EP4060280B1 - Protected component, protected vehicle and method - Google Patents

Description

The present invention relates to a protected component, in particular a hatch cover, a protected vehicle with such a protected component and a method for producing such a protected component.

Various hatch covers, flaps or doors are installed on protected vehicles, which must fulfill the protective functions required for the vehicle. According to internal company knowledge, a protective structure can be used for this purpose, which, in addition to the hatch cover, which is preferably made of metallic protective materials, has additional screwed-on armor and, if necessary, an adhesive or screwed-on splinter guard on the inside. The high weight of such a protective structure not only affects the overall weight of the vehicle, but also impairs the ergonomic properties of such a hatch cover, as considerable operating forces are required when opening or closing it.

Furthermore, various manufacturing processes, such as welding, gluing and/or screwing, must be used to manufacture such a hatch cover, which entails increased costs and time. Spring-assisted or driven opening and closing mechanisms can be used to reduce the operating forces. However, such opening and closing mechanisms lead to increased weight and increased costs. In order to simplify production, a one-piece design of the hatch cover made of metallic protective materials is also possible, but this also leads to a high weight. This needs to be improved.

The US 4 716 810 A describes a protective arrangement in which protective plates are arranged within an enclosure filled with a plastic material. Spacers are provided between the protective plates. The spacers can be screwed to a wall of a vehicle using fastening elements.

Against this background, an object of the present invention is to provide an improved protected component.

Accordingly, a protected component, in particular a hatch cover, is proposed. The protected component comprises an outer cover layer, an inner splinter protection layer, a plurality of spacers arranged between the cover layer and the splinter protection layer in order to keep the cover layer spaced apart from the splinter protection layer so that an intermediate space is provided between the cover layer and the splinter protection layer, a casting compound which fills the intermediate space, and an intermediate layer arranged between the cover layer and the splinter protection layer in the intermediate space, wherein the casting compound connects the cover layer, the splinter protection layer, the spacers and the intermediate layer to one another, wherein the spacers are positively connected to the intermediate layer, wherein the spacers have a contact surface on the outside, and wherein the intermediate layer has correspondingly shaped openings which enable a positive connection of the openings to the contact surface of the spacers, whereby the spacers are secured against twisting relative to the intermediate layer. Because the gap is filled with the casting compound, it is possible to firmly connect all parts of the protected component to form a single part in one step. Furthermore, because a plastic material is used for the casting compound, can achieve a low weight. The combination of different materials makes it possible to fulfill the required protective function with the lowest possible weight. The protected component can thus be manufactured cost-effectively as a composite structure as a one-piece component. Time-consuming and costly manufacturing steps such as welding, riveting or screwing are no longer necessary. Other functions such as a groove for a seal or fastening an opening and closing mechanism can also be integrated into the protected component.

The protected component can be any component of a protected vehicle. For example, the protected component can be a hatch cover as mentioned above, a door, a flap or any other component of the protected vehicle. The protected component can therefore also be referred to as a hatch cover, door or flap. "Protected" in this context means that the protected component protects against gunfire, booby traps, improvised explosive devices (IEDs), mines or the like.

The protective effect of the protected component can be adapted and optimized due to its layered structure by using a wide variety of materials and different thicknesses of the layers used. In addition to the cover layer and the splinter protection layer, the protected component can have any number of additional layers or layers, which are preferably arranged between the cover layer and the splinter protection layer. In particular, any number of intermediate layers or intermediate layers can therefore be provided in the space between them, which, for example, influence, in particular increase, the protective effect of the protected component.

In this case, "outside" means that the cover layer faces the surroundings of the protected vehicle and faces away from the interior of a passenger compartment of the protected vehicle. Accordingly, "inside" means that the splinter protection layer faces the interior of the passenger compartment and faces away from the surroundings. The cover layer is therefore arranged on the enemy side. The splinter protection layer is accordingly arranged on the friend side.

The cover layer is particularly suitable for protecting the protected component from external influences, such as weather influences or even bullets. The cover layer can be made from an aluminum alloy or a steel alloy, for example. The cover layer can also be made from a fiber composite material or a ceramic material. The cover layer can be an aluminum sheet or a steel sheet. The cover layer is in particular plate-shaped or sheet-shaped.

The splinter protection layer is in particular a so-called liner or spall liner or can be referred to as such. The splinter protection layer is preferably a fabric or scrim that has fibers such as glass fibers, carbon fibers or aramid fibers. The splinter protection layer protects crew members in the event of a fire attack on the protected component, for example from splinters released from the protected component. The splinter protection layer is therefore suitable for preventing splinters from penetrating the interior of the passenger compartment. The splinter protection layer can be flexibly deformable.

The number of spacers is basically arbitrary. The spacers can, for example, be constructed rotationally symmetrically to an axis of symmetry. This means that the spacers can be manufactured cost-effectively as turned components. The spacers can also be cast components. For weight reasons, the spacers can be made of an aluminum alloy, for example. However, the spacers can also be made from a steel alloy or a fiber composite material. A ceramic material can also be used. The spacers can also be made from a thermosetting or thermoplastic plastic material, for example. For example, the spacers can be made from polyethylene (PE), polypropylene (PP), polyoxymethylene (POM), acrylonitrile butadiene styrene (ABS), polyether ether ketone (PEEK) or the like. The plastic materials can be fiber-reinforced. The spacers can be plastic injection molded components. The spacers can be sleeve-shaped. The spacers can therefore also be referred to as spacer sleeves.

