DE102016116289A1 - Grid composite for air openings - Google Patents

Abstract

The invention relates to a grid composite (21) for a motor vehicle (10), which grid composite (21) has a grid (30) and a frame (23) for the grid (30). The grid (30) has a rim (31), and the frame (23) has a first portion (40) and a second portion (60) which together form a receptacle for the edge (31) of the grid (30). The first portion (40) is formed of a first plastic, and the second portion (60) of a second plastic, wherein the first plastic is harder than the second plastic. The invention also relates to a method for producing the lattice composite.

Description

The invention relates to a grid composite for an air opening, in particular in the bow part of a motor vehicle.

Due to legal requirements, an object with a given diameter must not be submerged in air openings in the front area (frontend). For thermal and optical reasons, however, these air openings must be made larger. In order to comply with the legal requirements, slats are inserted into the openings so that the object can no longer dip. Usually, a grid is used in the air opening.

Usually, the integration of a grid by a sandwich construction consisting of two frames and a grid. The front support frame forms the transition to the bow fairing and is bolted to the second, rear frame, which clamp the grid between them.

In the sandwich construction, the front holding frame is first latched or clipped into the bow lining. Thereafter, the metal grid and the rear support frame is inserted. Then the three components are fixed by mounting a few screws or U-clamps. This complex and time-consuming assembly is acceptable for small numbers of series. For larger quantities, this approach is uneconomical.

The DE 10 2004 020 085 A1 shows a method for producing a plastic-coated stamped grid, on which components are provided. This has is embedded in a housing.

The DE 10 2014 210 480 A1 shows a stamped with plastic punched grid made of metal. An adhesive material, eg an adhesive, can be applied to the stamped grid.

The DE 10 2007 022 385 A1 shows a hybrid manufacturing process in which first a sheet metal component and a plastic insert component are manufactured separately. A plastic component is then injected by means of two-component injection molding onto the plastic insert component,

The DE 43 21 969 A1 shows a synthetic resin framework of a grid part and a surrounding the grid part frame part, wherein the frame part is made in a sandwich construction.

The US 2002/0171169 A1 shows a method for producing a plastic layer on a metal plate.

The object of the invention is to develop a grid composite, which significantly reduces the assembly time, ideally with better component performance in terms of function and weight.

The object is achieved by a grid composite according to claim 1.

• 1. Geringere Einzelkosten durch Entfall von Befestigungselementen
• 2. Geringeres Gewicht durch Entfall von Befestigungselementen
• 3. Geringere Montagekosten durch Entfall von zusätzlichem Rahmen und Befestigungselementen
• 4. Geringere Logistik- und Lagerkosten durch Reduzierung auf ein Bauteil
• 5. Reduzierung der Fehlerquellen bei der Montage auf ein Minimum
• 6. Keine Knarren und Quietschen durch „gummigelagerten“ Festsitz des Gitters
• 7. Höheren Luftdurchsatz durch Entfall von Versteifungsmaßnahmen wie Stegen
• 8. Mögliche Reduzierung der Strömungsleckage durch Anliegen der Weichkomponente an Luftführung
• 9. Teilweise Integration der Luftführungsfunktion in die Weichkomponente
• 10. Keine Spannungen im Bauteilverbund (Wärmeausdehnung) durch „gummigelagerten“ Festsitz
• 11. Verdeckter Spritzaustrieb

Such a grid composite with a first section and a second section made of different plastics has clear advantages. In particular, the following advantages can result from the embodiment, wherein not all advantages must be given simultaneously:

• 1. Lower individual costs due to elimination of fasteners
• 2. Lower weight due to elimination of fasteners
• 3. Lower installation costs by eliminating additional frame and fasteners
• 4. Lower logistics and storage costs by reducing to one component
• 5. Reduce sources of error during assembly to a minimum
• 6. No creaking and squeaking through "rubber-mounted" tight fit of the grid
• 7. Higher air flow through elimination of stiffening measures such as bars
• 8. Possible reduction of the flow leakage due to contact of the soft component with the air duct
• 9. Partial integration of the air guide function into the soft component
• 10. No stresses in the component assembly (thermal expansion) due to "rubber-mounted" interference fit
• 11. Hidden spray ejection

In the past, attempts have been made to optimize the air flow by attaching a sealing profile or directly sprinkling a soft component on an air guide part with respect to leakage to the bow part. However, all these concepts had a decisive disadvantage: Due to the mounting tolerances, so much clearance had to be provided that the advantage over the currently used type of labyrinth seal was quickly consumed.

