CN110582395A - 车辆外表面构件和用于制造车辆外表面构件的方法 - Google Patents

车辆外表面构件和用于制造车辆外表面构件的方法 Download PDF

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CN110582395A
CN110582395A CN201880029760.1A CN201880029760A CN110582395A CN 110582395 A CN110582395 A CN 110582395A CN 201880029760 A CN201880029760 A CN 201880029760A CN 110582395 A CN110582395 A CN 110582395A
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layer
smc
exterior surface
vehicle exterior
surface member
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M·鲍曼
F·基赛韦特
D·莱格勒
J·沃考克
M·斯维贝里
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Webasto Thermosysteme GmbH
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
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Abstract

本发明涉及一种具有层结构的车辆外表面构件，所述车辆外表面构件具有构成外表层(8)的SMC层(9)并且具有与所述SMC层(9)连接的和包括核心层(3)的加强结构(2)，其中，根据本发明设置，所述SMC层(9)具有小于2mm、尤其1.5mm至2.0mm并且特别优选1.5mm至1.8mm的减小的厚度和/或小于1.3kg/dm3、尤其在1.2kg/dm3和1.0kg/dm3之间的减小的密度，以及涉及一种用于制造这种车辆外表面构件的方法。

Description

车辆外表面构件和用于制造车辆外表面构件的方法
技术领域
本发明涉及一种具有层结构的车辆外表面构件，所述车辆外表面构件具有构成外表层的SMC层并且具有与SMC层连接的和包括核心层的加强结构以及涉及一种用于制造车辆外表面构件的方法。
背景技术
这种车辆外表面构件例如是车顶开口系统(如滑动式车顶或扰流器车顶)的盖、车顶模块的面构件或车辆的包覆构件。
由EP 1 524 175 A2已知一种车辆外表面构件，所述车辆外表面构件具有由高表面品质的塑料(例如由SMC材料)制成的外壳和在内侧面式地贴靠在外壳上的加强结构。加强结构由相互间隔开的两个塑料层组成，在所述塑料层之间设置蜂窝结构或泡沫状材料。
发明内容
基于本发明的任务在于，实现开头提到的车辆外表面构件，所述车辆外表面构件在高强度的情况下在减小重量方面被改善，以及提供一种用于制造这种车辆外表面构件的方法。
根据本发明，所述任务在开头提到的车辆外表面构件中如下解决：SMC层具有小于2mm、尤其1.5mm至2.0mm并且特别优选1.5mm至1.8mm的减小的厚度和/或具有小于1.3kg/dm3、尤其在1.2kg/dm3和1.0kg/dm3之间的减小的密度。
此外，该任务通过具有权利要求8的特征的方法以及通过具有权利要求11的特征的方法解决。
本发明的有利构型分别在从属权利要求中说明。
由此，根据第一种解决方案，SMC层(片状模塑料，sheet moulding compound)具有小于2mm、尤其1.5mm至2.0mm并且特别优选1.5mm至1.8mm的减小的厚度，所述SMC层能够与轻且牢固的加强结构关联地实现车辆外表面构件，所述车辆外表面构件由于SMC层的减小的厚度与已知的车辆外表面构件相比明显更轻。