Preferably, different types of spacers are provided. The spacers can also serve, for example, as fastening points for fastening the protected component to the protected vehicle or for fastening the opening and closing mechanism to the protected component. The spacers are preferably arranged in a grid or matrix shape. This means in particular that the spacers are arranged in rows and columns. Preferably, the spacers rest on a rear side of the cover layer and on a front side of the splinter protection layer facing the rear side of the cover layer, so that the spacers keep the cover layer and the splinter protection layer spaced apart from one another by the gap.

The gap is filled with the casting compound. This means in particular that the casting compound is filled into the gap in a liquid or pasty state and then hardens and/or cross-links. The casting compound connects the cover layer, the splinter protection layer and the spacers with one another in a material-locking manner. In material-locking connections, the connecting partners are held together by atomic or molecular forces. Material-locking connections are non-detachable connections that can only be by destroying the connecting means and/or the connecting partners. In particular, the casting compound bonds the cover layer, the splinter protection layer and the spacers together. The casting compound is not necessarily only intended for the space between them. The casting compound can also at least partially cover or envelop the cover layer and/or the splinter protection layer.

The component is preferably plate-shaped. In the present case, "plate-shaped" means in particular that the component has a larger geometric extension in an x-direction and a z-direction than in a y-direction. The directions form a coordinate system of the component and are oriented perpendicular to one another. The component is made of different materials. The component can therefore also be referred to as a composite component or composite material component. Due to its plate shape, the component can also be referred to as a composite plate, composite armor plate, composite material plate or composite material armor plate.

According to one embodiment, the casting compound is a, in particular fiber-reinforced, plastic material, in particular an epoxy resin or polyurethane.

The casting compound can also be referred to as a plastic casting compound. The casting compound can be any castable plastic material. However, the casting compound can also be a ceramic material, in particular a ceramic slip. In the event that the casting compound is fiber-reinforced, it is preferably short-fiber reinforced. For example, the casting compound can comprise natural fibers, glass fibers, carbon fibers, aramid fibers or the like. The casting compound is in particular a thermosetting plastic. The casting compound can be foamed to reduce weight. In this case, the casting compound is porous and comprises a large number of pores provided in it. By using a plastic material for the casting compound, the component can be manufactured particularly lightly. If the component is a hatch cover or the like, the opening and closing mechanism can be made smaller or motor support or spring support can be dispensed with entirely. The component can therefore also be referred to as a lightweight component and, if the component is a hatch cover, as a lightweight hatch cover.

According to a further embodiment, the spacers are passed through the cover layer and/or the splinter protection layer at least in sections.

The cover layer and the splinter protection layer can have a large number of holes, openings or recesses through which the spacers are guided. This means in particular that the spacers can protrude beyond the cover layer and/or the splinter protection layer. Alternatively, for example, a recess can also be provided in the cover layer which does not completely penetrate the cover layer and in which a spacer is accommodated. In this case, the spacer is at least not completely guided through the cover layer. The spacers can also be arranged flush with the cover layer and/or the splinter protection layer.

According to a further embodiment, the spacers each comprise a shoulder which rests on the cover layer and/or on the splinter protection layer.

Preferably, the spacers each have a cylindrical base body, on each end of which a shoulder is provided, which rests on the rear side of the cover layer or on the front side of the splinter protection layer.

The protected component comprises an intermediate layer, in particular an armor steel plate, which is arranged between the cover layer and the splinter protection layer in the intermediate space, wherein the casting compound connects the cover layer, the splinter protection layer, the spacers and the intermediate layer to one another.

In particular, the spacers are passed through the intermediate layer. The intermediate layer can be made of any material. For example, the intermediate layer can be made of a fiber composite material or a ceramic material. The intermediate layer preferably comprises any number of openings through which the spacers are passed. The intermediate layer leads to additional stiffening of the protected component. Furthermore, the intermediate layer also increases the protective effect of the protected component. The intermediate layer can be designed as a perforated sheet. This leads to weight savings.

The spacers are positively connected to the intermediate layer.

A positive connection is created by two connecting partners engaging one another or behind one another. For this purpose, the spacers or at least some spacers can have, for example, a ring-shaped collar which, for example, rests on a front side of the intermediate layer facing the cover layer, so that the intermediate layer is axially fixed relative to the spacer. The spacer has a contact surface on the outside, for example in the form of an external square or external hexagon, with the intermediate layer having a correspondingly shaped opening which enables a positive connection of the opening to the contact surface of the spacer. This secures the spacer against twisting relative to the intermediate layer. The contact surface can be a key surface. In this case, a "key surface" is understood to mean a geometry which can be gripped by a tool, for example a square key. or a hexagon wrench. The contact surface can also be toothed in any way, for example in the form of a splined shaft. The intermediate layer then has a correspondingly toothed opening. Spacers with such a collar and/or such a contact surface can serve as introduction points for introducing a force or a moment, in particular a torque, for example from an attachment of the protected component to the protected vehicle, into the protected component, since the spacers can introduce the force or the moment into the high-strength intermediate layer.

According to a further embodiment, the intermediate layer is perforated so that the casting compound extends through the intermediate layer.

This means in particular that the casting compound can flow through the intermediate layer in its liquid state. After the casting compound has hardened and/or cross-linked, it is then additionally connected to the intermediate layer in a form-fitting manner. By perforating the intermediate layer, a weight reduction and an increase in the protective effect can also be achieved. The casting compound preferably completely envelops the intermediate layer.

