Composite component with integrated ducts

Abstract

This application relates to a composite part with an integrated conduit. An injection molded composite part includes: a groove extending from a first surface of the composite part; and a pipe placed within the groove and integrally formed with the composite part such that the pipe forms an integrated conduit on the first surface of the composite part.

Description

Technical Field

[0001] The present disclosure generally relates to a vehicle component, such as a liftgate, having an integrated conduit formed therewith via a molding process. Background Art

[0002] Pipes, such as for windshield wiper fluid, are typically attached to vehicle components, such as liftgates, using clips or other types of mechanical fasteners. This assembly increases manufacturing complexity and assembly time. Summary of the Invention

[0003] Embodiments in accordance with the present disclosure provide numerous advantages. For example, embodiments in accordance with the present disclosure achieve the integration of pipes and / or wiring with the vehicle component by integrating the conduit with the vehicle component during an overmolding manufacturing process.

[0004] In one aspect of the present disclosure, a composite component includes a first surface and a conduit integrated with the first surface and having a first end extending from the conduit at a first location of the composite component and a second end extending from the conduit at a second location of the composite component. The conduit protrudes from the first surface of the composite component.

[0005] In some aspects, one of a rubber tube, a plastic tube, a metal tube, a bare wire, and a shielded wire is molded into the first surface of the composite component.

[0006] In some aspects, the first surface includes a resin laminated on a preform, and the conduit includes a pipe material bonded to the preform using the resin such that the resin forms around the pipe material.

[0007] In some aspects, the preform includes a first preform and a second preform, and the pipe material is surrounded by the second preform such that the pipe material is between the first and second preforms.

[0008] In some aspects, the first surface includes a groove protruding from the first surface, and the groove is configured to receive one of a tube and a wire.

[0009] In some aspects, the conduit includes a pipe material surrounded by a foam material, and the pipe material and the foam material are overmolded together with the first surface.

[0010] In some aspects, the conduit is formed by a cavity in a foam material, and the foam material is overmolded together with the first surface.

[0011] In some aspects, an inner surface area of the cavity is coated with a sealant.

[0012] In some aspects, the composite component is a vehicle liftgate, and the conduit is configured to convey windshield wiper fluid.

[0013] In another aspect of the present disclosure, a method for manufacturing a composite component with an integrated conduit includes: providing a first mold for the composite component; placing a preform on the first mold; placing a tube on the preform; placing a second mold for the composite component on an assembly including the first mold, the preform, and the tube such that the preform and the tube are between the first and second molds; and performing an overmolding process by injecting resin between the first and second molds such that the tube is encapsulated by the resin and integrally formed with the composite component.

[0014] In some aspects, the first mold includes a groove configured to receive the tube.

[0015] In some aspects, the preform includes a first preform and a second preform, and the method includes placing the tube on the first preform and placing the second preform on top of the tube.

[0016] In some aspects, the tube is surrounded by a foam material, and both the tube and the foam material are encapsulated by the resin during the overmolding process.

[0017] In some aspects, the method further includes pressurizing the tube during resin injection to prevent compression of the tube during the overmolding process.

[0018] In some aspects, the second mold includes a groove configured to receive the tube.

[0019] In some aspects, the tube is one of a rubber tube, a plastic tube, a metal tube, a bare wire, and a shielded wire.

[0020] In another aspect of the present disclosure, an injection-molded composite component includes: a groove extending from a first surface of the composite component; and a tube placed within the groove and integrally formed with the composite component such that the tube forms an integrated conduit on the first surface of the composite component.

[0021] In some aspects, the tube includes one of a rubber tube, a plastic tube, a metal tube, a bare wire, and a shielded wire, which is molded into the first surface of the composite component.

[0022] In some aspects, the pipe is surrounded by foam material, and the pipe and the foam material are overmolded together with the first surface.

[0023] In some aspects, the pipe is pressurized.

