DE10161155A1 - Method for producing compound components involves positioning of at least one polymer coated insert in the molding tool, and hardening of the component in the closed molding tool - Google Patents

Abstract

The method for producing compound components consists of introducing a foil (i) into a molding tool, positioning at least one insert with a polymer coating in the top section of the molding tool, positioning a layer (ii) of fiber reinforced polyurethane on top of the layer (i), and hardening the compound in the closed molding tool. Independent claims are also included for the following: (a) a resultant compound component (b) and application of compound components as parts of vehicle bodyworks (c) an application of polymer coated inserts for production of compound components

Description

The invention relates to composite components constructed from a film and containing a layer of fiber reinforced polyurethane Inlay, the inlay being covered with a polymer layer are, as well as a process for their preparation and their Use as body components.

EP-A-1 077 225 and EP-A-995 667 describe composite components, in particular roof modules for motor vehicles that are manufactured by molding a thermoplastic film and then Applying fiber-reinforced polyurethane to this film. The Thermoplastic, colored film replaces the paint job. The described composite components can be found, for example Use in motor vehicles of the "Smart" type.

To improve the torsional rigidity of such composite components or the attachment of attachments such as To enable grab handles, it is necessary to have one or more Inlay, preferably in the form of profiled hoops, in the Incorporate composite component.

It is generally known from the prior art that inserts or bow by inserting into a mold and then Integration in a polyurethane matrix in polyurethane components can be integrated. However, this procedure proves Composite components made of film and polyurethane matrix have the disadvantage that after the component has cooled and removed from the mold Geometry of the insert or bow on the foil side of the Component.

The object of the invention was therefore to provide a process for the production of composite components, made of foil and fiber-reinforced Polyurethane to be provided, the composite components Inlays should contain without changing the geometry of the inlays on the foil side of the composite components. Furthermore was it object of the invention corresponding composite components ready put.

The task could be solved in that the depositors, preferably profiled inserts, before inserting them into the mold were coated with a polymer layer.

The invention therefore relates to composite components from a film (i) and a layer of fiber-reinforced Polyurethane (ii) containing inserts, the inserts with a Polymer layer are coated.

• A) Einlegen einer Folie (i) in ein Formwerkzeug,
• B) Anbringen von mindestens einem Einleger am Werkzeugoberteil, wobei die Einleger mit einer Polymerschicht beschichtet sind,
• C) Aufbringen einer Schicht aus faserverstärktem Polyurethan (ii) auf die Folie (i) und anschließend
• D) Aushärten des Verbundbauteils bei geschlossener Form.

The invention furthermore relates to a method for producing composite components, comprising the steps

• A) inserting a film (i) into a mold,
• B) attaching at least one insert to the upper part of the tool, the inserts being coated with a polymer layer,
• C) applying a layer of fiber-reinforced polyurethane (ii) to the film (i) and then
• D) curing the composite component with the mold closed.

The invention furthermore relates to the use of inserts, which are covered with a polymer layer for improvement the rigidity of composite components, comprising a film and a layer of fiber reinforced polyurethane and use of the composite components mentioned for the production of Body components.

The composite components according to the invention consist of two Layers. Layer i) of the composite component according to the invention comprises a foil, which is usually made of metal, for example made of aluminum, preferably aluminum coil coating, or of can consist of a thermoplastic. As Thermoplastic films can use generally known films are, for example, conventional films based on Acrylonitrile butadiene styrene (ABS), polymethyl methacrylate (PMMA), Acrylonitrile styrene acrylic ester (ASA), Acrylonitrile styrene acrylic ester and polycarbonate blend (ASA-PC), polycarbonate (PC), thermoplastic polyurethane, polypropylene, polyethylene, and / or Polyvinyl chloride (PVC).

Such films are commercially available and their manufacture is well known. The foils usually have one Thickness from 0.1 to 15 mm, preferably from 1 to 3 mm. At least two are preferred as the thermoplastic film (i) Layers containing film used, the one layer an ASA and / or polycarbonate and / or ASA-PC blend material contains. At least one is particularly preferably used Two-layer film, the first layer based on PMMA and the second layer on ASA and / or ASA-PC and / or PC. You sit down Two-layer film, so it sticks Polyisocyanate polyadducts preferably on ASA and / or ASA / PC and / or PC.