This disadvantage, the invention in which the softer component is on the grid composite, not. On the contrary - here, the sealing lip is pressed even with increasing airflow fixed to the air duct or to another element.

The object is also achieved by a method according to claim 15. In this case, the first section ( 40 ) optionally in the partial form ( 101 ) remain 101 = 109 ) and to the second partial form ( 110 ) (turntable tool), whereupon the grid ( 30 ) to the first section ( 40 ) is created.

The object is also achieved by a lattice composite, which is integrated by means of two-component injection molding technology in a visual component, wherein the first component is designed as a hard component and the second component as a soft component, which reduces the flow leakage by abutting the air duct.

The design of the grid composite as a single component is possible by a two-component tool. For this purpose, first a hard component, the actual holding frame, injected. Subsequently, the component is transferred to a second cavity. A metal grid is placed on the component. Thereafter, a second component, a soft component, is injected. The grid is firmly connected to the holding frame.

The invention will be described in more detail with reference to the drawing. Showing:

1 a front part of a motor vehicle with air inlet openings according to the prior art,

2 a front part of a motor vehicle with a grid composite according to the invention,

3 the lattice covenant of 2 without the bow part,

4 in a cross section along the section line IV-IV of 3 the grid network of 3 .

5 a production process for a lattice composite according to the invention,

6 a grid in installation position with adjoining air duct,

7 a lattice composite according to the invention in installation position with adjacent air duct,

8th the lattice composite according to the invention as a visible component, and

9 a production tool with a die pressing against the hard component.

1 shows a bow area (front area) 20 a motor vehicle, in particular a passenger car, according to the prior art.

It is a bow fairing 80 provided in the air inlets as an example of a central air intake grille 81 , two side air intake grilles 82 and an upper air intake grille 83 are provided.

The central air intake grille 81 has an example of a front support frame 81A , a metal grid 81B , a rear support frame 81C and as a fastener 18 U-brackets 81D ,

The side air intake grille 82 has a front support frame 82A , a metal grid 82B , a rear support frame 82C and as a fastener 10 U-brackets 82D ,

The upper air intake grille 83 has an upper support frame 83A , a metal grid 83B , a lower support frame 83C and as a fastener 23 screw 83D ,

The air intake grille 81 . 82 . 83 are thus realized by a sandwich construction, and the metal grid is in each case clamped between two holding frame. One of the frames, usually the front frame, is here with the bow fairing 80 connected. It is therefore not a composite.

This type of construction and installation is expensive.

2 shows the bow area 20 of a motor vehicle 10 with the bow fairing 80 and a grid composite according to the invention 21 ,

3 shows the grid connection 21 with a grid 30 and a frame 23 for the grid 30 in a schematic representation. The frame 23 preferably extends around the whole grid 30 but it can only be around part of the grid 30 be trained around.

4 shows a partial section through the grid composite 21 according to the section line IV-IV of 3 ,

The grid 30 has a border 31 ,

The grid 30 defines a grid area 32 which is between a first area 33 and one to the first area 33 opposite second area 34 is provided. The grid 30 and thus the grid area 32 may be flat or curved, depending on the contour of the bow fairing 80 ,

The frame 23 has a first section 40 and a second section 60 , which together a recording 24 for the edge 31 of the grid 30 form.

The first paragraph 40 is formed of a first plastic, and the second section 60 is formed of a second plastic. The first plastic is preferably harder than the first second plastic. Preferably, the first plastic is a hard component and the second plastic is a soft component. Preferably, the first plastic is a thermoplastic and the second plastic is a thermoplastic elastomer or elastomer.

