EP3277485A1

EP3277485A1 - Method for the production of an insert for an opening panel of a motor vehicle

Info

Publication number: EP3277485A1
Application number: EP16730443.5A
Authority: EP
Inventors: David Tresse; Emilien HUMMER; Issam KHAYAT; Jean-François PRAT
Original assignee: Plastic Omnium SE
Current assignee: Plastic Omnium SE
Priority date: 2015-04-03
Filing date: 2016-04-01
Publication date: 2018-02-07
Also published as: US20180147756A1; FR3034337B1; MA41859A; FR3034337A1; WO2016156750A1

Abstract

According to the method, an elongate element (20) is formed from a composite material and a coil is formed by winding the elongate element (20) around a master model (24). The master model (24) provides the coil with the general shape of a continuous ring and with dimensions that allow the resulting coil to form an insert (2) equipped with at least two parts that are intended to extend through at least two separate opening panel zones to be reinforced.

Description

Method of manufacturing an insert of an opening of a motor vehicle

The present invention relates to a method of manufacturing a reinforcement insert of a motor vehicle opening.

It applies more particularly to the manufacture of inserts for rear windows of a motor vehicle, usually called hatches.

Most often, a motor vehicle tailgate is made of metal material such as steel. To reduce the weight of the opening, it is known to achieve in part composite material comprising at least one polymer, for example thermoplastic.

However, in an opening, some areas are more subject to mechanical stresses, for example the support areas of certain equipment of the opening, such as a lock, hinge means of the opening, means of anchoring means of assistance to the operation of the opening, etc.

In the case of an opening made in part of composite material, it is known to reinforce the areas subjected to greater mechanical stress by placing metal inserts in a mold intended to form the opening and injecting a material comprising at least one polymer in the mold, the inserts being positioned in the zones of the mold intended to form the areas to be reinforced

The invention aims to further reduce the weight of an opening, more particularly of an opening composite material, replacing the metal inserts by lighter reinforcement means having adequate mechanical properties and easy to manufacture.

For this purpose, the subject of the invention is a method for manufacturing an insert of an opening leaf of a motor vehicle, characterized in that an elongated element made of composite material is formed and a winding is formed by winding the element longiligne around a master-model, the model master imposing on the winding a general shape of continuous ring and dimensions allowing the resulting winding to form an insert provided with at least two parts intended to extend respectively through at least two separate zones to reinforce the opening.

According to the embodiments, the two parts of the insert are either two zones of the same insert in one piece, or two sections formed by cutting the same insert.

The insert, manufactured according to the process according to the invention, is made of composite material. It is therefore lighter than metal inserts. As it is essentially feasible by simple winding, it is compatible with the requirements of pace and manufacturing costs of the automotive industry. The simple and continuous winding of the elongate element of composite material on a master model avoids complex placements and / or pivoting of the elements constituting the insert. In addition, it makes it possible to simplify the removal of the elongate element with respect to a localized placement of directly deposited reinforcement elements directly on the panel. The proposed manufacturing process is therefore particularly simple to implement.

The term "continuous winding" means that the elongated element deposited is preferably in one piece throughout the winding. It will be noted that the elongated element can thus be wound by making several turns around the master model. If the winding is interrupted at the end of a turn, it will be best to start the winding of the next turn at a place other than the one where the previous turn was interrupted.

Therefore, it is not necessary to provide expensive equipment to achieve and control complex movements. The costs related to the manufacturing method according to the invention are therefore low.

By choosing a master model having an outline substantially coinciding with the desired path of the insert in the opening, it can be given to the insert all the forms necessary to adapt to the more or less complex usual shapes of the openings and the molds that can be used for their manufacture.

According to a particular embodiment, the elongate element is wound around the master model by rotating the master model with respect to means for applying the elongate element to the master model.

One can either rotate the master model on itself, the application means remaining fixed, or move the application means around a fixed master model, or both at once.

In the case where the application means remain fixed, one can rotate the master model on itself at a variable angle relative to the application means to facilitate removal.

This allows to apply the elongated element accurately and quickly, without involving complex means of placement of the elongated element.

According to a particular embodiment, the elongated element is formed by pultrusion through a shaping die of the section of the elongate element.

