DE102016000726B4 - Composite element for a vehicle - Google Patents

Abstract

Composite element (10) for a vehicle, with cover layers (14, 16) made of fiber-reinforced plastic and with a between the cover layers (14, 16) arranged and with the cover layers (14, 16) connected core layer (18) made of a plastic foam, characterized in that a first of the cover layers (14, 16) is in the form of non-laminated cover layer (14) as side (24) facing away from the core layer (18) and comprises natural fibers as reinforcing fibers, the second cover layer (16) being formed on one of the core layer (18 ) facing away from side (26) by means of at least one decor (28) of the composite element (10) is laminated and of natural fibers having different reinforcing fibers.

Description

The invention relates to a composite element for a vehicle, according to the preamble of claim 1.

Such a composite element, in particular for a vehicle, for example, is already the WO 2015/090574 A1 to be known as known. The composite element comprises cover layers, which are each formed from a fiber-reinforced plastic. Furthermore, the composite element comprises a core layer of a plastic foam arranged between the cover layers and connected to the cover layers, wherein a sandwich composite or a sandwich composite system is formed by the core layer and the cover layers, for example. The composite element can be a ready-made composite component or sandwich component or else a semi-finished product which can be further processed, for example.

The DE 101 09 709 A1 discloses a sidewall for trucks, with at least one built-in support rail, wherein the side wall is formed as a sandwich composite and consists of a middle layer of foam plastic and these outer enclosing cover layers. Further, the DE 10 2004 053 871 A1 a sandwich material comprising a middle layer and two cover layers, between which the middle layer is arranged.

Moreover, from the DE 198 32 721 A1 a layered composite for stabilizing a core component of molded articles, the layers of the composite consisting of a thermoplastic layer and a fabric containing natural fibers and a longitudinally and transversely stretchable cover layer.

The EP 0 855 974 B1 shows a motor vehicle interior lining with layers containing natural fibers. The fibers are exposed at the edges of the trim panel and are touched by fitters or even by users of the vehicle. The handling of the glass fiber can cause skin irritation, and thus it is desirable to minimize the contact between the glass fibers and users. By dispensing with glass fibers and using natural materials such as hemp or sisal, skin irritation is less pronounced than with glass fibers.

Object of the present invention is to develop a composite element of the type mentioned so that the composite element can be processed in a particularly advantageous manner while achieving particularly advantageous mechanical properties of the composite element.

This object is achieved by a composite element with the features of claim 1. Advantageous embodiments with expedient developments of the invention are specified in the remaining claims.

In order to develop a composite element for a vehicle specified in the preamble of claim 1 type such that the composite element processed in a particularly advantageous manner, in particular mounted, can be at the same time implementing particularly advantageous mechanical properties of the composite element, it is provided according to the invention that a first of the Cover layers as on one side facing away from the core layer uncoated cover layer is formed and having natural fibers as reinforcing fibers. The first cover layer is thus not laminated on the side facing away from the core layer. This means that the first cover layer on the side facing away from the core layer is not provided with a decoration, an additional layer or another layer and thus is not covered or covered on the side facing away from the core layer.

Furthermore, it is provided according to the invention that the second cover layer is laminated on one side facing away from the core layer and thus the first cover layer by means of at least one decoration of the composite element and has different reinforcing fibers of natural fibers. This means that the second cover layer is formed in contrast to the first cover layer as a laminated cover layer and thus on the side facing away from the core layer is provided with a decor, so that the second cover layer is covered on the side facing away from the core layer with the decor. The decor is also referred to as decorative or decorative element and conceals the second cover layer.

In the context of the above-described processing of the composite element, for example, it is processed, in particular reshaped, and / or assembled. As part of the assembly, the composite element is connected, for example, with at least one other component of the vehicle and / or mounted on the vehicle. For example, a person performs the processing, particularly the assembly, of the composite element so that the person handles the composite element, for example. In this case, it may happen that the person comes into contact with the composite element. However, since the first cover layer is indeed unlaminated, but has natural fibers as reinforcing fibers, can be caused by the first cover layer caused skin irritation and Itching be avoided in the person when human skin or the person comes into contact with the composite element, in particular the first cover layer. As a result, the composite element can be processed in a particularly simple and uncomplicated manner.