另一方面，根据第二解决方案，由于SMC层具有小于1.3kg/dm3、尤其在1.2kg/dm3和1.0kg/dm3之间的减小的密度，车辆外表面构件的重量优点能通过减小SMC材料的比重(spezifischer Gewicht)实现。尽管如此，车辆外表面构件的强度能够通过轻的加强结构相对于已知的车辆外表面构件被保持或者甚至提升。密度的减小能够通过加入填料(如空心玻璃珠或类似物)实现，所述填料的重量明显低于SMC材料的树脂重量。
第一解决方案与第二解决方案的组合统一了能相应地实现的优点。
在这些解决方案中实用的是，SMC层具有小于4kg/m2并且尤其在2.5kg/m2和1.2kg/m2之间的单位面积重量。由此提供一种在强度和重量方面优化的车辆外表面构件。
在优选的构型中，在SMC层上施加可涂装的模内涂覆层(In Mold Coat)。在其密度方面减小的薄SMC层不能涂装或不能以足够的质量涂装。与SMC层共同构成外表层的模内涂覆层能够实现具有A级表面质量的涂装。
实用地，加强结构包含内塑料盖层，所述内塑料盖层主要包含聚氨酯或者由聚氨酯制造并且在所述核心层的与外表层对置的内侧上施加在核心层上。借助作为粘接剂的聚氨酯实现塑料盖层在核心层上的固定，所述粘接剂提供与核心层的密切连接并且能够使对此合适的材料渗入到所述核心层中。在构件内侧能够直接粘合材料。
在优选的构型中，所述外表层借助外塑料盖层施加在核心层的面对外表层的外侧上，所述外塑料盖层主要包含聚氨酯或者由聚氨酯制造。外塑料盖层能够例如通过纤维加强部或纤维垫而具有加强部，由此提高强度。为了施加外表不但能够使用这类加强的外塑料盖层也能够使用不设置这种加强部的外塑料盖层。
特别优选地，内塑料盖层和/或外塑料盖层具有例如包括玻璃纤维的纤维加强部或纤维垫。可选地使用纤维加强部或纤维垫加强部能够在优化的高强度、尤其弯曲强度或例如抵抗冰雹冲击的强度方面实现不同层的特定构型。塑料或者聚氨酯基本上构成粘接剂，而纤维加强部提供需要的强度。
特别优选的实施方式设置：加强结构的核心层由蜂窝或泡沫材料制造。在此，所述蜂窝优选由纸、由铝或由塑料(例如酚醛树脂)制造。蜂窝也被理解为例如波形延伸的构件或间隔件，所述构件或间隔件垂直于至少一个塑料盖层延伸。
通过根据本发明的根据权利要求9的方法能够制造尤其如前面所说明的特别轻但仍然牢固的车辆外表面构件。用于制造尤其根据前述实施方式构成的车辆外表面构件的方法包含以下步骤：
a)以用于SMC构件的标准制造方法制造包括IMC薄层的SMC层作为构成外表层的半成品，
b)将已涂覆的SMC层置入到复合材料模具的模具半部中，
c)在车辆外表面构件的成型中，将具有还未交联的粘接剂或聚氨酯的、承载外表层的加强结构压入到所述SMC层中，所述加强结构具有被至少一个塑料盖层遮盖的核心层，和
d)将车辆外表面构件脱模。
实用地，接着车辆外表面构件的脱模(步骤d)能够实施至少一个另外的方法步骤，例如修剪或切割车辆外表面构件的棱边。
此外，在这个方法中在步骤a)中或者使IMC薄层设置有外表面涂层或者对此替代地使SMC层设置有可涂装的IMC薄层，并且在步骤e)中例如以车身颜色或以对比颜色涂装所述车辆外表面构件。
此外，通过根据权利要求12的根据本发明的方法也能够制造特别轻但仍然牢固的车辆外表面构件。在此，实施以下步骤：
a)以用于SMC构件的标准制造方法制造SMC层作为半成品，
b)将SMC层置入到模具的第一模具半部中并且借助第二模具半部挤压所述SMC层，
c)将IMC涂装层施加到面对第一模具半部的SMC层上，用于构成外表层，
d)将第二模具半部更换为具有扩大的模具型腔的模具半部，
e)将承载外表层的加强结构置入到所述扩大的模具型腔中，所述加强结构具有被至少一个塑料盖层遮盖的核心层，和
f)在车辆外表面构件的成型中，将具有还未交联的粘接剂或聚氨酯的加强结构压入到所述SMC层中。
如在首先提及的方法中，能够在脱模之后进行进一步的方法步骤并且也进行涂装。
附图说明
下面，参照附图借助根据本发明的车辆外表面构件的实施例进一步阐明本发明。其示出了：
图1根据本发明的车辆外表面构件的截面视图；
图2图1的车辆外表面构件的外表层的截面视图；