A film is preferably used which has a Class-A surface generated. Class-A surface is a surface which appears visually high quality when viewed visually. at the assessment of the high quality can long and Short ripple, defects and / or degree of gloss are taken into account.

Layer ii) of the composite components according to the invention fiber-reinforced polyurethane and serves as a carrier that the Composite component advantageous mechanical properties, such as for example, gives high strength.

Fiber-reinforced polyurethane is polyurethane that Contains fibers for reinforcement, these fibers preferably so are that they do not have a conventional High pressure mixing head can be processed. The fibers can for example by the LFI method known from the prior art (Long Fiber Injection) into the polyurethane and generally have a length of more than 5 mm, preferably of more than 10 mm, particularly preferably from 10 mm to 10 cm. Furthermore, it is also possible to use the fibers in the form of mats to introduce the polyurethane (mat insertion process).

The fibers used can be glass fibers, Natural fibers, such as flax, jute or sisal, synthetic fibers, such as polyamide fibers, polyester fibers, carbon fibers or act as polyurethane fibers. Preferably used Glass fibers.

The fibers are usually used in an amount of 0.1 to 90% by weight, preferably from 1 to 50, more preferably from 5 to 40 and particularly preferably from 10 to 30% by weight, based on the total weight of layer ii) used.

Layer ii) of the composite components according to the invention has usually a density of 0.1 to 1.3 kg / l, preferred from 0.3 to 1.0 kg / l. To achieve this density compact or cellular polyurethanes used, wherein Rigid polyurethane foams are preferably used.

The thickness of layer ii) in the invention Composite components are usually 0.1 to 250 mm, preferred 0.5 to 100 mm, more preferably 1 to 50 mm, particularly preferably 1 to 10 mm.

The composite components according to the invention are preferred Adhesion between layer i) and layer ii) before, d. H. the Adhesion between the layers is preferably greater than that Cohesion within a layer. To increase the adhesion between layers i) and ii) layer i) before Back foams are pretreated, for example by application. a primer, by flame treatment or mechanical roughening or irradiation with light (wavelength of radiation smaller 800 nm) or particles (sandblasting). This pretreatment is however optional.

Layer ii) of the composite elements according to the invention comprises Polyurethanes. The term polyurethane refers to here Polyisocyanate polyadducts by implementation of a) polyisocyanates with b) reactive with isocyanate Compounds optionally in the presence of c) blowing agent, d) Catalysts and e) auxiliaries and additives are available.

Well-known (cyclo) aliphatic can be used as isocyanates (a) and / or in particular aromatic polyisocyanates become. For the production of the composite elements according to the invention aromatic or aliphatic diisocyanates are particularly suitable, preferably diphenylmethane diisocyanate (MDI), tolylene diisocyanate (TDI) and hexamethylene diisocyanate (HDI). The isocyanates can Form of pure connection or in modified form, for example in the form of urethdiones, isocyanurates, allophanates or Biurethene, preferably in the form of urethane and isocyanate groups containing reaction products, so-called Isocyanate prepolymers can be used.

Compounds which are reactive towards isocyanates (b) are compounds which have two or more reactive groups selected from OH groups, SH groups, NH groups, NH ₂ groups and CH-acidic groups, such as, for. B. β-diketo groups in the molecule.

Those with a functionality of 1.8 to 8, preferably 2 to 6, and a molecular weight of 300 to 8000, preferably of 400 to 4000, are expediently used. Have proven themselves. B. polyether polyamines and / or preferably polyols selected from the group of polyether polyols, polyester polyols, polythioether polyols, polyester amides, hydroxyl-containing polyacetals and hydroxyl-containing aliphatic polycarbonates or mixtures of at least two of the polyols mentioned. Polyester polyols and / or polyether polyols are preferably used. Polyether polyols which have at least 10% primary hydroxyl groups are particularly preferably used. The hydroxyl number of the polyhydroxyl compounds is usually 50 to 1000 . Furthermore, the compounds (b) can be used in a mixture with customary chain extenders and / or crosslinking agents.

As blowing agents (c) can be used to produce foamed Products generally known chemically or physically active Connections are used. As a chemical agent Blowing agent can preferably be used water. Examples for physical blowing agents are inert (cyclo) aliphatic Hydrocarbons with 4 to 8 carbon atoms, which under evaporate the conditions of polyurethane formation. The amount the blowing agent used depends on the desired Density of the foams.