The first plastic is for example a
PPE - polyphenylene ether
PA 6.12 - Poly (hexa-methylene-dodecane-diamide)

The second plastic is for example a
SBR - styrene-butadiene rubber
NBR - nitrile rubber

The first paragraph 40 and the second section 60 are in a connection area 70 connected with each other. In the preferred compound by means of multi-component injection molding the expert speaks of compound adhesion. This composite adhesion leads to a bond strength of the composite 40 . 60 and possibly 30 ,

The first paragraph 40 has a base area 41 , and the second section 60 has a base area 61 , The base areas 41 . 61 are juxtaposed, and the connection area 70 is between the base areas 41 . 61 intended. In other words, the first base area 41 and the second base area 42 in a connection area 70 Contact with each other.

The first base area is preferred 41 and the second base area 62 in the connection area 70 firmly connected to each other, particularly preferably by composite adhesion, as can be achieved in particular by multi-component injection molding. This may be the connection area 70 also in the area of the grid 30 extend by the soft component through a grid opening of the grid 30 through to the first base area 41 extends. This gives a particularly stable connection of the grid 30 in the first section 40 and the second section 60 formed recording.

The second base area 62 extends from the edge 31 of the grid 30 at a lateral area of the grid 30 along inside. This allows a good fit of the grid 30 as part of 23 and optionally a composite adhesion between the second base region 62 and the grid 30 ,

The second base area 62 is also on the outer edge of the edge 31 arranged. As a result, a good damping during movement of the grid 30 towards this area, since the second base area 62 is formed of a softer and preferably also elastic material.

The first section is preferred 40 and the second section 60 each formed of a plastic, wherein the first section 40 harder than the second section 60 ,

The first paragraph 40 and the second section 60 enclose the edge 31 of the grid 30 at least in certain areas.

The grid 30 allows air to flow through the grid 21 , The first area 33 is preferred as an inflow area 33 and the second area 34 provided as outflow area. Air can from the inflow area 33 over the grid 30 to the outflow area 34 flow like this with an arrow 25 is indicated.

The first paragraph 40 has a first lead 42 and a second projection 43 , which are each to the first area 33 extend. The second section 60 has a third lead 62 which deals with the second 34 extends.

The projections 42 . 43 and 62 may also be referred to as lips, and they preferably run around the entire grid 30 around, but at least partially around it.

The first advantage 42 preferably serves as air duct. It tapers in cross section preferably with increasing distance from the grid 30 to reduce weight.

The second projection 43 is outside the first projection 42 arranged and used for mounting the grid composite 21 on the motor vehicle 10 from 2 , In this case, it is advantageous for the structural stability that the first section 40 harder than the second section 60 ,

The first advantage 42 and the second projection 43 have in common a U-shaped profile in cross-section, and this ensures good stability of the first section 40 ,

The third projection allows air guidance in the second area 34 of the grid 30 , Preferably, the third projection tapers 62 in cross-section with increasing distance from the grid 30 , and thereby a deformability of the third projection 62 elevated.

The grid 30 is preferably formed as a metal grid. This allows a high stability of the grid composite 21 ,

5 shows a method for producing the lattice composite 21 ,

Left (A) is a first injection mold 101 with a first part form (matrix) 105 and a second Part form (core) 106 which together form a first cavity (cavity to be filled) 107 form.

With the first injection mold 101 becomes the first section 40 produced as a component made of a harder plastic (hard component) (B).

Subsequently, a second injection mold 102 with a third part form (matrix) 109 and a fourth partial form (core) 110 uses a second cavity (cavity to fill in) 111 form.

The injection molds 101 and 102 they can be the same. In this case, the component remains in the die (turntable tool).

The first paragraph 40 becomes the third part form 109 inserted (C), and the grid 30 gets to the first section 40 created (D).

Subsequently (E) becomes the fourth part form 110 to the first section 40 and preferably also to the grid 30 created, and in the fourth partial form 110 existing second cavity 111 is filled with a softer plastic (soft component), leaving the first section 40 and the second section 60 form a composite, wherein composite adhesion (bond adhesion) between the first section 40 and the second section 60 arises, which these sections 40 . 60 holds together. This is called a plastic-plastic composite. An additional bond between the first plastic and the grid 30 and / or in particular between the second plastic and the grid 30 is possible. A floating storage of the grid 30 as part of 23 is advantageous, in particular for the damping of movements of the grid.

