Reinforcement insert made of composite material provided with anchoring elements

Abstract

The invention relates to a reinforcing element (100) made of composite plastic for a body part (200), forming an insert that can be at least partially overmolded into the body part (200), the reinforcing element (100) comprising a wall (300) defined by a profile (330). The reinforcing element (100) is made of composite plastic, and at least a portion of the profile (330) comprises an overmolded mechanical anchoring recess (400).

Description

Technical Field

[0001] The present invention relates to the field of the motor vehicle industry and, in particular, to the field of plastic body parts locally reinforced by overmoulded inserts. Background Art

[0002] In particular, the invention relates to a reinforcing element made of composite plastic of the insert type, which can be partially overmolded into a vehicle body part in order to mechanically reinforce the latter.

[0003] In the prior art, rear opening elements made of plastic, in particular of the tailgate type, are known, which comprise an external skin and a structural inner lining made of thermoplastic material with a filler material. The thermoplastic material constituting the lining is filled, for example, with talc or glass fibers to increase its strength properties.

[0004] The tailgate lining is subject to many mechanical stresses during its manufacture, mainly due to the geometric deformations inherent in the moulding process, and also during use after it has been assembled to the vehicle.

[0005] To better withstand the mechanical forces of vehicle use, the interior lining is generally reinforced with reinforcing elements made of sheet metal, obtained by conventional cutting, stamping, or punching processes. These reinforcing elements can be overmolded into the thermoplastic material of the lining in the area of ​​hinges, ball joints, or locks to mitigate the various forces generated by the equipment (ejectors, stops, or seals) that cause deformation.

[0006] The reinforcement efficiency of the overmolded insert depends on the quality and robustness of the mechanical connection between the vehicle body part and the reinforcing insert.

[0007] It is known to mechanically lock a reinforcing insert in a component by at least partially encapsulating the overmolded insert in a plastic material. This encapsulation consists in overmolding the insert by at least partially covering two opposite faces of the insert, or more generally, overmolding the insert on both sides of a given point of the insert.

[0008] The encapsulation may also be at the periphery of an overmolded insert, where the overmolded material passes from one face of the part to the other, surrounding and covering the edge of the part.

[0009] Such encapsulation alone does not provide a completely satisfactory solution in terms of mechanical anchoring.

[0010] To improve the mechanical anchoring properties, it is known to mechanically lock the reinforcing insert in the part by providing the overmolded insert with holes extending through the thickness of the part, through which the plastic material passes, thus ensuring the mechanical retention of the two elements (insert and part). These through-holes are easy to obtain for inserts made of sheet metal in traditional production processes; however, they present industrial difficulties for inserts made of composite materials.

[0011] Thus, existing solutions are not entirely satisfactory and a solution for improving the anchoring properties of such inserts is necessary. Summary of the Invention

[0012] The present invention aims in particular to overcome the drawbacks of the prior art solutions by providing a solution comprising a reinforcing insert made of composite plastics and provided with an overmolded mechanical anchor. "Composite plastics with filler material" refers to materials consisting of thermoplastic or thermosetting resins containing inorganic or natural fillers (e.g. talc) and / or reinforcing fibers (e.g. carbon, glass, flax, hemp, etc.).

[0013] To this end, the present invention provides a reinforcing element made of composite plastic for a body part, forming an insert that can be at least partially overmolded into the body part, the reinforcing element comprising a wall defined by a profile. The reinforcing element is made of composite plastic, and at least a portion of the profile comprises an overmolded mechanical anchoring recess.

[0014] The reinforcing element may additionally comprise one or more of the following features, taken alone or in combination:

[0015] - the mechanical anchoring recess has a shape comprising a narrowing;

[0016] The mechanical anchoring recess has a generally flared shape starting from the profile edge;

[0017] - the mechanical anchoring notches are regularly distributed over said portion of the profile;

[0018] - the portion of the profile comprising the recess comprises a bearing surface forming an extension of the wall as claimed in the preceding claim, wherein the thickness of said bearing surface is less than the thickness of the projection;

[0019] - the wall comprises a first face and a second face opposite the first face, the overmolded mechanical anchoring recess being formed on the first face and / or the second face;

[0020] a first set of overmolded mechanical anchoring recesses formed on a first face and a second set of overmolded mechanical anchoring recesses formed on a second face, the recesses on one face being the inverse of the recesses on the other face;

[0021] - the wall of the reinforcing element comprises an overmolded mechanical anchor projecting on the wall in a direction locally non-perpendicular to said wall;

[0022] - Mechanical anchors form a tenon in the wall.

[0023] The invention also relates to a motor vehicle body part made of plastic material comprising a reinforcing element according to the invention.