According to a further embodiment, the protected component comprises at least one molded element molded onto the potting compound, in particular with a groove.

The molded element can, for example, serve to accommodate a seal for sealing the protected component against the vehicle. The groove can be provided for this purpose. In the case of a molded element molded onto the casting compound, the casting compound is not only provided in the gap, but is also provided on the back of the splinter protection layer in order to form the molded element. The molded element can, for example, ring-shaped or in the form of a wall completely encircling the protected component.

According to a further embodiment, the spacers comprise a through hole, an internal thread and/or an external thread.

As previously mentioned, the spacers are preferably designed differently. For example, some spacers may comprise a through hole, other spacers may comprise an internal thread, and still other spacers may comprise an external thread. Spacers may also be provided which comprise both a through hole, an internal thread, and an external thread.

Furthermore, a protected vehicle with at least one such protected component is proposed.

The protected vehicle may have any number of protected components. The protected vehicle is preferably a wheeled vehicle. However, the protected vehicle may also be a tracked vehicle. The protected vehicle preferably comprises a passenger compartment as mentioned above, on which the protected component or any number of protected components may be provided. For example, protected components in the form of hatch covers, doors or flaps may be mounted on the protected vehicle.

Furthermore, a method for producing such a protected component, in particular a hatch cover, is proposed. The method comprises the following steps: a) providing an outer cover layer, an inner splinter protection layer, several spacers and a casting compound, b) arranging the spacers between the cover layer and the splinter protection layer such that the cover layer is held at a distance from the splinter protection layer, so that an intermediate space is provided between the cover layer and the splinter protection layer, and c) filling the intermediate space with the casting compound, wherein in step a) an intermediate layer is provided, which in step b) is arranged in the intermediate space between the cover layer and the splinter protection layer, wherein in step c) the cover layer, the splinter protection layer, the spacers and the intermediate layer are connected to one another with the aid of the casting compound, wherein the spacers are positively connected to the intermediate layer, wherein the spacers have a contact surface on the outside, and wherein the intermediate layer has correspondingly shaped openings which enable a positive connection of the openings to the contact surface of the spacers, whereby the spacers are secured against twisting relative to the intermediate layer.

The provision of the cover layer, the splinter protection layer and the spacers can, for example, involve manufacturing or cutting them. The casting compound is provided in a liquid state in particular. For this purpose, a resin can be mixed with a suitable hardener, for example. By arranging the spacers between the cover layer and the splinter protection layer, a pre-component is produced which differs from the protected component in that the pre-component does not yet have the casting compound. The pre-component is manufactured in such a way that it can be handled as a component and, for example, can be inserted into a mold. For this purpose, the spacers are firmly connected to the cover layer and/or the splinter protection layer. This can be done, for example, by screwing, riveting, gluing, caulking or otherwise firmly connecting the spacers to the cover layer and/or the splinter protection layer. Alternatively, the arrangement of the spacers between the cover layer and the splinter protection layer can also be made directly in the previously mentioned mold. In this case, a firm connection of the spacers, the cover layer and the splinter protection layer to the pre-component is not necessary. When the gap is filled with the casting compound, this is poured into the gap. This means that the cover layer, the splinter protection layer and the spacers are firmly connected to one another, in particular glued to one another.

According to one embodiment, step c) is carried out by means of a mold into which the cover layer, the splinter protection layer and the spacers are inserted before step c).

In particular, the pre-component is placed in the mold. The mold preferably comprises a lower mold part and an upper mold part, which are made of a silicone material, for example. The casting compound is preferably introduced into the mold without pressure or only under low pressure. The casting compound can also be poured under negative pressure or vacuum. The mold has a cavity, which is a negative image of the protected component. The cavity is filled with the pre-component and the casting compound.

In step a), an intermediate layer, in particular an armored steel plate, is provided, which in step b) is arranged in the intermediate space between the cover layer and the splinter protection layer, wherein in step c) the cover layer, the splinter protection layer, the spacers and the intermediate layer are connected to one another by means of the casting compound.

The spacers are preferably guided through the intermediate layer. Providing the intermediate layer can include manufacturing it. When manufacturing the intermediate layer, it is made from an armored steel sheet, for example. cut and perforated. Any number of different layers, plies or intermediate layers can be arranged between the top layer and the splinter protection layer. This allows the protective effect of the protected component to be adjusted as required.

According to a further embodiment, the spacers comprise a through hole, an internal thread and/or an external thread, wherein the through hole, the internal thread and/or the external thread are covered before step c).

Caps or closures can be provided to close or cover the through hole, the internal thread and/or the external thread so that they are not wetted with the casting compound. After the protected component has been demolded, the closures are removed again. The component can then preferably be installed without further processing.

According to a further embodiment, in step c) at least one shaped element, in particular with a groove, is molded onto the casting compound.

For this purpose, the mold has a corresponding geometry in the cavity, which is a negative of the mold element. The groove can be used to accommodate a seal. Any mold element can be molded onto the protected component.

The embodiments and features described for the proposed protected component apply to the proposed protected vehicle and/or the proposed method accordingly and vice versa.

In this case, "one" is not necessarily to be understood as being limited to just one element. Rather, several elements, such as two, three or more, can also be provided. Any other counting word used here should not be understood as meaning that there is a limitation to the exact number of elements mentioned. Rather, numerical deviations upwards and downwards are possible, unless otherwise stated.