[0024] 1. A composite component, comprising:

[0025] A first surface; and

[0026] A conduit integrated with the first surface and having a first end extending from the conduit at a first location of the composite component and a second end extending from the conduit at a second location of the composite component;

[0027] wherein the conduit protrudes from the first surface of the composite component.

[0028] 2. The composite component according to aspect 1, wherein one of a rubber tube, a plastic tube, a metal tube, a bare wire, and a shielded wire is molded into the first surface of the composite component.

[0029] 3. The composite component according to aspect 1, wherein the first surface comprises a resin laminated on a preform, and the conduit comprises a pipe bonded to the preform using the resin such that the resin forms around the pipe.

[0030] 4. The composite component according to aspect 3, wherein the preform comprises a first preform and a second preform, and the pipe is surrounded by the second preform such that the pipe is between the first preform and the second preform.

[0031] 5. The composite component according to aspect 1, wherein the first surface comprises a groove protruding from the first surface, and the groove is configured to receive one of a tube and a wire.

[0032] 6. The composite component according to aspect 1, wherein the conduit comprises a pipe surrounded by foam material, and the pipe and the foam material are overmolded together with the first surface.

[0033] 7. The composite component according to aspect 1, wherein the conduit is formed by a cavity in the foam material, and the foam material is overmolded together with the first surface.

[0034] 8. The composite component according to aspect 7, wherein the inner surface area of the cavity is coated with a sealant.

[0035] 9. The composite component according to embodiment 1, wherein the composite component is a vehicle liftgate, and the conduit is configured to convey windshield wiper fluid.

[0036] 10. A method for manufacturing a composite component with an integrated conduit, comprising:

[0037] Providing a first mold for the composite component;

[0038] Placing a preform on the first mold;

[0039] Placing a pipe on the preform;

[0040] Placing a second mold for the composite component on an assembly including the first mold, the preform, and the pipe, such that the preform and the pipe are between the first mold and the second mold; and

[0041] Performing an overmolding process by injecting resin between the first mold and the second mold, such that the pipe is encapsulated by the resin and integrally formed with the composite component.

[0042] 11. The method according to embodiment 10, wherein the first mold includes a groove configured to receive the pipe.

[0043] 12. The method according to embodiment 10, wherein the preform includes a first preform and a second preform, and the method includes placing the pipe on the first preform and placing the second preform on top of the pipe.

[0044] 13. The method according to embodiment 10, wherein the pipe is surrounded by a foam material, and both the pipe and the foam material are encapsulated by the resin during the overmolding process.

[0045] 14. The method according to embodiment 10, further comprising pressurizing the pipe during resin injection to prevent compression of the pipe during the overmolding process.

[0046] 15. The method according to embodiment 10, wherein the second mold includes a groove configured to receive the pipe.

[0047] 16. The method according to embodiment 10, wherein the pipe is one of a rubber pipe, a plastic pipe, a metal pipe, a bare wire, and a shielded wire.

[0048] 17. An injection-molded composite component, comprising:

[0049] A groove extending from a first surface of the composite component; and

[0050] A pipe, the pipe is placed in the groove and integrally formed with the composite component, such that the pipe forms an integrated conduit on the first surface of the composite component.

[0051] 18. The composite component according to aspect 17, wherein the pipe comprises one of a rubber pipe, a plastic pipe, a metal pipe, a bare wire, and a shielded wire, which is molded into the first surface of the composite component.

[0052] 19. The composite component according to aspect 17, wherein the pipe is surrounded by a foam material, and the pipe and the foam material are co-molded with the first surface.

[0053] 20. The composite component according to aspect 17, wherein the pipe is pressurized. BRIEF DESCRIPTION OF THE DRAWINGS

[0054] The present disclosure will be described in connection with the following figures, wherein like reference numerals denote like elements.

[0055] Figure 1 FIG. is a schematic view of the underside of a vehicle component including an integrated conduit according to an embodiment.

[0056] Figure 2 FIG. is a schematic view of the free end of a pipe extending from the integrated conduit of the vehicle component of Figure 1 FIG.

