CN101130292A - 制造车身面板部件的方法、车身面板部件以及车身面板部件制造中的中间产品 - Google Patents

制造车身面板部件的方法、车身面板部件以及车身面板部件制造中的中间产品 Download PDF

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CN101130292A
CN101130292A CNA2007101452913A CN200710145291A CN101130292A CN 101130292 A CN101130292 A CN 101130292A CN A2007101452913 A CNA2007101452913 A CN A2007101452913A CN 200710145291 A CN200710145291 A CN 200710145291A CN 101130292 A CN101130292 A CN 101130292A
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马蒂亚斯·路德维希
托比亚斯·尼斯纳
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Abstract

一种制造车身面板部件(10)的方法，其包括以下步骤：对用作外层的透明板(12)进行再成形，所述板(12)具有一前侧面(14)和一后侧面(16)，将一面板(18)施加于所述板(12)的所述后侧面(16)的某些区域上，所述面板(18)由透明或半透明材料制成，并且在其后侧面上具有一保护层(24)，将油漆湿法施加在所述板(12)的所述后侧面(16)上，以形成一着色层(22)，并且在所述后侧面上，至少在所述板(12)未被所述面板(18)遮盖的区域中，为所述板(12)提供一泡沫背衬，且形成有一泡沫层(20)。本发明进一步涉及一种车身面板部件以及一种在制造所述车身面板部件中获得的中间产品。