Pultrusion is a manufacturing process that makes it possible, in a simple and effective manner, to give a composite material an elongated shape.

Advantageously, the section of the elongate element which is wound on the master model is varied to create in the insert reinforcing parts alternating with connecting parts, the reinforcing parts being intended to extend across the reinforcement areas of the opening, the connecting portions being thinner than the reinforcing portions.

An elongated element of variable section may be provided for example by fiber ribbons impregnated with a matrix material at the time of their removal on the master model, the section variation being obtained by superposition and / or folding ribbons.

It will be appreciated that the elongated member will preferably be provided with a section to facilitate its removal from the master model, such as open sections, such as I, L or V shaped sections, having a suitable undercut.

Optionally, the fiber ribbons may be pre-impregnated before they are laid on the master model, a matrix addition being added if necessary during the laying of these ribbons on the master model.

According to a particular embodiment resulting from a compromise between lightness and mechanical strength of the insert, the composite material comprises a reinforcement material embedded in a matrix, for example a reinforcing material made of glass fibers or carbon embedded in a polyamide matrix.

According to a particular embodiment, the insert is cut to separate the two parts intended to extend through the two zones to be reinforced.

Preferably, the orientation of a surface delimiting the section of the elongate element around a neutral fiber of this elongate element is varied so that this surface is intended to extend through the zones to be reinforced by opening with different orientations. This variation of the orientation of the surface is performed during the winding of the elongate element on the master model.

This advantageously makes it possible to orient the surface according to the stresses to be undergone by the reinforcement.

According to a particular embodiment, the elongated element having a polygonal section, for example rectangular, the orientation of the faces of this elongate element is varied so that the faces are intended to extend through the zones to be strengthen the opening with different orientations.

The invention also relates to a method of manufacturing an opening leaf made of a composite material of a motor vehicle, this opening comprising a body molded on an insert, characterized in that

an insert made of composite material is formed by means of a method according to the invention;

the insert or parts of the insert are placed in a mold; and

- Distributing, preferably by injection, a material comprising at least one polymer in the mold to form the body overmolded on the insert. This method thus makes it possible to obtain an opening of a motor vehicle by overmolding the insert made by the manufacturing method according to the invention, which is a quick and inexpensive manufacturing technique, and therefore compatible with the requirements of cadence and speed. cost in the automotive industry.

More particularly, the method of manufacturing an opening of a motor vehicle according to the invention can be applied to the manufacture of a tailgate.

The invention also relates to an installation for manufacturing an insert of a motor vehicle door, characterized in that it comprises:

means for supplying an elongate element made of composite material; and

means for winding the elongated element around a master model, the model master having a shape and dimensions for imposing on the wound elongated element a general shape of continuous ring and dimensions allowing the elongated element wound to form an insert for extending through at least two separate zones to strengthen the opening.

This installation does not require expensive means and therefore reduces investment costs. It also allows rapid manufacturing.

It will be noted that the supply means may be either forming means or means for simply dispensing an elongated element made of composite material.

According to a particular embodiment, the winding means comprise means for applying the elongated element to the master model and means for driving the master model in rotation with respect to these application means. elongated element on the master model.

In a particular simple embodiment, the application means comprise a guide roller and application of the elongate member on the master model.

In a particular embodiment, the installation further comprises a robot intended to carry the master model, the drive means for rotating the master model being formed by a part of an arm of the robot.

The invention also relates to an installation for manufacturing an opening leaf of a motor vehicle, characterized in that it comprises an installation for manufacturing an insert according to the invention and:

a mold in which the insert is intended to be placed; and

material distribution means comprising at least one polymer in the mold, preferably injection means.

The invention also relates to an opening made of composite material of a motor vehicle, characterized in that it comprises an insert made of composite material comprising a reinforcement material embedded in a matrix, the insert having a general shape of continuous ring extending through at least two separate zones to reinforce the opening.

Advantageously, the opening comprising a bay, the insert surrounding the bay.

