RU2650254C1 - Lattice position for air intakes - Google Patents

Abstract

FIELD: transport.

SUBSTANCE: group of inventions refers to lattice (21) position for a vehicle air intake, a vehicle with such a lattice position, and a method for manufacturing a lattice position. Lattice 21 position comprises a lattice 30 and a frame 23 for the lattice 30. Lattice 30 has an edge 31, and the frame 23 has a first point 40 and a second point 60 that together form a receiving element for the edge 31 of the lattice 30. First point 40 is made of a first polymer material, and the second point 60 is made of a second polymer material. First polymer material is harder than the second polymer material. Invention also relates to a method for manufacturing a lattice position comprising a specific sequence of operations.

EFFECT: time for installation of such a unit is reduced with a reduction in the weight of the structure.

15 cl, 9 dwg

Description

The invention relates to a grill assembly for an air intake, in particular in front of a vehicle.

According to the requirements established by law, an object with a given diameter cannot enter the air intakes (air inlets) in the front area (front). However, for thermal as well as optical reasons, these large air intakes must be made. To meet the requirements established by law, plates are inserted into the air intakes so that the object cannot go inside. As a rule, a grille is inserted into the air intake for this.

As a rule, the integration of the lattice is carried out using a multilayer (like a sandwich) structure consisting of two frames and a lattice. The front holding frame forms a transition to the front casing and is screwed to the second, rear frame, while they clamp the grille together.

In a multi-layer construction, the front holding frame is first latched or clamped into the front skin. After that, the metal grill and the rear holding frame are inserted. Then these three structural parts are fixed by installing several screws, respectively, U-shaped clamps. This time-consuming and time-consuming installation is suitable for a range with a small number of manufactured products. With a larger number of manufactured products, this order of execution is uneconomical.

DE 10 2004 020 085 A1 describes a method for manufacturing a stamped grating with a polymer coating on which structural elements are provided. It is integrated in the housing.

DE 10 2014 210 480 A1 describes a stamped metal grate coated with a polymer material. Adhesive material, such as adhesive, may be applied to the stamped grate.

DE 10 2007 022 385 A1 describes a hybrid manufacturing method in which first the sheet metal structural part and the plug-in structural part are made separately from a polymeric material. The polymer component of the material is then sprayed onto the inserted structural part from a polymeric material using two-component injection molding.

DE 43 21 969 A1 describes a frame structure based on artificial resin from the grating part and surrounding the grating part of the frame part, wherein the frame part is made in the form of a multilayer structure.

US 2002/0171169 A1 describes a method for manufacturing a layer of polymer material on a metal plate.

The objective of the invention is to develop a node lattice, which significantly reduces installation time, ideally with the best characteristics of the structural part with respect to function and weight.

This problem is solved using the lattice node according to paragraph 1 of the claims.

Such a lattice assembly with a first portion and a second portion of different polymeric materials has clear advantages. In particular, the following advantages may result from this embodiment, while not all advantages should be provided at the same time:

1. Lower unit costs due to the exclusion of fasteners.

2. Less weight due to the exclusion of fasteners.

3. Lower installation costs (installation costs) due to the exclusion of additional frames and fasteners.

4. Lower logistics costs and storage costs by reducing to one structural part.

5. Minimize sources of error during installation.

6. Lack of creaking and rattling sound due to the "elastically propped" tight fit of the grill.

7. Higher air passage by eliminating stiffening measures, such as ribs.

8. The ability to reduce flow leakage due to the fit of soft components to the air flow guide.

9. Partial integration of the airflow guide function into soft components.

10. The absence of tension in the connection of the structural part (thermal expansion) due to the "elastically supported" tight fit.

11. Overlap foundry flake.

In the past, attempts have been made to optimize the airflow guide for leakage to the front by inserting a profiled sealing head or injection of a soft component onto a portion of the airflow guide. However, all these concepts have a significant drawback: due to mounting tolerances, such a large free space (gaps) should have been provided that the advantage over the labyrinth seals that are generally accepted today has quickly disappeared.

