Fabric-reinforced three-dimensional plastic component manufacturing process, in particular for production of vehicle interior cladding panels, instrument panels and rear sills

The invention relates to a method for producing a three-dimensional molding of flat fabric reinforced Plastic in a sealable with a with a undeliverable heater provided mold, with a Forming die, at least one fluid connection, a tenter for the edge of the plastic and a deliverable form table having a a master mold for the molded body Mold according to the preamble of claim 1.

Such a method is for example. Forth in EP 017 452. Such moldings are today in many areas of Technique. For example. they serve in the automotive industry u as cladding, fittings mountings, rear shelves. like. High demands are placed on the accuracy and they must respect their surface also the are varied demands justice. Last but not least also a certain rigidity required so that she possibly loads occurring retain their shape.

In prior art methods, each shaped body is in a welded specially prepared for him casing airtightly and is, for example, is evacuated by means of a syringe. This case is made of two sheets, the first to above and below the fabric-reinforced flat are plastic or its components.

After the final forming the sheath is removed and must be disposed of. But before that is pre-shaped, in the case removed situated molded body from the first mold and brought into a holding form. There occurs a heating and pressurizing and subsequently cooling. After these operations is the sheath slit and from the finished article removed.

This manufacturing method is very complex and requires a high equipment costs. She is also a lot of manual work connected and therefore can not be automated. she is consequently very expensive.

Another method for producing a shaped body obtained from DE-OS 20 56 477. The amount of equipment is here Although low, but is charging a tenter with a sandwich of two sheets, an intermediate Reinforcing layer and the latter soaking liquid Resin so far very expensive, as to no air bubbles respected and the reinforcing layer against the two larger sheets exactly aligned in the stretcher has to be introduced. It must be prevented namely, that by the tenter, the reinforcement layer during Tensioning operation and during the deformation process is retained and thus a free-floating displacement during curing can not take place.

For automatic production of this process is therefore less suitable. Incidentally, it is very time consuming and if only because expensive.

Another method in accordance with DE-AS 11 31 871 is so far very consuming than initially an impregnated fiber mat on both sides is covered with a film, and after forming in a decreased vacuum drawing means one of the two films back must become. There must therefore be a film that is with the fiber mat can not connect. After removing the Sheet is liquid, curable resin applied and the Sprinkle with another sheet covered again. Well done the final molding and curing.

It is apparent that also this method complicated and consuming and therefore expensive, and for mass production is not very suitable.

It is consequently the task ahead, a method of further develop the generic type so that this three-dimensional shaped bodies from flat fabric reinforced Plastic easily and if you or physically chemically induced delays aside, also quickly and inexpensive and above all in the same device can be prepared without reacting, this is The method in particular for an automatic production should be suitable.

To achieve this object the invention provides a method proposed that the features indicated in claim 1 characteristics having.

In this method, there is no waste in the form of while manufacturing use cases, not reacting a Device to another and it is not necessary, during part of the method steps a film remove and replace later by another again. If one or two films - for two-sided coating - are used, these are intended to later on moldings remain, that is part of the same form. To this extent, located in the films is not a tool for Production, but for example, to provide a means for the aesthetic Configuration of the surface of the shaped body on at least its use page or after installation to be seen side.

There is in this method, neither a deformation in the free space in which the accuracy of the molding is detrimental, even deforming means male and female parts, which due to the specific deformation mechanisms fabric-reinforced plastics the risk of locally different contact pressures includes.

The final shaping is done using a Differential pressure on both sides of the mechanically pre-formed Molding. The load during mechanical preforming low, because the material for the molded body at the edge region only is held down, but not held against displacement. To the degree in which the material is pre-formed, the from the edge to a certain extent "slippage" of material so that it the desired shear deformation between the warp and Wefts of fabric comes and thus load restrictions the fabric-reinforced plastic are avoided. In the fluidic final forming can by corresponding printing job for a slow pressing against the original form of the mold be taken care of. On the other hand enables the Compression molding a more complicated than with Male and female parts with minimal effort. Compression means, for. Example, the evacuation or Partial evacuation of the located on the one side chamber, wherein then in the room on the other side atmospheric pressure or preferably a positive pressure prevails. As fluid comes primarily air in question.

Preferred variants of this process are evident from the Dependent claims and the following description of Preparation of an embodiment.

The mentioned in the claims 4-6 paint film takes while a number of tasks, namely, it provides firstly for a pleasing surface on at least one side of the Shaped body and secondly prevents it because they accordance Claim 6 is exposed to the higher pressure, and the Ingress of air into the glass fiber reinforced plastic material, that pore formation is avoided. The essential task of Film, however, is by a separation of the pressure acted, or evacuated spaces to build one for the contribute shaping necessary pressure difference. In contrast to the above-mentioned sheath, which is also the Elimination of air bubbles is used and after curing is no longer needed, the paint film adorns the Finished product, and it also ensures a very smooth Surface. You will be part of the final product.

The invention is described in greater detail on the drawing explained.

