DE102007007554B4 - Method for producing a flat composite component of a vehicle - Google Patents

Abstract

A method for producing a composite sheet-like component of a vehicle, in particular a sliding sky, a parcel shelf, an inner lining element or the like, comprising the following steps: producing a core layer (24) from a foam material; Introducing at least one cut representing a recess (26) for a profile-like reinforcing element (22) into the core layer (24); Inserting the reinforcing element (22) into the recess (26) of the core layer (24); Producing a sandwich arrangement (13) from two fiber layers (28, 28 '), between which the core layer (24) is arranged; spraying the sandwich assembly with a polyurethane material on both sides; Pressing the sandwich assembly in a pressing tool, so that the polyurethane material hardens and forms a geometry of the sheet-like composite component; and demolding of the sheet-like composite component from the pressing tool.

Description

The invention relates to a method for producing a flat composite component of a vehicle.

From the publication DE 23 32 778 A is a construction element is known, which is formed of alternately joined core elements and reinforcing elements. On both sides, the construction element is provided with a cover layer.

From the publication DE 10 2004 013 146 A1 For example, a method is known for reinforcing core structures to form bilayer-coated core composites. The core structure has an open three-dimensional structure. In the area of the core structure, a local reinforcement zone is formed.

From the publication WO 03/064154 A1 a composite component is known, which has a core layer which is penetrated by reinforcing plates.

From the publication EP 1 609 576 A1 is a method for the production of Polyurthan molded bodies known. In this case, a sandwich of a core layer and two reinforcing fiber cover layers is produced.

A flat composite component of a vehicle is for example also from the DE 10 2004 010 810 A1 known and represents a lightweight composite component that can be used as door trim, vehicle floor, instrument panel, instrument panel or the like. This composite component forms a sandwich construction comprising a core layer which is covered on both sides by a cover layer. The cover layers each consist of a film, a plate, a fiber mat and / or a foam, wherein a connection to the core layer is achieved by means of a polyurethane casting resin system. In the production of the composite component, the individual layers are pressed together in a pressing tool, whereby the polyurethane casting resin system hardens.

Furthermore, it is known to use a paper honeycomb as the core layer of a sandwich construction of a composite component. However, the paper honeycomb limits the variety of manufacturable geometries of the composite component. In particular, only beads with limited depths can be made.

It is also known to use composite components of the aforementioned type as a sliding sky for shading a roof opening, which can optionally be closed by means of a transparent cover element or at least partially opened. When producing a sliding headliner with a paper honeycomb as a core layer, it is necessary to use gliders for the sliding headliner, which are spring-mounted, since the paper honeycomb is very pressure-resistant, so that the sandwich construction can not be compressed well under high pressure. The installation of glides is associated with additional costs.

Furthermore, high demands are placed on the flexural stiffness thereof, particularly in the case of sliding skylights for large vehicle roofs or large roof opening systems. For example, sliding headliners must have a particularly high flexural rigidity in the region of a handle-fan bar. In a sliding headliner, which consists of a composite of polyurethane-impregnated glass fiber mats and a core layer of a honeycomb, the mechanical properties, in particular the bending stiffness and the like, essentially determined by the height and the glass fiber content in the outer layers. For a given height, d. H. a maximum allowable height, so can only be influenced by the use of materials on the bending stiffness. In this context, it is known, for example, insert inserts, which at the top, d. H. be pressed on the outside of the composite. Such an insert may for example be a rotationally symmetrical profile element, but after pressing, d. H. is visible on the surface of the finished component, which is undesirable. Also, when using such arranged inserts the so-called bimetallic effect can occur. In addition, rotationally symmetrical profile elements do not use the material used in terms of flexural rigidity of the composite component in an optimal manner.

For composite components without inserts as stiffening elements, however, only a limited flexural rigidity is achievable. If necessary, this may not meet the requirements of the individual case.

The invention has for its object to provide a method for producing a flat flexurally rigid composite component, which is used in an advantageous manner as a sliding sky, parcel shelf or loading floor of a motor vehicle.