The invention finally relates to an opening of a motor vehicle according to the invention, this opening forming a tailgate of the vehicle and comprising at least two separate zones to be reinforced forming support means selected from:

locking means;

articulation means; and

means for anchoring assistance means to maneuver the tailgate. The invention will be better understood on reading the appended figures, which are provided by way of examples and are in no way limiting, in which:

- Figure 1 is a front view of a motor vehicle tailgate panel comprising a composite insert according to the invention;

- Figure 2 is a side view of the tailgate and the insert of Figure 1;

FIG. 3 is a diagrammatic front view of a part of an installation according to the invention;

FIG. 4 is a perspective view of a robot of the installation according to the invention;

FIG. 5 is a perspective view of a detail of a composite insert according to the invention;

- Figure 6 is a schematic front view of the molding means of the installation according to the invention.

FIGS. 1 and 2 show a panel 1 of an opening of a motor vehicle made of composite material. This panel 1 comprises an insert 2 extending into a body 4 of conventional material comprising at least one polymer. The body 4 is overmolded on the insert 2.

The opening is more particularly a tailgate for closing a rear bay of a motor vehicle body.

Note that the insert 2 is visible in Figures 1 and 2 although it is partially or completely embedded in the body 4.

The panel 1 of the tailgate comprises a lower side wall 61, a left lateral post 6G, a top wall 6S and a right side post 6D. These walls and elements delimit a bay 8 of the tailgate. The insert 2 extends through at least two separate zones to reinforce the panel 1. Indeed, the tailgate (and therefore the panel) comprises, in this example, five zones to strengthen each forming a support for a panel 1 of the tailgate equipment. This equipment, not shown for the sake of clarity, is more particularly:

locking means forming a lock for the tailgate of the motor vehicle,

means of articulation of the tailgate, in particular hinges, to ensure its pivoting relative to the body of the motor vehicle during its maneuver, and

means for anchoring assistance means to maneuver the tailgate, such as assistance cylinders for opening and / or closing the tailgate.

In FIG. 1, the arrow V indicates the position of the locking means, the arrows P the position of the articulation means for the pivoting of the tailgate, and the arrows at the position of the means for anchoring the assistance means to the Maneuver panel 1 of the tailgate.

Thus, in this example, there is an area to be reinforced 10 serving to support the lock of the panel 1 of the tailgate, which is located on a lower wall 61 of the tailgate 1 opposite the arrow V. More precisely, this area to be reinforced 10 is located halfway down the bottom wall 6 and at the outer edge 16 of the bottom wall 61.

There are also, in this example, two zones to be reinforced 12, each serving as a support for a hinge of the tailgate 1, which are located on the upper wall 6S of the tailgate 1 opposite the arrows P. More specifically, the zones to be reinforced 12 are located at two points of the upper wall 12 of the tailgate, symmetrically with respect to an axis of symmetry of the tailgate 1.

Finally, in this example, there are two separate zones to be reinforced 14 each serving as support for a means of anchoring means for assisting with the maneuvering of the tailgate 1, which are located respectively on the left pillar 6G and the right lateral pillar 6D next to arrows A.

It will be understood that the areas to be reinforced 10, 12 and 14 are areas that are to be strengthened to resist certain efforts related to the presence of the equipment mentioned above.

Note that the insert 2 has the general shape of a continuous ring extending through at least two separate zones to strengthen the tailgate. Preferably, the insert 2 extends through all the areas to be reinforced with locking 10, articulation 12 and anchoring 14.

The insert 2 is made of a composite material, more particularly a composite material comprising a reinforcement material embedded in a matrix. Preferably, the reinforcing material is composed of glass fibers or carbon, and the matrix is made of a polymeric material, preferably thermoplastic, such as polyamide.

The body 4 is preferably made of thermoplastic polymer material, both easy to form and lightweight, preferably by injection molding.

FIGS. 3 and 4 show parts of an example of an installation according to the invention for the manufacture of the insert 2.

The installation comprises supply means 18 for an elongated element 20 made of composite material and winding means 22 for this elongate element 20 on a master model 24 shown in FIG. 3, as well as a robot 25 shown in figure 4.

The supply means 18 are either means for forming the elongated element 20 or distribution means for this elongate element 20.

In the illustrated example, the supply means are pultrusion forming means.

For this purpose, they may comprise means 26 for continuously supplying a reinforcing material, in the form of a ribbon 28, such as glass or carbon fibers. The feed means 26 are not shown in detail because known per se.

