DE102010003656B4 - Vehicle cladding component with it partially provided heat protection component made of plastic material and method for producing the same - Google Patents

Abstract

A vehicle trim component comprising a trim element (18) on which only at least one heat protection component is provided in regions, the heat protection component being at least partially formed from a heat protection component plastic material (46), characterized in that the trim element (18) is at least in those regions wherein a thermal protector is provided comprising porous cladding substrate material, the thermal protector being provided on the cladding substrate (18) such that pores (44) of the cladding substrate material are at least partially filled with thermal protector plastic material (46).

Description

The present invention relates to a motor vehicle trim component having a trim base component, to which only at least one heat protection component is provided in some areas, wherein the heat protection component is at least partially, preferably completely, formed from a heat protection component plastic material. The invention further relates to a method for producing such a vehicle trim component.

Such cladding components are used as cladding of motor vehicle surfaces and spaces, in particular of automotive underbody. A generic automotive trim component and a manufacturing method thereof are known from DE 10 2009 016 240 A1 known.

This document generally teaches to make the trim base by injection molding or extrusion molding and to manufacture the heat shield by injection molding.

Preferably, in accordance with the method already known from the prior art, the heat protection component designated there as "shielding element" is prefabricated, inserted in an injection molding or extrusion press tool and then encapsulated or pressed through the material for producing the trim component.

Alternatively or additionally, from the DE 10 2009 016 240 A1 known heat protection component in the context of a two-component injection molding process with the cladding base component or back-injected.

Thus, an unspecified positive or / and material connection between the materials used for the cladding base part on the one hand and the heat protection component on the other hand to be created.

The document goes to the nature of the positive or / and cohesive connection between the cladding basic component and the heat protection component of the prior art DE 10 2009 016 240 A1 not closer. Due to the process steps and their sequence which are only roughly described therein, the material-bonding connection can only be understood to mean a mixing of substantially identical plastics during injection molding and can only be designated as a macroscopic positive fit by encapsulation of a correspondingly contoured component section with the positive-locking connection.

From the publication DE 10 2005 029 729 A1 For example, a trim or housing part of a vehicle and a method for its manufacture are known. This document discloses a semi-finished product comprising a web of two different fibers with different melting temperatures. The semifinished product is heated in a mold to a processing temperature which is between the melting temperatures of the two fiber types, thereby melting the lower melting point fibers while retaining the higher melting point fibers than fibers. When heated to the processing temperature, the semi-finished product in the mold is locally pressed to different degrees from the final molded part, cooled and demolded. The semifinished product can be multi-layered and comprise, as a further layer, a further nonwoven of two different fibers with different high melting points or a film.

From the DE 100 49 765 A1 describes a vehicle trim component referred to as a "heat shield", which has a carrier element with a heat-insulating coating provided thereon. The heat insulating coating is at least partially formed of plastic material. That from the DE 100 49 765 A1 known carrier element is not porous. The heat-insulating coating may be glued, screwed, riveted or stapled to the support element. The carrier element can also be cast onto the heat-insulating coating, be it by encapsulating undercuts of the coating component, or by partial penetration of the material of the carrier element into the material of the coating component.

From the CH 684 530 A5 For example, a trim component is known which has a shaped body as the base component and a mat or plate arranged on the shaped body. The shaped body is not porous. The mat or plate can be porous. The molded body is molded onto the mat or plate.

Object of the present invention is therefore to improve the known from the prior art automotive trim component on.

This object is achieved in accordance with the invention by a vehicle trim component of the type mentioned at the beginning, the covering basic component of which comprises porous cladding basic component material at least in those areas in which a heat protection component is provided, the heat protection component being provided on the cladding basic component in such a way that pores of the cladding basic component are provided. Material are at least partially filled with heat protection component plastic material.

By the use of porous cladding basic material at least in those areas where a heat protection component is provided on the cladding basic component, it is possible to connect the heat-shielding member to the trim base member by micro-mating engagement.

As "pores" in the context of the present application, any material-related cavity is referred to, such as voids between fibers of a Fasergewirrs, cavities between boundary walls of a foamed plastic, cavities, which are produced by meshes of a fabric and the like.