The drawing shows an apparatus for carrying out the Process or for the production of a three dimensional Molded body according to the above description.

A flat panel-like, fabric-reinforced plastic <b>1</b> becomes according to arrow <b>2</b> suitably in the device brought in. Once in<b>Fig.</b> reaches 2 state shown is a two-piece in the embodiment with heating an upper heater <b>3</b> and a lower heating element <b>4</b> in the Direction of the arrows <b>5</b> introduced, in which case according to <b>Fig.</b> 3 the upper heater <b>3</b> above and the lower heater <b>5</b> beneath the plastic <b>1</b> is. Symbolically in<b>Fig.</b> 3 indicated that the heating system is then turned on to the plastic <b>1</b> to heat and to make them flexible.

Once it is warm enough, the heating elements are <b>3</b>. <b>4</b> according to <b>Fig.</b> 4 in the direction of arrow <b>6</b> again released.

According to <b>Fig.</b> 5 now is a form of table <b>7</b> with a Master mold for the molded body having mold <b>8th</b> for the purpose of the arrows <b>9</b> booted. At the same time in opposite direction, ie in the direction of the arrows <b>10</b>, A clamping frame against the mold table <b>7</b> toward lowered until on the edge region <b>12</b> the plastic <b>1</b> rests. He is then, however, not pressed, but holds the plastic down only such that between the tenter <b>11</b> and facing the opposite, outward border area <b>13</b> of the mold <b>8th</b> can slide.

Then, a forming die <b>14</b> according to arrow <b>15</b> against the heated and consequently flexible plastic <b>15</b> down delivered, although he only central to this Area acts. Overall, however, there is a bulge against the interior of the mold <b>8th</b> out.

Once a predetermined bulge of the plastic <b>1</b> reached is that creases frictional result of Through sliding under the stretcher <b>11</b> achieved through will be prepared in accordance <b>Fig.</b> 7 a pressure bell <b>16</b> in arrow <b>17</b> to until the free edge of the outside tenter <b>11</b> firmly on the edge region <b>12</b> the plastic <b>1</b> rests. At the same time then the pressure of the will tenter <b>11</b> reinforced, which by compressing the symbolically drawn springs <b>17</b> is clarified. To this Way arise airtight cavities <b>18</b> above and <b>19</b> below the pre-deformed plastic <b>1</b>, Plastic<b>1</b> is now detained gleitfrei so that further deformation not by moving up of the edge region, but by elastic deformation occur.

<b>Fig.</b> 8 illustrates that this further deformation of one or Final forming by means of a fluid, in particular of Compressed air, causes. To this can be eg. The lower cavity<b>19</b> evacuate, as indicated by the arrow <b>20</b> is symbolized.

Alternatively, or as provided in the embodiment, in addition, the upper cavity <b>18</b> pneumatically applied what the arrow <b>21</b> should clarify. One notices in <b>Fig.</b> 8 that now the preformed plastic <b>1</b> from Vordehnstempel apart and he into the cavity <b>22</b> of mold <b>8th</b> is drawn (<b>Fig.</b> 5). If there is sufficient Pressure and sufficient stretchability of the plastic places the latter finally under <b>Fig.</b> 9 fully to the Inner wall of the mold <b>8th</b> and takes its shape at. He has yet to solidify, however. For this is the upper cavity <b>18</b> initially pressurized to a sufficient cooling of the plastic <b>1</b> is reached. when this is done you open the air supply to the cavities <b>18</b> and <b>19</b>What the arrows <b>23</b> and <b>24</b> symbolize. Now you can according to <b>Fig.</b> 11 the mold table <b>7</b> Lower and the tenter <b>11</b>, The forming die <b>14</b> and the pressure bell <b>16</b> each lead back to the starting position, which the <b>Fig.</b> 11 and 12 as well as the corresponding arrows in <b>Fig.</b> 11 clarify. The mold may now be opened and the moldings <b>26</b> according to arrow <b>25</b> be removed.

Also in the symbolic representation of the process was not shown that according to the last feature of the labeling Claim 1 before the fluidic or pneumatic deformation the plastic <b>1</b> on at least one side of the latter a Film is laid. It takes over two tasks, namely, on the one hand it makes the finished product the visible side and on the other it has at least throttling properties, so that the flowing into the upper cavity compressed air not or possible can not take refuge in the plastics and Consequently, the time required for forming pressure difference between upper and lower cavity remains. If instead of a at least throttling film uses an airtight film is, there is a risk of penetration of air or Air bubbles in the plastic <b>1</b> not.

On the opposite underside of the plastic <b>1</b> is this Attaching a film not necessary for technical reasons, but at most for other reasons, for example. to the finished Product a better surface on the underside or the to obtain the use of non-visible area.

reached a particularly beautiful surface of the finished product one example. when using a paint film. In the case of Using only a single sheet is this the embodiment of course also on the Top, ie against the upper pressure chamber or cavity <b>18</b> down pointing or those delimiting.