Further possible implementations of the protected component, the protected vehicle and/or the method also include combinations of features or embodiments described above or below with regard to the exemplary embodiments that are not explicitly mentioned. The person skilled in the art will also add individual aspects as improvements or additions to the respective basic form of the protected component, the protected vehicle and/or the method.

Fig. 1

zeigt eine schematische Seitenansicht einer Ausführungsform eines geschützten Fahrzeugs;

Fig. 2

zeigt eine schematische Teilschnittansicht einer Ausführungsform einer geschützten Komponente für das geschützte Fahrzeug gemäß Fig. 1;

Fig. 3

zeigt eine schematische Schnittansicht einer Ausführungsform eines Abstandshalters für die geschützte Komponente gemäß Fig. 2;

Fig. 4

zeigt eine schematische Teilschnittansicht einer Vorkomponente für die geschützte Komponente gemäß Fig. 2;

Fig. 5

zeigt eine schematische Teilschnittansicht einer Ausführungsform einer Gussform zum Herstellen der geschützten Komponente gemäß Fig. 2;

Fig. 6

zeigt eine weitere schematische Teilschnittansicht der Gussform gemäß Fig. 5; und

Fig. 7

zeigt ein schematisches Blockdiagramm einer Ausführungsform eines Verfahrens zum Herstellen der geschützten Komponente gemäß Fig. 2.

Further advantageous embodiments and aspects of the protected component, the protected vehicle and/or the method are the subject of the subclaims and the exemplary embodiments of the protected component, the protected vehicle and/or the method described below. The protected component, the protected vehicle and/or the method are explained in more detail below using preferred embodiments with reference to the attached figures.

Fig.1

shows a schematic side view of an embodiment of a protected vehicle;

Fig.2

shows a schematic partial sectional view of an embodiment of a protected component for the protected vehicle according to Fig.1 ;

Fig. 3

shows a schematic sectional view of an embodiment of a spacer for the protected component according to Fig. 2 ;

Fig.4

shows a schematic partial sectional view of a pre-component for the protected component according to Fig.2 ;

Fig.5

shows a schematic partial sectional view of an embodiment of a mold for producing the protected component according to Fig.2 ;

Fig.6

shows another schematic partial sectional view of the mold according to Fig.5 ; and

Fig.7

shows a schematic block diagram of an embodiment of a method for producing the protected component according to Fig.2 .

In the figures, identical or functionally equivalent elements have been given the same reference numerals unless otherwise stated.

The Fig.1 shows a schematic side view of an embodiment of a protected vehicle 1. The protected vehicle 1 is referred to below simply as a vehicle. The vehicle 1 can be a military vehicle, in particular a military utility vehicle. The vehicle 1 comprises a protected passenger compartment 2. The passenger compartment 2 is protected against gunfire, booby traps, improvised explosive devices (IED), mines or the like.

The passenger compartment 2 is armoured. The passenger compartment 2 encloses an interior I in which crew members can stay. The passenger compartment 2 has a roof 3 on which a hatch 4 with an openable hatch cover 5 is provided. To open the hatch cover 5, it can be lifted and pivoted. A corresponding opening and closing mechanism can be provided for this purpose. The interior I of the passenger compartment 2 can be entered and exited from an environment U of the vehicle 1 via the opened hatch cover 5.

The vehicle 1 can be a wheeled vehicle. Alternatively, the vehicle 1 can also be a tracked vehicle. The vehicle 1 comprises several wheel axles on which wheels 6, 7 are provided. The number of wheel axles is basically arbitrary. For example, two wheel axles or three wheel axles can be provided. The vehicle 1 preferably comprises an all-wheel drive. This means that all wheel axles are driven. The vehicle 1 is assigned a coordinate system with a width direction or x-direction x, a height direction or y-direction y and a depth direction or z-direction z. The directions x, y, z are oriented perpendicular to one another. A direction of gravity g can be oriented opposite to the y-direction y.

The Fig.2 shows a schematic partial sectional view of an embodiment of a hatch cover 5 as mentioned above. The hatch cover 5 is a protected component of the vehicle 1 and is therefore generally referred to below as component 5. The component 5 can be any component of the vehicle 1, such as the hatch cover mentioned above, a flap, a door or the like. The component 5 can be any attachment part of the vehicle 1.

The component 5 is plate-shaped. "Plate-shaped" in this case means in particular that the component 5 has a larger geometric extension in the x-direction x and the z-direction z than in the y-direction y. The component 5 is made of different materials. Therefore, the component 5 can also be referred to as a composite component or composite material component. Due to its plate shape, component 5 can also be referred to as a composite plate, composite armor plate, composite material plate or composite armor plate.

The component 5 comprises an external cover layer 8. "External" in this case means facing away from the interior I and facing the environment U. The cover layer 8 is thus arranged on the enemy side. The cover layer 8 protects the component 5 from environmental influences, such as weather influences. However, the cover layer 8 can also have bullet-resistant properties. For example, the cover layer 8 is an aluminum sheet or a steel sheet. However, the cover layer 8 can also be made of a ceramic material or a fiber composite material. The cover layer 8 comprises a front side 9 facing the environment U and a rear side 10 facing the interior I. The cover layer 8 is in the form of a sheet or plate.

The cover layer 8 has several holes, openings or recesses 11 to 14 that either break through the cover layer 8 or do not break through it completely. The recesses 11 to 13 break through the cover layer 8 completely. The recess 14, on the other hand, is designed as a blind hole that extends from the rear side 10 into the cover layer 8. The number of recesses 11 to 14 is arbitrary. Preferably, a large number of recesses 11 to 14 are arranged in a matrix-like or pattern-like manner in a plane spanned by the x-direction x and the z-direction z. "Matrix-like" in this case means that the recesses 11 to 14 are arranged in rows and columns evenly distributed over the cover layer 8.