The heat-protection component-plastic material can flow as a melt or as another flowable raw material, depending on its viscosity, without pressure or pressure induced at least partially in the pores provided by the cladding component material pores and thereby create the desired micro-positive connection.

The result is a motor vehicle connection component which is optimally thermally shielded, has a low weight and can be made flatter than the components known from the prior art, since the mentioned micro-form-locking does not produce any structure of macroscopic form-fitting structures on one of the two components Panel basic component and heat protection component required. Since it does not depend on a material connection, one is free in the choice of the component materials.

In order to avoid or at least limit the amount of an undesired shrinkage of the heat protection component plastic material, it can be provided that the heat protection component comprises a filled plastic, in particular fiber-filled plastic, which preferably contains a mineral filler. On the other hand, attention should also be paid to the viscosity of the flow mass, in particular the melt, which should not be too high, so that it can no longer flow into the micropores of the cladding basic material. For this reason, the filler content should not be too high.

From a practical point of view, it has proven to be advantageous if the heat protection component plastic material has a filler content in a range of 15% vol. to 85% vol., preferably in a range of 20% vol. up to 80% vol. and more preferably in a range of 30% vol. up to 70% vol. having. In the case of filler contents within the stated limits, on the one hand the shrinkage and, on the other hand, the viscosity of the flow compound are in processable, in particular readily processable ranges of values.

In principle, it may be envisaged to select the heat-shielding plastic material to be pourable so that it may flow, at least partially, into the micropores of the trim base material in the castable state, whether as a melt or as a non-chemically-cured liquid.

However, preference is given to using an injection-moldable heat-protection component-plastic material, since this can be easily brought into easily controllable processes with well-defined cavities in the desired shape and on the other hand, the injection pressure an inflow of the flowable, in particular molten heat protection plastic material when penetrating the micropores of the panel basic component supported.

For the connection of heat protection component and covering basic component, it has been found to be particularly advantageous if the porosity of the lining basic component by fibers, be it as scrim, fabric or particularly preferably as Fasergewirr provided. The pore size is then comparatively large with sufficient component stiffness based on the size of the pore-limiting fibers, which facilitates the flow of heat protection component plastic material into the pores of the cladding base material. In addition, in the case of the above-mentioned cladding basic component materials, the pores are configured in such a way that fibers in the cladding basic component material are surrounded by the inflowing heat-shielding plastic material and can thus be fixed in a form-fitting manner in a plastic matrix of the then hardened heat-resistant plastic material.

Therefore, it is preferable if the cladding base material at least in a region in which a heat protection member is provided, a fiber structure portion, which fiber material and fibers of the fiber material binding binder material has. For cladding basic components, fiber materials with thermoplastic binders have proven to be particularly advantageous, since they have a low weight, can be processed without further problems, and have good sound absorption properties with sufficient component rigidity.

Therefore, it is preferable if the trim base material is a trim base plastic material and as such comprises LWRT material with fiber material and a thermoplastic binder (LWRT = Light Weight Reinforced Thermoplastic).

The trim base material may further include layers to provide solutions to different technical problems provide. For this purpose, provision may in particular be made for the cladding basic component material to comprise a plurality of layers in the thickness direction, of which at least two differ with respect to material and / or density and / or rigidity and / or porosity.

For example, the trim base member material may include a first layer of fibrous material and binder, preferably thermoplastic binder, to provide good sound absorption. Frequently, however, such layers have a large void content and are therefore not particularly impact-resistant.

In order to increase the impact resistance and impact resistance of the vehicle trim component, in particular of the trim base component, it can therefore be further provided that the trim base component material on each side of the first layer each have a cover layer which covers the first layer. Such cover layers can then be designed to be impact-resistant and / or impact-resistant so that solid objects impacting on operation, such as stones, clods and the like, do not damage the sound-absorbing first layer. For the above-mentioned reasons of a particularly simple inflow of heat protection component plastic material into the material of the cladding basic component, it can be provided that at least one of the cover layers comprises a cover sheet, ie a layer with a fiber tangle.

