Method for producing continuous-fiber-reinforced molded parts from thermoplastic plastic, and motor vehicle molded part

Abstract

A method for producing continuous-fiber-reinforced molded parts from thermoplastic plastics. The method includes several steps. In a first step, preparing cut-to-size, substantially flat, unidirectionally fiber-reinforced mats are prepared with a thermoplastic matrix which at least partially surrounds the fibers. In a second step, the mats are transferred to a workpiece carrier which predetermines the rough contour of the molded part. In a third step, the mats are deposited and progressively built up on the workpiece carrier to form a three-dimensional preform such that the fiber orientation of the mats is adapted to the forces applied during the subsequent use of the molded part and to the load paths resulting therefrom within the molded part. In a fourth step, the mats are secured in place relative to each other during or after completion of the build-up of the perform. In a fifth step, the preform is heated up to or above the melting temperature of the thermoplastic matrix of the perform. In a sixth step, the three-dimensional preform is introduced into a mold tool forming the final contour of the molded part. In a seventh step, a homogenous pressure is set within the mold tool in order to ensure that the preform consolidates whilst simultaneously retaining the orientation of the fibers within the perform. In an eighth step, the resulting consolidated molded part is removed from the mold tool.

Dependencies are inferred from the claim text.