图3在第一制造步骤期间，具有两个闭合的模具半部和车辆外表面构件的布置在其中的SMC半成品的模具的截面视图；和
图4在第二制造步骤期间，具有被更换的第二模具半部和布置在其中的车辆外表面构件的模具的截面视图。
具体实施方式
车辆外表面构件1例如是车顶模块或可开口的车顶(如滑动式车顶)的盖，该车辆外表面构件具有加强结构2，所述加强结构具有由蜂窝(例如纸蜂窝)或由泡沫材料制造的核心层3。核心层3在两侧、即向车辆外表面构件1的构件外侧4以及构件内侧5分别配置有塑料盖层6或者7。外塑料盖层6以及内塑料盖层7包含薄粘接剂层或由下述材料构成，所述材料尤其由聚氨酯组成并且尤其包含加强的纤维层或纤维垫，所述加强的纤维层或纤维垫例如由具有玄武岩纤维、碳纤维、天然纤维或玻璃纤维的纤维材料组成。
车辆外表面构件1的外表层8借助外塑料盖层6的塑料或聚氨酯与加强结构2或者核心层3连接。外表层8由内层和外层构成。所述内侧是密度减小的且不能涂装的薄SMC层9。外层由模内涂覆(IMC)层10组成。
SMC层9相对于已知的SMC构件以小于2mm的减小的厚度构成。SMC层9优选具有1.5mm至2.0mm、并且尤其1.5mm至1.8mm的厚度。此外，SMC层9具有小于1.3kg/dm3并且尤其在1.2kg/dm3和1.0kg/dm3之间的减小的密度。
相对于已知的SMC构件或SMC半成品的减小的密度例如能够通过相应地添加填料(如空心玻璃珠)实现。
当SMC层9承担外塑料盖层6的结构特性时，外塑料盖层6也能够作为含纤维层被省去。在此，SMC层9直接与核心层3的粘接仅借助塑料(例如聚氨酯)实现。
一种用于制造这种车辆外表面构件1的方法设置为：首先，以用于SMC构件的标准制造方法制造包括可涂装的外IMC薄层10的SMC层9作为半成品。
接着将半成品(具有IMC层10的SMC层9)置入到复合材料模具的模具半部中。如有必要，所述半成品借助真空被吸入到模具半部上。
在接下来的另一方法步骤中，具有还未交联的粘接剂(例如聚氨酯)的加强结构2被压入到半成品中。在这个方法步骤中，在面向SMC层9的面上进行加强结构2的成型。
可选地，接着复合构件或车辆外表面构件1的脱模进行进一步的方法步骤，例如修剪或切割车辆外表面构件1的棱边。接着能够将车辆外表面构件1以车身颜色或以对比颜色进行涂装。
另一替代的方法(见图3和4)示出SMC工艺与复合材料工艺的结合。模具11具有第一模具半部或上模具半部12和第二模具半部或下模具半部13。在两个模具半部12和13之间的模具型腔14中首先挤压SMC层9并且接着在之后的构件外侧上借助第一模具半部或上模具半部12(A级模具半部)加入IMC涂装层10。与最先提及的方法不同地，所述半成品或外表层8(具有IMC涂装层10的SMC层9)不从模具11取出，而是模具11的阳模、即下模具半部13被用于制造最后的复合材料几何形状的更换的第二模具半部13’替代。这能够通过更换阳模或通过模具半部13或13’的往复或经过(Shutteln oder Verfahren)实现，其中，SMC层9保持在上模具半部12上。更换的下模具半部13’具有扩大的模具型腔14’，在所述模具型腔中布置加强结构2。接下来进行复合材料工艺，在所述复合材料工艺中向外表层8的SMC层9挤压并且与所述外表层连接。
替代地，下模具半部13也能够是A级模具半部，并且所述A级模具半部不但能够替换下模具半部13也能够替换上模具半部12。可选地，SMC层9也能够保持在下模具半部13’上并且用于置入加强结构2的工艺能够在第二挤压模具中进行。
这种方法最大的优点是：省去附加的用于搬运半成品的手动操作步骤、避免损害之后的表面，以及避免复合材料模具被杂质污染。
本发明在说明书中和根据实施例以及在附图中公开的单个特征能够以任意在技术上实用的布置和构型与在一般形式中的本发明内容组合。
附图标记列表
1 车辆外表面构件 10 模内涂覆层
2 加强结构 11 模具
3 核心层 12 第一模具半部
4 构件外侧 13 第二模具半部
5 构件内侧 13’ 被更换的第二模具半部
6 外塑料盖层 14 模具型腔
7 内塑料盖层 14‘ 扩大的模具型腔。
8 外表层
9 SMC层