The present invention does not have such a disadvantage, since there is a softer component on the lattice assembly. On the contrary, in this case, the sealing sponge, with an increase in the oncoming air flow, is even more strongly pressed against the air flow guide or another element.

The problem is also solved using the method according to paragraph 15 of the claims. In this case, the first section (40) optionally remains in partial form (101) (101 = 109) and rotates to the second partial form (110) (a tool with a rotating plate), after which the grating (30) is applied to the first section (40) .

The problem is also solved by means of a lattice assembly, which is integrated using the technology of two-component injection molding into the visible structural part, the first component being made as a solid component and the second component being made as a soft component, which reduces leakage due to the fit to the air guide flow.

This embodiment of the lattice assembly in the form of a separate structural part is possible due to a two-component tool. To do this, first cast the solid component that actually holds the frame. Then this structural part is transferred to the second cavity. A metal grate is laid on said structural parts. Then the second component, the soft component, is molded under pressure. The grill is rigidly connected to the holding frame.

The invention is described in more detail by means of graphic materials. They show:

figure 1 - the front part of the vehicle with air intakes according to the prior art;

figure 2 - the front part of the vehicle with the node grille according to the invention;

figure 3 - node lattice in figure 2 without a front part;

figure 4 is a cross section along the line IV-IV in figure 3 node lattice in figure 3;

5 is a method of manufacturing a lattice assembly according to the invention;

6 is a lattice in the embedment position with an adjacent air flow guide;

Fig. 7 shows a grating assembly according to the invention in the built-in position with an adjacent air flow guide;

Fig. 8 shows a grating assembly according to the invention as a visible structural part; and

Fig.9 is a tool for manufacturing with a matrix that clicks on a solid component.

Figure 1 shows the front region (frontal region) 20 of a vehicle, in particular a passenger car, according to the prior art.

A front casing 80 is provided in which, for example, a central air intake safety grill 81, two side air intake grilles 82 and an upper air intake safety grill 83 are provided as air inlets.

The central intake grill 81 includes, as an example, a front holding frame 81A, a metal grill 81B, a rear holding frame 81C, and 18 U-clamps 81D as fixing means.

The side air intake guard 82 includes a front holding frame 82A, a metal grill 82B, a rear holding frame 82C, and 10 U-clips 82D as fasteners.

The upper intake guard grill 83 includes an upper retaining frame 83A, a metal grill 83B, a lower retaining frame 83C, and screws 83D as fixing means.

The safety grilles 81, 82, 83 of the air intake are thus realized by means of a multilayer structure, and the metal grill is sandwiched between the two holding frames, respectively. One of the frames, usually the front frame, is connected with the front casing 80. Therefore, we are not talking here about one node.

This type of construction and installation is costly.

Figure 2 shows the front region 20 of the vehicle 10 with the front skin 80 and the node 21 of the lattice according to the invention.

Figure 3 shows in a schematic representation a lattice assembly 21 with a grill 30 and a frame 23 for the grill 30. The frame 23 preferably extends around the entire grill 30, but it can also be made only around a part of the grill 30.

Figure 4 shows a partial section of the node 21 of the lattice along the section line IV-IV of figure 3.

The grill 30 has an edge 31.

The grill 30 defines the surface 32 of the grill, which is provided between the first region 33 and opposite the first region 33 of the second region 34. The grill 30 and, thus, the surface 32 of the grill can be made even or curved, depending on the contour of the front skin 80.

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

The first portion 40 is made of a first polymeric material, and the second portion 60 is made of a second polymeric material. The first polymeric material is preferably harder than the second polymeric material. Preferably, the first polymeric material is a solid component, and the second polymeric material is a soft component. Preferably, the first polymeric material is thermoplastic, and the second polymeric material is a thermoplastic elastomer, respectively, an elastomer.

The first polymeric material, for example, is:

PPE - polyphenylene ether;

PA 6.12 - Poly (hexamethyleneendodecandiamide).

The second polymeric material, for example, is:

SBR - styrene butadiene rubber;

NBR is nitrile rubber.

The first portion 40 and the second portion 60 are connected to each other in the connection region 70. In a preferred bonding by multi-component injection molding, the specialist is referring to multi-component bonding (in English compound adhesion). This bonding results in a bond strength of 40, 60 and, if necessary, 30.

