CN111051049B - 车辆夹层构件和用于制造车辆夹层构件的方法 - Google Patents

车辆夹层构件和用于制造车辆夹层构件的方法 Download PDF

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CN111051049B
CN111051049B CN201880056192.4A CN201880056192A CN111051049B CN 111051049 B CN111051049 B CN 111051049B CN 201880056192 A CN201880056192 A CN 201880056192A CN 111051049 B CN111051049 B CN 111051049B
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layer
honeycomb
sandwich element
honeycomb layer
vehicle
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CN111051049A (zh
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M·鲍曼
F·基赛韦特
D·莱格勒
J·沃考克
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Webasto SE
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Abstract

本发明涉及一种车辆夹层构件(1)，所述车辆夹层构件层结构，所述层结构具有蜂窝结构(2)，其特征在于，所述蜂窝结构(2)具有第一下蜂窝层(7)和第二上蜂窝层(8)，所述第一下蜂窝层(7)具有至少一个边缘区段(9)以及中央蜂窝层区域或压缩区域(16)，所述边缘区段沿横向方向在侧面超过所述第二上蜂窝层(8)突出，所述中央蜂窝层区域或压缩区域具有通过压缩而相对于所述边缘区段(9)减少的厚度并且在该中央蜂窝层区域或压缩区域上布置有所述第二上蜂窝层(8)，以及本发明涉及一种用于制造这样的车辆夹层结构(1)的方法。