This object is achieved according to the invention by the method according to claims 1 and 2.

The flat composite component of a vehicle according to the invention comprises a sandwich construction which is provided with a core layer which is arranged between two cover layers, which are each formed independently of each other as a polyurethane layer in which a fiber layer is embedded. In the core layer is at least one embedded profile-shaped reinforcing element.

By using the reinforcing element, which represents a depositor or an insert, the flexural rigidity of the composite component increases in particular at the location of the reinforcing element. Due to the internal, locally arranged reinforcing element, which is not visible on the outside of the composite component substantially, the material used for the production of the composite component can be optimized. In particular, by using the insert polyurethane material and material for the fiber layers can be saved. Also, a core layer with a low intrinsic stiffness can be used, which in turn leads to weight savings. In particular, a light honeycomb layer can also be used as the core layer. Against buckling, the reinforcing element is protected by the core layer and the polyurethane material covering the reinforcing element.

The composite component with the inner insert part can be used in particular as a sliding sky, as parcel shelf, as a cargo floor or the like. Insert parts can be provided locally according to the respective requirements, for example, for stiffening in the region of cutouts of the composite component, such as in the region of a cutout for a handle-fan bar.

In a preferred embodiment of the composite component, the reinforcing element has a rectangular cross-section, wherein the long cross-sectional sides are aligned substantially perpendicular to the plane of the composite component. As a result of this orientation and this cross-sectional profile of the reinforcing element, the bending stiffness of the composite component can be increased in a particularly effective manner since the edge length of the reinforcing element oriented at right angles to the plane of the composite component enters into the bending stiffness in the case of a rectangular cross-section of the third power.

The reinforcing element is in a preferred embodiment with its neutral fiber in the neutral fiber or neutral plane of the composite component.

In a particularly cost-effective embodiment of the composite component, the reinforcing element is formed from a metal wire.

The core layer may have a honeycomb structure or else be formed from a foam layer made of a thermoset material.

The method for producing the above-described two-dimensional composite component with reinforcing element in the core layer comprises according to claim 1 the following steps. First, a core layer is produced with a recess for a profile-like reinforcing element. The core layer is of a foam material, so that it may be sufficient to introduce a simple cut into the foam material that constitutes the recess.

When using a paper honeycomb as the core layer, adhesive lines can be omitted in the areas in which the reinforcing element is to be arranged, so that the reinforcing element can be inserted between individual paper layers without destroying the paper honeycomb. The paper honeycomb then also provides a clamping force which holds the reinforcing element in position during the further manufacturing steps. The cross section of the recess preferably corresponds to the cross section of the profile-like reinforcing element.

After the reinforcing element has been introduced into the recess, a sandwich arrangement is produced, which comprises two fiber layers, between which the core layer provided with the reinforcing element is arranged. This can be done so that a blank made of a fiber material is placed around the core layer with the reinforcing element, so that its two large surfaces are covered by the fiber material blank. Then, the sandwich assembly thus produced, in which the glass fiber blank can be connected to the core layer via staples sprayed on both sides with a polyurethane material. Subsequently, the sprayed sandwich assembly is pressed in a pressing tool, so that the polyurethane material hardens and forms a geometry of the sheet-like composite component. Finally, the laminar composite component is removed from the press tool.

For the production of this composite component, the same pressing tool can be used, which is also used for the production of such composite components without reinforcing elements.

In a method for producing a laminar composite component comprising a sandwich construction, which in turn comprises a core layer, which are arranged between two cover layers, which are each independently formed as a polyurethane layer, in which is embedded in a fiber layer, the core layer can a soft foam or semi-rigid foam layer may be formed from a thermosetting plastic.

When using such a composite component as a sliding sky can be dispensed with the use of glides and can be pressed, lateral Edges of the composite component can be performed directly in each associated guide channels of a guide rail assembly, since the use of a flexible foam or semi-rigid foam layer as the core layer allows high flexibility of the composite component perpendicular to the plane of the composite component, which in turn leads to good sliding properties. Compared to the use of a honeycomb as the core layer, foam layers can also be produced with a higher porosity, which in turn leads to weight savings.