[0024] The body part may further include one or more of the following features, taken alone or in combination:

[0025] - the reinforcing element is formed as an insert encapsulated by the plastic material of the body part over at least a portion of the contour of the wall, preferably over the entire contour;

[0026] - the plastic material of the body part covers the supporting surface and fills the recess;

[0027] - The plastic material of the body part covers the edge of the wall at the contour.

[0028] According to one embodiment, the body part forms a tailgate lining. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The invention will be better understood from the following description which is given by way of example only and which refers to the accompanying drawings in which:

[0030] Figure 1 An example of a tailgate liner is shown that includes an overmolded reinforcement insert that forms a reinforcing element at a stress-bearing area of ​​the liner;

[0031] Figure 2 Show Figure 1 Detail showing the location of the reinforcing side inserts in the hinge and side pillar areas of the liner;

[0032] Figure 3 An example of a reinforcing element according to the invention is shown: an overmolded side insert;

[0033] Figure 4 Show Figure 3 Detail of a reinforcing element comprising a mechanical anchor for overmolding, the mechanical anchor being provided with a bearing surface and an anchoring recess on the edge of the insert;

[0034] Figure 5 Shown in bottom view Figure 4 Details;

[0035] Figure 6 shows the mechanical anchoring between the part and an overmolded mechanical anchor provided with a bearing surface and anchoring recesses;

[0036] Figure 7A ,

[0037] Figure 7B ,and

[0038] Figure 7C Shown is the mechanical anchoring between the part and an over-molded mechanical anchoring member protruding from the wall. DETAILED DESCRIPTION

[0039] Figure 1 An example of a body part 200 made of plastic, preferably thermoplastic, comprising a reinforcing element 100 according to the invention is shown. According to this example, this is a tailgate lining 200, which comprises overmolded reinforcing inserts forming reinforcing elements in the following stressed areas of the lining: side pillars, hinge area, ejector fastening area, latch area, etc.

[0040] Figure 2 Show Figure 1 A detail of FIG. 1 showing a reinforcing element 100 forming a reinforcing insert overmolded in a tailgate lining 200 , located at a side pillar extending from the hinge to the region of the articulation ball joint and the fixed ejector.

[0041] Now refer to Figure 3 , which shows an example of a reinforcing element 100 according to the present invention. This reinforcing element 100 forms an insert that can be at least partially overmolded into a body part 200. The reinforcing element 100 comprises a wall 300 defined by a contour 330. A contour forms the outer limit of an object's surface. Thus, the contour 330 forms the outer limit of the wall 300, also referred to as the terminal end of the reinforcing element 100.

[0042] The overall shape of the wall 300 is constrained by the shape of the area in which it is overmolded in the body part 200 .

[0043] The reinforcing element 100 is made of composite plastic.

[0044] The composite plastic is preferably a filled thermosetting plastic comprising inorganic or natural fillers (eg talc) and / or comprising reinforcing fibers (eg fibers of carbon, glass, flax, hemp, etc.).

[0045] As shown in the attached drawings (especially Figure 4 ), at least a portion of the profile 330 of the wall 300 includes an overmolded mechanical anchoring recess 400.

[0046] A "recess" is understood to be a very short groove relative to the dimensions of the insert 100. The recess thus forms a cutout in the wall 300 at the contour 330. The recess thus forms a hollowing out of a given geometry realized in the thickness of the wall 300, that is to say a hollow shape that does not completely pass through the entire thickness of the reinforcing element 100.

[0047] The recesses 400 are intended to be filled during overmolding by the plastic material of the part 200. They thus resist separation of the overmolding when the part is subjected to mechanical stresses such as tension, bending, shear or torsion of the insert 100 relative to the part 200 in a local plane substantially parallel to the wall 300.

[0048] According to an advantageous embodiment, the recess 400 has a shape that widens from the edge of the part, projected onto a local plane of the wall 300, thus having, for example, a "puzzle piece" shape, a trapezoidal shape, or a dovetail shape. This shape further improves the mechanical anchoring properties of the overmolding by resisting the mutual separation of the part and the insert in a direction generally perpendicular to the part contour, along shear or tensile movements generally parallel to the support surface 500. This tear-resistant function is achieved by all recesses whose sides, projected onto a local plane of the wall 100, have a narrowing point, preferably located closer to the part contour than the bottom of the recess.

[0049] Between two consecutive recesses 400 , a raised portion 410 is defined which, in projection onto a local plane of the wall 300 , has a shape defined by and complementary to the shape of the two adjacent recesses.