Description

车辆夹层构件和用于制造车辆夹层构件的方法
技术领域
本发明涉及一种具有层结构的车辆夹层构件，所述层结构具有蜂窝结构；以及涉及一种用于制造车辆夹层构件的方法。
背景技术
这样的车辆夹层构件例如是车顶打开***如滑动式车顶或绕流车顶的盖、车顶模块的面构件、车辆的衬里构件或后座包裹架或滑动天窗。
车辆结构中的夹层构件大多数实施为具有统一构件厚度的面构件。这尤其适用于构件如后座包裹架、滑动天窗或整个车辆车顶。这些构件的芯结构借助具有恒定蜂窝厚度的均质蜂窝芯制成。对于具有提高的强度要求或由于设计而限定轮廓的构件，例如具有大的厚度突变的敞篷车车篷弓形架，不能使用具有恒定厚度的蜂窝。专门地在构件边缘区域中要求特别薄的横截面，而在构件的内部区域中要求大的厚度。与此相应地，必须以费事的机械切削方式加工蜂窝，因为否则存在以下危险：在该方法中被压缩的、在边缘区域中的蜂窝部分由于过少的塑料穿透尤其通过湿气的作用而可能膨胀。
由EP 3 037 601 A1已知一种蜂窝芯结构以及一种具有这样的蜂窝芯结构的夹层构件，所述蜂窝芯结构具有两个蜂窝芯或蜂窝层。所述两个蜂窝芯具有一个布置在这两个蜂窝芯之间的连接层，该连接层仅在蜂窝芯的桥接部区域中具有用于与蜂窝芯连接的粘接剂。该蜂窝芯结构借助在一侧或两侧施加的盖层在成型挤压工具中被挤压成形为夹层构件。
发明内容
本发明所基于的任务是，实现一种开头所述的车辆夹层构件，所述车辆夹层构件在其制造成本方面得到改善；以及提供一种用于制造这样的车辆夹层构件的方法。
根据本发明，该任务在开头所述的车辆夹层构件中通过以下方式来解决：蜂窝结构具有第一下蜂窝层和第二上蜂窝层，第一下蜂窝层具有至少一个边缘区段以及中央蜂窝层区域或压缩区域，所述边缘区段沿横向方向在侧面超过第二上蜂窝层突出，所述中央蜂窝层区域或压缩区域具有通过压缩而相对于边缘区段减小的厚度并且在所述中央蜂窝层区域或压缩区域上布置有第二上蜂窝层。
此外，所述任务通过根据本发明的方法来解决。
在下面说明了本发明的有利构型。
在所提出的汽车夹层构件中，具有不同厚度的蜂窝结构，例如在相对于边缘区域的中央区域中能够以成本低的方式在无需切削加工蜂窝层的情况下被制造。在此，在两个蜂窝层为了形成蜂窝结构而相互连接之前，具有较小抗压刚度的蜂窝层原则上可以借助独立的变形或挤压过程在所设置的压缩区域中被减小到希望的厚度。然而，尤其优选的是，在成型或挤压工具中，将两个尚未变形的蜂窝层以希望的相互定向相对彼此定位地保持并且通过挤压压力将抗压性较高的蜂窝层压入到抗压性较低的蜂窝层中，使得抗压性较低的蜂窝层在抗压性较高的蜂窝层的贴靠区域中被压缩到希望减小的厚度。在此，抗压性较低的蜂窝层的至少一个边缘区域不被压缩或者仅轻微地被压缩，并且必要时仅在其外轮廓上匹配夹层构件的希望的形状，并且例如向边缘倾斜。
根据待制造的夹层构件选择相应蜂窝层的厚度和抗压强度。所述两个蜂窝层中的每一个的抗压刚度例如可以通过使用不同的蜂窝材料和蜂窝结构、较小的纸厚度或在纸蜂窝中的不同纸类型或例如通过使用不同的蜂窝粘合剂来调整。
所述两个蜂窝层被称为第一蜂窝层和第二蜂窝层，并且可以根据它们在成型工具中或在车辆夹层构件的随后安装位置中相对彼此的相应位置也被称为下蜂窝层和上蜂窝层，其中，这些位置说明因而也是可互换的。
根据一个特别优选的构型设置，上方的或抗压性较高的蜂窝层与下方的或抗压性较低的蜂窝层在中央压缩区域或蜂窝层区域中具有共同的接触或贴靠面。为了连接两个蜂窝层可以设置，尤其纤维增强的下塑料层的塑料，例如聚氨酯穿过下蜂窝层的中央压缩区域或蜂窝层区域延伸并且与上蜂窝层形成固定连接，所述下塑料层在下方或抗压性较低的蜂窝层上形成盖层，其中，所述下塑料层符合目的地仅在薄的接触区域中侵入到该未变形的蜂窝层中。因此不需要附加的固定器件。固定的塑料连接防止夹层构件的蜂窝结构在负载下弹性地弯曲运动。抗压性较高的蜂窝层的未变形区域由于该构成轻量化构件的夹层构件的节省重量的原因而不应被塑料加固。
符合目的地，尤其纤维增强的下塑料层构成下方或内侧的盖层，并且尤其纤维增强的上塑料层构成夹层构件的上方或外侧的盖层。
夹层构件的边缘区段环绕地或至少在一个或多个区段中形成在夹层构件上，该边缘区段相对于夹层构件的中央区域以减小的厚度形成。
通过根据本发明的方法，可以如前面所说明的那样通过成型过程在无切削加工的情况下制造具有不同构件厚度的特别轻，但仍然牢固的车辆夹层构件。在一种用于制造具有带有蜂窝结构以及第一或内盖层的层结构的车辆夹层构件的方法中，在挤压工具中将两个由具有不同抗压刚度的蜂窝材料制成的蜂窝层彼此挤压，并且在此，抗压性较高的第二蜂窝层将抗压性较低的第一蜂窝层在压缩区域或蜂窝层区域中的共同的贴靠面区域中压缩到减小的厚度。此外，尤其纤维增强的外塑料层的塑料穿过压缩后的第一蜂窝层的压缩区域或蜂窝层区域侵入并且与另一第二蜂窝层形成固定连接，所述外塑料层在压缩后的蜂窝层上形成盖层。
在此，在该方法中可以有利地设置，制造具有至少一个边缘区段的夹层构件，该边缘区段在抗压性较低的第一蜂窝层中在其压缩区域或蜂窝层区域外并且在另一抗压性较高的第二蜂窝层外形成。
符合目的地，第二盖层或外盖层被施加到蜂窝结构上。
符合目的地，设置前面所说明的、用于制造根据前面阐述的车辆夹层构件的方法。
附图说明
下面参照附图借助根据本发明的车辆夹层构件的实施例详细地阐述本发明。附图示出了：