Conventional compounds which accelerate the reaction of component (a) with component (b) can be used as catalysts (d). For example, tertiary amines and / or organic metal compounds are suitable. For example, the following compounds can be used as catalysts: triethylenediamine, aminoalkyl and / or aminophenyl imidazoles, e.g. B. 4-chloro-2,5-dimethyl-1- (N-methylaminoethyl) imidazole, 2-aminopropyl-4,5-dimethoxy-1-methylimidazole, 1-aminopropyl-2,4,5-tributylimidazole, 1- Aminoethyl-4-hexylimidazole, 1-aminobutyl-2,5-dimethylimidazole, 1- ( 3- aminopropyl) -2-ethyl-4-methylimidazole, 1- ( 3- aminopropyl) imidazole and / or 1- ( 3- aminopropyl) - 2-methylimidazole, tin (II) salts of organic carboxylic acids, e.g. B. tin (II) diacetate, tin (II) dioctoate, tin (II) diethylhexoate and tin (II) dilaurate and dialkyltin (IV) salts of organic carboxylic acids, e.g. B. dibutyltin diacetate, dibutyltin dilaurate, dibutyltin maleate and dioctyltin diacetate.

The reaction is optionally carried out in the presence of (g) Auxiliaries and / or additives, such as. B. cell regulators, separation medium, pigments, surface-active compounds and / or Stabilizers against oxidative, thermal or microbial Degradation or aging.

The isocyanates (a) and the compounds (b) reactive toward isocyanates in such Amounts implemented that the equivalence ratio of NCO groups of (a) to the sum of the reactive hydrogen atoms of (b) preferably 0.90 to 1.5: 1, particularly preferably 1 to 1.2: 1 is.

Layer ii) of the composite components according to the invention contains Depositors. Depositor is understood to mean objects that are completely or partially in the fiber reinforced polyurethane layer can be foamed. The inserts used exist preferably made of plastic and / or metal. Examples of preferred Metals are steel, copper, zinc, aluminum or mixtures thereof.

The shape of the insert can vary depending on the application. to Improved torsional rigidity is preferred profiled Inlay (bow) used. These can spread across the entire Extend the width or length of the composite component.

Furthermore, attachments such as screws or Handles, for example for loudspeakers, lamps or antennas, be integrated into the PUR matrix.

Fig. 1 illustrates a composite component that contains coated inserts. The composite component has the shape of a roof module, which contains both an insert as a crossbar and inserts for handles.

• 1. 1 Dachmodul (Draufsicht)
• 2. 2 Vorderseite
• 3. 3 Rückseite
• 4. 4 Einleger für Haltegriffe
• 5. 5 Querspriegel
• 6. 6 Versteifungsrippen

.: In Figure 1 means

• 1. 1 roof module (top view)
• 2. 2 front
• 3. 3 back
• 4. 4 inserts for handles
• 5. 5 cross bars
• 6. 6 stiffening ribs

The inserts used in this invention are coated with a polymer layer. This coating can generally with all known from the prior art Methods are done. For example, the polymer layer as Spray skin to be applied to the insert. It is also possible the inlay with a film from the corresponding To stick on polymer. It is also possible to insert the so in a mold that is between the mold wall and the insert there is a desired distance, in this space then the polymer is introduced.

The polymer layer generally has a thickness of 0.5 to 20 mm, preferably from 1 to 10 mm.

As a polymer, any plastic is generally suitable that the occurring in the manufacture of the composite component Resists internal pressure. This internal mold pressure is generally included 2 to 15 bar.

It is also advantageous to choose the type of polymer so that the linear expansion coefficients of the polymer layer surrounding the insert and the fiber-reinforced polyurethane layer are adapted. A linear expansion is understood to mean the change in length dL which a solid body, ie here layer i), experiences when the temperature changes dT. It is described in a first approximation by dL / L = a.dT, whereby the linear expansion coefficient a is given in the order of 10 ^-6 / K.