[0050] Thus, at least a portion of the profile 330 of the wall 300 comprises successive notches 400 and protrusions 410 defining the typical shape of a so-called "crenelation". Figure 3 、 Figure 4 、 Figure 5 ), the mechanical anchoring recesses 400 are distributed along at least a portion of the profile 330 of the wall 300 according to a substantially regular step size.

[0051] It can be understood that the function of the alternating arrangement of the recesses 400 and the protrusions 410 is to resist the relative movement of the insert 100 relative to the part 200 in a direction substantially perpendicular to the local plane of the wall 300. In fact, when the two faces 310, 320 (upper and lower) of the package are overmolded, since the recesses 400 between each protrusion 410 do not penetrate the thickness of the part (the depression of the protrusion is closed), the movement of the part 200 in a direction substantially perpendicular to the local plane of the wall 300 is prevented by the material below each recess 400.

[0052] The recesses 400 may have any shape, and thus the raised portions 410 formed between the recesses 400 may also have any shape. Figure 3 、 4 5, the recess 400 has the same generally trapezoidal shape and forms a protrusion 410 having a complementary shape, also trapezoidal.

[0053] The wall 300 includes a first face 310 and a second face 320 opposite the first face, and overmolded mechanical anchoring recesses 400 are formed on the first face and / or the second face.

[0054] According to one embodiment, the reinforcing element 100 includes recesses on both faces 310 and 320. Thus, a first set of overmolded mechanical anchoring recesses 400 is formed on the first face 310, and a second set of overmolded mechanical anchoring recesses 400 is formed on the second face 320. The recesses 400 on one face are reciprocal to the recesses on the other face, i.e., each recess on one face is substantially opposite a protrusion on the other face. This arrangement of two rows of recesses 400 (protrusions 410) further improves the mechanical anchoring properties of the overmolding. The reciprocal arrangement of the recesses 400 between each row avoids very small material thicknesses at the edge of the component, which are therefore at least equal to the thickness of the protrusions 410.

[0055] According to a particularly Figure 4 In the preferred embodiment shown in FIG, the portion of the profile 330 comprising the recess 400 further comprises a support surface 500 forming an extension of the wall 300. The thickness of the support surface 500 is preferably less than the thickness of the protrusion 410. According to one embodiment, the thickness of the support surface 500 is substantially equal to the thickness of the wall 300 remaining below the recess 400. Thus, the support surface 500 can form a layer having a thickness of less than 3 mm, preferably less than 2 mm.

[0056] According to one embodiment illustrated in the figures, the support surface 500 forms a continuation of the wall 300 constituting the bottom of the recess 400 .

[0057] Figure 6 The mechanical anchoring between the part and the overmolded mechanical anchor is shown, the mechanical anchor being provided with a bearing surface and an anchoring recess. Figure 6 The lower left figure shows, in top view, the mechanical anchoring between the component 200 and an overmolded mechanical anchor provided with a bearing surface 500 and an anchoring recess 400. Each protrusion 410 is bounded on two sides by a recess 400. It will be understood that the bearing surfaces 500 also function to resist relative movement of the insert 100 with respect to the component 200 in a direction generally perpendicular to the plane defined by the bearing surfaces 500.

[0058] Figure 6 The right and top diagrams show Figure 6 The two sections AA (upper) and BB (right) indicated in the left figure show that according to this embodiment, the overmolding fills the recess 400 and does not overmold the raised portion 410. Of course, the overmolding could also cover the raised portion 410.

[0059] Advantageously, during the process of molding the reinforcing element 100 , the recess 400 and the bearing surface 500 are obtained by molding.

[0060] The recess 400 , filled with the plastic material of the part 200 during overmolding, thus counteracts separation of the insert 100 relative to the part 200 in a plane substantially parallel to the support surface 500 .

[0061] Furthermore, when the shape of the notch 400 includes a narrowing that lies in a plane generally parallel to the support surface 500 , the notch 400 can resist tearing caused by translational movement of the part along a plane generally parallel to the support surface 500 .

[0062] According to another embodiment ( Figure 5 、 7A to 7C ), the reinforcing element 100 includes additional mechanical anchors, which are preferably located outside the edges of the reinforcing element 100 and outside the area of ​​the profile containing the notch. The wall 300 of the reinforcing element 100 includes an overmolded mechanical anchor 700 that protrudes on the wall 300 in a direction that is partially non-perpendicular to the wall 300.

[0063] This overmolded mechanical anchoring portion 700 further improves the mechanical anchoring properties of the overmolding by resisting tearing caused by a tearing and tensile movement of the part along a direction substantially locally perpendicular to the wall 300. Said anchoring properties are even better if the tongue is arranged in the area 316 where it is obtained by a natural demoulding in a direction not perpendicular to the surface: this angle (less than 90°) enhances the anchoring properties.

