Composite component, lighting device and structural unit for motor vehicle, and method for producing composite component

Abstract

The invention relates to a composite component, a lighting device and a structural unit for a motor vehicle and a method for producing a composite component. The invention relates to a composite component (100) for integration into a lighting device of a motor vehicle, into a front apron or a rear apron of a motor vehicle or into the interior of a motor vehicle, comprising a support (1) and at least one front cover (2) connected to the support (1), in particular in the form of a closure panel (2a), a cover panel (2b) or a decorative panel (2c), the front cover (2) has a base body (21) comprising a polyurethane coating (22).

Description

Technical Field

[0001] The present invention relates to a composite component for integration into a lighting device of a motor vehicle, into a front apron or a rear apron of a motor vehicle, or into the interior of a motor vehicle. Furthermore, the present invention relates to a lighting device and a structural unit comprising such a composite component, and to a method for manufacturing the composite component. Background Art

[0002] In the area of the vehicle body or in the interior of a motor vehicle, there are various attractive applications for surface coatings made of polyurethane (PUR). The PUR coating as a protective layer is characterized by high tolerance, chemical durability, and a certain degree of self-healing ability after mechanical damage. In addition, the PUR coating can form a very smooth and aesthetically appealing surface. Therefore, currently, there is particular interest in the use of PUR coatings on the closure panels of lighting devices, on the covering baffles of sensor devices, such as antenna covers, or on the visible surfaces in the interior of a motor vehicle.

[0003] The challenge lies in the efficient mass production of such components including PUR coatings by means of multi-component injection molding, where it is sought to locally cover-inject the component injection-molded in the first process step with polyurethane in the second process step. In particular, components to be integrated into the vehicle body structure (Fahrzeugstrak), such as the closure panels of lighting devices, usually have complex free-form geometries and are multiply provided with undercuts. Here, it has proven to be impossible to effectively seal a complex injection mold equipped with slides against the relatively low-viscosity polyurethane in the second process step after the injection in the first process step. Summary of the Invention

[0004] Disclosure of the Invention

[0005] The object of the present invention is to provide an alternative embodiment of a component comprising a PUR coating of the type mentioned above, which can be manufactured by injection molding in an effective manner and without manufacturing-determined restrictions regarding the moldable geometry.

[0006] This object is solved by the composite component according to claim 1. Advantageous further configurations of the present invention are given in the dependent claims.

[0007] The technical teaching of the present invention discloses a composite component for integration into a lighting device of a motor vehicle, into a front apron or a rear apron of a motor vehicle, or into the interior of a motor vehicle, the composite component having a support and at least one front cover connected to the support, in particular a front cover in the form of a closure panel, a covering baffle, or a decorative baffle, wherein the front cover has a substrate comprising a polyurethane coating.

[0008] The present invention starts from the idea of dividing the component into two components that can be manufactured independently of each other: on the one hand, a substantially upper planar front cover, for example with a 2.5D geometric structure, coated with PUR, and on the other hand, a bracket with a geometric structure that can be arbitrarily complex in principle, which is used for the structural integration of the composite component into the installation environment on a motor vehicle. When manufacturing the front cover by multi-component injection molding, the geometrically simple matrix injection molded in the first process can be covered with polyurethane injection molding without problems in the second process. The manufacture of the bracket can be carried out independently of the manufacture of the front cover and thus advantageously involves different materials. Finally, the bracket and the at least one front cover are connected to each other to form the composite component according to the invention, wherein the bracket basically assumes the function of a structural component and the PUR-coated front cover satisfies the protection function and the desired aesthetic design requirements as a visible component.

[0009] In particular, the bracket has a thermoplastic or thermosetting plastic, and / or the matrix of the front cover has a thermoplastic, such as polycarbonate. The bracket can, for example, have a synthetic thermosetting plastic such as synthetic resin and contain glass fibers embedded therein for reinforcement. Depending on the specific application, the matrix of the front cover can be made transparent, translucent or opaque.

[0010] In one embodiment, the bracket has at least one receiving section for receiving components and / or at least one connecting section for connecting to the front apron or rear apron of the motor vehicle or the interior of the motor vehicle. The bracket can thus be used as a central interface for receiving in particular electronic components, such as lighting or sensor devices, and for connecting to the body of the motor vehicle. Here, the bracket can be configured in particular to be so rigid and stable that components of the body, such as cross members, can be replaced by the bracket, that is, the bracket can act as a structural component of the body. For this purpose, the bracket can, for example, be configured as a hybrid component with at least one metal sheet component and thus have increased stiffness and load-bearing capacity. In addition, the bracket can have a suitable frame-like structure for externally enclosing at least one component to be received on the bracket.