[0057] Figure 3 FIG. is a schematic cross-sectional view of a vehicle component including an integrated conduit according to an embodiment.

[0058] Figure 4 FIG. is a schematic perspective view of a vehicle component including an integrated conduit according to an embodiment.

[0059] Figure 5 FIG. is a schematic cross-sectional view of a vehicle component including an integrated conduit according to another embodiment.

[0060] Figure 6 FIG. is a schematic cross-sectional view of an overmolding configuration for manufacturing a vehicle component with an integrated conduit according to an embodiment.

[0061] Figure 7 FIG. is a schematic cross-sectional view of another overmolding configuration for manufacturing a vehicle component with an integrated conduit according to an embodiment.

[0062] Figure 8 FIG. is a schematic cross-sectional view of another overmolding configuration for manufacturing a vehicle component with an integrated conduit according to an embodiment.

[0063] Figure 9 is a schematic cross-sectional view of another overmolding configuration for manufacturing a vehicle component with an integrated conduit according to an embodiment.

[0064] Figure 10 is a schematic cross-sectional view of another overmolding configuration for manufacturing a vehicle component with an integrated conduit according to an embodiment.

[0065] Figure 11 is a flowchart of a method for manufacturing a vehicle component with an integrated conduit according to an embodiment.

[0066] In conjunction with the accompanying drawings, the foregoing and other features of the present disclosure will become more fully apparent from the following description and the appended claims. It should be understood that these drawings illustrate only several embodiments in accordance with the present disclosure and should not be considered as limiting its scope, and thus the present disclosure will be described with additional features and details by using the drawings. Any dimensions disclosed in the drawings or elsewhere in this document are for illustrative purposes only. Detailed Description

[0067] Embodiments of the present disclosure are described herein. However, it should be understood that the disclosed embodiments are merely examples, and other embodiments may take various and alternative forms. The figures are not necessarily drawn to scale; some features may be exaggerated or minimized to show details of particular components. Thus, the specific structural and functional details disclosed herein should not be construed as limiting, but rather as a representative basis for teaching one skilled in the art to employ the present disclosure in various ways. Those of ordinary skill in the art will understand that the various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to produce embodiments not explicitly illustrated or described. Combinations of the illustrated features provide representative embodiments for typical applications. However, for a particular application or implementation, various combinations and modifications of features consistent with the teachings of the present disclosure may be desired.

[0068] Certain terms may be used for reference purposes only in the following description and thus are not intended to be limiting. For example, terms such as "above" and "below" refer to the directions referenced in the figures. Terms such as "front," "rear," "left," "right," "rearward," and "side" describe the orientation and / or position of several portions of a component or element within a consistent but arbitrary reference system, which can be clearly seen by referring to the text of the component or element being discussed and the associated drawings. Additionally, terms such as "first," "second," "third," etc. may be used to describe individual components. Such terms may include the specifically mentioned words above, their derivatives, and words with similar meanings. Throughout the following description, like reference numerals refer to like components.

[0069] In Figure 1 and Figure 2 illustrated are vehicle components, such as vehicle liftgate 10. In this embodiment, liftgate 10 is formed of a composite material via a co - molding process. As part of the co - molding process, an integrated conduit 100 is formed with liftgate 10 on the first or inner surface 13 of liftgate 10. Integrated conduit 100 provides a conduit for fluid and / or electrical wiring from a first location 11 to a second location 12 of liftgate 10. In various embodiments, integrated conduit 100 includes a tubing 108 that extends from liftgate 10 to enable connection to other vehicle components such as, for example but not limited to, a fluid reservoir. In one example, integrated conduit 100 includes a tubing 108 that is a fluid conduit for delivering fluid from a fluid reservoir to a windshield wiper assembly. In another example, integrated conduit 100 is a molded conduit that includes a female port such that a male port can be directly coupled to integrated conduit 100 without additional piping.