The first portion 40 has a supporting region 41, and the second portion 60 has a supporting region 61. The supporting regions 41, 61 are adjacent to each other, and a connection region 70 is provided between the supporting regions 41, 61. In other words, the first supporting region 41 and the second supporting an area 42 is in contact with each other in a connection area 70.

Preferably, the first abutment region 41 and the second abutment region 62 are rigidly connected to each other in the joining region 70, particularly preferably by multicomponent bonding, which can be achieved, in particular, by multicomponent injection molding. In this case, the connection region 70 can also extend into the region of the lattice 30 due to the soft component passing through the opening of the lattice 30 to the first support region 41. This ensures a particularly stable connection of the lattice 30 in the receiving element formed by the first section 40 and the second section 60.

The second supporting region 62 extends from the edge 31 of the grating 30 to the lateral region of the grating 30 in the longitudinal direction inward. This ensures a good fit of the grating 30 in the frame 23 and, if necessary, gluing between the second supporting region 62 and the grating 30.

In addition, the second abutment region 62 is located on the outer edge of the edge 31. In this way, good damping is ensured when the lattice 30 moves toward this region, since the second abutment region 62 is made of a softer and preferably also elastic material.

Preferably, the first portion 40 and the second portion 60, respectively, are made of polymeric material, while the first portion 40 is harder than the second portion 60.

The first portion 40 and the second portion 60 at least in separate areas surround the edge 31 of the grating 30.

The grill 30 allows air to pass through the grill assembly 21. The first region 33 is preferably provided as a free-flow region 33, and the second region 34 as a leak-out region. Air may pass from the free-flow region 33 through the grill 30 to the out-flow region 34, as shown by arrow 25.

The first portion 40 has a first protrusion 42 and a second protrusion 43, each of which extends toward the first region 33. The second portion 60 has a third protrusion 62 that extends toward the second region 34.

The protrusions 42, 43 and 62 may also be called jaws, and they preferably extend around the entire grate 30, however, at least partially around it.

The first protrusion 42 preferably serves as an air flow guide. It tapers in cross section, preferably with an increasing interval from the grate 30, to reduce weight.

The second protrusion 43 is located outside relative to the first protrusion 42 and serves to install (install) the node 21 of the lattice on the vehicle 10 of FIG. 2. Moreover, it is preferable for structural stability that the first portion 40 is harder than the second portion 60.

The first protrusion 42 and the second protrusion 43 together have a U-shaped cross section in cross section and it provides good stability to the first portion 40.

The third protrusion provides an airflow guide in the second region 34 of the grill 30. Preferably, the third protrusion 62 narrows in cross section with an increasing interval from the grill 30, and thus, the deformability of the third protrusion 62 is increased.

The grill 30 is preferably made in the form of a metal grill. This provides high stability node 21 of the lattice.

In FIG. 5 shows a method of manufacturing a lattice assembly 21.

To the left (A) is the first injection mold 101 with a first partial mold (die) 105 and a second partial mold (casting bar) 106, which together form the first cavity 107 (fillable hollow space).

Using the first injection molding mold 101, the first portion 40 is manufactured as a structural part from a harder polymer material (solid component) (B).

Then, a second mold 102 for injection molding is applied with a third partial mold (die) 109 and a fourth partial mold (core) 110, which form the second cavity 111.

Injection molds 101 and 102 may also be the same. In this case, part of the structure is in the matrix (a form with a rotating plate).

The first portion 40 is embedded (C) in the third partial mold 109, and the grill 30 is applied (D) to the first portion 40.

Then (E) a fourth partial mold 110 is applied to the first portion 40 and preferably also to the grill 30, and the second cavity 111 present in the fourth partial mold 110 is filled with a softer polymeric material (soft component), so that the first portion 40 and the second portion 60 form a composite, whereby bonding (adhesion of the joint) occurs between the first portion 40 and the second portion 60, which holds these portions 40, 60 together. It is a composite “polymer material – polymer material”. Additional bonding (setting) between the first polymeric material and the grill 30 and / or, in particular, between the second polymeric material and the grill 30 is possible. The floating support of the grill 30 in the frame 23 is preferred, in particular for damping the lattice movements.

