to a method for producing such a vehicle component (100).

Description

Mittels Ablegetechnik verstärktes Fahrzeugbauteil sowie Vorrichtung und Vehicle component, device and device reinforced by means of discarding technology
Verfahren zur Herstellung Manufacturing process
BESCHREIBUNG: DESCRIPTION:
Die Erfindung betrifft ein verstärktes Fahrzeugbauteil gemäß Oberbegriff des Patentanspruchs 1. Die Erfindung betrifft ferner eine Vorrichtung sowie ein Verfahren zur Herstellung eines solchen Fahrzeugbauteils. Bauteile, insbesondere flächige Bauteile, können durch Aufbringen eines Faserkunststoffverbunds (FKV) bzw. eines faserverstärkten Kunststoffs (FVK) verstärkt werden, wie bspw. in der DE 101 34 372 A1 beschrieben. The invention relates to a reinforced vehicle component according to the preamble of claim 1. The invention further relates to a device and a method for producing such a vehicle component. Components, in particular flat components, can be reinforced by applying a fiber-plastic composite (FKV) or a fiber-reinforced plastic (FRP), as described, for example, in DE 101 34 372 A1.
Die DE 10 2013 021 672 A1 beschreibt ein Verfahren zur Herstellung eines Hybridbauteils, das als ein Bauteilverbund aus einem Trägerprofilteil, insbe- sondere Blechteil, und einem faserverstärkten Kunststoff bereitgestellt wird. In einer Tapelegetechnik wird zumindest ein mit einem Matrixmaterial vorim- prägniertes Faserhalbzeug als ein Band unter Druck und Wärme in einem gemeinsamen Prozessschritt auf das Trägerprofi Iteil gelegt und irreversibel damit verbunden. DE 10 2013 021 672 A1 describes a method for producing a hybrid component, which is provided as a composite of a carrier profile part, in particular sheet metal part, and a fiber-reinforced plastic. In a tape laying technique, at least one semi-finished fiber product pre-impregnated with a matrix material is placed as a band under pressure and heat in a common process step on the carrier professional part and irreversibly connected to it.
Die thermische Aushärtung erfordert eine Heiz- und/oder Kühleinrichtung und eine genaue Temperatursteuerung, wofür eine Temperatur- Regel/Steuereinheit benötigt wird. Trotzdem kann es zu Temperaturschwan- kungen kommen (bspw. durch Wärmestauung oder ungleichmäßige Wärme- ableitung), was eine fehlende Reproduzierbarkeit und hohe Ausschussraten zur Folge hat. Zudem können, insbesondere wenn Werkstoffe bzw. Materia- lien mit unterschiedlichen Wärmeausdehnungskoeffizienten verbunden bzw. gefügt werden, beim Abkühlen Spannungen auftreten, die die Eigenschaften des Bauteils beeinflussen und zu Bauteilverzügen oder sogar zur Delamina- tion führen können. Thermal curing requires a heating and / or cooling device and precise temperature control, for which a temperature control unit is required. Nevertheless, temperature fluctuations can occur (for example due to heat accumulation or uneven heat dissipation), which results in a lack of reproducibility and high reject rates. In addition, especially when materials or materials with different coefficients of thermal expansion are connected or joined, stresses can occur during cooling that affect the properties of the component and can lead to component distortion or even delamination.
Mit der Erfindung soll wenigstens ein mit dem Stand der Technik einherge- hender Nachteil vermieden oder zumindest vermindert werden. The invention is intended to at least avoid or at least reduce a disadvantage associated with the prior art.
Dies gelingt mit einem erfindungsgemäßen Bauteil entsprechend den Merk- malen des Patentanspruchs 1 sowie mit einer erfindungsgemäßen Vorrich- tung und mit einem erfindungsgemäßen Verfahren entsprechend den Merk- malen der nebengeordneten Patentansprüche. Weiterbildungen und Ausge- staltungen der Erfindung ergeben sich analog für alle Erfindungsgegenstän- de aus den abhängigen Patentansprüchen, der nachfolgenden Erfindungs- beschreibung und den Figuren. This is achieved with a component according to the invention in accordance with the features of patent claim 1 and with a device according to the invention and with a method in accordance with the invention in accordance with the features of the independent claims. Further developments and refinements of the invention result analogously for all objects of the invention from the dependent patent claims, the following description of the invention and the figures.