The idea underlying the invention is that usually composite elements are used in particular in the form of pressed trim parts in vehicles, wherein such trim parts are used in particular as interior trim parts and are installed in the interior of vehicles. The pressed trim parts are often made from hybrid thermoplastic nonwovens. These denote a combination of reinforcing and plastic fibers, which form a composite material by confused arrangement, in particular natural or glass fibers are used as reinforcing component. While natural fiber systems are characterized by easy handling in production, use and disposal and have a favorable fracture behavior, glass fiber reinforced systems have better mechanical properties in terms of compression and flexural strength, strength, and heat and dimensional stability. A disadvantage of corresponding fiber optic systems, however, is a difficult handling. In particular, the high fiber fineness of glass fibers in conjunction with their rigidity in direct contact with the human body lead to irritating microcuts in the skin.

Accordingly, when using glass-reinforced systems, it is usually necessary to use an additional layer for encapsulating unlaminated surfaces, which entails additional costs. This encapsulation is usually carried out by a polyester nonwoven which is intended to prevent human skin from coming into direct contact with the glass fiber system.

The composite element according to the invention has a structure which combines the advantages of natural fiber reinforced systems and systems reinforced by fibers other than natural fibers. In this case, the composite element is designed, for example, as a multi-layer composite or as a sandwich composite and therefore has, for example, a sandwich composite, which may be formed by the core layer and the cover layers. Furthermore, the decor is used as decorative goods. In the composite element according to the invention, a lamination of the first cover layer can be avoided since, for example, skin irritation and itching caused by glass fibers can not occur. Furthermore, it is possible to use different from natural fibers reinforcing fibers of the second cover layer, thereby realizing particularly advantageous mechanical properties of the composite element.

The composite element according to the invention thus has an asymmetrical or asymmetrical structure, which allows a simple processing of the composite element. Furthermore, the structure allows the realization of a particularly low weight. In particular, a lower weight than in a pure sandwich fiberglass system can be realized, since an encapsulating layer to avoid itching and skin irritation can be omitted. Furthermore, the cost of the composite element, especially in comparison to pure sandwich fiberglass systems, can be kept particularly low. In addition, particularly advantageous pressure and bending properties can be realized as in a pure natural fiber system, in particular sandwich natural fiber system. Furthermore, a higher heat resistance than in a pure natural fiber system, in particular sandwich natural fiber system can be represented.

In an advantageous embodiment of the invention, all the reinforcing fibers of the first cover layer are formed as natural fibers. As a result, a particularly simple and thus time-consuming and cost-effective processing of the composite element can be realized, since even with direct contact of human skin with the composite element, in particular with the first cover layer, there is no itching and skin irritation. As a result, complex protective measures can be avoided.

Another embodiment is characterized in that the first cover layer has at least one natural fiber-reinforced nonwoven. As a result, particularly advantageous mechanical properties of the composite element can be realized.

To realize particularly advantageous mechanical properties, it is provided in a further embodiment of the invention that the reinforcing fibers of the wide cover layer are formed as carbon, basalt or glass fibers. In other words, the second cover layer comprises, for example, glass fibers as reinforcing fibers. Alternatively or additionally, the second cover layer may comprise further, different from glass fibers reinforcing fibers such as carbon fiber, aramid fibers, etc.

A further embodiment is characterized in that the decor comprises at least one plastic film of thermoplastic polyolefins (TPO), but especially of polyvinyl chloride (PVC). As a result, the second cover layer can be laminated in a particularly simple manner and in terms of weight and cost. By means of the decoration, the second cover layer can be laminated particularly well, so that direct contact of human skin with the second cover layer can be avoided particularly well.

