WO2001026878A1 - Method for producing a roof stiffening for vehicles and a roof stiffening - Google Patents

Method for producing a roof stiffening for vehicles and a roof stiffening Download PDF

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Publication number
WO2001026878A1
WO2001026878A1 PCT/DE2000/002759 DE0002759W WO0126878A1 WO 2001026878 A1 WO2001026878 A1 WO 2001026878A1 DE 0002759 W DE0002759 W DE 0002759W WO 0126878 A1 WO0126878 A1 WO 0126878A1
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WO
WIPO (PCT)
Prior art keywords
roof
layer
foamed
cover layer
foam
Prior art date
Application number
PCT/DE2000/002759
Other languages
German (de)
French (fr)
Inventor
Manfred Ewen
Uwe Königer
Denis Louis
Original Assignee
Johnson Controls Headliner Gmbh
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Johnson Controls Headliner Gmbh filed Critical Johnson Controls Headliner Gmbh
Publication of WO2001026878A1 publication Critical patent/WO2001026878A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
    • B60R13/0212—Roof or head liners
    • B60R13/0225—Roof or head liners self supporting head liners
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/56—After-treatment of articles, e.g. for altering the shape
    • B29C44/5627—After-treatment of articles, e.g. for altering the shape by mechanical deformation, e.g. crushing, embossing, stretching
    • B29C44/5654—Subdividing foamed articles to obtain particular surface properties, e.g. on multiple modules

Definitions

  • the invention relates to a method for producing a roof reinforcement for vehicles and a roof reinforcement produced by this method.
  • a method for producing a roof reinforcement for vehicles and a roof reinforcement manufactured according to the method are known, in which a flat, multi-layer semi-finished product is first produced from a middle hard foam layer and two outer kraftliners, this is then split in the middle and one of the two Parts of the split semi-finished product are then connected on the exposed side of the rigid foam layer with a single kraft liner via an adhesive layer.
  • the material added by the kraftliner is shaped to the final shape in a mold that corresponds to the curvature and contour of the roof skin and the adhesive is cured in this form.
  • the reshaping of the multi-layer material is made possible by the fact that the split material has only one side of a strength liner firmly connected to the foam layer, so that there is a much lower rigidity than a foam layer firmly connected to both sides of the strength liner.
  • the rigidity of the material formed into the contour of the roof arch in the molding tool only occurs when the adhesive layer of the additional Kraftliners under heat.
  • the shaping process results in an asymmetrical expansion and compression behavior of the foam material. This property may include the risk of the component being distorted later.
  • the foam layer consisting of hard foam has a relatively high basis weight in the known material, which is due to the manufacturing process on a belt foaming system.
  • DE 196 32 054 discloses a method for internally installing a roof reinforcement on the roof skin of a vehicle by gluing the roof reinforcement to the roof skin.
  • the roof stiffening is provided in the outer area of its mounting surface with a closed adhesive tape running all around and the central area lying within this adhesive tape with at least one multi-interrupted adhesive tape.
  • the roof stiffener is pressed against the roof skin until the closed adhesive tape that runs all around is completely in contact with the roof skin and seals.
  • a vacuum is generated and maintained between the roof reinforcement and the roof skin through at least one hole arranged within the area surrounded by the closed adhesive tape, until the roof reinforcement lies against the roof skin and the adhesive has tightened.
  • DE 40 35 822 describes an interior trim part for vehicles which consists of a shape-forming foam layer, a cushion layer and a surface layer made of a plastic film.
  • the cushion layer is formed either by a textile fleece or by a flocking layer.
  • DE 40 35 822 describes various manufacturing processes for the interior part for vehicles. Among other things, the flakes are applied to the still viscous plastic film produced by rotary sintering.
  • a headliner for vehicles consisting of a carrier layer made of corrugated cardboard, a relatively hard to medium-hard foam layer and a three-layer laminate.
  • the laminate is composed of an impermeable backing film, an open-cell, soft-elastic foam layer and a surface layer made of textile.
  • the carrier layer made of corrugated fibreboard is placed in a negative form of a shaping tool. Then a foam-forming chemical is applied to the carrier layer and covered with the three-layer laminate. During the molding process, the foam-forming chemical is foamed, so that the resulting foam represents a layer between the carrier layer and the carrier film of the three-layer laminate.
  • the invention has for its object to improve methods for producing a roof stiffener for vehicles and the roof stiffeners produced by this method itself in such a way that a further weight reduction and greater dimensional stability is achieved.
  • a foamed strip material is first produced which has approximately twice the thickness of the desired roof reinforcement. During the foaming process, the material is covered on both sides with a top layer.
  • the cover layers themselves or via an inner coating facing the foamed band material have an affinity for the foamed band material or a hardening and adhesive agent that can be added to the foamed band material. This ensures that the cover layers are firmly connected to the foamed strip material.