Das erfindungsgemäße Fahrzeugbauteil umfasst ein Grundbauteil, das ins- besondere flächig oder als Profilteil ausgebildet ist, und wenigstens eine da- rauf aufgebrachte Verstärkung aus einem Faserkunststoffverbund-Material. Erfindungsgemäß weist die Verstärkung wenigstens einen (mit UV- härtbarem Flarz) harzgetränkten, auf dem zu verstärkenden Grundbauteil abgelegten sowie anschließend daran angedrückten und UV-gehärteten Strang auf. The vehicle component according to the invention comprises a basic component, which is in particular flat or as a profile part, and at least one reinforcement made of a fiber-plastic composite material applied thereon. According to the invention, the reinforcement has at least one (with UV-curable flarz) resin-impregnated strand, deposited on the base component to be reinforced and then pressed on and UV-hardened.
Bei der Verstärkung handelt es sich bevorzugt um eine lokale Verstärkung, die das Grundbauteil bereichsweise bzw. stellenweise verstärkt. Es können mehrere solcher lokalen Verstärkungen vorgesehen sein, die bei einem flä- chigen Grundbauteil auch beidseitig aufgebracht sein können. The reinforcement is preferably a local reinforcement that reinforces the basic component in regions or in places. Several such local reinforcements can be provided, which can also be applied to both sides of a flat basic component.
Das erfindungsgemäße Fahrzeugbauteil ist leicht und stabil und kann günstig hergestellt werden, wie nachfolgend noch näher erläutert. Außerdem kann das erfindungsgemäße Fahrzeugbauteil ohne Wärmeeinbringung hergestellt werden, da die Aushärtung des Flarzes mittels UV-Licht (d. h. mittels Ultra- violettstrahlung) erfolgt, sodass die oben genannten Nachteile nicht auftre- ten. Die Erfindung begünstigt zudem neue lastpfadoptimierte Konstruktions- konzepte. Das erfindungsgemäße Fahrzeugbauteil ist insbesondere ein Karosseriebau- teil, womit sowohl ein Strukturbauteil als auch ein Außenhautbauteil gemeint sein kann. Durch die Verstärkung kann z. B. gezielt das Crash-Verhalten von Frontklappen, Stoßfängern, Seitenwandsäulen, Schwellern und dergleichen verbessert werden. Ferner können solche Fahrzeugbauteile auch teure Tai- lored-Blank-Teile ersetzen. Das erfindungsgemäße Fahrzeugbauteil kann aber auch ein Einbauteil, wie bspw. eine Flutablage oder eine Rücksitzlehne, sein. The vehicle component according to the invention is light and stable and can be manufactured cheaply, as explained in more detail below. In addition, the vehicle component according to the invention can be produced without the introduction of heat, since the flarz is cured by means of UV light (ie by means of ultraviolet radiation), so that the above-mentioned disadvantages do not occur. The invention also favors new load path-optimized design concepts. The vehicle component according to the invention is in particular a body component, by which both a structural component and an outer skin component can be meant. Through the reinforcement z. B. specifically improve the crash behavior of front flaps, bumpers, side wall pillars, sills and the like. Furthermore, such vehicle components can also replace expensive waisted blank parts. However, the vehicle component according to the invention can also be an installation part, such as, for example, a flood shelf or a rear seat backrest.
Das zu verstärkende Grundbauteil kann aus einem Metallblech (z. B. einem Stahlblech), insbesondere aus einem Leichtblech (z. B. einem Aluminium- blech), aus einem Organoblech, aus einem Kunststoff, insbesondere aus einem spritzgegossenen oder blasgeformten Kunststoff, aus einem Faser- kunststoffverbund (FKV) bzw. faserverstärktem Kunststoff (FVK), aus einem geschäumten Material bzw. einer geschäumten Struktur (sowohl Kunststoff als auch Metall) oder aus einem Metallguss gefertigt sein. The basic component to be reinforced can be made from a metal sheet (e.g. a steel sheet), in particular from a light sheet (e.g. an aluminum sheet), from an organic sheet, from a plastic, in particular from an injection-molded or blow-molded plastic, from a Fiber-plastic composite (FKV) or fiber-reinforced plastic (FVK), be made of a foamed material or structure (both plastic and metal) or from a metal casting.