In a further advantageous embodiment of the invention, the first cover layer and / or the second cover layer on a thermoplastic resin matrix, in which the respective reinforcing fibers are embedded. As a result, particularly advantageous mechanical properties of the composite element can be realized. Furthermore, the composite element can be processed particularly well.

It has been found to be particularly advantageous if the thermoplastic polymer matrix is formed from polypropylene (PP). As a result, particularly advantageous mechanical properties can be realized.

Another embodiment is characterized in that a foam element is arranged between the decor and the second cover layer. The foam element acts, for example, as a foam backing and enables the realization of particularly advantageous properties of the composite element, since, for example, by using the foam element, a particularly advantageous haptic of the composite element can be realized. The foam element allows, for example, the representation of a pressure softness to create a high-quality haptic appearance.

By decor, for example, in the installed position facing the interior of the vehicle and persisting in the interior of the vehicle people optically and haptically perceptible surface or side of the composite element is formed, said surface or side is also referred to as the visible side. Through the use of the foam element, the visible side of a person touching the visible side can be pressed something, creating a particularly good haptic value impression is created. The foam backing allows an increase in the area moment of inertia and thus a further increase in the flexural rigidity. The composite element takes its installation position in finished manufactured state of the vehicle.

To realize particularly advantageous properties of the composite element, it is provided in a further embodiment of the invention that the plastic foam is formed from a thermoplastic.

It has been found to be particularly advantageous if the plastic foam is formed as polyethylene terephthalate (PET). As a result, particularly advantageous properties of the composite element can be created.

The invention also includes a method for producing a composite element according to the invention. Advantages and advantageous embodiments of the composite element according to the invention are to be regarded as advantages and advantageous embodiments of the method according to the invention.

The composite element is, for example, a finished composite component or sandwich component which, for example, is processed, in particular assembled, within the scope of a production of the vehicle. Alternatively, it is conceivable that the composite element is a semi-finished product, which, for example, further processed, in particular formed, can be.

The composite element is, for example, a trim part, in particular an interior trim part, wherein, for example, a structure, in particular the body, of the vehicle by means of the trim part to the interior of the vehicle is at least partially disguised. In particular, the composite element may be formed as a hat rack, a map pocket, a back panel or a door base support. The said back panel is also referred to as a backrest clamping part, wherein such a backrest clamping part is used for the back-side dressing of backrests and seat systems, in particular vehicle seats. Such a backrest clamping part is also referred to as a backrest facing.

Further advantages, features and details of the invention will become apparent from the following description of a preferred embodiment and from the drawing. The features and feature combinations mentioned above in the description as well as the features and feature combinations mentioned below in the figure description and / or alone in the single figure can be used not only in the respectively indicated combination but also in other combinations or alone, without the frame to leave the invention.

The drawing shows in the single FIGURE is a schematic sectional view of a composite element for a vehicle, with cover layers of fiber reinforced plastic and with a disposed between the cover layers and the outer layers core layer of a plastic foam, wherein a first of the cover layers facing away from on one of the core layer Unclad cover layer is formed and has natural fibers as reinforcing fibers, and wherein the second cover layer is laminated on a side facing away from the core layer by means of at least one decor of the composite element and of natural fibers has different reinforcing fibers.

The single FIGURE shows a schematic sectional view of a designated as a whole with 10 composite element for a vehicle, in particular a motor vehicle such as a passenger car. The composite element is for example a finished manufactured component or a semi-finished product, which can be further processed and thereby, for example, formed. For example, the composite element 10 formed as a trim part, so that, for example, a structure, in particular the body of the vehicle to the interior of the vehicle towards at least partially by means of the trim part is to dress.

The composite element 10 in the present case has a sandwich composite 12 trained multilayer composite, wherein the sandwich composite 12 Also referred to as sandwich construction. Thus, the composite element 10 designed as a sandwich or sandwich component.