[0011] The bracket and the front cover are optionally connected to each other in a material-locking manner, in particular by means of a welding connection or an adhesive connection, or detachably, in particular by means of a clamping device or a threaded connection device. Preferably, the bracket and the front cover are connected to each other in a media-sealed manner, in particular with respect to penetrating moisture, for example in the case of a detachable connection using a separate sealing element.

[0012] In another embodiment, the composite member has at least one rear cover connected to the bracket, the rear cover being disposed on a side of the bracket facing away from the front cover, wherein the bracket and the rear cover are preferably detachably and / or medium-sealedly connected to each other. By the accessibility on the back side in the detachable rear cover, expanded assembly options are created for the components to be installed inside on the housing-like bracket, and the serviceability is also increased.

[0013] The invention further relates to a lighting device for a motor vehicle, having at least a composite member and a light module according to one of the above-mentioned embodiments, wherein the front cover of the composite member is configured as a transparent closure sheet, and / or the light module is received on the bracket of the composite member. In particular, the bracket can form a housing section and completely surround the received light module in a circumferential manner.

[0014] Furthermore, the invention relates to a structural unit for integration into the front apron or rear apron of a motor vehicle, having at least a composite member, a lighting device, a sensor device and / or a decorative element according to one of the above-mentioned embodiments, wherein the composite member has a plurality of front covers, the front covers being configured as closure sheets for the lighting device, covering baffles for the sensor device and / or decorative baffles for the decorative element, and / or the lighting device, the sensor device and / or the decorative element are received on the bracket of the composite member. Thus, the composite member can be part of a large-area structural unit extending over the entire vehicle width and has a plurality of differently configured, PUR-coated front covers, such as transparent closure sheets of a lighting device and opaque covering baffles in front of a sensor device, on a common bracket.

[0015] The invention further discloses a method for manufacturing a composite member according to the above-mentioned embodiments, the method having at least the following steps in no particular order:

[0016] - Injecting the bracket with a thermoplastic or thermosetting plastic,

[0017] - Multi-component injection molding of the at least one front cover, wherein in a first process step, the base body is injection molded with a thermoplastic plastic and in a second process step, the base body is overmolded with polyurethane while forming a PUR coating, and

[0018] - Connecting the bracket and the front cover to each other.

[0019] According to the present invention, the bracket and the front cover are manufactured separately and independently of each other. The PUR coating is applied only to the geometrically relatively simply configured substrate of the front cover, which does not cause difficulties with respect to the method of die sealing for low-viscosity polyurethanes. In particular, the front cover is manufactured by means of rotational / translational technology or core withdrawal technology. In the injection molding of the bracket, a metal sheet member can be placed in the injection mold, and the sheet member is encapsulated and injection molded as a particularly rigid and load-bearing hybrid member in the formation of the bracket.

[0020] In a method variant, the bracket and the front cover are connected by means of welding, and subsequently the welded joint is heated for stress reduction. Such heat treatment is particularly advantageous in the joint portion made of polycarbonate, because thereby the possibility of stress crack formation that impairs the medium tightness in the region of the welded joint is significantly reduced. The locally increased temperature and the treatment time caused by the heat treatment can be adapted to the specific material used in the corresponding application cases, so that the intentional stress reduction is carried out to an appropriate extent without affecting the integrity of the welded joint. Description of the Drawings

[0021] Preferred Embodiments of the Present Invention

[0022] Subsequently, other measures for improving the present invention are further described in conjunction with the description of the preferred embodiments of the present invention with the aid of schematic diagrams. Among them:

[0023] Figure 1 Shows a first embodiment of the composite member according to the present invention;

[0024] Figure 2 Shows a second embodiment;

[0025] Figure 3 Shows a third embodiment;

[0026] Figure 4 Shows a fourth embodiment; and

[0027] Figure 5 Shows the structural unit according to the present invention. Detailed Description of the Invention

[0028] Figures 1 to 4Schematic sectional view showing an embodiment of a composite component 100 according to the invention, said composite component having a bracket 1 and a front cover 2 connected thereto, said front cover having a base body 21 with a polyurethane coating 22. The front cover 2 has, for example, the structure of a flat bowl, including a flat central section and a circumferential joint surface on the edge side for connection to the bracket 1. The injection-molded base body 21 is covered with a PUR coating 22 on the outside by injection molding. The bracket 1, as a component manufactured separately by single-component injection molding, can form a significantly more complex free form, wherein the bracket 1 has a housing or frame-like structure in this embodiment and is closed on the front side by the front cover 2.