This is the frame 23 produced in a two-component injection molding process. Of course, a multi-component injection molding process with more than two components is also possible. The finished lattice composite can also be referred to as an integrated molding to distinguish it from a component in sandwich construction.

The grid composite 21 allows the supply of air in the inner region of the motor vehicle. For this purpose, the grid composite acts 21 preferably in the interior of the motor vehicle with an air duct 120 together, so for example a wall.

For efficient cooling and to avoid noise, it is advantageous if the interaction of lattice composite 21 and airflow 120 works well and little leakage occurs.

6 shows various methods for sealing between the grid composite 21 and the air duct 120 ,

In the left illustration has the air duct 120 at her the lattice composite 21 facing the end of a sealing lip 122 ,

In the middle illustration has the air duct 120 at her the lattice composite 21 facing end a piping 124 ,

In the right-hand illustration, the lattice composite has a projection 126 made of a hard component that is responsible for airflow 120 extends.

The methods with the sealing lip 122 and the piping 124 have the disadvantage that due to the assembly tolerances to be considered a large clearance between the air duct 120 and the grid composite 21 must be provided. Therefore, these methods do not have a great positive effect, but on the other hand, they are expensive to produce. The method with the labyrinth 126 (in cooperation with the air duct 120 ) works and is relatively easy to assemble.

7 shows a preferred possibility for sealing between the grid composite 21 and the air duct 120 , The grid composite 21 has the second section accordingly 4 which is softer than the first section 40 , preferably from a soft component.

In the left picture, little air flows through the grid 30 , what with few arrows 25 is hinted at, and the second section 60 has largely its basic form.

In the right picture, however, a lot of air flows through the grid 30 For example, at a high speed of the motor vehicle, and this is by many arrows 25 indicated. The leakage air flow 130 grows with increasing speed, and thereby deforms the relatively soft second section 60 to the air duct 120 and seals it off additionally. It is believed that the law of Bernoulli, according to which a higher flow rate is associated with a pressure reduction, this is responsible.

The deformation leads with increasing speed to an increasing seal between the air duct 120 and the second section 60 , It is advantageous that the second section 60 (Deformation) is softer than the first section 40 (Assembly).

8th shows what a viewer is 142 in an arrangement of the grid composite 21 with the grid 30 and the frame 23 sees in the field of vision.

Because the first section 40 produced in a first step, the edges etc. can with Good quality and produced without larger burrs. The second section 60 is on the inside of the grid compound 21 arranged and therefore not immediately visible. In addition, the second section 60 slightly outward from the first section (relative to the grid 30 ), so that the area 140 is not visible. In other words, the first section extends 40 relative to the grid 30 further inward than the second section 60 ,

The embodiment of the grid composite 21 allows the grid composite 21 directly as a visual component in the motor vehicle 10 use.

A production of the lattice composite 21 in the 1K injection molding process would be in the area of the grid 30 produce a Materialaustrieb or wide ridge, as a good seal in the grid 30 poorly possible by the injection mold. Such budding disturbs visually. Therefore, it would be a grid group produced in this way 21 not suitable for a visual component.

9 shows an embodiment for the production of the grid composite 21 corresponding 5 , Steps.

It can be seen that the fourth part form 110 both against the first section 40 as well as against the grid 30 is present, with part of the grid 30 protrudes into the cavity. This allows the plastic for the second section both with the first section 40 as well as with the grid 30 form a composite. It is also seen that the area 140 (see. 8th ) farther out on the grid 30 lies as the first section 40 so that the area where the second section 60 is injected, relative to the grid 30 further out. This determines the first section 40 the visual impression when viewed from the outside, and it is a shapely lattice composite 21 achievable.

In other words, the grid is integrated into a viewing component by means of two-component injection molding technology, wherein the second component is designed as a soft component, which significantly reduces the flow leakage by abutting the air guide.

Due to the two-component injection molding technology, it is possible to lay the material outlet in a non-visible area. This is achieved by pressing in the second cavity of the core against the inserted article, the hard component, and thus assumes the sealing function.