The sandwich composite 12 includes a first cover layer 14 and a second cover layer 16 , Furthermore, the sandwich composite comprises 12 one between the cover layers 14 and 16 arranged core layer 18 which is formed of a plastic foam. In the present case, the plastic foam is formed from a thermoplastic, in particular from PET, so that the core layer 18 is designed as a PET core. The cover layer 14 is on one of the topcoat 16 opposite side 20 the core layer 18 arranged, with the cover layer 16 on one of the topcoat 14 and thus the page 20 opposite side 22 the core layer 18 is arranged. In the present case are the outer layers 14 and 16 with the core layer 18 connected. In particular, it is provided in the present case that the cover layers 14 and 16 each the core layer 18 directly contact or touch.

The respective cover layer 14 respectively 16 is - as will be explained in more detail below - made of a fiber-reinforced plastic. Here, the respective cover layer comprises 14 respectively 16 a plastic matrix and reinforcing fibers embedded in the plastic matrix.

For increased bonding between the cover and core layers it is possible to use an adhesive layer e.g. on thermoplastic basis (PP film).

An alternative to the bonding of the outer layers to the core layer is possible by needling the individual layers together. Here, the fibers of the cover layers are guided through the core layer and connected to this.

In order now to a particularly advantageous processing, in particular assembly, of the composite element 10 realize and at the same time particularly advantageous mechanical properties of the composite element 10 Being able to represent is the first cover layer 14 as one on one of the core layer 18 opposite side 24 the topcoat 14 unclad cover layer formed. This means that the first cover layer 14 on the core layer 18 and thus the page 22 and the topcoat 16 opposite side 24 not laminated, that is not covered or covered with another layer. Further, the reinforcing fibers of the cover layer 14 formed as natural fibers. In particular, it is provided that all reinforcing fibers cover layer 14 are formed as natural fibers.

In contrast to the first cover layer 14 is the second cover layer 16 formed as a laminated cover layer. In other words, the second cover layer 16 on one of the core layer 18 and thus the page 20 and the topcoat 14 opposite side 26 by means of at least one decoration 28 of the composite element 10 , in particular the sandwich composite 12 , laminated. Furthermore, it is provided that at least a part of the reinforcing fibers of the cover layer 16 are formed as different from the natural fibers reinforcing fibers. In particular, all reinforcing fibers, in particular all fibers, are the cover layer 16 formed as fibers different from natural fibers. For example, the reinforcing fibers of the cover layer 16 designed as eg glass fibers, carbon fibers or basalt fibers.

The sandwich composite 12 thus has a structure which combines the respective advantages of natural fiber and glass fiber reinforced systems. For example, the respective fibers or reinforcing fibers of the outer layers form 14 and 16 at least one fleece, so that the respective cover layer 14 respectively 16 has at least one fleece. As the reinforcing fibers of the cover layer 14 are formed as natural fibers, the cover layer comprises 14 for example, at least one natural fleece. As the reinforcing fibers of the cover layer 16 for example, are formed as glass fibers, the cover layer comprises 16 at least one glass fiber fleece. Thus, the cover layer comprises 14 For example, at least one natural fiber-reinforced nonwoven fabric, wherein the cover layer 16 For example, has at least one glass fiber reinforced nonwoven fabric. Thus, the structure of the sandwich composite connects 12 the particular advantages of natural fiber and glass fiber reinforced nonwovens. This construction includes the unlaminated cover layer 14 , which is not provided with a decor or an additional layer. Furthermore, the structure comprises the core layer 18 as core material as well as the laminated cover layer 16 which with the decor 28 is provided. In addition, the structure includes the decor 28 , An additional layer for encapsulating glass fibers is with respect to the cover layer 14 not provided and not required because the top layer 14 has no glass fibers.