Although it is stated herein that a cover layer covers the first layer on each side, this is not intended to mean that the cover layer is directly attached to the first layer, although this is not excluded. Rather, at least one further layer may be provided between the cover layer and the first layer, which may in turn preferably be formed from a fiber tangle or a foam, in particular open-cell foam.

Preferably, the first layer to provide the best possible sound absorption at the same time high impact and impact resistance of the vehicle trim component and also at the same time as low overall thickness as possible formed thicker than each cover layer. Particularly preferably, the first layer is thicker than the two outer layers together.

In order to provide the desired heat resistance of the heat protection component, it may be provided that the heat protection component plastic material comprises at least one plastic of polyvinylidene fluoride, polyamide, in particular PA6-6T, polybutylene terephthalate, polyethylene terephthalate, polyethersulfone, polyphenylsulfide, polysulfone, polyetherimide and liquid crystal polymer.

If it is stated at the beginning of this application that the cladding basic component only partially has at least one heat protection component, then this is to exclude the case that the cladding basic component is completely covered by the heat protection component described in this application. This means that there are areas of the vehicle trim component on which no heat protection component is provided. Protective edges of the cladding basic component are particularly worthy of protection in terms of thermal influences, wherein an edge of the cladding basic component provided with a heat-protection component is preferably encompassed by the provided heat-protection component at two, particularly preferably at three sides.

The heat-shielding effect of the heat-shielding member can be further influenced and, in particular, increased by increasing the reflectivity of the heat-shielding member plastic material for heat radiation. For this purpose, it can be provided that the heat protection component plastic material contains color pigments, in particular metal-colored and / or metallic color pigments.

The object mentioned at the outset is also achieved by a method for producing a motor vehicle trim component with a trim base component and with at least one heat protection component provided only partially thereof, wherein the trim base component is formed at least partially, preferably completely, from a porous trim base component material and wherein the heat protection component at least partially, preferably completely, is formed from a heat protection component plastic material. The method is designed in particular for producing a vehicle trim component, which is constructed as described above.

• - Einlegen wenigstens eines flächigen Verkleidungsgrundbauteils in eine Spritzgussform derart, dass ein poröser Abschnitt des Verkleidungsgrundbauteils in eine nachfolgend durch Spritzgießen zu füllende Spritzgusskavität hineinragt oder diese durchsetzt,
• - Einspritzen von, vorzugsweise gefülltem, besonders bevorzugt fasergefülltem, Wärmeschutzbauteil-Kunststoffmaterial in die Spritzgusskavität,
• - Entnehmen des Verkleidungsgrundbauteils mit daran angespritztem Wärmeschutzbauteil als das KFZ-Verkleidungsbauteil aus der Spritzgussform.

According to the invention, the method comprises the following steps:

• Inserting at least one planar cladding basic component into an injection mold such that a porous section of the cladding basic component protrudes into or penetrates an injection molding cavity to be subsequently filled by injection molding,
• Injecting, preferably filled, particularly preferably fiber-filled, heat-protection component-plastic material into the injection-molding cavity,
• - Removing the trim base member with the heat shield member molded thereon as the automotive trim component from the injection mold.

As already stated above, the injection molding process is the preferred method of simultaneously producing the heat-shielding member and attaching it to the trim base member.

Since the lining basic component can already be elastically deformable due to its porosity when exposed to relatively small forces, it is preferably provided for the method that the step of injection takes place with a low injection pressure based on an injection pressure usual for the respective injection molding material. Thus, on the one hand, it can be ensured that the thermal protection component is produced and sprayed onto the cladding basic component as desired, without an overmolding of thermal protector plastic material taking place in areas in which such a material should not be provided on the final automotive cladding component.

The surface quality of the injection molded heat protection component and thus its heat protection properties can be further improved by heating the injection mold.

To increase the per-injection cycle producible automotive trim components, it may further be provided that the injection mold is configured to receive at least two separate panel trim components, and the loading step comprises inserting at least two trim base members into the injection mold such that each trim base member is formed into at least one an injection molding cavity assigned to it protrudes or penetrates it. Then, a plurality of automotive trim components can be produced per injection cycle, depending on how many trim base components can be inserted into the injection mold.

Preferably, the sprue of the injection mold is located at substantially the same distance from the individual trim base components inserted into the injection mold.