Unter einem Strang wird allgemein ein band-, schnür- oder schlauchartiges Gebilde aus einem Verstärkungsfasern enthaltenden Material verstanden. Ein Strang im Sinne der Erfindung ist insbesondere ein Verstärkungsfasern enthaltendes Band (Tape) oder eine Verstärkungsfasern enthaltende Schnur (Roving) oder dergleichen, wobei auch schlauchförmige Ausbildungen mög- lich sind. Bei den Verstärkungsfasern kann es sich um Kohlenstofffasern, Glasfasern, Kunstfasern oder Metallfasern handeln, wobei auch Fasergemi- sche möglich sind. Bevorzugt handelt es sich um Endlosfasern, wobei auch Stapelfasern (mit begrenzter Länge) verwendet werden können. Die Verstär- kungsfasern können im Strang als UD-Lage(n) mit unidirektional orientierten Fasern, als Geflecht oder auch als Gestrick vorliegen. Bevorzugt ist der Strang textilartig ausgebildet. A strand is generally understood to mean a band-like, cord-like or hose-like structure made of a material containing reinforcing fibers. A strand in the sense of the invention is, in particular, a tape (tape) containing reinforcing fibers or a cord (roving) or the like containing reinforcing fibers, wherein tubular designs are also possible. The reinforcing fibers can be carbon fibers, glass fibers, synthetic fibers or metal fibers, whereby fiber mixtures are also possible. They are preferably continuous fibers, and staple fibers (of limited length) can also be used. The reinforcing fibers can be present in the strand as a UD layer (s) with unidirectionally oriented fibers, as a braid or as a knitted fabric. The strand is preferably textile-like.
Bevorzugt ist vorgesehen, dass der wenigstens eine Strang für die Verstär- kung It is preferably provided that the at least one strand for the reinforcement
- aus einem Verstärkungsfasern enthaltenden Material; - aus einem Verstärkungsfasern, insbesondere Metallfasern, enthaltenden Textil, das mit Zusatzstoffen (z. B. Füllstoffen oder sonstigen Hilfsmitteln) versehen ist, welche die Anhaftung bzw. den Stoffschluss am/zum Grund- bauteil verbessern und/oder die Haftung zwischen den Verstärkungsfasern verbessern und/oder den Wärme- bzw. Längenausdehnungskoeffizient der Verstärkung an das Grundbauteil anpassen; - Made of a material containing reinforcing fibers; - from a textile containing reinforcing fibers, in particular metal fibers, which is provided with additives (e.g. fillers or other auxiliaries) which improve the adhesion or the material connection to / to the basic component and / or improve the adhesion between the reinforcing fibers and / or adapt the coefficient of thermal expansion or linear expansion of the reinforcement to the basic component;
- aus einem Verstärkungsfasern enthaltenden Band (Tape) mit Zusatzstof- fen, welche die Anhaftung am Grundbauteil verbessern und/oder den Wär- meausdehnungskoeffizient anpassen; oder  - from a tape containing reinforcing fibers with additives which improve the adhesion to the basic component and / or adjust the coefficient of thermal expansion; or
- aus einem Gemisch von Verstärkungsfasern und anderen Verstärkungs- stoffen (wie z. B. Hohlkugeln, Blähglas, Ton, womit insbesondere im Crash- fall Energie abgebaut werden kann, wobei sich diese Verstärkungsstoffe be- vorzugt im Inneren eines schlauchartigen Strangs befinden können);  - from a mixture of reinforcing fibers and other reinforcing materials (such as hollow spheres, expanded glass, clay, which can be used to break down energy, particularly in the event of a crash, whereby these reinforcing materials can preferably be located inside a tube-like strand);
gefertigt ist. is made.