  • the plate coated on one side with a cover layer has a much lower rigidity than a foam layer firmly connected on both sides with cover layers. It follows that the shark sandwich element can be adapted to any roof skin without prior shaping and without any significant restoring force occurring.
  • the foam material can be deformed - despite being connected to a cover layer - along a relatively neutral central surface, the half-sandwich element having no endeavor to return to the originally planar, non-contoured shape, so that the subsequent shaping process to the final shape is facilitated by mechanical behavior is achieved.
  • the stiffness of the half sandwich element is achieved by gluing to the roof skin, the composite of roof skin and half sandwich element then forming a sandwich element. This is the only way to give the semi-sandwich element its final shape. This has the advantage that complex tools for the prior shaping of the half-sandwich element and the associated costs can be saved.
  • the stiffness of the foam can be adapted to the requirements through the metered addition of this agent.
  • a semi-hard foam is required in particular.
  • the mechanical properties of the finished composite of half-sandwich element and roof skin correspond to those of a corresponding foam layer firmly connected on both sides with cover layers.
  • the half-sandwich element can be attached to the roof skin by conventional methods.
  • the attachment according to the method described in DE 196 32 054 has proven to be particularly advantageous.
  • the material of the foamed plate is a semi-rigid polyurethane foam. This is easier to shape, especially on small radii of curvature, and has a lower restoring force. There are also advantages in terms of the weight of the material used and the damping property for certain frequencies in the vehicle.
  • the cover layer can be a kraft liner or a fleece. This layer can be designed for high tensile strength and low elongation behavior. This ensures that the half sandwich element can be adapted to any roof skin and brought into its final shape.
  • the cover layer can be provided on the outside and inside with polyolefin coatings. This prevents moisture from penetrating from the outside into the kraft liner and the foam material or via the fundamentally water-permeable fleece into the foam material, so that its mechanical and physical properties remain largely constant over the period of use. On the side of the half-sandwich element facing the roof skin and without a covering layer, the penetration of moisture into the foam material is achieved through the water-impermeable roof skin, so that the mechanical and physical properties are not impaired here either.
  • the additional inner layer improves the binding of the cover layer with the foamed strip material either directly or via a reaction with the hardening and adhesive agent. In addition, a possible risk of void formation in the foam layer due to the moisture in the paper of the kraftliner is prevented.
  • Diisocyanate is suitable as a hardening and adhesive agent. This substance hardens to polyurea under the influence of heat and is therefore particularly suitable for stiffening the foam.
  • the sheet made of foamed material has a density between 30 kg / m 3 and 45 kg / m 3 . Although foamed strip material is actually too heavy in volume to be used as roof reinforcement, this weight range in conjunction with the omission of a cover layer permits the use of the foamed strip material.
  • the cover layer used can have a basis weight between 100 g / m 2 and 250 g / m 2 . These possible basis weights ensure that the cover layer, which also contributes significantly to the rigidity of the finished material in connection with the foam layer, has sufficient stability.
  • Fig. 1 shows a cross section through a roof structure with the roof reinforcement
  • Fig. 2 is a schematic representation of the
  • Fig. 1 shows a cross section through a roof structure with the roof reinforcement according to the invention.
  • the roof consists of an outer roof skin 10, the shape of which is predetermined by the shape of the body, and which faces the vehicle interior pointing roof reinforcement 12.
  • the shape of the roof reinforcement 12 is adapted to the shape of the roof and is connected to it in whole or in part, preferably glued.
  • Fig. 2 shows a basic representation of the layer structure of the composite of the roof reinforcement according to the invention and a roof skin.
  • the roof reinforcement 12 consists of a plate 14 made of polyurethane foam and a cover layer 16 which is connected to the plate 14 made of polyurethane foam.
  • the cover layer 16 is glued to the plate 14 made of polyurethane foam via an adhesive layer 18.
  • This so-called half-sandwich element 12 is adapted to the shape of the roof and is connected to it in whole or in part, preferably glued to it by means of an adhesive layer 20.
  • the cover layer 16 can be provided on the outside and / or inside with coatings made of polyolefins. For the sake of clarity, these coatings are not shown in the drawing.
  • the plate 14 coated on one side with a cover layer 16 can be adapted to any roof skin 10 and brought into the final shape due to its substantially low rigidity without prior shaping.
  • the rigidity of the roof reinforcement 12 is achieved by gluing the uncoated side to the roof skin 10, the composite of roof skin 10 and roof reinforcement 12 then forming a sandwich element.