[0064] exist Figure 5 、 7A to 7C In the example shown, the mechanical anchor 700 forms a tenon on the wall 300.

[0065] Figure 7A The mechanical anchoring between the part 200 and an overmolded mechanical anchor 700 protruding on the wall 300 is shown. Figure 7B and 7C Shown enlarged Figure 7A The two sections indicated are AA (7B) and BB (7C).

[0066] The invention also relates to a motor vehicle body part 200 made of plastic, comprising a reinforcing element 100 according to the invention.

[0067] The reinforcing element 100 forms an insert on at least a portion of the contour 330 of the wall 300 , preferably encapsulated on the contour 330 by the plastic material of the body part 200 .

[0068] According to one embodiment, the plastic material of the body part 200 covers the support surface and fills the recess 400 .

[0069] According to one embodiment, the plastic of the body part 200 covers the support surface and the edge of the wall 300 at the contour 330 .

[0070] Reference Signs List

[0071] 100: Reinforcement element of body part 200

[0072] 200: Body parts made of plastic

[0073] 300: Wall of reinforcing element 100

[0074] 310: First side of wall 300

[0075] 320: A second surface of the wall 300 opposite to the first surface 310

[0076] 330: Defines the outline of the wall 300

[0077] 400: Overmolded mechanical anchoring recess of reinforcing element 100

[0078] 410: raised portion defined between the two notches 400

[0079] 500: Support surface forming an extension of wall 300

[0080] 700: Overmolded mechanical anchor protruding from wall 300

Claims

1. A reinforcing element (100) made of composite plastic for a body part (200), forming an insert that can be at least partially overmolded into the body part (200), the reinforcing element (100) comprising a wall (300) defined by a profile (330), characterized in that The reinforcing element (100) is made of composite plastic and at least a portion of the profile (330) comprises an overmolded mechanical anchoring recess (400) forming a hollowing-out of a given geometry realized in the thickness of the wall (300) and having a hollow shape that does not completely penetrate the wall (300) of the reinforcing element (100).

2. The reinforcing element (100) according to claim 1, wherein The mechanical anchoring recess (400) has a shape comprising a narrowing.

3. The reinforcing element (100) according to claim 1 or 2, wherein The mechanical anchoring recess (400) has a shape that generally flares out from the edge of the profile (330).

4. The reinforcing element (100) according to claim 1 or 2, wherein The mechanical anchoring recesses (400) are regularly distributed over the portion of the profile (330).

5. The reinforcing element (100) according to claim 1 or 2, wherein The portion of the profile (330) comprising the mechanical anchoring recess (400) comprises a bearing surface (500) forming an extension of the wall (300).

6. The reinforcing element (100) according to claim 5, wherein The thickness of the support surface (500) is smaller than the thickness of the raised portion (410).

7. The reinforcing element (100) according to claim 1 or 2, wherein The wall (300) comprises a first face (310) and a second face (320), the second face being opposite the first face, the overmolded mechanical anchoring recess (400) being formed on the first face and / or the second face.

8. The reinforcing element (100) according to claim 7, wherein A first set of overmolded mechanical anchoring recesses (400) is formed on the first face, and a second set of overmolded mechanical anchoring recesses (400) is formed on the second face, the mechanical anchoring recesses (400) on one face being the inverse of the mechanical anchoring recesses (400) on the other face.

9. The reinforcing element (100) according to claim 1 or 2, wherein The wall (300) of the reinforcing element (100) comprises an overmolded mechanical anchor (700) protruding on the wall (300) in a direction that is locally non-perpendicular to the wall (300).

10. The reinforcing element (100) according to claim 9, wherein The mechanical anchor (700) forms a tenon on the wall (300).

11. A motor vehicle body part (200) made of plastic material, characterized in that: It comprises a reinforcing element (100) as claimed in any one of the preceding claims.

12. The vehicle body part (200) according to claim 11, wherein The reinforcing element (100) forms an insert encapsulated by the plastic material of the body part (200) on at least a portion of the contour (330) of the wall (300).

13. The vehicle body part (200) according to claim 12, wherein The reinforcing element (100) forms an insert encapsulated by the plastic material of the body part (200) over the entire contour (330).

14. The vehicle body part (200) according to claim 12, wherein: The portion of the profile (330) comprising the mechanical anchoring recess (400) comprises a bearing surface (500) forming an extension of the wall (300), the plastic material of the body part (200) covering the bearing surface (500) and filling the mechanical anchoring recess (400).

15. The vehicle body part (200) according to claim 14, wherein The plastic material of the body part (200) covers the edge of the wall (300) at the contour (330).

16. The body part (200) according to any one of claims 11 to 15, which forms a tailgate lining.

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