Die erfindungsgemäße Vorrichtung ist dafür vorgesehen, wenigstens einen harzgetränkten Strang an ein damit zu verstärkendes Grundbauteil anzudrü- cken und den harzgetränkten Strang dabei zumindest bereichsweise mit UV- Licht zu beleuchten. Die erfindungsgemäße Vorrichtung weist eine Andrück- einrichtung auf, mit der der harzgetränkte Strang (beim Ablegen und/oder nach dem Ablegen) an das zu verstärkende Grundbauteil andrückbar ist, und wenigstens eine UV-Lampe, mit der der abgelegte und angedrückte Strang zumindest bereichsweise mit UV-Licht beleuchtbar und dadurch aushärtbar ist bzw. UV-gehärtet wird. The device according to the invention is intended to press at least one resin-impregnated strand onto a base component to be reinforced therewith and to illuminate the resin-impregnated strand with UV light at least in some areas. The device according to the invention has a pressing device with which the resin-impregnated strand (when laying down and / or after laying down) can be pressed onto the basic component to be reinforced, and at least one UV lamp, with which the deposited and pressed-on strand is at least partially included UV light can be illuminated and can therefore be cured or UV-cured.
Bevorzugt ist vorgesehen, dass die Andrückeinrichtung eine Andrückrolle oder -walze ist, die zumindest teilweise aus einem transparenten oder transluzenten Material gebildet ist, und dass die UV-Lampe in die Andrück- rolle integriert ist, sodass gleichzeitig mit dem Andrücken die UV-Härtung erfolgen kann. Die Andrückrolle wird beim Einschalten der UV-Lampe quasi mit UV-Licht durchflutet. Das erfindungsgemäße Verfahren wird vorzugsweise automatisch auf einer erfindungsgemäßen Vorrichtung ausgeführt und umfasst zumindest die fol- genden Schritte: It is preferably provided that the pressure device is a pressure roller or roller, which is at least partially formed from a transparent or translucent material, and that the UV lamp is integrated in the pressure roller, so that UV curing takes place simultaneously with the pressure can. The pressure roller is literally flooded with UV light when the UV lamp is switched on. The method according to the invention is preferably carried out automatically on a device according to the invention and comprises at least the following steps:
- Ablegen des harzgetränkten Strangs auf dem Grundbauteil;  - Placing the resin-impregnated strand on the basic component;
- Andrücken des abgelegten Strangs (mittels einer Andrückeinrichtung, ins- besondere einer Andrückrolle), wobei das Andrücken direkt beim Ablegen erfolgen kann;  - pressing the deposited strand (by means of a pressing device, in particular a pressing roller), the pressing being able to take place directly when being deposited;
- UV-Härten des angedrückten Strangs, bevorzugt direkt nach dem Andrü- cken oder unmittelbar beim Andrücken, insbesondere mittels einer in der An- drückrolle angeordneten UV-Lampe (s. o.).  UV curing of the pressed strand, preferably directly after pressing on or immediately upon pressing, in particular by means of a UV lamp arranged in the pressing roller (see above).
Dabei können auch Geometrieelemente mit angeformt werden, die dann bspw. als Abstandshalter fungieren.  Geometric elements can also be formed, which then function as spacers, for example.
Dieser Prozess bzw. Verfahrensablauf kommt ohne Temperaturregelung aus und ist daher sehr stabil und reproduzierbar sowie auch kostengünstig. This process or procedure does not require temperature control and is therefore very stable and reproducible as well as inexpensive.
Auf diese Weise können mehrere Verstärkungslagen erzeugt werden. Au- ßerdem können (nacheinander) mehrere Stränge lastpfadgerecht abgelegt werden, auch mit unterschiedlichen Ausrichtungen, wobei auch Überschnei- dungen erzeugt werden können. In this way, several reinforcement layers can be created. In addition, several strands can be deposited (one after the other) according to the load path, even with different orientations, whereby overlaps can also be generated.
Mit dem erfindungsgemäßen Verfahren können auch Sandwichbauteile mit einem Schaumkern hergestellt werden. The method according to the invention can also be used to produce sandwich components with a foam core.