In addition to the cover layer 8, the component 5 comprises an internal splinter protection layer 15. "Inside" means facing the interior I and facing away from the environment U. The splinter protection layer 15 is thus arranged on the friend side. The splinter protection layer 15 is a so-called liner or spall liner. The The splinter protection layer 15 is in particular a fiber fabric. For example, the splinter protection layer 15 can comprise glass fibers, carbon fibers, aramid fibers or the like. The splinter protection layer 15 is plate-shaped. The splinter protection layer 15 is flexible. The splinter protection layer 15 is suitable for preventing splinters detached from the component 5 from penetrating the interior I in the event of a shot or explosion of the component 5.

The splinter protection layer 15 has a rear side 16 facing the interior I and a front side 17 facing the environment U. Like the cover layer 8, the splinter protection layer 15 comprises a large number of holes, openings or recesses 18 to 21. The number of recesses 18 to 21 preferably corresponds to the number of recesses 11 to 14 in the cover layer 8. The recesses 18 to 21 all penetrate the splinter protection layer 15 completely. However, this is not absolutely necessary. Some of the recesses 18 to 21 may not penetrate the splinter protection layer 15 completely. Any number of recesses 18 to 21 is provided, which may be arranged in a matrix-like or pattern-like manner in the previously mentioned plane spanned by the x-direction x and the z-direction z.

A plurality of spacers 22 to 25 are arranged between the cover layer 8 and the splinter protection layer 15. The number of spacers 22 to 25 is arbitrary. The number of spacers 22 to 25 preferably corresponds to the number of recesses 11 to 14 in the cover layer 8 and the number of recesses 18 to 21 in the splinter protection layer 15. The spacers 22 to 25 can be made from an aluminum alloy or a steel alloy, for example. Alternatively, the spacers 22 to 25 can also be made from a fiber composite material or a ceramic material.

The spacers 22 to 25 can also be made from a thermosetting or thermoplastic plastic material, for example. For example, the spacers 22 to 25 can be made from polyethylene (PE), polypropylene (PP), polyoxymethylene (POM), acrylonitrile butadiene styrene (ABS), polyetheretherketone (PEEK) or the like. The plastic materials can be fiber-reinforced. The spacers 22 to 25 can be plastic injection-molded components. The spacers 22 to 25 are preferably each constructed rotationally symmetrically to a central or symmetry axis 26 to 29. The spacers 22 to 25 can all be constructed identically or differently.

The Fig. 3 shows an example of a sectional view of an embodiment of the spacer 23. As previously mentioned, the spacer 23 is constructed rotationally symmetrically to its axis of symmetry 27. The spacer 23 has a cylindrical base body 30. The base body 30 has, for example, a diameter d30. A circumferential shoulder 31 is provided on the base body 30, which rests against the rear side 10 of the cover layer 8. The shoulder 31 is followed by a cylindrical section 32, which has a diameter d32 that is smaller than the diameter d30. The section 32 is received in the recess 12 of the cover layer 8.

Facing away from the shoulder 31, the base body 30 comprises a second shoulder 33, which rests against the front side 17 of the splinter protection layer 15. Each of the spacers 22 to 25 has two such shoulders 31, 33. The shoulder 33 is followed by a cylindrical section 34, which has a diameter d34 that is smaller than the diameter d30. The diameters d32, d34 can be the same size. However, this is not absolutely necessary. The section 34 is accommodated in the recess 19 of the splinter protection layer 15.

Depending on the thickness of the cover layer 8 and the splinter protection layer 15, the sections 32, 34 can have different heights when viewed along the y-direction y. The sections 32, 34 can also protrude beyond the cover layer 8 and/or the splinter protection layer 15 when viewed along or against the y-direction y. The sections 32, 34 can also be arranged flush with the cover layer 8 and/or the splinter protection layer 15.

A central bore 35 is also provided in the base body 30, which extends along the axis of symmetry 27. The bore 35 does not, however, completely penetrate the base body 30 and is therefore a blind hole. An internal thread 36 is provided on the bore 35. An annular collar 37 runs around the outside of the base body 30. The collar 37 has a diameter d37. The diameter d37 is larger than the diameter d30.

In the orientation of the Fig.3 A contact surface 38 is provided on the outside of the base body 30 below the collar 37. The contact surface 38 can be, for example, an external hexagon or an external square. The contact surface 38 can be a wrench surface. In this case, a "wrench surface" is understood to mean a geometry that can be gripped by a tool, for example a square wrench or a hexagon wrench. The contact surface 38 can also be toothed in any way. This toothing can be provided, for example, in the form of a splined shaft.

The spacer 23 is a one-piece component, in particular a one-piece component. "One-piece" or "one-piece" means that the spacer 23 is not made up of different components. "One-piece" means that the spacer 23 is made entirely of the same material. The spacer 23 can be a cast component, a plastic injection-molded component or a turned component. The spacers 22, 24, 25 are essentially, that is, except for different dimensions and geometric details, it is constructed identically to the spacer 23.