图1用于制造夹层构件的蜂窝结构的两个蜂窝层部件的侧视图；
图2具有两个闭合的工具半部和布置在其中的、具有两个盖层的变形蜂窝结构的成型工具的侧视图；和
图3制成的夹层构件的侧视图。
具体实施方式
车辆的夹层构件1(参见图3)，例如车顶模块的部件或者能打开的车顶如滑动式车顶或滑动升降式车顶等的盖具有层结构，所述层结构具有作为芯层的中央蜂窝结构2和施加在夹层构件两侧或者说夹层构件1的外侧3和内侧4上的盖层5或6。
蜂窝结构2包含第一蜂窝层7和第二蜂窝层8。在图1中作为下部件示出并且在夹层构件1中形成内侧下蜂窝层7的第一蜂窝层7比在图1中作为上部件示出并且在夹层构件1中形成外侧上蜂窝层8的第二蜂窝层8更大面积地构造。第一下蜂窝层7具有特别均匀的厚度，该厚度小于第二上蜂窝层8的厚度。第一下蜂窝层7具有一抗压刚度，该抗压刚度小于第二上蜂窝层8的抗压刚度。抗压刚度是指蜂窝或蜂窝层7和8在挤压工具的负载下抵抗压缩变形的刚度或强度。
为了制造蜂窝结构2，两个蜂窝层7和8这样地彼此相叠放置，使得第一下蜂窝层7以侧边缘区段9在侧面超过第二上蜂窝层8突出。两个蜂窝层7和8例如借助夹子、喷胶或双面胶带等以手工固定的方式彼此固定。固定的力对于操作相互连接的蜂窝层7和8而言在放入到挤压工具之前和期间应足够，因此不需要较大的连接力。
两个相互连接的蜂窝层7和8被放入到成型或挤压工具10在内部的或下方的纤维增强的塑料层11和外部的或上方的纤维增强的塑料层12之间的空腔中。两个塑料层11和12例如作为层被放入或者借助喷射工具喷射，其中，塑料材料例如是纤维增强的聚氨酯或环氧树脂。在挤压工具10闭合时，基本上包含成型空腔的上挤压工具半部13将第二上蜂窝层8压向第一下蜂窝层7，该第一下蜂窝层在下塑料层11在中间放置有下塑料层11的情况下贴靠在例如具有平坦挤压面的下挤压工具半部14上并且在此由于所述第一下蜂窝层的较低的抗压刚度而在上蜂窝层8的贴靠面15的区域中被压扁和压缩，而第二上蜂窝层8由于其较高的抗压刚度基本上保持其厚度。因此，第一下蜂窝层7具有带有减小的厚度的中央变形的变形或压缩区域16以及边缘区域9，该边缘区域位于中央压缩的蜂窝层区域或压缩区域16和上蜂窝层8外并且基本上保持其原始厚度和通过基本上上挤压工具半部13的成型部而获得其对于夹层构件1所设置的形状。上挤压工具半部13例如包含这样的成型部，使得相应的边缘区域9在其外边缘处被挤压成薄的桥接部17，在该桥接部处，在挤压工具10中制造的夹层构件1的突出部分18能够被分离。为了示出用于分离的示例性位置，在图2中用虚线绘制出分离线19。
两个蜂窝层7和8中的每一个的抗压刚度例如可以通过使用不同的蜂窝材料、较小的纸厚度或在纸蜂窝中不同的纸类型或例如通过使用不同的蜂窝粘合剂来调整。第一下蜂窝层7或者其蜂窝的厚度或高度相应于夹层构件1在其边缘区域9中的最大厚度或者仅略微更大并且在挤压时被压缩到希望的厚度。第二上蜂窝层8仅包括夹层构件1的芯区域，该芯区域相对于边缘区域9以两层蜂窝结构2形成。根据下蜂窝层7的中央部分或压缩区域16的压缩程度，第二上蜂窝层8的最大厚度最大基本上相应于夹层构件1的最大构件高度，或者该最大厚度由于下蜂窝层7的中央部分的厚度而与之相比更小。
因此，在用于制造夹层构件1的复合生产过程中，嵌入到两个纤维增强的塑料层11和12之间的两个蜂窝层7和8被挤压成希望的形状，其中，两个塑料层11和12在制成的夹层构件1中形成两个盖层5和6。在挤压过程中，首先下方的抗压性较低的蜂窝层7压扁。由此，下方的第一蜂窝层7在夹层钩件1的内部区域中的蜂窝厚度剧烈减小，并且纤维增强塑料层11和12的将纤维增强部的纤维附接在蜂窝层7和8的外侧或外表面上的塑料可以从塑料层11起穿过第一下蜂窝层7直至第二上蜂窝层8侵入到夹层构件1的蜂窝芯结构中。现在将两个蜂窝层7和8在其共同的接触或贴靠面15上包围的硬化的塑料将这两个蜂窝层7和8牢固地保持在一起。通过该固定连接排除两个蜂窝层7和8之间的弹性效应并且提供形状稳定的蜂窝结构2。
在选择和设计蜂窝层7和8时应考虑两个盖层的厚度，例如0.5mm至1.0mm。原则上，另外的盖层(例如作为模内覆层(In Mold Coat)或IMC层)也可以被施加在挤压工具10中或随后施加在挤压工具10外。
增强纤维可以例如是玄武岩纤维、碳纤维、天然纤维或玻璃纤维。
蜂窝层的蜂窝优选由纸、铝或塑料，例如酚醛树脂制造。蜂窝也被理解为例如波浪形延伸的构件或垂直于蜂窝层的外表面延伸的间隔件，或者格状结构。
包含的在上面说明中方向说明“上方”和“下方”以及“外部”和“内部”仅涉及附图中的实施例示图并且不限制例如两个蜂窝层7和8的布置，使得较抗压的蜂窝层8也可以占据蜂窝结构和夹层构件1中的下方或内部位置。
可选地，紧接着将夹层构件1从成型或挤压工具中脱模，进行另外的方法步骤，例如修整或裁剪夹层构件1的边缘或棱边。
本发明的在说明书中和根据实施例以及在附图中公开的各个特征能够以任意技术上符合目的的布置和构型与本发明主题以其通常的形式进行组合。
附图标记列表
1 夹层构件
2 蜂窝结构
3 外侧
4 内侧
5 盖层
6 盖层
7 第一蜂窝层
8 第二蜂窝层
9 边缘区段
10 挤压工具
11 内塑料层
12 外塑料层
13 上挤压工具半部
14 下挤压工具半部
15 贴靠面
16 压缩区域
17 桥接部
18 部分
19 分离线