  • the mechanical properties of the finished composite of half-sandwich element 12 and roof skin 10 surprisingly correspond to those of a foam layer firmly connected on both sides with cover layers.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Body Structure For Vehicles (AREA)
  • Laminated Bodies (AREA)

Abstract

The invention relates to a method for producing a roof stiffening (12) for vehicles and a roof stiffening that is produced according to the inventive method. The roof stiffening which can be applied to the roof skin (10) of the vehicle from the interior consists of a foam layer and an outer cover layer. A foamed strip material (14) which has approximately twice the thickness of the desired roof stiffening is produced. A cover layer (16) is applied to both sides of the strip material during foaming. The foamed strip material is subsequently cut into two plates of a constant thickness and without a contour by splitting said material in a centric manner. The plates are each provided with a cover layer on one side. The compound gets the final shape thereof by gluing the uncovered side of the plate together with the roof skin.

Description

Verfahren zur Herstellung einer Dachversteifung für Fahrzeuge und DachversteifungMethod of manufacturing roof reinforcement for vehicles and roof reinforcement
Die Erfindung betrifft ein Verfahren zur Herstellung einer Dachversteifung für Fahrzeuge und eine nach diesem Verfahren hergestellte Dachversteifung.The invention relates to a method for producing a roof reinforcement for vehicles and a roof reinforcement produced by this method.
Aus der EP 0 825 066 A2 ist ein Verfahren zur Herstellung einer Dachversteifung für Fahrzeuge und eine nach dem Verfahren hergestellte Dachversteifung bekannt, bei der zunächst ein planes mehrschichtiges Halbzeug aus einer mittleren Hartschaumschicht und zwei äußeren Kraftlinern hergestellt, dieses anschließend mittig gespalten und eines der beiden Teile des gespaltenen Halbzeugs dann auf der freiliegenden Seite der Hartschaumschicht mit einem einzelnen Kraftliner über eine Klebeschicht verbunden wird. Ehe jedoch die Klebeschicht abbindet, wird das durch den Kraftliner ergänzte Material in einem der Wölbung und Kontur der Dachhaut entsprechenden Formwerkzeug auf die endgültige Form umgeformt und in dieser Form der Klebstoff ausgehärtet. Das Umformen des mehrschichtigen Materials wird dadurch möglich, daß das gespaltene Material nur auf einer Seite einen fest mit der Schaumschicht verbundenen Kraftliner besitzt, so daß eine wesentlich geringere Steifigkeit vorliegt, als bei einer beidseitig mit Kraftlinern fest verbundenen Schaumschicht. Die Steifigkeit des im Formwerkzeug in die Kontur der Dachwölbung umgeformten Materials tritt erst dann ein, wenn auch die Klebeschicht des zusätzlichen Kraftliners unter Wärmeeinwirkung abgebunden hat.From EP 0 825 066 A2 a method for producing a roof reinforcement for vehicles and a roof reinforcement manufactured according to the method are known, in which a flat, multi-layer semi-finished product is first produced from a middle hard foam layer and two outer kraftliners, this is then split in the middle and one of the two Parts of the split semi-finished product are then connected on the exposed side of the rigid foam layer with a single kraft liner via an adhesive layer. However, before the adhesive layer sets, the material added by the kraftliner is shaped to the final shape in a mold that corresponds to the curvature and contour of the roof skin and the adhesive is cured in this form. The reshaping of the multi-layer material is made possible by the fact that the split material has only one side of a strength liner firmly connected to the foam layer, so that there is a much lower rigidity than a foam layer firmly connected to both sides of the strength liner. The rigidity of the material formed into the contour of the roof arch in the molding tool only occurs when the adhesive layer of the additional Kraftliners under heat.
Da beim bekannten Material bereits vor dem Umformvorgang eine Seite der Hartschaumschicht fest mit einem Kraftliner verbunden ist, ergibt sich beim Umformvorgang ein unsymmetrisches Dehnungs- und Stauchverhalten des Schaummaterials. Diese Eigenschaft beinhaltet unter Umständen die Gefahr eines nachträglichen Verzugs des Bauteils. Ferner besitzt die aus Hartschaum bestehende Schaumschicht beim bekannten Material ein relativ hohes Flächengewicht, was durch den Herstellungsprozeß auf einer Bandschäumanlage begründet ist .Since, in the known material, one side of the rigid foam layer is firmly connected to a kraft liner before the shaping process, the shaping process results in an asymmetrical expansion and compression behavior of the foam material. This property may include the risk of the component being distorted later. Furthermore, the foam layer consisting of hard foam has a relatively high basis weight in the known material, which is due to the manufacturing process on a belt foaming system.