By using the core layer of a soft or semi-rigid foam, a softer surface than the use of a paper honeycomb core layer can also be produced, which in turn leads to an optically attractive component.

The use of a composite component formed in the above manner is very diverse, since a variety of geometries can be produced in such a composite component by the high flexibility of the flexible foam or semi-rigid foam core layer. The sheet-like composite component with a soft or semi-rigid foam core made of a thermoset plastic but can be used in particular as a sky element or sliding sky, interior trim part, trunk cover, parcel shelf or the like.

When using the composite component as an interior trim element or sky element of a vehicle decorative material is preferably arranged on one side of the sandwich construction, which forms the visible surface of the composite component. The decorative material can also be designed as a polyester fleece.

The fiber layers, which may each consist of a glass fiber mat, a glass fiber fleece, a glass fiber knitted fabric, a glass fiber fabric or the like or else cut or ground glass or material fibers, natural fiber mats or the like, each have, for example, a basis weight of about 300 g / m ² .

To produce the composite component described above, the sandwich arrangement is initially stacked, which consists of two fiber layers, between which a soft foam layer of a Douroplasten forming a core layer is arranged. Subsequently, the sandwich arrangement is sprayed on both sides with a polyurethane material. Then, the sandwich assembly is pressed in a pressing tool, so that the polyurethane material hardens and forms a geometry of the sheet-like composite component. Finally, the laminar composite component is removed from the press tool.

Further advantages and advantageous embodiments of the article according to the invention are the description, the drawings and the claims removed.

Two embodiments of composite components produced in accordance with the invention are shown schematically simplified in the description and are explained in more detail in the following description. It shows:

1 a structure of a sliding sky with a foam core;

2 a first method step for producing a sliding headliner with an internal reinforcing element;

3 a second manufacturing step;

4 a third manufacturing step; and

5 a section through the finished pressed sliding sky.

In 1 is a layered structure of a sliding sky 10 shown, which serves in the region of a vehicle roof for shading a roof opening, which can be selectively closed or at least partially opened, in particular by means of a transparent cover element. The composite part representing sliding sky 10 includes a core layer 12 , which is formed from a thermosetting polyurethane foam, in particular a flexible polyurethane foam or halbhartschaum. On both sides of the core layer 12 is to form a sandwich arrangement 13 one glass fiber mat each 14 respectively. 14 ' arranged to stiffen the sliding headliner 10 serves. In the production of the sliding headliner 10 become the fiberglass mats 14 and 14 ' after their arrangement on the core layer in each case on the outside with a polyurethane material 16 respectively. 16 ' sprayed after pressing the glass fiber layers 14 and 14 ' with the core layer 12 connects these layers together. This is done with the polyurethane material 16 respectively. 16 ' sprayed arrangement of the glass fiber mats 14 and 14 ' and the core layer 12 introduced and pressed in a pressing tool, not shown, so that the desired geometry is produced and the polyurethane material hardens. The polyurethane material penetrates the glass fiber mats in the pressing tool 14 and 14 ' as well as the core layer 12 at least partially. The polyurethane system thus also fills the cavities of the core layer 12 and the glass fiber mats 14 and 14 ' at least partially.

By applying the polyurethane from the outside to the fiberglass layers 14 and 14 ' This results in perfect adhesion between the individual layers 12 . 14 and 14 ' , The structure is very stiff, but has by using a soft or semi-rigid foam as the core layer 12 a soft appearance and flexibility perpendicular to the plane of the sliding headliner, providing a skid-free guidance of the sliding headliner 10 in roof-fixed guide rails of the vehicle permits.

In the 2 to 5 is the production of a sliding headliner 20 shown in a highly schematic manner, which consists of a core layer 24 and on both sides arranged cover layers is formed and to increase the flexural rigidity with a an inner insert representing reinforcing element 22 that is in the core layer 24 is embedded.