[0070] Figure 3 Illustrated is a cross - section of conduit 100 that is formed as part of liftgate 10 as shown in Figure 1 FIG. Figure 4 Illustrated is a perspective view of conduit 100. Conduit 100 is formed via a co - molding process that includes a first layer of resin 102 on a first side of a preform 104. A second layer of resin 106 is formed around tubing 108, which is placed on preform 104 at a desired location of conduit 100. Tubing 108 forms an enclosed conduit (illustrated as opening 109 in cross - section) through which fluid and / or wires extend. In various embodiments, a groove protrudes from the surface of a composite component (such as a vehicle liftgate) at a desired location of conduit 100. The groove receives tubing 108, which in various embodiments is, for example but not limited to, a rubber tube, a plastic tube, a metal tube, a bare wire, and / or a shielded wire, which is then molded into the composite component as shown in Figure 1 FIG.

[0071] In various embodiments, the formation of conduit 100 within a composite component (such as liftgate 10) includes adding a layer of preform on top of the tubing, as shown in Figure 5 FIG. In this embodiment, similar to Figure 3In the embodiment shown, the catheter 100 is formed via an overmolding process that includes a first layer of resin 102 on a first side of a first preform 104. A second preform 204 is added on top of the tubing 108. In various embodiments, the second preform 204 surrounds the tubing 108 between the first preform 104 and the second preform 204. A second layer of resin 106 is formed around the tubing 108 and laminated on top of the second or opposite side of the first preform 104. The tubing 108 forms an enclosed conduit (illustrated as an opening 109 in cross-section) through which fluids and / or wires extend.

[0072] In Figure 6 Another example of the manufacturing process of the catheter 100 is schematically illustrated. In this example, the catheter 100 is formed via an overmolding process. The preform 104 is placed on the lower mold 120. The tubing 108 is placed at a desired location on the preform 104, and the upper mold 122 is placed on top of the lower mold 120 and the tubing 108. Then resin is injected into the assembly, thereby forming a first layer of resin 102 between the lower mold 120 and the first side of the preform 104 and a second layer of resin 106 that surrounds the tubing 108 and covers the second side of the preform 104. In various embodiments, a fluid (such as air) is pumped through the opening 109 defined by the tubing 108 to prevent the tubing 108 from being squeezed and deformed during the resin injection step of the overmolding process.

[0073] In some embodiments, as Figure 7 and Figure 8 shown, a foam material is used to resist the compression of the tubing 108 during the overmolding process. Referring to Figure 7 , the catheter 200 includes a first layer of composite material or resin 220. The tubing 108 is surrounded by a foam material 221. A second layer of composite material or resin 222 is laminated on top of the foam material 221 and the tubing 108. The foam material 221 surrounds the tubing 108 such that the tubing 108 is not squeezed or deformed during the application of the first and second layers of composite materials 220, 222.

[0074] Similarly, as Figure 8 shown, the catheter 300 includes a foam material 321 that surrounds the tubing 108 on all sides, where first and second composite materials 320, 322 are laminated on top of the foam material 321. Each of the catheters 200, 300 is formed with a foam material surrounding the tubing to resist the compression of the tubing during the overmolding process and is configured for various applications based on the use of the catheter and space constraints.

[0075] In some embodiments, the tubing 108 is replaced by a sealant that coats the inner surface of a cavity formed within the foam material. The inner surface area of the cavity is coated with a sealant material to prevent leakage. Similar to Figure 7 and Figure 8 the embodiments shown in

[0076] Figure 9 and Figure 10 FIGS. 400 and 500 schematically illustrate two embodiments of forming conduits, depending on the construction of the mold. In Figure 9 FIG. 420, a first cavity mold 420 is covered with a fabric layer 423. The tubing 108 is placed on the fabric layer 423, and a second cavity mold 422 is placed over the tubing 108. Resin is then injected into the mold to secure the tubing 108 in the desired position. However, it can be seen that placing the tubing 108 in this mold construction may be difficult because the tubing 108 is not restricted on both sides within the first cavity mold 420.