Aus der DE 196 32 054 ist ein Verfahren zur Innenmontage einer Dachversteifung an der Dachhaut eines Fahrzeugs durch Verkleben der Dachversteifung mit der Dachhaut bekannt. Die Dachversteifung wird im äußeren Bereich ihrer Montagefläche mit einem ringsum verlaufenden, geschlossenen Klebstoffband und der innerhalb dieses Klebstoffbandes liegende mittlere Bereich mit wenigstens einem mehrfach unterbrochenen Klebstoffband versehen. Die Dachversteifung wird soweit gegen die Dachhaut gedrückt, bis das ringsum verlaufende, geschlossene Klebstoffband vollständig an der Dachhaut anliegt und abdichtet. Durch wenigstens ein innerhalb des vom geschlossenen Klebstoffband umgebenen Bereichs angeordnetes Loch wird ein Unterdruck zwischen der Dachversteifung und der Dachhaut erzeugt und aufrechterhalten, bis die Dachversteifung an der Dachhaut anliegt und der Klebstoff angezogen hat. In der DE 40 35 822 wird ein Innenausstattungsteil für Fahrzeuge beschrieben, das aus einer formbildenden Schaumschicht, einer Polsterschicht, sowie einer Oberflächenschicht aus einer Kunststoffolie besteht. Die Polsterschicht wird entweder durch ein Textilvlies oder eine Beflockungsschicht gebildet. Außerdem sind in der DE 40 35 822 verschiedene Herstellverfahren für das Innenaustattungsteil für Fahrzeuge beschrieben. Unter anderem werden die Flocken auf die noch zähflüssige, durch Rotationssintern erzeugte Kunststoffolie aufgebracht .DE 196 32 054 discloses a method for internally installing a roof reinforcement on the roof skin of a vehicle by gluing the roof reinforcement to the roof skin. The roof stiffening is provided in the outer area of its mounting surface with a closed adhesive tape running all around and the central area lying within this adhesive tape with at least one multi-interrupted adhesive tape. The roof stiffener is pressed against the roof skin until the closed adhesive tape that runs all around is completely in contact with the roof skin and seals. A vacuum is generated and maintained between the roof reinforcement and the roof skin through at least one hole arranged within the area surrounded by the closed adhesive tape, until the roof reinforcement lies against the roof skin and the adhesive has tightened. DE 40 35 822 describes an interior trim part for vehicles which consists of a shape-forming foam layer, a cushion layer and a surface layer made of a plastic film. The cushion layer is formed either by a textile fleece or by a flocking layer. In addition, DE 40 35 822 describes various manufacturing processes for the interior part for vehicles. Among other things, the flakes are applied to the still viscous plastic film produced by rotary sintering.
Aus der EP 0 364 102 ist ein Dachhimmel für Fahrzeuge bestehend aus einer Trägerschicht aus Wellfaserpappe, aus einer verhältnismäßig harten bis mittelharten SchaumstoffSchicht und einem dreischichtigen Laminat bekannt.From EP 0 364 102 a headliner for vehicles is known consisting of a carrier layer made of corrugated cardboard, a relatively hard to medium-hard foam layer and a three-layer laminate.
Das Laminat setzt sich aus einer undurchlässigen Trägerfolie, aus einer offenzelligen weichelastischen Schaumstoffschicht und aus einer Oberflächenschicht aus Textilstoff zusammen.The laminate is composed of an impermeable backing film, an open-cell, soft-elastic foam layer and a surface layer made of textile.
Zur Herstellung des Dachhimmels wird die Trägerschicht aus Wellfaserpappe in eine Negativform eines Ausformwerkzeugs gelegt. Daraufhin wird eine schaumstoffbildende Chemiekalie auf die Trägerschicht aufgetragen und mit dem dreischichtigen Laminat bedeckt. Beim Ausformen kommt es zum Verschäumen der schaumstoffbildenden Chemikalie, so daß der dabei entstehende Schaumstoff eine Schicht zwischen der Trägerschicht und der Trägerfolie des dreischichtigen Laminats darstellt. Der Erfindung liegt die Aufgabe zugrunde, Verfahren zur Herstellung einer Dachversteifung für Fahrzeuge sowie die nach diesen Verfahren hergestellten Dachversteifungen selbst dahingehend zu verbessern, daß eine weitere Gewichtsreduzierung und eine größere Formbeständigkeit erzielt wird.To produce the headlining, the carrier layer made of corrugated fibreboard is placed in a negative form of a shaping tool. Then a foam-forming chemical is applied to the carrier layer and covered with the three-layer laminate. During the molding process, the foam-forming chemical is foamed, so that the resulting foam represents a layer between the carrier layer and the carrier film of the three-layer laminate. The invention has for its object to improve methods for producing a roof stiffener for vehicles and the roof stiffeners produced by this method itself in such a way that a further weight reduction and greater dimensional stability is achieved.
Diese Aufgabe wird bei einem Verfahren zur Herstellung einer Dachversteifung für Fahrzeuge nach dem Oberbegriff des Anspruchs 1 durch die im Kennzeichen des Anspruchs 1 angegebenen Merkmale gelöst und bei einer nach diesem Verfahren hergestellten Dachversteifung nach dem Oberbegriff des Anspruchs 2 durch die im Kennzeichen des Anspruchs 2 angegebenen Merkmale gelöst. Weiterbildungen und vorteilhafte Ausgestaltungen ergeben sich aus den Unteransprüchen.This object is achieved in a method for producing a roof reinforcement for vehicles according to the preamble of claim 1 by the features specified in the characterizing part of claim 1 and in a roof reinforcement produced by this method according to the preamble of claim 2 by the characteristics specified in the characterizing part of claim 2 Features resolved. Further developments and advantageous refinements result from the subclaims.