Description

制造车身面板部件的方法、车身面板部件以及车身面板部件制造中的中间产品
技术领域
本发明涉及一种制造车身面板部件的方法以及此类车身面板部件。本发明进一步涉及一种在车身面板部件的制造中获得的中间产品。
背景技术
车身面板部件被安装到车身。它们在最后的装配状态中界定了车辆的至少多段外层，并且这些车身面板部件从外面是可见的。车身面板部件可以是盖板(车门、遮板)、保险杠或者车顶模块(也可以是其它部件)。存在包括玻璃纤维增强PU材料的车身面板部件，例如，将玻璃纤维以所谓的LFI方法注入到塑料材料中(长纤维注入)。在这种工艺中，将一个由塑料材料或铝制成的深拉式实底色板置于发泡模具中，且为该深拉式实底色板提供一泡沫背衬。所述实底色板代替了外部油漆作业构成车辆的外层。
在车身面板部件制造中的重要之处在于，车身面板部件的颜色与相邻涂漆车身的颜色不存在差异，这样就制成了连续的着色表面。然而，在对现有技术中已知的实底色板进行再成形时，在拐角和边缘处可能会出现颜色深浅不一或颜色淡的情况(特别是对于金属色)，这打断了均匀的着色表面。另一个缺点在于，需要为每种颜色预先制造数量十分巨大的适当实底色的板。
为了将透明或半透明部分整合到车身面板部件中，从而以这种方式形成全景车顶，例如在EP1669277中公开了通过将透明或半透明组件胶粘到相邻框架部件上，从而将它们附连到相邻框架部件上。这类车身面板部件的缺点在于，组件间的间隙需要使用密封件，而这些密封件会受到磨损，并且有损视觉外观。
发明内容
本发明的目的是要提供一种车身面板部件，其具有在高度上无偏移量的连续外表面。本发明进一步的目的是要提供一种制造车身面板部件的方法，通过该方法可以具有成本效率地以一种简单的方式制造出车身面板部件，该车身面板部件具有在高度上无偏移量的连续外表面。本发明还有另一个目的是要提供一种车身面板部件制造中的中间产品，该车身面板部件具有在高度上无偏移量的连续外表面。
本发明的目的是由一种根据本发明的、用于制造车身面板部件的方法来实现的，所述方法包括以下步骤：
对用作外层的透明板进行再成形，所述板具有一前侧面和一后侧面，
将面板施加于所述板后侧面的某些区域上，所述面板由透明或半透明材料制成，并且在其后侧面上具有一保护层，
将油漆湿法施加在所述板的后侧面，以形成着色层，和
在所述后侧面上，至少在所述板未被所述面板遮盖的区域中，为所述板提供泡沫背衬，且形成有泡沫层。
外层是透明的无色板，其具有的优选厚度范围为0.5-2mm，而且其被再成形。然后，将由透明或半透明材料制成的优选固有刚性面板施加于所述板的后侧面上，所述面板被提供有保护层。随后，将油漆湿法施加在所述板的后侧面上，也就是说，着色层不是一块例如胶粘上去的板。油漆在施加后变干，并形成用于所述车身面板部件外表面的着色层，不再需要在外部对其进行油漆。所述板随后在后侧面上，至少在那些未被所述面板遮盖的区域中，被提供有泡沫背衬，也就是说，优选在未被所述面板遮盖的所有区域中提供泡沫背衬。在所述面板被提供的那些区域中，被提供在所述面板后侧面上的保护层使所述面板免受所述油漆湿法施加(例如通过雾化喷射)期间或者PU材料施加期间可能造成的任何“污染”。在湿法施加了所述油漆后或者在提供了所述泡沫背衬后，能够简单地将所述保护层随污染物(油漆、PU材料)一起去除掉。与现有技术不同的是，用作外层的所述板本身并不是实底色的，但独立的着色层透过无色透明板，从而使所述车身面板部件在提供有着色层的那些区域中呈现出着色层的颜色。所述车身面板部件的颜色与所述车身其余部分的颜色对应。以这种方式，可以制造出的车身面板部件具有透明或半透明区域以及稳定的泡沫层，并且特征在于具有连续的外表面，而在不同区域之间没有任何间隙，并且在该车身面板部件中油漆正是能够延伸到没有间隙的面板。
此外，所述面板可被配置在边缘区域中，以致其具有在所述泡沫层和所述面板之间允许联锁配合的几何结构，例如成圆锥形地延伸到所述后侧面的侧向边缘、凹槽、底切部、横梁等等。
本发明进一步涉及一种用于车辆的车身面板部件，特别是车顶模块，其包括一个完全构成所述车身面板部件外层的透明板、一个在所述后侧面上附连于所述板一部分且由透明或半透明材料制成的面板、一个在所述板后侧面上未被所述面板遮盖的区域中提供的泡沫层、以及一个提供在所述泡沫层和所述板之间的着色层。关于优点，请参考上文的讨论。
根据一个实施例，所述面板是固有刚性板，与用作外层的所述板相比，所述面板具有较高的抗弯能力，因此获得了所述车身面板部件所需的刚性。
根据一个进一步的实施例，所述面板由玻璃制成。
本发明进一步涉及一种在车身面板部件的制造中获得的中间产品，其包括：透明板；面板，其被附连于所述板的后侧面，且部分地遮盖着所述板，所述面板由透明或半透明材料制成；泡沫层，其是通过为所述板在未被所述面板遮盖的区域中提供泡沫背衬制成的；着色层，其被提供在所述泡沫层和所述板之间；和可去除的保护层，其被施加在所述面板的后侧面上。
附图说明
根据下文的描述和附图，进一步的特征和优点将变得明显。将参考一个实施例来描述本发明。附图中：
图1示出了一车辆的透视图，该车辆带有车顶模块形式的根据本发明的车身面板部件；和
图2-4示出了不同方法步骤中根据本发明的车身面板部件的基本结构，其中图4示出了完工的车身面板部件，而图3示出了一种根据本发明的中间产品。
具体实施方式
图1示出了处于安装到车辆状态的、车顶模块形式的车身面板部件10。车身面板部件10还可以是车辆的挡泥板、车门、盖板(发动机罩、行李箱盖)。
图4中示出了车身面板部件的基本结构。
车身面板部件10具有外层，该外层在安装到车辆的状态中从外面可见，且由一薄的、透明的、用热处理方法再成形的板12形成。板12由透明或半透明的塑料材料制成，且具有一个在安装状态中从外面可见的前侧面14以及一个后侧面16。板12后侧面上的某些区域被提供有至少一个透明或半透明的面板18(示出的为两个)，其是固有刚性板或者由玻璃制成。面板18例如是胶粘到板12上的。
在板12后侧面16上未施加面板18的那些区域中，板12在后侧面上被提供有泡沫背衬。在该工艺中制成的泡沫层20由玻璃纤维增强PU泡沫构成。通过利用LFI方法(长纤维注入)将玻璃纤维F引入泡沫中，增强了泡沫层20(与用作外层的板12相比，其具有较高的抗弯能力)，并构成一种支承框架。
提供在板12和泡沫层之间的是着色层22，其形式例如为涂漆层，并且由于着色层22透过无色透明板12，从外面可见，因此起到了外部油漆作业的功能。
在制造车身面板部件10的方法中，板12是通过深拉再成形的，或者是以热塑方式再成形的。
随后，将面板18胶粘到板12的后侧面16上，为面板18在其后侧面上提供保护层24，特别是剥落膜(图2)。
将油漆湿法施加在板12的后侧面16上，优选施加在整个组件上(即板12和保护层24上)；所述湿法施加可通过刮刀涂布、滚涂，或者利用喷染方法来进行。当湿法施加的油漆已经变干时，就形成了着色层22。
利用发泡模具的开口(未示出)，将液态PU材料施加在板12后侧面上至少未被面板18遮盖的那些区域中，同时注入玻璃纤维F(LFI方法)。
两件式发泡模具变成封闭状态，PU材料膨胀并充填下部件和上部件(未示出)之间形成的腔，从而在发泡工艺后，形成泡沫层20。当下部件和上部件已被分离时，从发泡模具(未示出)中去除掉中间产品(图3)。所述中间产品的后侧面的特征在于保护层24，其使面板18不受任何污染物(油漆、PU材料)的污染。面板18的边际区域具有的几何结构26(底切部、凹槽、倒角、横梁等等，参见图2中的虚线)允许面板18和层20之间形成联锁配合。
然后，从面板18上去除掉保护层24，这样就从面板18的后侧面16上去除了在油漆或者PU材料施加过程中可能造成的所有污染物。在面板18的区域内，车身面板部件保持透明或半透明，而在提供了着色层22的区域中，这一着色层会透过板12，因此不再需要对车身面板部件10进行任何外部油漆作业。透过板12的着色层22与车身其余部分的颜色并没有什么不同。
可用上文所述的方法简单地以合理成本制造出具有连续外表面的车身面板部件，特别是全景车顶。这意味着，在需要进行复杂密封的、由多个部件构成的车身面板部件之间没有间隙。与板12相比，面板18和泡沫层20具有较高的抗弯能力，这样就形成了坚固的车身面板部件10，并且实现了所需的刚性。