Als Kunststoffmatrix wird insbesondere ein UV-härtender Duroplast verwen- det. Der zunächst noch trockene (d. h. nicht vorimprägnierte) Strang kann zur Tränkung durch ein Harzbad mit dem flüssigen Matrixmaterial (Kunst- harz) geführt werden (wie in der DE 10 2013 021 672 A1 ) beschrieben. An- schließend kann der derart harzgetränkte Strang im Nasszustand auf dem Grundbauteil abgelegt, angedrückt und durch UV-Beleuchtung bzw. mittels UV-Licht ausgehärtet werden. Die Verstärkungsfasern werden dabei in die Kunststoffmatrix eingebettet, sodass ein Faserkunststoffverbund entsteht. Der Matrixwerkstoff kann einen Haftvermittler enthalten. Das Harz, mit dem der Strang getränkt ist bzw. getränkt wird, kann ein auf- schäumendes Harz sein, das dann, insbesondere nach dem Ablegen, vor oder während der UV-Härtung bzw. beim UV-Härten aufschäumt, sodass die Verstärkung zumindest abschnittsweise eine geschäumte Kunststoffmatrix aufweist. Die Verstärkung kann dadurch zusätzlich eine Dichtfunktion, Schallschutz- oder Wärmeschutzfunktion und/oder Energieabsorptionsfunkti- on übernehmen. Es kann sich um ein physikalisches Schäumen oder chemi- sches Schäumen handeln. Bevorzugt wird der Schäumvorgang erst durch das UV-Licht aktiviert. In particular, a UV-curing thermoset is used as the plastic matrix. The strand, which is initially still dry (ie not pre-impregnated), can be passed through a resin bath with the liquid matrix material (synthetic resin) for impregnation (as described in DE 10 2013 021 672 A1). The strand so impregnated with resin can then be deposited on the base component in the wet state, pressed on and cured by UV lighting or by means of UV light. The reinforcement fibers are embedded in the plastic matrix so that a fiber-plastic composite is created. The matrix material can contain an adhesion promoter. The resin with which the strand is impregnated or is impregnated can be a foaming resin which then foams, in particular after being deposited, before or during UV curing or during UV curing, so that the reinforcement at least in sections has a foamed plastic matrix. As a result, the reinforcement can additionally take on a sealing function, sound insulation or heat protection function and / or energy absorption function. It can be physical foaming or chemical foaming. The foaming process is preferably only activated by the UV light.
Das Grundbauteil kann beim Ablegen des harzgetränkten Strangs zumindest an der zu verstärkenden Stelle vom Strang umwickelt werden. Das Ablegen des Strangs kann also in einem wickelprozessartigen Vorgang erfolgen. Auf diese Weise können bspw. sogenannte Gussknoten (Knotenelemente), die bei einer sogenannten Space-Frame-Karosserie zum Einsatz kommen, ver- stärkt werden. When the resin-impregnated strand is put down, the basic component can be wrapped around the strand at least at the point to be reinforced. The strand can therefore be deposited in a winding-like process. In this way, for example, so-called cast knots (knot elements), which are used in a so-called space frame body, can be strengthened.
Die Erfindung wird nachfolgend anhand der Figuren beispielhaft näher erläu- tert. Die in den Figuren gezeigten und/oder nachfolgend erläuterten Merkma- le können, auch unabhängig von bestimmten Merkmalskombinationen, all- gemeine Merkmale der Erfindung sein und die Erfindung entsprechend wei- terbilden. The invention is explained in more detail below using the figures as an example. The features shown in the figures and / or explained below can, regardless of certain combinations of features, be general features of the invention and further develop the invention accordingly.
Fig. 1 veranschaulicht ein erfindungsgemäßes Fahrzeugbauteil. 1 illustrates a vehicle component according to the invention.
Fig. 2 zeigt schematisch eine erfindungsgemäße Vorrichtung, mit der das in Fig. 1 gezeigte Fahrzeugbauteil herstellbar ist. FIG. 2 schematically shows a device according to the invention with which the vehicle component shown in FIG. 1 can be produced.