In particular, when the trim base is comprised of LWRT material or even made entirely of LWRT material, the method of providing a panel fairing may further comprise a step of compression molding, which in turn advantageously comprises a step of lofting the trim base.

By "lofts" is meant a process in which the dimension in the thickness direction of a previously compacted fiber composite material is increased under the action of heat.

In the present application, "flat" designates a component which has a substantially smaller dimension in the thickness direction than in two spatial directions which are orthogonal both to one another and to the thickness direction. In this case, a flat component within the meaning of the present application may well be curved about an axis of curvature orthogonal to the thickness direction, so that "area" does not necessarily mean "level", although planar components are not excluded as flat components.

• 1 ein Querschnitt durch eine Spritzgussform mit darin eingelegtem Verkleidungsgrundbauteil, welches in eine Spritzgusskavität der Spritzgussform hineinragt und
• 2 eine stark vergrößerte Ansicht der Bindung von Verkleidungsgrundbauteil und Wärmeschutzbauteil

The present invention will now be described with reference to the accompanying drawings. It shows:

• 1 a cross section through an injection mold with inserted basic lining component, which protrudes into an injection molding cavity of the injection mold and
• 2 a greatly enlarged view of the tie of trim basic component and heat protection component

In 1 a partially illustrated injection mold is generally designated 10. The injection mold 10 consists of several injection molded parts 12 and 14 , which are closed with the injection mold 10 along a separation surface 16 touch. The mold separation surface 16 is not flat in the illustrated example but has curvatures.

In the injection mold 10 is a panel basic component 18 inserted, which is preferably formed from Light Weight Reinforced Thermoplastic (LWRT), ie a fiber composite material with thermoplastic binder.

A longitudinal end 20 protrudes into a mold cavity 22 a, which has a filling space for injection molding material around the longitudinal end 20 of the panel basic component 18 defined around.

The feeder or sprue of the injection mold 10 is with 24 referred to and shown only schematically as a dot-dash line.

Like in the 1 is indicated, the injection mold 10 over the moldings 12 and 14 In addition, further moldings have, which define further injection molding cavities and offer further possibilities for inserting fairing basic components, so that a plurality of automotive fairing components can be completed with an injection molding process. For example, the Spritzgusskavität 22 through the food rack 24a be filled with injection-molding compound, while another, in 1 not shown and to the cavity shown 22 preferably mirror-image oriented. Mold cavity during the same injection process over the feed branch 24b can be supplied.

The mold cavity 22 can also for the formation of other shape geometries, such as through the Nietdom-Kavitätsabschnitt 22a for forming a rivet dome or the like, be formed.

The mold cavity 22 is used for molding a Wärmutrutrbauteils to the trim base member 18 filled with preferably fiber-reinforced thermoplastic, for example polyphenylene sulfide, polysulfone or polyethersulfone, to name but a few possibilities.

In this case, a relatively low injection pressure is selected for the materials used in order to over-spray the heat protection component plastic material via the critical connection points 26 and 28 to avoid, in which the injection molding cavity 22 limiting shape wall 30 to the panel basic component 18 invests.

Due to the fiber composite structure of the cladding basic component 18 Namely, if the injection pressure is too high, the trim basic component 18 compressed in the thickness direction D by the inflowing heat protection member plastic material and so from the mold wall 30 be lifted, which could then lead to the undesirable overspray. This can be counteracted with the above-mentioned low injection pressures.

As in 1 is shown, that from the Spritzgusskavität 22 resulting heat protection component a longitudinal end 20 a panel basic component 18 embrace on three sides, which leads to a particularly good anchoring of the heat protection component on the trim base component.

Likewise, however, the heat protection member may be the trim base member 18 embrace only on two sides or can only on an outer surface of the lining basic component 18 be set up.

Furthermore, as in the example of the rivet dome cavity section 22a is indicated, in a single processing step, not only the heat protection component to the trim base member 18 molded, but also with function geometries, such as connection preparations, sealing lips, ram lips, Strömungsleitrippen and the like be educated.

In 2 a schematic microscopic view of the structure of the finished vehicle trim component is shown.