For example, skin irritation and itching on contact of the non-laminated side 24 of the composite element 10 To avoid being on the the decor 28 opposite side 20 the natural fiber reinforced cover layer 14 used, which has, for example, at least one natural fiber-reinforced nonwoven. Natural fibers have the advantage over glass fibers that they do not lead to microsections in the skin surface due to their lower fiber fineness. In order to realize advantageous properties such as heat resistance, compressive rigidity and compressive strength as well as an advantageous flexural rigidity, is on the decor 28 facing, laminated side 22 the glass fiber reinforced cover layer 16 used, which has, for example, at least one glass fiber reinforced nonwoven. This prevents the decor 28 a contact of the glass fibers with the human skin. An increased in comparison to natural fiber-reinforced nonwovens compressive strength and compressive strength is mainly due to a two-dimensional application of force and thus lower stress concentration in the underlying arranged and designed as a foam core core layer 18 ,

Because the cover layers 14 and 16 Have different reinforcing fibers, an asymmetric structure is realized, which leads to a significantly increased bending stiffness compared to sandwich structures with natural fiber reinforced cover layers, since the inherent stiffness of the glass fibers compared to natural fibers is much higher. The use of glass fibers leads due to the constant material properties under different climatic conditions (temperature and humidity) to a significant stabilization of dimensional stability at elevated temperature and humidity.

Usually in sandwich composite systems an asymmetrical structure is usually avoided, as this can lead to a delay of the component, for example. Such a distortion occurs, for example, due to different thermal expansion coefficients and stiffnesses of the cover layer materials. The maximum benefit of component stiffness can not be exploited due to the eccentric neutral fiber. Taking into account the inherent rigidity of the decorative material, the component stiffness can be optimized. Due to the solid connection to the asymmetrical sandwich structure (sandwich composite 12 ) also carries the decor 28 for flexural rigidity of the composite element 10 at, causing the eccentric neutral fiber of the outer layers 14 and 16 at least partially compensated. By using the sandwich construction, for example, parcel shelves, map pockets, back panels, headliner and door base support can be produced inexpensively.

In order to give the composite element or the sandwich construction an advantageous pressure softness for a favorable haptic value appearance, an optional is between the decoration 28 and the topcoat 16 arranged foam element 30 arranged, through which one under the decor 28 lying foam backing is formed. As a decor 28 For example, plastic films or textile fabrics can be used. The foam backing allows an increase in the area moment of inertia and thus a further increase in the bending stiffness.

Claims (10)

Composite element (10) for a vehicle, with cover layers (14, 16) made of fiber-reinforced plastic and with a between the cover layers (14, 16) arranged and with the cover layers (14, 16) connected core layer (18) made of a plastic foam, characterized in that a first of the cover layers (14, 16) is in the form of non-laminated cover layer (14) as side (24) facing away from the core layer (18) and comprises natural fibers as reinforcing fibers, the second cover layer (16) being formed on one of the core layer (18 ) facing away from side (26) by means of at least one decor (28) of the composite element (10) is laminated and of natural fibers having different reinforcing fibers. Composite element (10) after Claim 1 , characterized in that all the reinforcing fibers of the first cover layer (14) are formed as natural fibers. Composite element (10) after Claim 1 or 2 , characterized in that the first cover layer (14) comprises at least one natural fiber reinforced nonwoven. Composite element (10) according to one of the preceding claims, characterized in that the reinforcing fibers of the second cover layer (16) are formed as carbon, basalt or glass fibers. Composite element (10) according to one of the preceding claims, characterized in that the decor (28) comprises at least one plastic film or textile layer, in particular of polyvinyl chloride. Composite element (10) according to one of the preceding claims, characterized in that the first cover layer (14) and / or the second cover layer (16) comprises a thermoplastic resin matrix in which the respective reinforcing fibers are embedded. Composite element (10) after Claim 6 , characterized in that the thermoplastic resin matrix is formed from polypropylene. Composite element (10) according to one of the preceding claims, characterized in that a foam element (30) is arranged between the decor (28) and the second cover layer (16). Composite element (10) according to one of the preceding claims, characterized in that the plastic foam is formed from a thermoplastic. Composite element (10) according to one of the preceding claims, characterized in that the plastic foam is formed from polyethylene terephthalate.

Images