[0077] As Figure 10 shown in Figure 9 FIG. 520, the tubing 108 is placed within a well or groove 525 formed in a first cavity mold 520. The groove 525 holds the tubing 108 in place within the mold. As in the construction shown in Figure 1 FIG. 520, a fabric layer 523 covers the first cavity mold 520. A second cavity mold 522 is placed over the tubing 108, and resin is injected during the molding process to integrate the tubing 108 with a composite component (such as the component 10 shown in Figure 10 FIG. 520). The groove 525 is shown as a circular groove in

[0078] Figure 11 FIG. 520; however, in some embodiments, the groove may be rectangular, oval, or any other shape, depending on the desired shape and use of the conduit 500 (i.e., whether the conduit 500 encloses wiring or fluid and the position of the conduit 500 within the component 10). Figure 11 FIG. 600 illustrates a method 600 for manufacturing a component including an integrated conduit. The method 600 can be used in conjunction with any one of the conduits 100, 200, 300, 400, 500 discussed herein. The order of operations of the method 600 is not limited to being performed in the order shown in

[0079] Method 600 begins at 602 where a first mold for a composite part is provided. Method 600 continues at 604 where a preform is placed on the first mold. A tube is placed on the preform at a desired location, as shown at 606. In some embodiments, the tube is placed within a groove in the first mold. In some embodiments, the tube is placed on a flat portion of the first mold. In some embodiments, as Figure 7 and Figure 8 shown, the tube is surrounded by a foam material to protect the tube from being compressed during the resin injection step of the molding process.

[0080] Method 600 continues at 608 where a second mold is placed over the first mold, preform, and tube assembly. Finally, at 610, resin is injected into the molds, thereby filling the space between the first and second molds and encapsulating the tube such that the tube is integrated into the molded composite part.

[0081] It should be emphasized that many variations and modifications can be made to the embodiments described herein, and the elements of the embodiments are to be understood among other acceptable examples. All such modifications and variations are intended to be included herein within the scope of this disclosure and are protected by the following claims. Additionally, any of the steps described herein can be implemented simultaneously or in an order different from the order of the steps arranged herein. Moreover, it should be apparent that the features and attributes of the specific embodiments disclosed herein can be combined in different ways to form additional embodiments, all of which additional embodiments fall within the scope of this disclosure.

[0082] Unless specifically stated otherwise or understood in context otherwise, conditional language used herein, such as, among other things, “can,” “could,” “might,” “may,” “e.g.,” and the like, generally is intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements, and / or states. Thus, such conditional language generally is not intended to imply that the features, elements, and / or states are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for determining, with or without author input or prompting, whether these features, elements, and / or states are included in any particular embodiment or will be implemented in any particular embodiment.

[0083] In addition, the following terms may have been used in this document. Unless the context clearly indicates otherwise, the singular forms "a", "an", and "the" include plural referents. Thus, for example, a reference to an item includes a reference to one or more items. The term "one" means one, two, or more, and generally applies to a selection of part or all of a quantity. The term "plurality" means two or more items. The term "about" or "approximately" means that the quantity, dimension, size, formulation, parameter, shape, and other characteristics need not be exact, but may be approximate and / or larger or smaller as desired, thereby reflecting acceptable tolerances, conversion factors, rounding, measurement errors, and the like, as well as other factors known to those skilled in the art. The term "substantially" means that the recited characteristic, parameter, or value need not be achieved exactly, but that deviations or variations (including, for example, tolerances, measurement errors, measurement precision limitations, and other factors known to those skilled in the art) may exist in amounts that do not preclude the effect expected from the characteristic.

[0084] For convenience, multiple items may be presented in a common list. However, these lists should be interpreted as if each member of the list were individually identified as a separate and unique member. Thus, no individual member of this list should be construed as a virtual equivalent of any other member of the same list solely based on its presentation in the common group, without contrary indication. In addition, where the terms "and" and "or" are used in conjunction with a list of items, they should be construed broadly, since any one or more of the listed items may be used alone or in combination with other listed items. The term "alternatively" refers to a choice of one of two or more alternatives, and is not intended to limit the choice to only those listed alternatives or to only one of the listed alternatives at a time, unless the context clearly indicates otherwise.

