CN104334334B - 带有薄膜表面的机动车构件及其制造方法 - Google Patents

带有薄膜表面的机动车构件及其制造方法 Download PDF

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CN104334334B
CN104334334B CN201380028177.6A CN201380028177A CN104334334B CN 104334334 B CN104334334 B CN 104334334B CN 201380028177 A CN201380028177 A CN 201380028177A CN 104334334 B CN104334334 B CN 104334334B
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film
supporting structure
coating
vehicle exterior
exterior trim
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CN104334334A (zh
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J·胡贝尔-黑塞尔伯格
M·施瓦茨
P·西姆森
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Bayerische Motoren Werke AG
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Abstract

本发明涉及一种车辆构件(10)，特别是用于机动车的外饰，其包括塑造定型的、未涂漆的支承结构(11)并包括薄膜(12)，其中，该薄膜(12)至少在支承结构(11)的一个表面上利用粘合材料固定，其中薄膜(12)是可热成形的。

Description

带有薄膜表面的机动车构件及其制造方法
技术领域
本发明涉及一种车辆构件，特别是用于机动车的外饰，其包括塑造定型的、未涂漆的支承结构并包括薄膜，其中，该薄膜至少在支承结构的一个表面上利用粘合材料固定。
背景技术
为了产生一种在视觉上悦人的可见表面，通常对装配在车辆外表区域的机动车构件进行涂漆。对纤维增强的车辆部件(诸如由碳纤维增强塑料所构成的运动轿车的车顶元件)还用透明漆进行涂层处理，以产生一种尽可能光滑的表面并保证位于其下的碳纤维结构的可视见性。
此外，在现有技术中覆膜法(Folienverfahren)是已知的，其中，将薄膜贴覆到车辆的外壳上。对整个车辆覆膜可用来实现个性化，其中，经常选择哑光颜色作为表面。另外，通过贴覆的薄膜来表明市政公用车辆的功能，诸如警车、消防车或其他专用车辆。通常在此借助刮板手动地将薄膜贴覆到车辆外壳上。然而这种薄膜的价值或耐用性并不是针对整车使用寿命设计的或者说不能覆盖整车使用寿命。基于刮板法(Rakelverfahren)，只能处理那些容易照样模仿表面轮廓的薄膜类型。这种柔顺的薄膜类型依循位于下面的构件的轮廓形状变化并且朝外可视见地、细节高度精确一致地照样模仿这些构件。但是为了改善较为刚硬的薄膜的柔顺性而在高温下对这种薄膜进行的加工处理却具有同时在表面上呈现出刮板痕迹的缺点。表面已经交联的薄膜(其具有特别高的耐用性)不能施用于车辆构件上。
此外，这种可用刮板处理的(rakelbar)薄膜达不到所要求的油漆质量标准。另外，这样的薄膜由于环境影响会受到局部损坏，例如形式上为裂纹或者变色。从这些裂纹开始，薄膜然后便大面积地从位于其下面的构件上脱落，使得构件暴露在外或者说原来的涂漆显露出来。
发明内容
因此本发明的目的是，提供一种车辆构件以及一种用于制造文首所述类型的车辆构件的方法，该车辆构件满足在价值和耐用性方面的要求以及对于表面的高质量要求。
为此，本发明提供一种车辆外饰构件，其包括：
-塑造定型的、未涂漆的支承结构，和
-薄膜，其中，
所述薄膜至少在所述支承结构的一个表面上利用粘合材料固定，
其特征在于：所述薄膜是可热成形的，该薄膜在与支承结构粘合时被热成形。
相应地，本发明提供一种用于制造如上所述的车辆外饰构件的方法，其包括步骤：
-制作出支承结构，
-将热成形的薄膜贴覆到支承结构的至少一个表面上，其中，所述薄膜构造成多层的并包括承载层和涂层，
-将所述薄膜与所述支承结构粘合，
其特征在于：
-在将薄膜贴覆到支承结构上之后使所述薄膜的所述涂层发生交联。
