Exterior Module with an Exterior Panelling for a Modularly Constructed Housing Component and the Modularly Constructed Housing Component Itself, and Method for Producing the Exterior Module

An exterior module of a motor vehicle having an exterior panelling for a modularly constructed housing component, the exterior module comprising:

• an inner surface layer;
• an outer surface layer;
• an exterior skin arranged on the outer surface layer, wherein the inner surface layer, outer surface layer and exterior skin form the exterior panelling;
• and
• a structural core of a foam material arranged between the outer surface layer and the inner surface layer,
• wherein at least the inner surface layer is a thermoplastic surface layer of fiber-reinforced plastic, which has stiffening elements at least on a side facing away from the outer surface layer, wherein the stiffening elements are ribs of thermoplastic matrix plastic.

A modularly constructed housing component, comprising:

• an interior module,
• an exterior module having exterior panelling, the exterior module connected to the interior module, wherein the exterior module comprises
• an inner surface layer;
• an outer surface layer;
• an exterior skin arranged on the outer surface layer, wherein the inner surface layer, outer surface layer and exterior skin form the exterior panelling;
• and
• a structural core of a foam material arranged between the outer surface layer and the inner surface layer,
• wherein at least the inner surface layer is a thermoplastic surface layer of fiber-reinforced plastic, which has stiffening elements at least on a side facing away from the outer surface layer, wherein the stiffening elements are ribs of thermoplastic matrix plastic.

A method for the production of an exterior module, having an inner surface layer and an outer surface layer forming a panelling, of a motor vehicle using a tool consisting of two tool halves, wherein one tool half is provided for formation of the panelling on an exterior of the exterior module and one tool half is provided for the formation of an interior of the exterior module, and wherein the tool possesses a sprue system, the method comprising the steps:

• pre-forming the inner and outer surface layers according to inner and outer exterior module contours, wherein at least the inner surface layer is provided by a thermoplastic FRP surface layer;
• inserting the pre-formed surface layers into corresponding tool halves;
• fixing the inner and outer surface layers during insertion into the tool halves by generating a negative pressure,
• closing the tool;
• injecting a foam-forming material between the inner and outer surface layers by means of the sprue system of the tool and forming a structural core;
• generating an exterior skin on the outer surface layer by partially opening the tool and coating the outer surface layer by means of the sprue system;
• generating stiffening elements on the inner surface layer or on both the inner surface layer and the exterior skin on the outer surface layer by injection-molding ribs with the thermoplastic matrix plastic in the tool by means of the sprue.