Claims (13)

1.一种车辆夹层构件（1），所述车辆夹层构件具有层结构，所述层结构具有蜂窝结构（2），其特征在于，所述蜂窝结构（2）具有第一蜂窝层（7）和第二蜂窝层（8），所述第一蜂窝层（7）具有至少一个边缘区段（9）以及中央蜂窝层区域或压缩区域（16），所述边缘区段沿横向方向在侧面超过所述第二蜂窝层（8）突出，所述中央蜂窝层区域或压缩区域具有通过压缩而相对于所述边缘区段（9）减小的厚度并且在所述中央蜂窝层区域或压缩区域上布置有所述第二蜂窝层（8）。
2.根据权利要求1所述的车辆夹层构件，其特征在于，所述第一蜂窝层（7）具有抗压刚度，所述抗压刚度小于所述第二蜂窝层（8）的抗压刚度。
3.根据权利要求1或2所述的车辆夹层构件，其特征在于，所述第二蜂窝层（8）与所述第一蜂窝层（7）在所述中央压缩区域或蜂窝层区域（16）中具有共同的接触或贴靠面（15）。
4.根据权利要求1或2所述的车辆夹层构件，其特征在于，下塑料层（11）的塑料穿过所述第一蜂窝层（7）的中央压缩区域或蜂窝层区域（16）延伸并且与所述第二蜂窝层（8）形成固定连接，所述下塑料层构成内盖层（6）。
5.根据权利要求1或2所述的车辆夹层构件，其特征在于，下塑料层（11）构成下方的内盖层（6），并且，上塑料层（12）构成所述夹层构件（1）的上方的外盖层（5）。
6.根据权利要求1或2所述的车辆夹层构件，其特征在于，所述边缘区段（9）具有减小的厚度地在所述夹层构件（1）上环绕地或至少区段地形成。
7.根据权利要求4所述的车辆夹层构件，其特征在于，所述下塑料层（11）是纤维增强的。
8.根据权利要求5所述的车辆夹层构件，其特征在于，所述下塑料层（11）和所述上塑料层（12）都是纤维增强的。
9.一种用于制造具有层结构的车辆夹层构件（1）的方法，所述层结构具有蜂窝结构（2）以及内盖层（6），其中，在挤压工具（10）中将由具有不同抗压刚度的蜂窝材料制成的两个蜂窝层（7, 8）彼此挤压，并且在此，抗压性较高的第二蜂窝层（8）将抗压性较低的第一蜂窝层（7）在压缩区域或蜂窝层区域（16）中的共同的贴靠面（15）的区域中压缩到减小的厚度，其中，下塑料层（11）的塑料穿过压缩后的第一蜂窝层（7）的所述压缩区域或蜂窝层区域（16）侵入并且与第二蜂窝层（8）形成固定连接，所述下塑料层在压缩后的第一蜂窝层（7）上形成内盖层（6）。
10.根据权利要求9所述的方法，其特征在于，制造具有至少一个边缘区段（9）的夹层构件（1），所述边缘区段在抗压性较低的所述第一蜂窝层（7）中在该第一蜂窝层的压缩区域或蜂窝层区域（16）外并且在抗压性较高的第二蜂窝层（8）外形成。
11.根据权利要求9或10所述的方法，其特征在于，外盖层（5）被施加到所述蜂窝结构（2）上。
12.根据权利要求9或10所述的方法，所述方法用于制造根据权利要求1至8中任一项所述的车辆夹层构件（1）。
13.根据权利要求9所述的方法，其特征在于，所述下塑料层（11）是纤维增强的。
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