You can see the long glass fibers 40 of LWRT material of panel basic component 18 ,

These are at points of contact at which the fibers 40 sufficiently close to each other, by thermoplastic binder 42 connected with each other.

The rest of the fibers 40 claimed space is essentially gas, especially air-filled. The space between the fibers 40 that is not made of thermoplastic binder 42 is taken, forms pores 44 ,

In these pores 44 is heat-shielding plastic material during injection molding 46 has flowed in and has a part of the fibers 40 lapped. The lapped areas of the fibers 40 are thus form-fitting in the cured heat protection component plastic material 46 anchored.

In the in 2 example shown is a front 48 to detect which indicates a limit to where the heat protection component plastic material 46 into the LWRT material of the panel basic component 18 has flowed.

It should be noted that, depending on the materials used and the parameters of the injection molding parameters, the LWRT material to which the heat protection component is molded can also be penetrated over its entire thickness with heat protection component plastic material.

Claims (16)

A vehicle trim component comprising a trim element (18) on which only at least one heat protection component is provided in regions, the heat protection component being at least partially formed from a heat protection component plastic material (46), characterized in that the trim element (18) is at least in those regions wherein a thermal protector is provided comprising porous cladding substrate material, the thermal protector being provided on the cladding substrate (18) such that pores (44) of the cladding substrate material are at least partially filled with thermal protector plastic material (46). Car fairing component after Claim 1 , characterized in that the heat protection component comprises a filled plastic. Car fairing component after Claim 2 characterized in that the heat-shielding plastic material (46) has a filler content in a range of 15% -vol. up to 85% -vol. having. Vehicle trim component according to one of the preceding claims, characterized in that the heat protection component plastic material (46) is injection-moldable. Vehicle trim component according to one of the preceding claims, characterized in that the trim base material at least in a region in which a heat protection member is provided, a fiber structure portion comprising fiber material and fibers (40) of the fiber material binding binder material. Car fairing component after Claim 5 characterized in that the trim base material is a trim component plastic material and, as such, comprises LWRT material with fiber material and a thermoplastic binder (42). Car fairing component after Claim 5 or 6 characterized in that the trim base member material in the thickness direction (D) comprises a plurality of layers at least two of which differ in material and / or density and / or stiffness and / or porosity. Car fairing component after Claim 7 characterized in that the trim base material comprises a first layer of fibrous material and binder (42), each side of the first layer being covered with a cover layer. Vehicle trim component according to one of the preceding claims, characterized in that the heat protection component plastic material (46) comprises at least one plastic of polyvinylidene fluoride, polyamide, polybutylene terephthalate, polyethylene terephthalate, polyethersulfone, polyphenylsulfide, polysulfone, polyetherimide and liquid crystal polymer. Vehicle trim component according to one of the preceding claims, characterized in that the heat protection component is provided on an edge of the trim base component (18). Vehicle trim component according to one of the preceding claims, characterized in that the heat protection component plastic material (46) contains color pigments. A method of making a vehicle trim component having a trim base member (18) and at least one heat shield member thereon, the trim member (18) being at least partially formed of a porous trim base material and wherein the heat shield member is at least partially made of a heat shield plastic material (46), characterized in that it comprises the following steps: inserting at least one planar lining basic component (18) into an injection mold (10) such that a porous portion of the lining basic component (18) can be injection molded into an injection molding cavity (hereinafter 22) protrudes or penetrates, injecting heat protection component plastic material (46) into the injection molding cavity (22), removing the covering basic component (18) with the heat protection component molded onto it as the vehicle covering component from Injection mold (10). Method according to Claim 12 , characterized in that the step of injection takes place with a, based on a customary for the respective injection molding material injection pressure, low injection pressure. Method according to Claim 12 or 13 , characterized in that the injection mold (10) is heated. Method according to one of Claims 12 to 14 characterized in that the injection mold (10) is adapted to receive at least two separate panel fairings (18), and the loading step comprises placing at least two fairing panels (18) in the mold (10) such that each fairlead assembly (18) projects into or passes through at least one injection molding cavity (22) assigned to it. Method according to one of Claims 12 to 15 characterized in that it comprises a step of compression molding involving a step of lofting the trim base (18).

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