The reinforcing material ribbon is then conveyed to impregnation means 30 of the ribbon 28 of a matrix, for example by passing through a bath filled with this matrix heated to its melting point. Preferably, this matrix comprises a thermoplastic polymer material, such as resin or polyamide.

The impregnated tape 28 is then moved by means known per se (not shown) through a die 32, the melting temperature of the matrix being maintained using conventional heating means not shown.

The die 32 makes it possible to shape the section of the elongate element 20.

In a variant not shown, the supply means 18 are means for dispensing a longiline element already formed, for example from a reel of pre-impregnated tape.

The winding means 22 comprise means 34 for applying the elongated element 20 to the master model 24 and means for driving in rotation 36 of the master model 24 with respect to the application means 34.

The master model 24 has a shape and dimensions intended to impose on the elongate element 20 wound a general shape of continuous ring and dimensions allowing the elongate element 20 wound to form the insert 2. The shape of the insert 2 is such that it extends through the body 4. The dimensions of the insert 2 are such that it extends through at least two zones to be reinforced, preferably through the five zones to strengthen the tailgate 1.

The application means 34 comprise a roller 38 for guiding and applying the elongated element 20 to the master model 24.

For this, the roller 38 guides the elongate element 20 out of the hot die 32 by placing it against the edge 40 of the master model 24, while pressing it lightly against this edge 40 to apply firmly to it.

The master model 24 has, as can be seen in Figure 3, an outline substantially coinciding with the desired path of the insert 2 in the tailgate 1, in other words to a general shape of continuous ring. Thus, the elongate element 20 applied on its edge 40 will have a similar shape.

It will be noted that, in the example described, the rotary drive means 36 are formed by a portion of the arm 42 of the robot 25 which carries the master-model 24.

The rotational drive means 36 are adapted to rotate the master model 24 so as to place any part of the wafer 40 opposite the roller 38, which is fixed, to continuously apply the elongated element 20 against the slice 40.

This rotational movement is represented by the arrow R in FIG.

The robot 25 is for example a six-axis robot usually used in the automotive industry, this type of robot generally comprising means capable of performing the rotational drive described above.

For example, a robot will be chosen for removal at a speed of about

1 meter per second. For an automobile tailgate, the perimeter of an insert will for example be between 1 and 7 meters, and will have for example a thickness of about 20mm. With ribbons having for example 0.2 mm thick, the tape will be deposited by making ten turns around the master model to obtain a thickness of about 20 mm. In another example, we will make three to five turns around the master model. Depending on the desired thickness, the winding time will for example be between 15 to 50 seconds.

In a variant not shown, the application means 34 rotate around a master model 24 fixed. In this case, it will be possible to rotate the master model 24 on itself at a variable angle relative to the application means 34 to facilitate the removal.

FIG. 5 shows a portion of the elongated element 20 once it has been applied to the master model 24.

During the application on the master model 24, the orientation of a surface delimiting the section of the elongate element 20 around a neutral fiber of this elongate element 20 has been varied so that this surface is intended to extend through the zones 10, 12, 14 to strengthen the opening with different orientations. In the example shown in this figure, the element 20 has a polygonal section, more particularly square.

Thus, during the application on the master model 24, the orientation of the faces of the elongated element 20 has been varied so that these faces are intended to extend through the zones to be reinforced. of the opening 1 with different orientations.

Thus, the face S intended to extend through the zone to be reinforced 14 has a different orientation of the face S12 intended to extend through the zone to be reinforced 12.

The orientation of the faces of the elongate element 20 varies, as can be seen in FIG. 5, during the winding of the elongate element on the master model, in particular during the path separating zones to be reinforced. As a result, the normal N at one of the surfaces of the elongate element (here its upper surface 10A) changes its direction, by pivoting about a neutral fiber of the elongated element 10, between the zone to be reinforced 14 and the area to be reinforced 12.

The installation also comprises overmolding means 44 of the body 4 around the insert 2 to form the tailgate 1.