Bei dem erfindungsgemäßen Verfahren wird zunächst ein geschäumtes Bandmaterial hergestellt, das etwa die doppelte Dicke der gewünschten Dachversteifung besitzt. Beim Schäumvorgang wird das Material beidseitig mit einer Deckschicht belegt .In the method according to the invention, a foamed strip material is first produced which has approximately twice the thickness of the desired roof reinforcement. During the foaming process, the material is covered on both sides with a top layer.
Die Deckschichten weisen selbst oder über eine innere, zum geschäumten Bandmaterial weisende Beschichtung eine Affinität zu dem geschäumten Bandmaterial oder einem dem geschäumten Bandmaterial zusetzbaren Härte- und Klebemittel auf. Dadurch wird erreicht, daß die Deckschichten fest mit dem geschäumten Bandmaterial verbunden werden.The cover layers themselves or via an inner coating facing the foamed band material have an affinity for the foamed band material or a hardening and adhesive agent that can be added to the foamed band material. This ensures that the cover layers are firmly connected to the foamed strip material.
Durch das anschließende mittige Spalten des geschäumten Bandmaterials in zwei einseitig mit einer Deckschicht versehene Platten konstanter Dicke wird erreicht, daß jeweils ein sogenanntes Halbsandwichelement entsteht, das als Dachversteifung dient und seine endgültige Form durch Verklebung der unbeschichteten Seite des geschäumten Bandmaterials mit der Dachhaut erhält. Dieses hat den Vorteil, daß - im Gegensatz zu herkömmlichen Verfahren - äußerst schnell zwei Halbsandwichelemente als Dachversteifungen erhalten werden, die nur noch an die Dachhaut angebracht werden müssen.Due to the subsequent central splitting of the foamed strip material into two with a cover layer on one side Sheets of constant thickness are achieved so that a so-called half-sandwich element is created, which serves as a roof reinforcement and receives its final shape by gluing the uncoated side of the foamed strip material to the roof skin. This has the advantage that - in contrast to conventional methods - two half-sandwich elements are obtained as roof reinforcements extremely quickly, which only have to be attached to the roof skin.
Gegenüber einer Dachversteifung bestehend aus einer mittleren Schaumstoffschicht und zwei äußeren Deckschichten entfällt eine Deckschicht. Dadurch ergibt sich außerdem eine signifikante Gewichts- und Materialeinsparung und somit auch eine Reduzierung der Kosten.Compared to a roof reinforcement consisting of a middle foam layer and two outer cover layers, there is no cover layer. This also results in significant weight and material savings and thus a reduction in costs.
Die einseitig mit einer Deckschicht beschichtete Platte besitzt eine wesentlich geringere Steifigkeit als eine beidseitig mit Deckschichten fest verbundene Schaumstoffschicht . Daraus ergibt sich, daß das Haibsandwichelement ohne vorherige Formgebung und ohne auftretende wesentliche Rückstellkraft an jede beliebige Dachhaut angepaßt werden kann.The plate coated on one side with a cover layer has a much lower rigidity than a foam layer firmly connected on both sides with cover layers. It follows that the shark sandwich element can be adapted to any roof skin without prior shaping and without any significant restoring force occurring.
Das Schaummaterial läßt sich - trotz Verbindung mit einer Deckschicht - entlang einer relativ neutralen Mittelfläche verformen, wobei das Halbsandwichelement kein Bestreben hat, in die ursprünglich planare, keine Kontur aufweisende Form zurückzukehren, so daß für den späteren Umformvorgang auf die endgültige Form ein erleichterndes mechanisches Verhalten erzielt wird. Die Steifigkeit des Halbsandwichelements wird durch Verkleben mit der Dachhaut erreicht, wobei der Verbund von Dachhaut und Halbsandwichelement dann ein Sandwichelement bildet. Erst dadurch erhält das Halbsandwichelement seine endgültige Form. Daraus ergibt sich der Vorteil, daß aufwendige Werkzeuge zur vorherigen Formgebung des Halbsandwichelements und die damit verbundenen Kosten eingespart werden können.The foam material can be deformed - despite being connected to a cover layer - along a relatively neutral central surface, the half-sandwich element having no endeavor to return to the originally planar, non-contoured shape, so that the subsequent shaping process to the final shape is facilitated by mechanical behavior is achieved. The stiffness of the half sandwich element is achieved by gluing to the roof skin, the composite of roof skin and half sandwich element then forming a sandwich element. This is the only way to give the semi-sandwich element its final shape. This has the advantage that complex tools for the prior shaping of the half-sandwich element and the associated costs can be saved.