Now returning to the Fig. 2 the spacer 22 comprises a through hole 39 that completely penetrates it. The spacer 24, on the other hand, comprises a threaded bolt 40 with an external thread 41 that projects beyond the rear side 16 of the splinter protection layer 15. The spacer 24 has a collar 37 as mentioned above and a contact surface 38. In principle, each spacer 22 to 25 can have such a collar 37 and/or such a contact surface 38. The spacer 24 has no holes or the like and is therefore made of solid material. The spacer 25, like the spacer 24, is made of solid material, although in the spacer 25 the section 32 is so short that it does not pass completely through the cover layer 8.

The spacers 22 to 25 are arranged between the cover layer 8 and the splinter protection layer 15 in such a way that the cover layer 8 and the splinter protection layer 15 are kept spaced apart from one another along the y-direction y, so that a gap 42 is formed between the cover layer 8 and the splinter protection layer 15. The gap 42 can be several centimeters.

An optional intermediate layer 43 is arranged in the intermediate space 42. In addition to the intermediate layer 43, further layers can be arranged in the intermediate space 42. The intermediate layer 43 can be an armored steel sheet, for example. The intermediate layer 43 is preferably arranged centrally between the cover layer 8 and the splinter protection layer 15, viewed along the y-direction y. The intermediate layer 43 is preferably perforated. This means that the intermediate layer 43 has first openings 44 to 47 through which the spacers 22 to 25 are guided. The spacers 22 to 25, which have a collar 37 as previously explained, can rest against the intermediate layer 43, so that the Intermediate layer 43 is fixed to the respective collar 37 when viewed along the y-direction y.

The first openings 44 to 47 can be circular. Alternatively, the first openings 44 to 47 or some of the first openings 44 to 47 can have a geometry corresponding to the contact surface 38, so that the contact surface 38 of the respective spacer 22 to 25 engages in a form-fitting manner in the corresponding first opening 44 to 47. This prevents undesired rotation of the respective spacer 22 to 25 relative to the intermediate layer 43. This enables the transmission of forces and/or moments from the respective spacer 22 to 25 to the intermediate layer 43. A form-fitting connection is created by the interlocking or engagement of two connection partners. For example, the corresponding first openings 44 to 47 can be square, hexagonal or arbitrarily toothed.

The intermediate layer 43 comprises a front side 48 facing the cover layer 8 and a rear side 49 facing the splinter protection layer 15. The respective collar 37 rests against the front side 48. In addition to the first openings 44 to 47, the intermediate layer 43 comprises second openings 50 to 54. The second openings 50 to 54 can be arranged in a matrix-like manner in the plane spanned by the x-direction x and the z-direction z. The second openings 50 to 54 can serve, for example, to save weight. Furthermore, the second openings 50 to 54 also improve the protective properties of the intermediate layer 43.

The gap 42 is filled with a casting compound 55, which completely fills the gap 42 in order to bond the cover layer 8, the splinter protection layer 15, the intermediate layer 43 and the spacers 22 to 25 together. In the case of bonded connections, the connection partners held together by atomic or molecular forces. Material-bonded connections are non-detachable connections that can only be separated by destroying the connecting means and/or the connecting partners. For example, the casting compound 55 bonds the cover layer 8, the splinter protection layer 15, the intermediate layer 43 and the spacers 22 to 25 together. The casting compound 55 preferably completely envelops the intermediate layer 43.

The potting compound 55 is a plastic material, for example an epoxy resin or a polyurethane. The potting compound 55 can be fiber-reinforced, in particular short-fiber-reinforced. To reduce weight, the potting compound 55 can also be foamed. If the potting compound 55 is fiber-reinforced, it can be filled with glass fibers, carbon fibers, aramid fibers, natural fibers or the like. The fibers preferably have a length of less than 5 mm. However, the length of the fibers can be arbitrary.

The casting compound 55 extends through the second openings 50 to 54 of the intermediate layer 43, whereby the intermediate layer 43 is positively connected to the casting compound 55. The casting compound 55 is not only accommodated in the intermediate space 42, but can also envelop or surround the cover layer 8 and/or the splinter protection layer 15 at least in sections. For example, the casting compound 55 can also be provided on the rear side 16 of the splinter protection layer 15. In particular, a molded element 56 molded onto the casting compound 55 can be cast onto the rear side 16 of the splinter protection layer 15. The molded element 56 can, for example, run completely around the component 5 in the form of a wall. For example, a groove 57 for receiving a seal or the like can be molded onto the molded element 56.

The following describes the production of component 5 using the Fig. 4 to 7 explained. The Fig.4 shows a schematic view of a pre-component 58 of the Component 5. The Fig.5 shows the insertion of the pre-component 58 into a mold 59. The Fig.6 shows a casting of the pre-component 58 with the casting compound 55 in the mold 59. The Fig.7 shows a schematic block diagram of an embodiment of a method for manufacturing component 5.

In a step S1, the cover layer 8, the splinter protection layer 15 and the spacers 22 to 25 are provided. Optionally, the intermediate layer 43 can also be provided. Furthermore, further layers can also be provided. The provision can include producing the cover layer 8, the splinter protection layer 15, the spacers 22 to 25 and/or the intermediate layer 43.

In a step S2, the spacers 22 to 25 are arranged between the cover layer 8 and the splinter protection layer 15 in such a way that the cover layer 8 is kept at a distance from the splinter protection layer 15. This forms the intermediate space 42 between the cover layer 8 and the splinter protection layer 15. In this case, the cover layer 8, the splinter protection layer 15 and, if applicable, the intermediate layer 43 are assembled to form the pre-component 58. The pre-component 58 differs from the component 5 in that the pre-component 58 does not have the casting compound 55.