Thereby, the frame 23 is manufactured using a two-component injection molding method. Of course, a multi-component injection molding process with more than two components is also possible. The finished lattice assembly may also be called an integrated shaped part to distinguish it from the structural part in a multilayer structure.

The lattice assembly 21 provides air to the interior of the vehicle. For this, the lattice assembly 21 preferably interacts within the vehicle with an air flow guide 120, for example, with a wall.

For efficient cooling and to eliminate noise, it is preferable that the grating assembly 21 and the air flow guide 120 interact well with good functioning and with little leakage.

6 shows various sealing methods between the grill assembly 21 and the air flow guide 120.

In the left image, the air flow guide 120 has a sealing lip 122 at its end facing the grating assembly 21.

In the middle image, the air flow guide 120 has on its end facing the lattice assembly 21 a keder 124.

In the right image, the lattice assembly has a protrusion 126 of a solid component that extends toward the air flow guide 120.

Methods using sealing lips 122 and Keder 124 have the disadvantage that due to mounting tolerances to be taken into account, a large gap (free movement) must be ensured between the air flow guide 120 and the grill assembly 21. Thus, these methods do not have any very large positive effect, and they are, on the other hand, costly in terms of manufacturing. Methods using the labyrinth seal 126 (when interacting with the airflow guide 120) works and is relatively simple to install.

FIG. 7 shows a preferred sealing arrangement between the grill assembly 21 and the air flow guide 120. The node 21 of the lattice has a second section in accordance with figure 4, while it is made softer than the first section 40, preferably from a soft component.

In the left image, a little air passes through the grill 30, as shown by several arrows 25, and the second portion 60 acquires largely its basic shape.

In the right image, on the contrary, a lot of air passes through the grill 30, for example, at a high speed of the vehicle, and this is shown by a large number of arrows 25. The leakage air stream 130 increases with increasing speed, and thus the relatively soft second section 60 deforms toward air guide 120 and further seals it. It is assumed that this is due to Bernoulli's law, according to which a higher flow rate is associated with a decrease in pressure.

The deformation leads with increasing speed to an increasing seal between the air flow guide 120 and the second section 60. It is preferable that the second section 60 (deformation) is softer than the first section 40 (installation / mounting).

Fig. 8 shows what an observer 142 sees in the field of view in the case of the system of the lattice assembly 21 with the lattice 30 and the frame 23.

Since the first portion 40 was made in the first step, edges and others can be made of good quality and without a large number of burrs. The second portion 60 is located on the inner side of the lattice assembly 21 and is therefore not directly visible. In addition, the second portion 60 is offset relative to the first portion slightly outward (relative to the grating 30), so that the region 140 is not visible. In other words, the first portion 40 extends relative to the grating 30 further inward than the second portion 60.

An embodiment of the lattice assembly 21 provides for the possibility of inserting the lattice assembly 21 into the vehicle 10 directly as a visible structural part.

In the manufacture of the lattice assembly 21 using a one-component injection molding method, a material burst is formed in the region of the lattice 30, respectively, a wide burr, since a good seal is unlikely in the region of the lattice 30 by means of a die-casting mold. Such an environment violates visual perception. Therefore, the lattice assembly 21 thus obtained is not suitable for the visible structural part.

Figure 9 shows an example implementation of the manufacture of the node 21 of the lattice in accordance with figure 5, step E.

It can be seen that the fourth partial shape 110 is adjacent to both the first portion 40 and the grating 30, while part of the grating 30 projects into the cavity. Thus, the polymeric material for the second portion forms a composite (complex) with both the first portion 40 and the lattice 30. It can also be seen that region 140 (cf. FIG. 8) lies on the lattice 30 further outward than the first portion 40, so that the region in which the second portion 60 is molded lies farther outward relative to the grate 30. Thus, the first portion 40 determines visual perception when viewed from the outside, and a beautifully shaped lattice assembly 21 is provided.