Bei Zusatz eines Härte- und Klebemittels kann die Steifigkeit des Schaumes über die dosierte Zugabe dieses Mittels den Erfordernissen angepaßt werden. Bei dem erfindungsgemäßen Verfahren ist insbesondere ein halbharter Schaum erforderlich.If a hardening and adhesive agent is added, the stiffness of the foam can be adapted to the requirements through the metered addition of this agent. In the method according to the invention, a semi-hard foam is required in particular.
Die mechanischen Eigenschaften des fertigen Verbundes aus Halbsandwichelement und Dachhaut entsprechen denen einer entsprechenden beidseitig mit Deckschichten fest verbundenen Schaumstoffschicht .The mechanical properties of the finished composite of half-sandwich element and roof skin correspond to those of a corresponding foam layer firmly connected on both sides with cover layers.
Die Anbringung des Halbsandwichelements an die Dachhaut kann nach herkömmlichen Verfahren erfolgen. Als besonders vorteilhaft hat sich die Anbringung gemäß des in der DE 196 32 054 beschriebenen Verfahrens herausgestellt.The half-sandwich element can be attached to the roof skin by conventional methods. The attachment according to the method described in DE 196 32 054 has proven to be particularly advantageous.
Bei einer nach Anspruch 2 hergestellten Dachversteifung ist das Material der geschäumten Platte ein halbharter Polyurethanschaum. Dieser läßt sich leichter besonders auf kleine Krümmungsradien umformen und besitzt eine geringere Rückstellkraft. Ferner ergeben sich Vorteile hinsichtlich des Gewichts des eingesetzten Materials und der Dämpfungseigenschaft für bestimmte Frequenzen im Fahrzeug. Die Deckschicht kann ein Kraftliner oder Vlies sein. Diese Schicht kann auf hohe Zugfestigkeit und geringes Dehnungsverhalten ausgelegt werden. Dadurch ist gewährleistet, daß das Halbsandwichelement an jede beliebige Dachhaut angepaßt und in die endgültige Form gebracht werden kann.In a roof reinforcement manufactured according to claim 2, the material of the foamed plate is a semi-rigid polyurethane foam. This is easier to shape, especially on small radii of curvature, and has a lower restoring force. There are also advantages in terms of the weight of the material used and the damping property for certain frequencies in the vehicle. The cover layer can be a kraft liner or a fleece. This layer can be designed for high tensile strength and low elongation behavior. This ensures that the half sandwich element can be adapted to any roof skin and brought into its final shape.
Die Deckschicht kann außen und innen mit Beschichtungen aus Polyolefinen versehen sein. Dies verhindert von außen ein Eindringen von Feuchtigkeit in den Kraftliner und das Schaummaterial oder über das grundsätzlich wasserdurchlässige Vlies in das Schaummaterial, so daß dessen mechanische und physikalische Eigenschaften über die Nutzungsdauer weitgehend konstant bleiben. Bei der zur Dachhaut weisenden, ohne Deckschicht versehenen Seite des Halbsandwichelements wird das Eindringen von Feuchtigkeit in das Schaummaterial durch die wasserundurchlässige Dachhaut erreicht, so daß auch hier die mechanischen und physikalischen Eigenschaften nicht beeinträchtigt werden. Durch die zusätzliche innere Schicht wird entweder direkt oder über eine Reaktion mit dem Härte- und Klebemittel die Bindung der Deckschicht mit dem geschäumten Bandmaterial verbessert. Außerdem wird eine wegen der Feuchtigkeit im Papier der Kraftliner mögliche Gefahr einer Lunkerbildung in der Schaumschicht verhindert.The cover layer can be provided on the outside and inside with polyolefin coatings. This prevents moisture from penetrating from the outside into the kraft liner and the foam material or via the fundamentally water-permeable fleece into the foam material, so that its mechanical and physical properties remain largely constant over the period of use. On the side of the half-sandwich element facing the roof skin and without a covering layer, the penetration of moisture into the foam material is achieved through the water-impermeable roof skin, so that the mechanical and physical properties are not impaired here either. The additional inner layer improves the binding of the cover layer with the foamed strip material either directly or via a reaction with the hardening and adhesive agent. In addition, a possible risk of void formation in the foam layer due to the moisture in the paper of the kraftliner is prevented.
Als Härte- und Klebemittel eignet sich Diisocyanat. Dieser Stoff härtet unter Wärmeeinwirkung zu Polyharnstoff aus und eignet sich damit besonders zur Versteifung des Schaums. Die Platte aus geschäumtem Material besitzt ein Raumgewicht zwischen 30 kg/m3 und 45 kg/m3. Obwohl geschäumtes Bandmaterial eigentlich ein zu schweres Raumgewicht besitzt, um als Dachversteifung eingesetzt zu werden, gestattet dieser Gewichtsbereich in Verbindung mit dem Weglassen einer Deckschicht die Verwendung des geschäumten Bandmaterials.Diisocyanate is suitable as a hardening and adhesive agent. This substance hardens to polyurea under the influence of heat and is therefore particularly suitable for stiffening the foam. The sheet made of foamed material has a density between 30 kg / m 3 and 45 kg / m 3 . Although foamed strip material is actually too heavy in volume to be used as roof reinforcement, this weight range in conjunction with the omission of a cover layer permits the use of the foamed strip material.