The spacers 22 to 25 can be glued, pressed, screwed or joined together in any other way with the cover layer 8, the splinter protection layer 15 and, if necessary, with the intermediate layer 43 in such a way that the pre-component 58 can be transported and handled as a single component. Then, as shown in the Fig.5 As shown, the through hole 39 of the spacer 22, the internal thread 36 of the spacer 23 and the external thread 41 of the spacer 24 are protected with caps or closures 60 to 62. The closures 60 to 62 prevent penetration of the casting compound 55.

The pre-component 58 is then placed in the mold 59, which has a lower mold part 63 and an upper mold part 64. Alternatively, the pre-component 58 can also be assembled in the opened mold 59. The lower mold part 63 and the upper mold part 64 can be made of silicone, for example. The mold 59 has a cavity 65, which is a negative image of the component 5. The mold element 56, for example, is molded into the cavity 65.

Subsequently, in a step S3, as in the Fig.6 shown, the intermediate space 42 is filled with the casting compound 55 in order to connect the cover layer 8, the splinter protection layer 15, the intermediate layer 43 and the spacers 22 to 25 to one another. The casting compound 55 can be poured in without pressure or under low pressure. The casting compound 55 can also be poured in under negative pressure or vacuum. The hardening and/or cross-linking of the casting compound 55 can take place with the introduction of heat, for example in an autoclave. After the hardening and/or cross-linking of the casting compound 55, the component 5 is demolded from the mold 59 and the closures 60 to 62 are removed.

The component 5 can then be installed on the vehicle 1. The spacers 22 to 25 can serve at least partially as connection points for connecting the component 5 to the vehicle 1. Forces and/or moments acting on the component 5 from the outside, which are then introduced into the component 5 via the spacers 22 to 25, can be transferred to the component 5 by, for example, some of the spacers 22 to 25 being positively connected to the high-strength intermediate layer 43 with the aid of the circumferential collar 37 and the contact surface 38, whereby the acting forces and/or moments can be introduced into the intermediate layer 43.

By using a plastic material for the casting compound 55, the component 5 can be made particularly light. This leads to a reduction in the weight of the entire vehicle 1. If the component 5 is a hatch cover or the like, an opening and closing mechanism can be made smaller or motor support or spring support can be dispensed with entirely. The component 5 can therefore also be referred to as a lightweight component and, if the component 5 is a hatch cover, as a lightweight hatch cover.

The component 5 can be manufactured by casting with the casting compound 55 as a one-piece or one-piece component in one manufacturing step, namely casting. The combination of several different manufacturing processes, such as welding, screwing or the like, is dispensable.

The design of component 5 as a composite structure or as a one-piece component is cost-effective. Time-consuming and costly manufacturing steps are dispensable. After component 5 has been removed from the mold 59, it can be immediately mounted on the vehicle 1 without any further processing. The required protective function can be achieved by combining different materials with the lowest possible weight.

With the help of the spacers 22 to 25 and the shaped element 56, additional functions can be integrated into the component 5. The spacers 22 to 25 can be used as connection points for connecting the component 5 to the vehicle 1, for connecting the opening and closing mechanism to the component 5 or the like. The shaped element 56 can serve to accommodate and fix a seal.

Component 5 has a sandwich structure with its multi-layer construction. The layers, for example the cover layer 8, the splinter protection layer 15 and the intermediate layer 43, of component 5 can each be adapted to the protection requirements of the vehicle 1 over a wide range in terms of their thickness and the materials used, while keeping the weight as low as possible.

The intermediate layer 43 can optionally be perforated to improve the ballistic protection properties and to reduce the weight. The perforation also creates a positive connection between the intermediate layer 43 and the casting compound 55. The cover layer 8 ensures environmental resistance, but can also have bullet-resistant properties, whereas the splinter protection layer 15 provides splinter protection.

Any desired shaped elements 56, radii, roundings or the like can be cast onto the component 5 using the casting compound 55. Forces and/or moments acting on the component 5 from the outside can be introduced into the component 5 via the spacers 22 to 25. In particular, those spacers 22 to 25 that are positively connected to the intermediate layer 43 ensure that the forces and/or moments are introduced into the high-strength intermediate layer 43 and thus into the component 5.

Compared to a multi-layer protective structure, component 5 can be manufactured more cost-effectively. Multiple manufacturing steps for welding, gluing or screwing different layers are not required. Component 5 is manufactured using a single casting process. The joining of seal carriers or connection points in further manufacturing steps is also not necessary, but can be achieved using the potting compound 55 and the spacers 22 to 25 used.

Compared to a one-piece hatch cover, which is manufactured as a milled and welded part, the multi-layer composite structure of component 5 has a significant weight advantage while providing the same level of protection. Compared to a one-piece hatch cover, which is manufactured exclusively as a plastic or fiber composite molded part, the described composite structure of component 5 has significantly better properties in terms of ballistic protection and resilience under blast impact, for example by blasting vehicle 1.