Bei dem in Fig. 1 gezeigten Fahrzeugbauteil 100 handelt es sich lediglich beispielhaft um eine Rücksitzlehnenverstärkung. Die Rücksitzlehnenverstär- kung 100 weist ein aus Blech, insbesondere Aluminiumblech, gefertigtes und rahmenartig ausgebildetes Grundbauteil 110 auf. Das Grundbauteil 110 kann aber auch aus einem anderen Material gefertigt sein, wie oben beschrieben. Dieses Grundbauteil 110 ist bspw. ein Tiefzieh-/Stanzteil und kann somit ei- ne räumliche Formgebung aufweisen. Die sich zwischen Ausnehmungen bzw. Ausstanzungen 120 erstreckenden Streben 130 sind mittels Verstär- kungen 140 aus einem Faserkunststoffverbund-Material gezielt verstärkt bzw. versteift, um Lastpfade zu optimieren und/oder eine höhere Crashsi- cherheit zu erreichen. Ferner wirken diese streifenartigen Verstärkungen 140 wie Zugbänder und bewirken, insbesondere bei Punktbelastung, eine Last- verteilung. Erfindungsgemäß weisen die Verstärkungen 140 wenigstens ei- nen harzgetränkten, auf dem zu verstärkenden Grundbauteil 110 abgelegten sowie anschließend daran angedrückten und UV-gehärteten Strang auf bzw. sind daraus gebildet. The vehicle component 100 shown in FIG. 1 is merely an example of a rear seat back reinforcement. The rear seat back reinforcement 100 has a basic component 110 made of sheet metal, in particular aluminum sheet, and formed like a frame. The basic component 110 can, however, also be made of another material, as described above. This basic component 110 is, for example, a deep-drawn / stamped part and can therefore be ne spatial shape. The struts 130 which extend between recesses or punched-out portions 120 are reinforced or stiffened in a targeted manner by means of reinforcements 140 made of a fiber plastic composite material in order to optimize load paths and / or to achieve greater crash safety. Furthermore, these strip-like reinforcements 140 act like tension bands and, particularly under point load, bring about a load distribution. According to the invention, the reinforcements 140 have at least one resin-impregnated strand, which is deposited on the base component 110 to be reinforced and then pressed on and UV-hardened, or are formed therefrom.
Fig. 2 veranschaulicht die Herstellung des Fahrzeugbauteils 100 mithilfe ei- ner erfindungsgemäßen Vorrichtung 200. Die Vorrichtung 200 ist bspw. als Ablegekopf ausgebildet und kann an einem Roboterarm befestigt sein und so mithilfe des Roboters bewegt werden, wie durch die Pfeil F veranschaulicht. (Eine ähnliche Vorrichtung ist aus der bereits oben zitierten Patentschrift DE 10 2013 021 672 A1 bekannt). 2 illustrates the production of the vehicle component 100 with the aid of a device 200 according to the invention. The device 200 is designed, for example, as a depositing head and can be fastened to a robot arm and can thus be moved with the robot, as illustrated by the arrow F. (A similar device is known from the patent DE 10 2013 021 672 A1 already cited above).
Die Vorrichtung 200 weist eine Wickelspule 210 auf, von der kontinuierlich ein Verstärkungsfasern enthaltender, bandartiger Strang (auch als Tape be- zeichnet) 220 abgewickelt wird. Der Strang 220 kann eine Dicke im Bereich von 0,1 mm bis 2,0 mm aufweisen, kann aber auch dünner oder dicker sein. Der abgewickelte Strang 220 wird in einem Harzbad 230 (oder einer funkti- onsgleichen Einrichtung) mit flüssigem, UV-härtbarem Harzmaterial getränkt und dann auf dem Grundbauteil 110 abgelegt, das dabei durch einen Tisch 300 oder dergleichen abgestützt wird. Der biegeschlaffe Strang 220 lässt sich sehr gut an die Kontur des Grundbauteils 110 anlegen. The device 200 has a winding spool 210, from which a band-like strand (also referred to as tape) containing reinforcing fibers is continuously unwound. The strand 220 can have a thickness in the range from 0.1 mm to 2.0 mm, but can also be thinner or thicker. The unwound strand 220 is soaked in a resin bath 230 (or a functionally equivalent device) with liquid, UV-curable resin material and then placed on the base component 110, which is supported by a table 300 or the like. The limp strand 220 can be placed very well on the contour of the basic component 110.