Die verwendete Deckschicht kann ein Flächengewicht zwischen 100 g/m2 und 250 g/m2 aufweisen. Mit diesen möglichen Flächengewichten ist sichergestellt, daß die Deckschicht, die auch wesentlich zur Steifigkeit des fertigen Materials in Verbindung mit der Schaumschicht beiträgt, eine ausreichende Stabilität besitzt.The cover layer used can have a basis weight between 100 g / m 2 and 250 g / m 2 . These possible basis weights ensure that the cover layer, which also contributes significantly to the rigidity of the finished material in connection with the foam layer, has sufficient stability.
Nachfolgend wird die Erfindung anhand der Zeichnung erläutert. In der Zeichnung zeigen:The invention is explained below with reference to the drawing. The drawing shows:
Fig. 1 einen Querschnitt durch einen Dachaufbau mit der erfindungsgemäßen Dachversteifung undFig. 1 shows a cross section through a roof structure with the roof reinforcement and
Fig. 2 eine prinzipielle Darstellung desFig. 2 is a schematic representation of the
Schichtaufbaus des Verbundes aus einer erfindungsgemäßen Dachversteifung und einer Dachhaut .Layer structure of the composite from a roof reinforcement according to the invention and a roof skin.
Fig. 1 zeigt einen Querschnitt durch einen Dachaufbau mit der erfindungsgemäßen Dachversteifung. Das Dach besteht dabei aus einer außenliegenden Dachhaut 10, die in ihrer Form von der Karosserieform vorgegeben ist, und der zum Fahreuginnenraum weisenden Dachversteifung 12. Die Dachversteifung 12 ist in ihrer Form an die Form des Daches angepaßt und mit diesem ganz- oder teilflächig verbunden, vorzugsweise verklebt.Fig. 1 shows a cross section through a roof structure with the roof reinforcement according to the invention. The roof consists of an outer roof skin 10, the shape of which is predetermined by the shape of the body, and which faces the vehicle interior pointing roof reinforcement 12. The shape of the roof reinforcement 12 is adapted to the shape of the roof and is connected to it in whole or in part, preferably glued.
Fig. 2 zeigt eine prinzipielle Darstellung des Schichtaufbaus des Verbundes aus der erfindungsgemäßen Dachversteifung und einer Dachhaut.Fig. 2 shows a basic representation of the layer structure of the composite of the roof reinforcement according to the invention and a roof skin.
Die Dachversteifung 12 besteht aus einer Platte 14 aus Polyurethanschaum und einer Deckschicht 16, die mit der Platte 14 aus Polyurethanschaum verbunden ist. Die Deckschicht 16 ist über eine Klebeschicht 18 mit der Platte 14 aus Polyurethanschaum verklebt . Dieses sogenannte Halbsandwichelement 12 ist an die Form des Daches angepaßt und mit diesem ganz- oder teilflächig verbunden, vorzugsweise über eine Klebeschicht 20 mit diesem verklebt. Die Deckschicht 16 kann abhängig vom Herstellungsverfahren der Dachversteifung 12 außen und/oder innen mit Beschichtungen aus Polyolefinen versehen sein. Diese Beschichtungen sind der Übersicht halber in der Zeichnung nicht dargestellt.The roof reinforcement 12 consists of a plate 14 made of polyurethane foam and a cover layer 16 which is connected to the plate 14 made of polyurethane foam. The cover layer 16 is glued to the plate 14 made of polyurethane foam via an adhesive layer 18. This so-called half-sandwich element 12 is adapted to the shape of the roof and is connected to it in whole or in part, preferably glued to it by means of an adhesive layer 20. Depending on the manufacturing method of the roof reinforcement 12, the cover layer 16 can be provided on the outside and / or inside with coatings made of polyolefins. For the sake of clarity, these coatings are not shown in the drawing.
