Structural Molded Part, Motor Vehicle Fitting Element and Method for Producing a Structural Molded Part

Abstract

A three-dimensional structural molded part is provided having one or more pre-formed organometallic sheet-metal parts each having at least one edge. The organometallic sheet-metal parts are connected at respective edges at least partly by an injection-molded plastics material.

Claims

1. A structural molded part comprising: one or more organopanel parts, each organopanel part having one or more edges, wherein at least one edge of the one or more organopanel parts is at least partially interconnected with at least one other edge of the one or more organopanel parts by an injection-molded plastics material.

2. The structural molded part of claim 1, wherein at least one organopanel part contains polypropylene and/or long glass fibers and/or carbon fibers.

3. The structural molded part of claim 2, wherein the carbon fibers are recycled carbon fibers.

4. The structural molded part of claim 1, wherein the injection-molded plastics material is a thermoplastic plastics material.

5. The structural molded part of claim 4, wherein the thermoplastics material contains polypropylene.

6. The structural molded part of claim 1, wherein the injection-molded plastics material contains fibers.

7. The structural molded part of claim 6, wherein the fibers are long glass fibers and/or carbon fibers.

8. The structural molded part of claim 7, wherein the carbon fibers are recycled carbon fibers.

9. The structural molded part of claim 1, wherein at least one organopanel part has a textile material on an internal side or on an external side.

10. The structural molded part of claim 1, wherein at least one organopanel part has a textile material on at least one visible side.

11. The structural molded part of claim 1, wherein an interface geometry and/or a functional geometry and/or a mounting is disposed on at least one organopanel part.

12. The structural molded part of claim 1, wherein ribs made of a plastics material are molded on at least one organopanel part such that the ribs connect or reinforce the organopanel parts.

13. A motor vehicle fitting element selected from one of: an instrument panel, a door trim, a center console, or a glove box, the motor vehicle fitting element comprising: the structural molded part of claim 1.

14. A method for manufacturing a structural molded part, the method comprising the following acts: pre-forming one or more organopanel parts, each organopanel part having one or more edges; laying up and arranging the one or more pre-formed organopanel parts in an injection-molding tool; closing the injection-molding tool; and at least partially interconnecting at least one edge of the one or more organopanel parts with at least one other edge of the one or more organopanel parts by injection-molding a plastics material.

15. The method of claim 14, wherein the plastics material is a thermoplastic plastics material containing fibers.

16. The method of claim 14, wherein at least one organopanel part is manufactured from polypropylene and/or long glass fibers and/or recycled carbon fibers, and/or the plastics material contains polypropylene and/or long glass fibers and/or recycled carbon fibers.

17. The method of claim 14, further comprising the act of: applying a textile material to an internal side or an external side of the one or more organopanel parts prior to forming the organopanel part, wherein textile material is applied to at least one visible side of at least one organopanel part.

18. The method of claim 14, further comprising the act of: attaching an interface geometry and/or a functional geometry and/or a mounting to at least one organopanel part.

19. The method of claim 14, further comprising the act of: molding ribs on at least one organopanel part such that the ribs connect or reinforce the organopanel parts.

Description

BRIEF DESCRIPTION OF THE DRAWING

[0033] FIG. 1 shows a schematic illustration of the manufacture of a structural molded part according to an advantageous refinement.

DETAILED DESCRIPTION OF THE DRAWING

[0034] The present invention will be discussed in detail by means of an exemplary embodiment. Only those parts of the structural molded part according to the invention that are of immediate interest are illustrated in FIG. 1, all other elements being omitted for the sake of clarity. Furthermore, the same components are identified by the same reference sign.

[0035] FIG. 1 schematically shows the manufacture of a structural molded part 10, which in an exemplary manner is configured in the form of a glove box. Furthermore, the structural molded part 10 in an exemplary manner comprises three basic components which are formed by organopanel parts 1. The organopanel parts may be organometallic sheet-metal parts. The organopanel parts 1 are punched from large organopanels and are converted to the desired three-dimensional shape by forming, for example. Each organopanel part 1 has a plurality of edges 2. The organopanel parts 1 are then laid up in an injection-molding tool. Laying up and arranging the organopanel parts 1 is performed such that edges 2 of the organopanel parts 1 that are to be connected lie opposite one another. Upon closing of the injection-molding tool, a plastics-material injection molding compound, which comprises a preferably thermoplastic plastics material that preferably contains PP, is injected such that the plastics material adheres to the edges 2 of the organopanel parts 1. The mutually opposite organopanel parts 1 are thereby interconnected by way of the edges 2 of the organopanel parts 1. The plastics material here preferably covers the edges 2 on the entire length thereof. The reference sign 3 in FIG. 1 represents the connection of the organopanel parts 1 that is obtained upon termination of the plastics injection molding of the plastics material. It can be seen that the plastics-material connection 3 only covers the edges 2 of the pre-formed organopanel parts 1. A materially integral connection of the organopanel parts 1 is formed on account thereof on the edges 2 of the organopanel parts 1 by way of the plastics-material connection 3.

[0036] The injection-molded plastics material preferably contains fibers. The fibrous material of the injection-molded plastics material preferably contains glass fibers, preferably long glass fibers, preferably long glass fibers and/or carbon fibers and in particular recycled carbon fibers. The organopanel parts preferably comprise long glass fibers and/or carbon fibers, further preferably including recycled carbon fibers, that are incorporated into a matrix of polypropylene.

[0037] Moreover, the structural molded part 10 of FIG. 1 has reinforcement elements in the form of ribs 4. The ribs 4 preferably connect various organopanel parts 1, and serve for reinforcing the dimensional rigidity of the structural molded part 10. The ribs 4 are advantageously formed from the same plastics material as the plastics-material connection 3 of the organopanel parts 1.

[0038] For improved capability of interfacing and integration and for increased functionality, the structural molded part 10 additionally has at least one interface geometry 5 and one mounting 6. The structural molded part 10 may be complemented by further elements.

[0039] The preceding description of the present invention serves only for illustrative purposes and is not intended to limit the scope of the invention. Various alterations and modifications are possible in the context of the invention, without departing from the scope of the invention and the equivalents thereof.

LIST OF REFERENCE SIGNS

[0040] 1 Organopanel part

[0041] 2 Edge of the organopanel part

[0042] 3 Connection between the edges of the organopanel parts

[0043] 4 Rib

[0044] 5 Interface geometry

[0045] 6 Mounting

[0046] 10 Structural molded part

[0047] The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.