Der nass abgelegte Strang 220 wird sodann mithilfe einer Andrückrolle 240 mit einem vorgegebenen Anpressdruck an das Grundbauteil 110 angedrückt und währenddessen und/oder direkt danach durch UV-Licht ausgehärtet, wozu in der Andrückrolle 240 und/oder neben der Andrückrolle 240 (d. h. der Andrückrolle 240 nachgeordnet) wenigstens eine UV-Lampe 250 angeordnet ist. Dadurch entsteht ohne Wärmeeinbringung eine untrennbare stoffschlüs- sige Verbindung mit dem Grundbauteil 110. Um die Haftung zu verbessern, kann das Grundbauteil 110 zumindest an den betreffenden Stellen vorbe- handelt werden (bspw. durch Sand- oder Plasmastrahlen). Am Ende des Ab- legevorgangs kann der Strang 220 dann mithilfe einer Schneideinrichtung 260 abgeschnitten werden. The wet deposited strand 220 is then pressed onto the base component 110 with a predetermined contact pressure using a pressure roller 240 and is cured during and / or immediately thereafter by UV light, for which purpose in the pressure roller 240 and / or next to the pressure roller 240 (ie the pressure roller 240 downstream) at least one UV lamp 250 is arranged. This creates an inseparable material bond without the introduction of heat. connection to the basic component 110. In order to improve the adhesion, the basic component 110 can be pretreated at least at the relevant points (for example by sand or plasma blasting). At the end of the laying process, the strand 220 can then be cut off using a cutting device 260.

Claims

PATENTANSPRÜCHE: CLAIMS:
Fahrzeugbauteil (100), mit einem Grundbauteil (110), das insbesondere flächig ausgebildet ist, und wenigstens einer darauf aufgebrachten Ver- stärkung (140) aus einem Faserkunststoffverbund-Material, Vehicle component (100), having a base component (110), which is in particular flat, and at least one reinforcement (140) made of a fiber-plastic composite material applied thereon,
dadurch gekennzeichnet, dass characterized in that
die Verstärkung (140) wenigstens einen harzgetränkten, auf dem zu verstärkenden Grundbauteil (110) abgelegten sowie anschließend da- ran angedrückten und UV-gehärteten Strang (220) aufweist. the reinforcement (140) has at least one resin-impregnated strand (220) which is deposited on the basic component (110) to be reinforced and then pressed thereon and UV-hardened.
Fahrzeugbauteil (100) nach Anspruch 1 , Vehicle component (100) according to claim 1,
dadurch gekennzeichnet, dass characterized in that
das zu verstärkende Grundbauteil (110) aus einem Metallblech, insbe- sondere aus einem Aluminiumblech, aus einem Organoblech, aus ei- nem Kunststoff, aus einem Faserkunststoffverbund, aus einem Schaummaterial oder aus einem Metallguss gefertigt ist. the basic component (110) to be reinforced is made from a metal sheet, in particular from an aluminum sheet, from an organic sheet, from a plastic, from a fiber-plastic composite, from a foam material or from a metal casting.
Fahrzeugbauteil (100) nach Anspruch 1 oder 2, Vehicle component (100) according to Claim 1 or 2,
dadurch gekennzeichnet, dass characterized in that
der wenigstens eine Strang (220) für die Verstärkung (140) the at least one strand (220) for the reinforcement (140)
- aus einem Verstärkungsfasern enthaltenden Material;  - Made of a material containing reinforcing fibers;
- aus einem Verstärkungsfasern, insbesondere Metallfasern, enthalten- den Textil, das mit Zusatzstoffen versehen ist, welche die Anhaftung am Grundbauteil (110) verbessern und/oder die Haftung zwischen den Verstärkungsfasern verbessern und/oder den Wärmeausdehnungsko- effizient anpassen;  - A textile containing reinforcing fibers, in particular metal fibers, which is provided with additives which improve the adhesion to the basic component (110) and / or improve the adhesion between the reinforcing fibers and / or adapt the thermal expansion coefficient;
- aus einem Verstärkungsfasern enthaltenden Band mit Zusatzstoffen, welche die Anhaftung am Grundbauteil (110) verbessern und/oder den Wärmeausdehnungskoeffizient anpassen; oder  - From a tape containing reinforcing fibers with additives that improve the adhesion to the basic component (110) and / or adjust the coefficient of thermal expansion; or
- aus einem Gemisch von Verstärkungsfasern und anderen Verstär- kungsstoffen;  - from a mixture of reinforcing fibers and other reinforcing materials;
gefertigt ist. Fahrzeugbauteil (100) nach einem der vorausgehenden Ansprüche, dadurch gekennzeichnet, dass is made. Vehicle component (100) according to any one of the preceding claims, characterized in that
dieses ein Karosseriebauteil oder ein Einbauteil ist. this is a body component or an installation part.