为实现上述目的，本发明提出一种车辆构件，特别是用于机动车的外饰，其包括塑造定型的、未涂漆的支承结构并包括薄膜，其中，该薄膜至少在支承结构的一个表面上利用粘合材料固定。在此，所述薄膜是可热成形的。在本发明之意义下所使用的、可热成形的薄膜的特点是，该薄膜加热时具备良好的变形特性并且同时提供很高的损伤抵抗能力。这种薄膜针对树脂、鸟粪、化学物品污染具备抵抗能力，以及抵抗刮划形式的机械作用负荷。通过使用可热成形的薄膜，将外壳构件的最外层的软化点向上推移，使得这些构件对于炎热生成作用是特别稳定的。在强烈日照的情况下，这种薄膜与由现有技术已知的薄膜相比具有不发生软化以及因此看不出表面变化的优点。特别是所述薄膜提供了能够实现A级(Class-A)表面的优点，这种表面是在现代车辆制造中所要求的，并且迄今为止通常都是通过油漆层来产生。
此外，所述薄膜可以构造成多层的，包括承载层和层涂层。
在此，承载层可以至少按局部区段构造成透明的、半透明的和/或不透明的。这样的薄膜可以实现那些利用涂漆只有采用最大可能花费才能够呈现的设计变型方案。因此，这种薄膜具备在制造车辆构件时降低费用的优点。另外，由此能够通过简单方式实现多彩的车辆构件，例如带有印刷或者名称结构。
在此，承载层可以特别是至少由聚碳酸酯、含聚碳酸酯的混合物、聚碳酸酯共聚物、聚对苯二甲酸乙二醇酯、聚醚砜、丙烯酸酯-苯乙烯-丙烯腈共聚物(ASA)、含丙烯酸酯-苯乙烯-丙烯腈共聚物的混合物、热塑性聚氨酯(TPU)、聚烯烃、聚甲基丙烯酸甲酯(PMMA)、聚偏氟乙烯(PVDF)和/或它们的组合构造而成。
特别是脂肪族聚氨酯适合作为用于所述涂层的材料。此外，所述涂层还可以包括添加剂，这些添加剂防止该涂层老化。另外，在所述涂层中还可以设置紫外线吸收剂，例如廷纳芬(Tinuvin)。此外，所述涂层可以借助短波辐射、特别是紫外线交联。这一点提供了下述优点：所述可热成形的薄膜在成形期间或者说在往支承结构上贴覆期间具有良好的成形特性并且在交联之后在构件表面上提供充分的硬度。
另外，所述车辆构件的支承结构可以由玻璃纤维或者碳纤维增强的塑料构成。然而本发明还可以应用于下述的车辆构件，在这些车辆构件中，支承结构由金属材料、在此特别是铁板或者铝板构成。当然所述支承结构也可以由其他的纤维增强塑料组成，其中，所述纤维由玄武岩、芳香族聚酰胺、天然纤维例如大麻构成。此外，作为支承结构，还可以使用一种轻质蜂窝状结构。
按照另一方面，本发明涉及一种用于制造前述类型的车辆构件的方法，其包括步骤：制作出支承结构；将热成形的薄膜贴覆到支承结构的至少一个表面上，其中，所述薄膜构造成多层的并包括承载层和涂层；将薄膜与支承结构粘合。此外，所述方法可以包括这样一个加工步骤，在该加工步骤中，在将薄膜贴覆到支承结构上之后使所述薄膜的涂层发生交联。在热成形法中以多层式薄膜敷盖支承结构以及接着使表面交联提供了下述优点(正如已经在上面阐述的那样)：可以保证所要求的持久使用特性，如耐刮划性和环境稳定性。优选地，薄膜与支承结构的热成形和粘合可以同时进行。
此外，可以利用短波辐射实现所述涂层的交联。在此，特别是对所述涂层施加紫外光。
此外，所述薄膜可以直接就在往支承结构上贴覆之前被热成形。
在本发明的第一实施方式中，制造出一薄膜，利用热成形法将该薄膜转换成其最终的外部几何形状。接着，将已成形的薄膜粘贴到支承结构上。通过这种方式，可以对小型构件如特别是反光镜盖配置薄膜。
在本方法的第二实施方式中，首先制造可热成形的薄膜并且在与支承结构粘合时将其热成形。
在此，所述薄膜在其制造过程中可以具有一承载层、一覆盖层和一粘合材料层。该粘合剂以压敏层的方式在往车辆构件的支承结构上挤压时被激活。在另一可选的形式中，薄膜可以具有一涂层和一承载层。在即将往支承结构上贴覆之前，把粘合材料涂覆到承载层的与涂层相对置的一侧上。对此，特别是涉及到一种反应时间为6至8小时的反应性热熔粘合材料。在该时间之内，薄膜必须与支承结构相连接，此后粘合材料便时效硬化。只有再通过破坏粘合剂层才可以将薄膜与支承结构分离。在制造薄膜时，首先制作出承载层，接着利用涂层材料对该承载层进行涂漆或者涂层。
附图说明
下文将借助一种实施方式参照图1详细地阐述本发明。在此，图1示意性地和示范性地示出了本发明的车辆构件的横截面。
具体实施方式
构件10具有一个支承结构11，该支承结构可以由纤维增强塑料、热塑性塑料或者由金属材料构造而成。支承结构11相应于机动车的外壳构件，例如车顶、车门、保险杠等。在支承结构11的朝向车辆外侧的表面上贴覆一薄膜12。该薄膜12包括一承载层12b和一涂层12a。在此，薄膜12借助粘合材料被粘贴到支承结构11上。其中，该薄膜可以设置有彩色或者构造成透明的或半透明的。在此，薄膜12可以具有光亮的、哑光的或者由它们相组合的表面。
通过这种方式可以放弃对车辆构件的涂漆，因此能够得到一种节能的汽车构件生产过程。此外，还节省了涂漆设备的设备投资成本。如果所使用的薄膜至少按局部区段为彩色的、透明的或者半透明，则对机动车外壳构件的覆膜便提供了多种多样的设计可能性，诸如多色彩、置入图标、图形等等。与涂漆方法相比，费用降低到了最低限度，从而也可实现对这种覆膜车辆构件的批量使用。