In other words, the grille is integrated into the visible part of the structure by means of two-component injection molding technology, while the second component is made as a soft component, which, due to its fit to the air flow guide, significantly reduces leakage.

Using the technology of two-component injection molding, it is possible to arrange the material cloud in an invisible area. This is achieved by pressing the casting core in the second cavity to the embedded product, the solid component, and thereby performing the sealing function.

Of course, numerous changes and modifications are possible within the scope of the invention.

Claims (23)

1. The lattice assembly for the air intake of the vehicle (10), which contains the lattice (30) and the frame (23) for the lattice (30), while the lattice (30) contains the edge (31) and defines the surface (32) of the lattice, which is provided between the first region (33) and the second region (34) located opposite the first region (33); in this case, the frame (23) contains the first section (40) and the second section (60), which together form a receiving element for the edge (31) of the lattice (30); wherein the first portion (40) is made of a first polymeric material, and the second portion (60) is made of a second polymeric material; wherein the first polymeric material is harder than the second polymeric material; wherein the first portion (40) comprises a first abutment region (41), and the second portion (60) comprises a second abutment region (61); wherein the first supporting region (41) and the second supporting region (42) are in contact with each other in the connection region (70); wherein the first support region (41) and the second support region (62) are rigidly connected to each other in this connection region (70). 2. The lattice assembly according to claim 1, wherein the first abutment region (41) and the second abutment region (62) are rigidly connected to each other in the joining region (70) by injection molding. 3. The lattice assembly according to claim 1 or 2, wherein the first abutment region (41) and the second abutment region (62) are rigidly connected to each other in the bonding region (70). 4. The lattice assembly according to claim 1, wherein the lattice contains metallic material. 5. The lattice assembly according to claim 1, wherein the first portion (40) relative to the lattice (30) extends inward further than the second portion (60). 6. The lattice assembly according to claim 1, wherein the second supporting region (62) extends from the edge (31) of the lattice (30) to the lateral region of the lattice (30) in the longitudinal direction inward. 7. The lattice assembly according to claim 1, wherein the second abutment region (62) is located at least in separate regions on the outer edge of the edge (31). 8. The lattice assembly according to claim 1, wherein the first portion (41) comprises a first protrusion (42) that extends in the first region (33) to provide an air flow guide there. 9. The lattice assembly according to claim 8, wherein the first protrusion (42) is narrowed in cross section with an increasing interval from the lattice (30). 10. The lattice assembly according to claim 8 or 9, wherein the first portion (41) comprises a second protrusion (43) that extends in the first region (33) and is located outside relative to the first protrusion (42) to ensure that the lattice assembly (21) is mounted on vehicle (10). 11. The lattice assembly of claim 10, wherein the first protrusion (42) and the second protrusion (43) together have a U-shaped profile in cross section. 12. The lattice assembly according to claim 1, wherein the second portion (60) comprises a third protrusion (62) that extends into the second region (34) to provide an air flow guide there. 13. The lattice assembly according to claim 12, wherein the third protrusion (62) in the cross section is narrowed with an increasing interval from the lattice (30) to increase the deformability of the third protrusion (62). 14. A vehicle with a lattice assembly (21) according to one of the preceding claims, wherein the lattice assembly is inserted as a visible structural part. 15. A method of manufacturing a lattice assembly, the lattice assembly comprising a lattice (30) and a frame (23) for the lattice (30); while the lattice (30) contains the edge (31); in this case, the frame (23) contains the first section (40) and the second section (60), which together form a receiving element for the edge (31) of the lattice (30); wherein the first portion (40) is made of a first polymeric material, and the second portion (60) is made of a second polymeric material; wherein the first polymeric material is harder than the second polymeric material; wherein the method includes the following steps: A) the manufacture of the first section (40) by injection molding of polymeric material; B) inserting the first portion (40) into the first partial mold (109) and applying the grating (30) to the first portion (40); C) positioning the second part (110) relative to the first partial shape (109) so that it has contact with both the grating (30) and the first section (40) and together with them forms a cavity (111); D) the manufacture of the second section (60) in the cavity (111) by injection molding of the polymer material.

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