Claims (9)

1.一种制造车身面板部件(10)的方法，
其特征在于以下步骤：
对用作外层的透明板(12)进行再成形，所述板(12)具有一前侧面(14)和一后侧面(16)，
将一面板(18)施加于所述板(12)的所述后侧面(16)的某些区域上，所述面板(18)由透明或半透明材料制成，并且在其后侧面上具有一保护层(24)，
将油漆湿法施加在所述板(12)的所述后侧面(16)上，以形成一着色层(22)，并且
在所述后侧面上，至少在所述板(12)未被所述面板(18)遮盖的区域中，为所述板(12)提供一泡沫背衬，且形成有一泡沫层(20)。
2.根据权利要求1所述的方法，其特征在于：在所述油漆已经变干后，将所述泡沫层(20)施加到所述着色层(22)上。
3.根据权利要求1或2所述的方法，其特征在于：在施加了所述油漆和/或所述泡沫层(20)后，从所述面板(18)上去除所述保护层(24)。
4.根据前述权利要求中任一项所述的方法，其特征在于：所述保护层(24)是膜。
5.根据前述权利要求中任一项所述的方法，其特征在于所述面板(18)是胶粘到所述板(12)的所述后侧面上。
6.一种用于车辆的车身面板部件，特别是一车顶模块，包括：
透明板(12)，其完全构成了所述车身面板部件(10)的外层，
面板(18)，其附连于所述板(12)后侧面上的一部分，且由透明或半透明材料制成，
泡沫层(20)，其被提供在所述板(12)的后侧面上未被所述面板(18)遮盖的区域中，和
着色层(22)，其被提供在所述泡沫层(20)和所述板(12)之间。
7.根据权利要求6所述的车身面板部件，其特征在于：所述面板(18)是固有刚性板。
8.根据权利要求6或7所述的车身面板部件，其特征在于：所述面板(18)由玻璃制成。
9.一种在车身面板部件(10)的制造中获得的中间产品，包括：
透明板(12)，
面板(18)，其被附连于所述板(12)的后侧面，且部分地遮盖着所述板，所述面板(18)由透明或半透明材料制成，
泡沫层(20)，其是通过为所述板(12)在未被所述面板(18)遮盖的区域中提供一泡沫背衬制成的，
着色层(22)，其被提供在所述泡沫层(20)和所述板(12)之间，和
可去除的保护层(24)，其被施加在所述面板(18)的后侧面上。
CNA2007101452913A 2006-08-21 2007-08-21 制造车身面板部件的方法、车身面板部件以及车身面板部件制造中的中间产品 Pending CN101130292A (zh)

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