Claims (15)

1.车辆外饰构件(10)，其包括：
-塑造定型的、未涂漆的支承结构(11)，和
-薄膜(12)，其中，
所述薄膜(12)至少在所述支承结构(11)的一个表面上利用粘合材料固定，
其特征在于：所述薄膜(12)是可热成形的，该薄膜在与支承结构粘合时被热成形。
2.如权利要求1所述的车辆外饰构件(10)，其特征在于：所述薄膜(12)构造成多层的，包括承载层(12b)和涂层(12a)。
3.如权利要求2所述的车辆外饰构件(10)，其特征在于：所述承载层(12b)至少按局部区段为透明的、半透明的和/或不透明的。
4.如权利要求2所述的车辆外饰构件，其特征在于：所述承载层(12b)至少包括聚碳酸酯、含聚碳酸酯的混合物、聚碳酸酯共聚物、聚对苯二甲酸乙二醇酯、聚醚砜、丙烯酸酯-苯乙烯-丙烯腈共聚物、含丙烯酸酯-苯乙烯-丙烯腈共聚物的混合物、热塑性聚氨酯、聚烯烃、聚甲基丙烯酸甲酯和/或聚偏氟乙烯。
5.如权利要求2所述的车辆外饰构件，其特征在于：所述涂层(12a)包括脂肪族聚氨酯。
6.如权利要求2至5之任一项所述的车辆外饰构件，其特征在于：所述涂层(12a)能够借助短波辐射交联。
7.如权利要求6所述的车辆外饰构件，其特征在于：所述涂层(12a)能够借助紫外光交联。
8.如权利要求1至5之任一项所述的车辆外饰构件(10)，其特征在于：所述支承结构(11)由玻璃纤维或者碳纤维增强的塑料构成。
9.如权利要求1至5之任一项所述的车辆外饰构件(10)，其特征在于：所述支承结构(11)由板材构成。
10.如权利要求1至5之任一项所述的车辆外饰构件(10)，其特征在于：所述支承结构(11)由铝板构成。
11.如权利要求1至5之任一项所述的车辆外饰构件(10)，其特征在于：所述支承结构(11)由轻质蜂窝状结构构成。
12.用于制造如权利要求1至11之任一项所述的车辆外饰构件(10)的方法，其包括步骤：
-制作出支承结构(11)，
-将热成形的薄膜(12)贴覆到支承结构(11)的至少一个表面上，其中，所述薄膜构造成多层的并包括承载层(12b)和涂层(12a)，
-将所述薄膜(12)与所述支承结构(11)粘合，
其特征在于：
-在将薄膜(12)贴覆到支承结构(11)上之后使所述薄膜(12)的所述涂层(12a)发生交联。
13.如权利要求12所述的方法，其特征在于：为使所述涂层(12a)交联，对该涂层施加短波辐射。
14.如权利要求13所述的方法，其特征在于：为使所述涂层(12a)交联，对该涂层施加紫外光。
15.如权利要求12至14之任一项所述的方法，其特征在于：所述薄膜(12)直接就在往支承结构(11)上贴覆之前得以热成形。
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