In general, layer ii) has a linear one Expansion coefficients from 0.1 to 65, preferably from 1 to 50, particularly preferably from 20 to 45. In a preferred embodiment shows the polymer layer used to coat the inserts a coefficient of linear expansion for which the following applies: Coefficient of linear expansion (polymer layer) Coefficient of linear expansion (fiber-reinforced polyurethane) ± 50, preferably ± 30.

Examples of suitable polymers are polyethylene, polypropylene, Acrylic acid-butadiene-styrene copolymers (ABS), polyvinyl chloride (PVC), acrylate rubber, polyester, polyoxymethylene (POM), Polyamide (PA), polycarbonate (PC) and polyurethane, in particular compact polyurethane, e.g. B. Thermoplastic Polyurethane (TPU) or rigid polyurethane foam. Compact are preferably used Polyurethanes, which are called "Coating Systems" Are known to a person skilled in the art.

The composite components according to the invention are produced preferably according to the following procedure.

In a first step A), a two-part mold through layer i) of the composite component Insert a film, if necessary beforehand, for example was preformed by vacuum deep drawing. The Surface, which prefers the Class-A surface of the later Composite component is facing the mold wall.

Then in a second step B) one or more Insert that is coated with a polymer layer, attached to the upper part of the mold. The fixation can for example by a clamping device or preferably by Magnets are made. In general, step B) can also be done before or at the same time as step A).

Then, in a third step C), layer ii) is made fiber-reinforced polyurethane, for example, by the known LFI process or mat insertion process on the film (layer i)) applied. The polyurethane matrix is applied preferably with open form.

After the fiber-reinforced polyurethane layer is applied the mold is generally closed and the composite component hardened. This will attach those to the top of the mold Insert brought into contact with the polyurethane matrix. ever The fixation of the inserts can be chosen according to the application that the inserts are complete in the finished composite component are covered by the fiber-reinforced polyurethane layer, or that this is only on one side for fiber reinforced Have polyurethane layer contact.

As molds for the manufacture of the products can be customary and commercially available tools are used, the Surface made of steel, aluminum, enamel, teflon, Epoxy resin or another polymeric material, the surface optionally being chrome-plated, for example can be chrome-plated. The molds should be preferred temperable to set the preferred temperatures too can, closable and preferably to exert pressure be equipped for the product.

The fiber-reinforced polyurethane layer is implemented usually at a mold temperature of 30 to 80 ° C and one Temperature of the starting components of preferably 18 to 65 ° C for a duration of usually 0.5 to 10 min, preferably 0.5 to 5 min.

The composite components according to the invention have their preferred use as flat moldings, for example as Substitute for metal sheets, preferably a flat structure on. The products have a thickness of 1 to 500 mm, preferably from 5 to 50 mm.

The composite components according to the invention are preferably found Use as components in vehicle, aircraft or Real estate construction, preferably as body components for motor vehicles, especially as roofs or roof modules, doors, bonnets, Trunk lid, end edge flaps, bumpers and hardtops.

In accordance with the present invention, inserts are found which have a Are coated polymer layer, use for installation in Composite components, comprising a film and a layer of fiber-reinforced polyurethane, for example to improve the Torsional rigidity. The use of these inserts is advantageous because the geometry of the insert is not on the side of the slide.

Claims (7)

1. A method for producing composite components, comprising the steps A) inserting a film (i) into a mold, B) attaching at least one insert to the upper part of the tool, the inserts being coated with a polymer layer, C) applying a layer of fiber-reinforced polyurethane (ii) to the film (i) and then D) curing the composite component with the mold closed. 2. The method according to claim 1, characterized in that the a polymer layer used to coat the inserts Has a thickness of 0.5 mm to 20 mm. 3. The method according to claim 1 or 2, characterized in that used to coat the inserts Polymer layer has a coefficient of linear expansion for which applies: coefficient of linear expansion (polymer layer) = Coefficient of linear expansion (fiber-reinforced polyurethane) ± 50. 4. The method according to any one of claims 1 to 3, characterized characterized that it is used to coat the insert polymer layer used is compact polyurethane. 5. Composite components, made up of a film and a layer made of fiber-reinforced polyurethane, containing insert, whereby the inserts are covered with a polymer layer. 6. Use of composite components according to claim 5 for Manufacture of body parts. 7. Use of inlays with a polymer layer are coated, for installation in composite components, comprising a Foil and a layer of fiber-reinforced polyurethane.