Vorrichtung (200) zur Herstellung eines Fahrzeugbauteils (100), das ein Grundbauteil (110) und wenigstens eine darauf aufgebrachte Verstär- kung (140) aus einem Faserkunststoffverbund-Material aufweist, wobei die Verstärkung (140) aus wenigstens einem harzgetränkten Strang (220) gebildet wird, Device (200) for producing a vehicle component (100) which has a base component (110) and at least one reinforcement (140) made of a fiber plastic composite material, the reinforcement (140) consisting of at least one resin-impregnated strand (220) is formed
dadurch gekennzeichnet, dass characterized in that
diese Vorrichtung (200) eine Andrückeinrichtung (240) aufweist, mit der der harzgetränkte Strang (220) an das zu verstärkende Grundbauteil (110) andrückbar ist, und wenigstens eine UV-Lampe (250), mit der der angedrückte Strang (220) zumindest bereichsweise mit UV-Licht be- leuchtbar und dadurch aushärtbar ist. this device (200) has a pressing device (240) with which the resin-impregnated strand (220) can be pressed onto the base component (110) to be reinforced, and at least one UV lamp (250) with which the pressed strand (220) at least can be illuminated with UV light in some areas and is therefore curable.
Vorrichtung (200) nach Anspruch 5, Device (200) according to claim 5,
dadurch gekennzeichnet, dass characterized in that
die Andrückeinrichtung (240) eine Andrückrolle ist, die aus einem transparenten oder transluzenten Material gebildet ist, wobei die UV- Lampe (250) in die Andrückrolle (240) integriert ist. the pressure device (240) is a pressure roller which is formed from a transparent or translucent material, the UV lamp (250) being integrated in the pressure roller (240).
Verfahren zur Herstellung eines Fahrzeugbauteils (100), das ein Grundbauteil (110) und wenigstens eine darauf aufgebrachte Verstär- kung (140) aus einem Faserkunststoffverbund-Material aufweist, wobei die Verstärkung (140) aus wenigstens einem harzgetränkten Strang (220) gebildet wird, wobei dieses Verfahren insbesondere mit einer Vor- richtung (200) gemäß Anspruch 5 oder 6 automatisch ausgeführt wird, umfassend die Schritte: Method for producing a vehicle component (100) which has a base component (110) and at least one reinforcement (140) made of a fiber plastic composite material, the reinforcement (140) being formed from at least one resin-impregnated strand (220), this method being carried out automatically, in particular with a device (200) according to claim 5 or 6, comprising the steps:
- Ablegen des harzgetränkten Strangs (220) auf dem Grundbauteil - Placing the resin-impregnated strand (220) on the basic component
(1 10); (1 10);
- Andrücken des abgelegten Strangs (220);  - pressing the deposited strand (220);
- UV-Härten des angedrückten Strangs (220). - UV curing of the pressed strand (220).
8. Verfahren nach Anspruch 7, 8. The method according to claim 7,
dadurch gekennzeichnet, dass  characterized in that
mehrere Stränge (220) lastpfadgerecht abgelegt werden. 9. Verfahren nach Anspruch 7 oder 8,  several strands (220) are laid down according to the load path. 9. The method according to claim 7 or 8,
dadurch gekennzeichnet, dass  characterized in that
das Harz, mit dem der Strang (220) getränkt ist, ein aufschäumendes Harz ist, das vor oder während dem UV-Härten aufschäumt. 10. Verfahren nach Anspruch 7, 8 oder 9,  the resin with which the strand (220) is impregnated is a foaming resin that foams before or during UV curing. 10. The method according to claim 7, 8 or 9,
dadurch gekennzeichnet, dass  characterized in that
das Grundbauteil (110) beim Ablegen vom harzgetränkten Strang (220) umwickelt wird.  the base component (110) is wrapped when the resin-impregnated strand (220) is deposited.
PCT/EP2019/069128 2018-08-20 2019-07-16 Vehicle component reinforced by means of deposition technology and device and method for producing same WO2020038659A1 (en)

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