These overmoulding means 44 comprise in particular a mold, in an impression 46 of which the insert 2 is intended to be placed. The molding means further comprise injection means 48 (shown schematically in Figure 6), in the mold, the material for forming the body 4 of the tailgate, namely, in this example, a thermoplastic polymer.

Note that it will be possible to use other means for dispensing the material intended to form the body 4 of the tailgate, for example overmolding means, where appropriate by compression. We can also directly assemble the insert 2 by gluing or screwing on the opening 1.

We will now describe the main steps related to the invention of the manufacturing process of the insert 2, this method being implemented by the installation described above.

Firstly, with the aid of the supply means 18 described above, an elongated element 20 made of composite material is formed, preferably by pultrusion through the die 32 for shaping the section of the element. slender 20.

In variants, for example to locally increase the section of the elongate element 20 at the zones to be reinforced, the section of this elongate element 20 is varied.

An elongated member 10 of variable section may be provided for example by fiber ribbons impregnated with a matrix material at the time of their installation on the master model 24, the section variation being obtained by superposition and / or folding ribbons. Optionally, the fiber ribbons may be pre-impregnated before they are laid on the master-model 24, a matrix addition being added, if necessary, during the laying of these ribbons on the master-model 24.

Those skilled in the art will be able to provide, according to the chosen embodiments, means of application 34 capable of heating and / or impregnating with resin, for example a polyamide resin, the elongated element 20, of cutting it, or of fold it.

This creates in the insert 2 alternating reinforcing portions with connecting portions, the connecting portions being thinner than the reinforcing portions. The reinforcing portions are intended to extend through the zones to be reinforced 10, 12, 14 of the tailgate.

Then, using the winding means 22 described above, a winding is formed by winding the elongate member 20 around the master model 24 which has the required shape.

For this, the model master 24 is carried by the arm 42 of the robot and this master model 24 is rotated relative to the roller 38 of the application means 34 by means of the rotational drive means 36 forming Part of the robot 25. The roller 38 thus guides the hot elongate element 20 against the edge 40 of the master model 24 by pressing it lightly against the edge 40 in order to firmly apply it to it.

During this step, the master model 24 imposes on the winding a general shape of continuous ring and dimensions allowing the resulting winding to form the insert 2 intended to extend through the areas to be reinforced 10, 12, 14 of the tailgate.

Finally, the elongate member 20 thus wound on the master model 22 is allowed to cool until it becomes rigid enough to be removed from the master model 24 and then placed in a mold.

In the embodiment shown in the figures, in order to manufacture the tailgate 1 made of composite material, the insert 2 thus obtained is placed in an impression 46 of the mold and dispensed, for example by means of injection means 48, the material comprising at least one polymer in the mold to form the body 4 overmolded on the insert 2.

The tailgate 1 is thus obtained in which the insert 2, in the general shape of a continuous ring, extends through all the zones to be reinforced of the tailgate 1.

As a variant, the material comprising at least one polymer in the mold may be overmolded, if necessary by compression, to form the body 4 overmoulded on the insert 2, or else the insert 2 may be directly assembled on the opening 1 by gluing. or screwing.

According to another embodiment not shown, after the cooling of the elongated element 20 thus wound on the master model 22, the insert 2 thus obtained is cut off so as to separate the parts intended to extend through at least two zones 10, 12, 14 to be reinforced. The parts of the insert 2 are then placed in the cavity 46 of the mold facing the zones to be reinforced, and the material comprising at least one polymer in the form of a polymer is dispensed, for example by means of injection means 48. mold for forming the body 4 overmolded on the insert 2.

As a variant, the material comprising at least one polymer in the mold may be overmoulded, if necessary by compression, to form the body 4 overmoulded on the insert 2, or the posts of the insert 2 may be directly assembled on the opening 1 by gluing or screwing next to the zones to be reinforced 10.

The invention is not limited to the embodiment shown and other embodiments will become apparent to those skilled in the art.

In particular, the method and the installation described can be used to manufacture motor vehicle openings other than tailgates, such as side doors.

Claims

1. Method for manufacturing an insert (2) of an opening (1) of a motor vehicle, characterized in that an elongated element (20) of composite material is formed and a winding is formed by winding the elongated element ( 20) around a master model (24), the model master (24) imposing on the winding a general shape of continuous ring and dimensions allowing the resulting winding to form an insert (2) provided with at least two parts intended to extend respectively through at least two zones (10, 12, 14) separated to reinforce the opening.