[0085] Although the exemplary embodiments have been described above, it does not mean that these embodiments describe all possible forms covered by the claims. The words used in the specification are words of description rather than limitation, and it should be understood that various changes can be made without departing from the spirit and scope of the present disclosure. As previously described, the features of various embodiments can be combined to form other exemplary aspects of the present disclosure that may not be explicitly described or illustrated. Although various embodiments may have been described as providing advantages over one or more desired characteristics or being superior to other embodiments or prior art implementations, those of ordinary skill in the art recognize that one or more features or characteristics may be compromised to achieve the desired overall system attributes, which depend on the particular application and implementation. These attributes may include, but are not limited to, cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, suitability, weight, manufacturability, ease of assembly, and the like. Thus, embodiments that are described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the present disclosure and may be desirable for a particular application.

Claims

1. A composite component, comprising: A first surface; And A conduit that is integrated with the first surface and has a first end extending from the conduit at a first location of the composite component and a second end extending from the conduit at a second location of the composite component; Wherein the conduit protrudes from the first surface of the composite component, Wherein the first surface includes a resin laminated on a preform, and the conduit includes a pipe material bonded to the preform using the resin such that the resin forms around the pipe material, Wherein the composite component is a vehicle liftgate, and the conduit is configured to convey windshield wiper fluid.

2. The composite component according to claim 1, wherein One of a rubber tube, a plastic tube, a metal tube, a bare wire, and a shielded wire is molded into the first surface of the composite component.

3. The composite component according to claim 1, wherein, The preform includes a first preform and a second preform, and the pipe material is surrounded by the second preform such that the pipe material is between the first preform and the second preform.

4. The composite component according to claim 1, wherein The first surface includes a groove protruding from the first surface, and the groove is configured to receive one of a tube and a wire.

5. A method for manufacturing a composite component with an integrated conduit, comprising: Providing a first mold for the composite component; Placing a preform on the first mold; Placing a pipe material on the preform; Placing a second mold for the composite component on an assembly including the first mold, the preform, and the pipe material such that the preform and the pipe material are between the first mold and the second mold; and Performing an overmolding process by injecting resin between the first mold and the second mold such that the pipe material is encapsulated by the resin and integrally formed with the composite component, Wherein the pipe material is surrounded by a foam material, and both the pipe material and the foam material are encapsulated by the resin during the overmolding process, Wherein the composite component is a vehicle liftgate, and the conduit is configured to convey windshield wiper fluid.

6. The method according to claim 5, wherein The first mold includes a groove configured to receive the pipe material.

7. The method according to claim 5, wherein: The preform includes a first preform and a second preform, and the method includes placing the pipe material on the first preform and placing the second preform on top of the pipe material.

8. The method according to claim 5, further comprising pressurizing the pipe material when injecting resin to prevent compression of the pipe material during the overmolding process.

9. The method according to claim 5, wherein The second mold includes a groove configured to receive the pipe material.

10. The method according to claim 5, wherein, The pipe material is one of a rubber tube, a plastic tube, a metal tube, a bare wire, and a shielded wire.

11. An injection-molded composite component, comprising: A groove extending from a first surface of the composite component; And A pipe material placed within the groove and integrally formed with the composite component such that the pipe material forms an integrated conduit on the first surface of the composite component, Wherein the pipe material is surrounded by a foam material, and the pipe material and the foam material are overmolded together with the first surface, wherein the composite component is a vehicle liftgate and the conduit is configured to carry windshield wiper fluid.

12. The composite component according to claim 11, wherein, The tubing includes one of a rubber tube, a plastic tube, a metal tube, a bare wire, and a shielded wire, which is molded into the first surface of the composite component.

13. The composite component according to claim 11, wherein, The tubing is pressurized.

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