Molding tool for a sandwich construction composite component has a low pressure inner punch for pressing composite material and high pressure outer punches for pressing thermoplastic around composite edges

A press tool(5), in or on which a composite material(4) is positioned, has an opposing inner punch(3) and one or more outer punches(2) which form the molding cavity with the press tool. The inner punch lowers onto the composite material at low pressure which retains the thickness and structure. Outer punches operate at high pressure forcing thermoplastic material(6) around the edges of the composite to flow and weld onto the latter. In the final position of the outer punches a clean edge and a set thickness is formed in the thermoplastic. Surfaces of each outer punch which contact the thermoplastic(6) correspond to the profile of the latter in the final compressed state. Pressure exerted by the outer punch(2) is not >250bar. The inner punch(3) operates at low pressures, preferably =20 bar, and may have projections for localized forming of the composite. Outer and inner punches are held apart by a spring system. A hydraulic drive unit raises and lowers at least the outer punch. Press tools(5) may have either a convex or concave profile on which the composite material is placed and pressing into the final three dimensional shape is effected by a corresponding concave or convex profiled punch as appropriate. The thermoplastic may have an internal chamber(43) which is pressurized during the pressing stage. Pressure is produced either by a fluid preloaded into the chamber or by injecting a fluid via a line with a needle which penetrates the chamber wall. All punches may be retracted slightly to leave space for injecting a coating(32). Independent claims are included for: (a) a process for manufacturing a thin walled plastic component based on a thermoplastic and a composite material in which each outer punch works at a pressure which causes the thermoplastic plastic to flow and form a welded joint with the composite; and (a) a component of a multi-layer composite material based on a core layer(16) between reinforcing layers and surrounding edges of thermoplastic plastic. Ein Verbundmaterial 4 wird mit thermoplastischem Kunststoffmaterial 6 im Pressverfahren oder Tiefziehverfahren gemeinsam verarbeitet. Das Verbundmaterial 4 wird in die Pressform 5 oder Tiefziehform eingelegt und unter Druck gefügt. An das Verbundmaterial 4 schließt an dessen Umfang eine Schicht aus thermoplastischem Kunststoffmaterial 6 an (z. B. verpresstes GMT, gespritztes PP). Das thermoplastische Kunststoffmaterial 6 wird durch mindestens einen Hochdruckstempel 2 unter hohem Druck in fließf