2. Method according to claim 1, wherein the elongated element is wound up.

(20) around the master model (24) by rotating the master model (24) relative to the application means (34) of the elongated member (20) on the master model (24).

3. Method according to claim 1 or 2, the elongate element (20) being formed by pultrusion through a die (32) shaping the section of the elongate element (22).

4. Method according to claim 1 or 2, wherein the section of the elongate element (20) is varied which is wound on the master model (24) to create in the insert (2) parts of alternating reinforcement with connecting parts, the reinforcing parts being intended to extend through the zones (10, 12, 14) to strengthen the opening, the connecting portions being thinner than the reinforcing portions.

5. A method according to any one of the preceding claims, wherein the composite material comprises a reinforcement material embedded in a matrix, for example a reinforcing material of glass fiber or carbon embedded in a polyamide matrix.

6. Method according to any one of the preceding claims, wherein the insert is cut (2) so as to separate the two parts intended to extend through the two zones (10, 12, 14) to be reinforced.

7. Method according to any one of the preceding claims, wherein the orientation of a surface delimiting the section of the elongate element (20) is varied around a neutral fiber of this elongate element (20) so as to that this surface is intended to extend through the zones (10, 12, 14) to reinforce the opening with different orientations.

8. The method of claim 7, wherein, the elongate member (20) having a polygonal section, for example rectangular, the orientation of the faces of this elongate element (20) is varied so that the faces are intended to extend through the zones (10, 12, 14) to reinforce the opening with different orientations.

9. Method of manufacturing an opening made of a composite material of a vehicle automobile, this opening comprising a body (4) overmolded on an insert (2), characterized in that

an insert (2) made of composite material is formed by means of a process according to any one of the preceding claims;

the insert (2) is placed in a mold (46); and

- It distributes, preferably by injection, a material comprising at least one polymer in the mold (46) to form the body (4) overmolded on the insert (2).

10. Manufacturing process according to claim 9, the opening (1) being a tailgate of the vehicle.

11. Installation for manufacturing an insert of a motor vehicle door, characterized in that it comprises:

supply means (18) for an elongate element (20) made of composite material; and

winding means (22) for the elongate element (20) around a master model (24), the master model (24) having a shape and dimensions for imposing on the elongate element (20) a generally continuous ring shape and dimensions that allow the elongate member (20) wound to form an insert (2) having at least two portions for extending through at least two zones (10, 12, 14) separated to strengthen the opening.

12. Installation for manufacturing an insert according to claim 11, the winding means (22) comprising means for applying (34) the elongate element (20) on the master model (24) and means driving (36) in rotation of the master model (24) with respect to these application means (34) of the elongated element (20) on the master model (24).

13. Installation for manufacturing an insert according to claim 12, wherein the application means (34) comprise a roller (38) for guiding and applying the elongate element (20) on the master model ( 24).

14. Installation for manufacturing an insert according to claim 12 or 13, further comprising a robot (25) for carrying the master model (24), the drive means (36) in rotation of the master model ( 24) being formed by a portion of an arm (42) of the robot.

15. Installation for manufacturing an opening of a motor vehicle, characterized in that it comprises an installation for manufacturing an insert (2) according to any one of claims 11 to 14 and:

a mold (46) in which the insert (2) is intended to be placed; and

- Material distribution means (48) comprising at least one polymer in the mold (46), preferably injection means.

16. Opening composite material of a motor vehicle, characterized in that it comprises an insert (2) of composite material comprising a reinforcement material embedded in a matrix, the insert (2) having a general shape of continuous ring s extending through at least two separate zones to be reinforced (10, 12, 14) of the opening.

17. Motor vehicle door according to claim 16, comprising a bay (8), the insert (2) surrounding the bay (8).

18. Opening of a motor vehicle according to claim 16 or 17, this opening (1) forming a tailgate of the vehicle and comprising at least two separate zones to reinforce (10, 12, 14) forming support means selected from:

locking means;

articulation means; and

means for anchoring assistance means to maneuver the tailgate (1).