LIST OF REFERENCE SYMBOLS

1

vehicle

2

Passenger cell

3

Roof

4

hatch

5

Hatch cover/component

6

wheel

7

wheel

8th

Top layer

9

front

10

back

11

Recess

12

Recess

13

Recess

14

Recess

15

Splinter protection layer

16

back

17

front

18

Recess

19

Recess

20

Recess

21

Recess

22

Spacers

23

Spacers

24

Spacers

25

Spacers

26

Axis of symmetry

27

Axis of symmetry

28

Axis of symmetry

29

Axis of symmetry

30

Base body

31

Paragraph

32

Section

33

Paragraph

34

Section

35

drilling

36

inner thread

37

Federation

38

Contact surface

39

Through hole

40

Threaded bolt

41

External thread

42

Space

43

Intermediate layer

44

breakthrough

45

breakthrough

46

breakthrough

47

breakthrough

48

front

49

back

50

breakthrough

51

breakthrough

52

breakthrough

53

breakthrough

54

breakthrough

55

Casting compound

56

Form element

57

Groove

58

Pre-component

59

mold

60

Closure

61

Closure

62

Closure

63

Mould bottom

64

Form top

65

cavity

d30

diameter

d32

diameter

d34

diameter

d37

diameter

G

Gravity direction

I

inner space

S1

Step

S2

Step

S3

Step

U

Vicinity

x

x-direction

y

y-direction

z

z-direction

Claims (14)

1. Protected component (5), comprising

   an external cover layer (8),

   an internal splinter protection layer (15),

   several spacers (22 - 25) arranged between the cover layer (8) and the splinter protection layer (15) to hold the cover layer (8) spaced apart from the splinter protection layer (15) so that a gap (42) is provided between the cover layer (8) and the splinter protection layer (15),

   a potting compound (55) which fills the gap (42),

   an intermediate layer (43) which is arranged between the cover layer (8) and the splinter protection layer (15) inside the gap (42),

   wherein the potting compound (55) joining together the cover layer (8), the splinter protection layer (15), the spacers (22 - 25), and the intermediate layer (43),

   characterized in that

   the spacers (22 - 25) are connected to the intermediate layer (43) in a form-locking manner,

   wherein the spacers (22 - 25) comprise a contact surface (38) on an outside thereof, and

   wherein the intermediate layer (43) comprises correspondingly shaped breakthroughs (44 - 47) which enable a form-locking connection of the breakthroughs (44 - 47) to the contact surface (38) of the spacers (22 - 25), by which form-locking connection the spacers (22 - 25) are secured against rotation relative to the intermediate layer (43).
2. Protected component according to claim 1,
   characterized in that
   the potting compound (55) is a plastic material.
3. Protected component according to claim 2,
   characterized in that
   the plastic material is fiber reinforced.
4. Protected component according to any one of claims 1 - 3,
   characterized in that
   the spacers (22 - 25) are guided through the cover layer (8) and/or the splinter protection layer (15) at least sectionally.
5. Protected component according to any one of claims 1 - 4,
   characterized in that
   the spacers (22 - 25) each comprise a shoulder (31, 33) which bears against the cover layer (8) and/or against the splinter protection layer (15).
6. Protected component according to any one of claims 1 - 5,
   characterized in that
   the intermediate layer (43) is an armored steel plate.
7. Protected component according to any one of claims 1 - 6,
   characterized in that
   the intermediate layer (43) is perforated so that the potting compound (55) extends throughout the intermediate layer (43).
8. Protected component according to any one of claims 1 - 7,
   characterized by
   at least one form element (56) molded onto the potting compound (55), wherein the potting compound (55) is not only provided in the gap (42) but is also provided at a rear of the splinter protection layer (15) to create the form element (56).
9. Protected component according to any one of claims 1 - 8,
   characterized in that
   the spacers (22 - 25) comprise a through hole (39), an internal thread (36) and/or an external thread (41).
10. Protected vehicle (1) comprising at least one protected component (5) according to any one of claims 1 - 9.
11. Method for manufacturing a protected component (5), comprising the following steps:

    a) Providing (S1) an external cover layer (8), an internal splinter protection layer (15), several spacers (22 - 25), and a potting compound (55),

    b) Arranging (S2) the spacers (22 - 25) between the cover layer (8) and the splinter protection layer (15) in such a way that the cover layer (8) is held spaced apart from the splinter protection layer (15) so that a gap (42) is provided between the cover layer (8) and the splinter protection layer (15), and

    c) Filling (S3) the gap (42) with the potting compound (55),

    wherein in step a) an intermediate layer (43) is provided, which, in step b), is arranged between the cover layer (8) and the splinter protection layer (15) inside the gap (42),

    wherein the cover layer (8), the splinter protection layer (15), the spacers (22 - 25), and the intermediate layer (43) being joined together by means of the potting compound (55) in step c),

    characterized in that

    wherein the spacers (22 - 25) are connected to the intermediate layer (43) in a form-locking manner,

    wherein the spacers (22 - 25) comprise a contact surface (38) on an outside thereof, and

    wherein the intermediate layer (43) comprises correspondingly shaped breakthroughs (44 - 47) which enable a form-locking connection of the breakthroughs (44 - 47) to the contact surface (38) of the spacers (22 - 25), by which form-locking connection the spacers (22 - 25) are secured against rotation relative to the intermediate layer (43).
12. Method according to claim 11,
    characterized in that
    step c) is carried out by means of a casting mold (59) into which the cover layer (8), the splinter protection layer (15), and the spacers (22 - 25) are inserted before step c).
13. Method according to claim 11 or 12,
    characterized in that
    the spacers (22 - 25) comprise a through hole (39), an internal thread (36) and/or an external thread (41), the through hole (39), the internal thread (36) and/or the external thread (41) being covered before step c).
14. Method according to any one of claims 11 - 13,
    characterized in that
    in step c) at least one form element (56) is molded onto the potting compound (55), wherein the potting compound (55) is not only provided in the gap (42) but is also provided at a rear of the splinter protection layer (15) to create the form element (56).

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