Die einseitig mit einer Deckschicht 16 beschichtete Platte 14 läßt sich wegen ihrer wesentlich geringen Steifigkeit ohne vorherige Formgebung an jedes beliebige Dachhaut 10 anpassen und in die endgültige Form bringen. Die Steifigkeit der Dachversteifung 12 wird durch Verkleben der unbeschichteten Seite mit der Dachhaut 10 erreicht, wobei der Verbund von Dachhaut 10 und Dachversteifung 12 dann ein Sandwichelement bildet. Die mechanischen Eigenschaften des fertigen Verbundes aus Halbsandwichelement 12 und Dachhaut 10 entsprechen überraschenderweise denen einer beidseitig mit Deckschichten fest verbundenen Schaumstoffschicht . The plate 14 coated on one side with a cover layer 16 can be adapted to any roof skin 10 and brought into the final shape due to its substantially low rigidity without prior shaping. The rigidity of the roof reinforcement 12 is achieved by gluing the uncoated side to the roof skin 10, the composite of roof skin 10 and roof reinforcement 12 then forming a sandwich element. The mechanical properties of the finished composite of half-sandwich element 12 and roof skin 10 surprisingly correspond to those of a foam layer firmly connected on both sides with cover layers.

Claims

P a t e n t a n s p r ü c h e Patent claims
1. Verfahren zur Herstellung einer Dachversteifung für Fahrzeuge, die von innen an die Dachhaut des Fahrzeugs anbringbar ist, bestehend aus einer Schaumschicht und einer äußeren Deckschicht, die an einer Seite der Schaumschicht befestigt ist, dadurch gekennzeichnet, daß ein geschäumtes Bandmaterial hergestellt wird, das etwa die doppelte Dicke der gewünschten Dachversteifung hat, wobei beim Schäumvorgang dem Bandmaterial beidseitig eine Deckschicht aufgelegt wird, die selbst oder über eine innere Beschichtung eine Affinität zu dem geschäumten Bandmaterial oder einem zusetzbaren Härte- und Klebemittel aufweist, daß daraufhin das geschäumte Bandmaterial durch mittiges Spalten in zwei einseitig mit einer Deckschicht versehene Platten konstanter Dicke und ohne Kontur geschnitten wird, und schließlich die endgültige Formgebung der Platte durch Verklebung der unbeschichteten Seite der Platte mit der Dachhaut erhalten wird.1. A method for producing a roof reinforcement for vehicles, which can be attached from the inside to the roof skin of the vehicle, consisting of a foam layer and an outer cover layer, which is attached to one side of the foam layer, characterized in that a foamed strip material is produced, the has approximately twice the thickness of the desired roof reinforcement, with a covering layer being placed on both sides of the tape material during the foaming process, which, itself or via an inner coating, has an affinity for the foamed tape material or an addable hardening and adhesive agent, so that the foamed tape material is split by central splitting is cut into two panels of constant thickness and without a contour provided with a covering layer, and finally the final shaping of the panel is obtained by gluing the uncoated side of the panel to the roof skin.
2. Nach Anspruch 1 hergestellte Dachversteifung, dadurch gekennzeichnet , daß das Material der geschäumten Platte ein halbharter Polyurethanschaum ist.2. Roof reinforcement manufactured according to claim 1, characterized in that the material of the foamed plate is a semi-rigid polyurethane foam.
3. Dachversteifung nach Anspruch 2, dadurch gekennzeichnet, daß die Deckschicht ein Kraftliner oder ein Vlies ist. 3. Roof reinforcement according to claim 2, characterized in that the cover layer is a kraft liner or a fleece.
4. Dachversteifung nach Anspruch 2 oder 3, dadurch gekennzeichnet, daß die Deckschicht außen und innen mit Beschichtungen aus Polyolefinen versehen ist.4. Roof stiffening according to claim 2 or 3, characterized in that the cover layer is provided on the outside and inside with coatings made of polyolefins.
5. Dachversteifung nach einem der Ansprüche 2 bis 4, dadurch gekennzeichnet, daß als Härte- und Klebemittel Diisocy- anat dient .5. Roof stiffening according to one of claims 2 to 4, characterized in that diisocyanate is used as the hardening and adhesive agent.
6. Dachversteifung nach einem der Ansprüche 2 bis 5, dadurch gekennzeichnet, daß die Platte aus geschäumtem Material ein Raumgewicht zwischen 30 kg/m3 und 45 kg/m3 aufweist.6. Roof stiffening according to one of claims 2 to 5, characterized in that the plate made of foamed material has a density between 30 kg / m 3 and 45 kg / m 3 .
7. Dachversteifung nach einem der Ansprüche 2 bis 6, dadurch gekennzeichnet, daß die Deckschicht ein Flächengewicht zwischen 100 g/m2 und 250 g/m2 aufweist. 7. Roof reinforcement according to one of claims 2 to 6, characterized in that the cover layer has a weight per unit area between 100 g / m 2 and 250 g / m 2 .
PCT/DE2000/002759 1999-10-14 2000-08-12 Method for producing a roof stiffening for vehicles and a roof stiffening WO2001026878A1 (en)

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DE1999149643 DE19949643C2 (en) 1999-10-14 1999-10-14 Process for manufacturing roof reinforcement for vehicles and roof reinforcement

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CN112689560A (en) * 2018-09-21 2021-04-20 大众汽车股份公司 Vehicle roof

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