Claims (12)

1.一种具有层结构的车辆外表面构件，所述车辆外表面构件具有构成外表层(8)的SMC层(9)并且具有与所述SMC层(9)连接的和包括核心层(3)的加强结构(2)，
其特征在于，
所述SMC层(9)具有小于2mm、尤其1.5mm至2.0mm并且特别优选1.5mm至1.8mm的减小的厚度和/或小于1.3kg/dm3、尤其在1.2kg/dm3和1.0kg/dm3之间的减小的密度。
2.根据权利要求1所述的车辆外表面构件，
其特征在于，所述SMC层(9)通过加入具有减小的密度的填料或空心玻璃珠构成。
3.根据权利要求1或2所述的车辆外表面构件，
其特征在于，所述SMC层(9)具有小于4kg/m2并且尤其在2.5kg/m2和1.2kg/m2之间的单位面积重量。
4.根据权利要求1至3中任一项所述的车辆外表面构件，
其特征在于，在所述SMC层(9)上施加能涂装的模内涂覆层(10)，所述模内涂覆层与所述SMC层(9)共同构成所述外表层(8)。
5.根据权利要求1至4中任一项所述的车辆外表面构件，
其特征在于，所述加强结构(2)具有内塑料盖层(7)，所述内塑料盖层由聚氨酯制造并且在所述核心层的与所述外表层(8)对置的内侧上施加在所述核心层(3)上。
6.根据权利要求1至5中任一项所述的车辆外表面构件，
其特征在于，所述外表层(8)借助由聚氨酯制造的外塑料盖层(6)施加在所述核心层(3)的面对所述外表层(8)的外侧上。
7.根据权利要求5或6所述的车辆外表面结构，
其特征在于，所述内塑料盖层(7)和/或所述外塑料盖层(6)具有纤维加强部或纤维垫。
8.根据权利要求1至7中任一项所述的车辆外表面构件，
其特征在于，所述加强结构(2)的核心层(3)由蜂窝或泡沫材料制造，其中，尤其所述蜂窝由纸、铝或塑料例如酚醛树脂制造。
9.一种用于制造尤其根据权利要求1至8中任一项所述的车辆外表面构件(1)的方法，具有以下步骤：
a)以用于SMC构件的标准制造方法制造包括IMC薄层(10)的SMC层(9)作为构成外表层(8)的半成品，
b)将已涂覆的SMC层(9)置入到复合材料模具的模具半部中，
c)在所述车辆外表面构件(1)的成型中，将具有还未交联的粘接剂或聚氨酯的、承载所述外表层(8)的加强结构(2)压入到所述SMC层(9)中，所述加强结构具有被至少一个塑料盖层(5，6)遮盖的核心层(3)，和
d)将所述车辆外表面构件(1)脱模。
10.根据权利要求9所述的方法，
其特征在于，接着所述车辆外表面构件(1)的脱模(步骤d)实施至少一个另外的方法步骤、例如修剪或切割所述车辆外表面构件(1)的棱边。
11.根据权利要求9或10所述的方法，
其特征在于，在步骤a)中，
-所述IMC薄层(10)设置有外表面涂装，或
-所述SMC层(9)设置有能涂装的IMC薄层(10)并且在步骤e)中进行所述车辆外表面构件(1)的涂装。
12.一种用于制造尤其根据权利要求1至8中任一项所述的车辆外表面构件(1)的方法，具有以下步骤：
a)以用于SMC构件的标准制造方法制造SMC层(9)作为半成品，
b)将所述SMC层(9)置入到模具(11)的第一模具半部(12)中并且借助第二模具半部(13)挤压所述SMC层(9)，
c)将IMC涂装层(10)施加到面对所述第一模具半部(12)的SMC层(9)上，用于构成外表层(8)，
d)将所述第二模具半部(13)更换为具有扩大的模具型腔的模具半部(13’)，
e)将承载所述外表层(8)的加强结构(2)置入到所述扩大的模具型腔中，所述加强结构具有被至少一个塑料盖层(5，6)遮盖的核心层(3)，和
f)在所述车辆外表面构件(1)的成型中，将具有还未交联的粘接剂或聚氨酯的所述加强结构(2)压入到所述SMC层(9)中。
CN201880029760.1A 2017-05-05 2018-04-24 车辆外表面构件和用于制造车辆外表面构件的方法 Pending CN110582395A (zh)

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