Naturally, many modifications and modifications are possible within the scope of the invention.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102004020085 A1 [0005]
• DE 102014210480 A1 [0006]
• DE 102007022385 A1 [0007]
• DE 4321969 A1 [0008]
• US 2002/0171169 A1 [0009]

Claims (15)

Grid composite for an air opening of a motor vehicle ( 10 ), which is a grid ( 30 ) and a frame ( 23 ) for the grid ( 30 ), which grid ( 30 ) a border ( 31 ) and a grid surface ( 32 ) defined between a first area ( 33 ) and one to the first area ( 33 ) opposite the second area ( 34 ), which frame ( 23 ) a first section ( 40 ) and a second section ( 60 ), which together form a receptacle for the edge ( 31 ) of the grid ( 30 ), which first section ( 40 ) is formed from a first plastic and which second section ( 60 ) is formed of a second plastic, wherein the first plastic is harder than the second plastic, which first section ( 40 ) a first base area ( 41 ) and which second section ( 60 ) a second base area ( 61 ), which first base area ( 41 ) and which second base area ( 42 ) in a connection area ( 70 ) Are in contact with each other, the first base region ( 41 ) and the second base area ( 62 ) in the connection area ( 70 ) are firmly connected. A lattice composite according to claim 1, wherein the first base region ( 41 ) and the second base area ( 62 ) in the connection area ( 70 ) are firmly connected to each other by an injection molding connection. A lattice composite according to claim 1 or 2, wherein the first base region ( 41 ) and the second base area ( 62 ) in the connection area ( 70 ) are firmly connected together by composite adhesion.  A grid assembly according to any one of the preceding claims, wherein the grid comprises a metallic material. A grid composite according to any one of the preceding claims, wherein the first section ( 40 ) relative to the grid ( 30 ) extends further inward than the second section ( 60 ). A lattice composite according to any one of the preceding claims, wherein the second base region ( 62 ) from the edge ( 31 ) of the grid ( 30 ) at a lateral area of the grid ( 30 ) extends inwards. A lattice composite according to any one of the preceding claims, wherein the second base region ( 62 ) at least partially on the outer edge of the edge ( 31 ) is arranged. A lattice composite according to any one of the preceding claims, wherein the first section ( 41 ) a first lead ( 42 ), which extends into the first area ( 33 ) extends to allow an air duct there. A lattice composite according to claim 8, wherein the first projection ( 42 ) in cross-section with increasing distance from the grid ( 30 ) rejuvenated. A lattice composite according to claim 8 or 9, in which the first section ( 41 ) a second projection ( 43 ), which extends into the first area ( 33 ) and outside the first projection ( 42 ) is arranged to a mounting of the grid composite ( 21 ) on a motor vehicle ( 10 ). A lattice composite according to claim 10, wherein the first projection ( 42 ) and the second projection ( 43 ) in cross-section together have a U-shaped profile. A lattice composite according to any one of the preceding claims, wherein the second section ( 60 ) a third projection ( 62 ) which extends into the second area ( 34 ) extends to allow an air duct there. A lattice composite according to claim 12, wherein the third projection ( 62 ) in cross-section with increasing distance from the grid ( 30 ) is tapered to a deformability of the third projection ( 62 ) increase. Motor vehicle with a grid composite ( 21 ) according to one of the preceding claims, in which the grid composite is installed as a visible component. Process for producing a lattice composite, which lattice composite a lattice ( 30 ) and a frame ( 23 ) for the grid ( 30 ), which grid ( 30 ) a border ( 31 ), which frame ( 23 ) a first section ( 40 ) and a second section ( 60 ), which together form a receptacle for the edge ( 31 ) of the grid ( 30 ), which first section ( 40 ) is formed from a first plastic and which second section ( 60 ) is formed of a second plastic, wherein the first plastic is harder than the second plastic, which method comprises the following steps: A) the first section ( 40 ) is produced by means of plastic injection molding B) The first section ( 40 ) is converted into a first partial form ( 109 ), and the grid ( 30 ) is sent to the first section ( 40 ) C) A second partial form ( 110 ) is relative to the first part ( 109 ) are positioned so that they both contact to the grid ( 30 ) as well as the first section ( 40 ) and together with these a cavity ( 111 ) D) The second section ( 60 ) is in the cavity ( 111 ) produced by plastic injection molding.

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