The production of the sliding headliner 20 takes place in the manner described below.

First, the core layer 24 made of a paper honeycomb or a flexible polyurethane foam. The core layer 24 has a thickness of about 5 mm and is made with a rectangular cross-section recess 26 Mistake. Subsequently, how 3 it can be seen in the recess 26 the core layer 24 a metal wire inserted with rectangular cross-section, which is the reinforcing element 22 forms. The length and cross section of the reinforcing element 22 correspond to the dimensions of the recess 26 the core layer 24 ,

Subsequently, on both sides of the core layer 24 according to the embodiment according to 1 one glass fiber mat each 28 respectively. 28 ' hung up ( 4 ). This will then also according to the embodiment according to 1 sprayed with a polyurethane material. The sprayed with the polyurethane material arrangement of the core layer 24 , the reinforcing element 22 and the glass fiber mats 28 and 28 ' will then, as already related to 1 described inserted into a non-illustrated press mold and pressed to produce a desired geometry. The pressed and hardened, in 5 represented composite component, which then the sliding sky 20 forms is finally removed from the press tool.

LIST OF REFERENCE NUMBERS

10

sliding sky

12

core layer

13

Sandwich

14, 14 '

fiberglass layers

20

sliding sky

22

stiffener

24

core layer

26

recess

28, 28 '

glass fiber mat

Claims (7)

Method for producing a planar composite component of a vehicle, in particular a sliding headliner, a parcel shelf, an inner lining element or the like, comprising the following steps: producing a core layer ( 24 ) of a foam material; Introducing at least one recess ( 26 ) for a profile-like reinforcing element ( 22 ) in the core layer ( 24 ); Inserting the reinforcing element ( 22 ) in the recess ( 26 ) of the core layer ( 24 ); Making a sandwich arrangement ( 13 ) of two fiber layers ( 28 . 28 ' ) between which the core layer ( 24 ) is arranged; spraying the sandwich assembly with a polyurethane material on both sides; Pressing the sandwich assembly in a pressing tool, so that the polyurethane material hardens and forms a geometry of the sheet-like composite component; and demolding of the sheet-like composite component from the pressing tool. Method for producing a planar composite component of a vehicle, in particular a sliding headliner, a parcel shelf, an inner lining element or the like, comprising the following steps: producing a core layer ( 24 ) of a paper honeycomb, wherein in regions in which a profile-like reinforcing element ( 22 ) should be arranged, adhesive lines are omitted; Insertion of the reinforcing element ( 22 ) between individual paper layers of the core layer ( 24 ), wherein the reinforcing member is held in position by a clamping force of the paper honeycomb; Making a sandwich arrangement ( 13 ) of two fiber layers ( 28 . 28 ' ) between which the core layer ( 24 ), double-sided spraying of the sandwich assembly with a polyurethane material; Pressing the sandwich assembly in a pressing tool, so that the polyurethane material hardens and forms a geometry of the sheet-like composite component; and demolding of the sheet-like composite component from the pressing tool. Method according to claim 1 or 2, characterized in that the fiber layers ( 14 . 14 ' ) each have a basis weight of about 300 g / m ² . Method according to one of claims 1 to 3, characterized in that the fiber layers ( 14 . 14 ' ) are each formed from a glass fiber mat, a glass fiber fleece, a glass fiber knitted fabric, a glass fiber fabric, cut or ground glass or mineral fibers, a natural fiber mat and / or a natural fiber knitted fabric. Method according to one of claims 1 to 4, characterized in that a decorative material is arranged on at least one side of the sandwich arrangement. Method according to one of claims 1 to 5, characterized in that the reinforcing element ( 22 ) has a rectangular cross-section, wherein the long cross-sectional sides are aligned substantially perpendicular to the plane of the composite component. Method according to one of claims 1 to 6, characterized in that the reinforcing element ( 22 ) is formed of a metal wire, a wooden rod, a plastic rod or a high-fiber filled plastic rod.

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