[0029] In Figure 1 and Figure 3 In the embodiments of, the bracket 1 and the front cover 2 are materially locked and hermetically connected to each other by a circumferentially surrounding welded joint 3. For this purpose, the bracket 1 and the base body 21 are respectively made of polycarbonate, especially. To ensure hermeticity, the welded joint 3 is preferably subjected to a post-treatment heat treatment for stress reduction.

[0030] In Figure 2 and Figure 4 In the embodiments of, the bracket 1 and the front cover 2 are detachably and hermetically connected to each other by a circumferentially surrounding clamping device 4. The clamping device 4 is realized by a plurality of clips 41, wherein the bracket 1 has a circumferential sealing bed including a sealing element 42 received therein.

[0031] In Figure 3 and Figure 4 In the embodiments of, the bracket 1 respectively has a receiving section 11 for receiving components, especially electronic components such as optical modules or sensor devices, inside the housing formed by the bracket 1 and the front cover 2. In addition, the bracket 1 respectively has a connecting section 12 for connection to the front apron or rear apron of a motor vehicle.

[0032] In Figure 4 In, the composite component 100 has a rear cover 5, which is arranged on the side of the bracket 1 facing away from the front cover 2. Here, the bracket 1 and the rear cover 5 are detachably and hermetically connected to each other by a clamping device 6 including clips 61 and a circumferential sealing element 62. By the detachable connection of not only the front cover 2 but also the rear cover 5, there is advantageously accessibility to both sides inside the bracket 1 in the range of assembly or repair of the components to be received on the receiving section 11.

[0033] Figure 5Schematic front view showing the structural unit 1000 according to the invention for integration into the front apron of a motor vehicle, having a composite member 100 according to the invention, which composite member has a bracket 1 and a plurality of front covers, the front covers being configured as two transparent closing sheets 2a for a headlight to be arranged behind them, two opaque covering flaps 2b for a radar sensor device, and a centrally arranged decorative trim flap 2c including a manufacturer's logo. A PUR coating is respectively provided on the facing front sides of the front covers 2a, 2b, 2c. In particular, the bracket 1 can be configured as a reinforced hybrid member including a metal sheet member and thereby have such a load-bearing capacity that the headlight and the sensor device are received thereon.

[0034] List of reference numerals

[0035] 1 Bracket

[0036] 11 Receiving section

[0037] 12 Connecting section

[0038] 2 Front cover

[0039] 2a Closing sheet

[0040] 2b Covering flap

[0041] 2c Trim flap

[0042] 21 Substrate

[0043] 22 Polyurethane coating

[0044] 3 Welding connection

[0045] 4 Clamping device

[0046] 41 Clip

[0047] 42 Sealing element

[0048] 5 Rear cover

[0049] 6 Clamping device

[0050] 61 Clip

[0051] 62 Sealing element

[0052] 100 Composite member

[0053] 1000 Structural unit

Claims

1. A composite component (100) for integration into a lighting device of a motor vehicle, into a front apron or a rear apron of a motor vehicle, or into the interior of a motor vehicle, the composite component comprising a support (1) and at least one front cover (2) connected to the support (1), in particular a front cover in the form of a closing plate (2a), a covering baffle (2b) or a decorative baffle (2c), wherein: The front cover (2) has a base body (21) with a polyurethane coating (22).

2. The composite component (100) according to claim 1, characterized in that The support (1) comprises thermoplastic or thermosetting plastic, and / or the base body (21) of the front cover (2) comprises thermoplastic plastic.

3. The composite component (100) according to claim 2, characterized in that The support (1) is designed as a hybrid component having at least one metallic sheet metal component.

4. The composite component (100) according to any one of the preceding claims, characterized in that The support (1) and the front cover (2) are connected to each other in a materially bonded manner, in particular by means of a welded connection (3) or an adhesive connection.

5. The composite component (100) according to any one of claims 1 to 3, characterized in that The bracket (1) and the front cover (2) are detachably connected to each other, in particular detachably connected to each other by means of a clamping device (4) or a screw connection.

6. The composite component (100) according to any one of the preceding claims, characterized in that The bracket (1) and the front cover (2) are connected to each other in a medium-tight manner.

7. The composite component (100) according to any one of the preceding claims, characterized in that The support (1) has at least one receiving section (11) for receiving a component and / or at least one connecting section (12) for connecting to a front apron or a rear apron of a motor vehicle or to an interior trim of a motor vehicle.

8. The composite component (100) according to any one of the preceding claims, characterized in that The support (1) has a frame-like structure for surrounding at least one component to be received on the support (1) on the outside.

9. The composite component (100) according to any one of the preceding claims, characterized in that The composite component (100) has at least one rear cover (5) connected to the support (1), the rear cover being arranged on a side of the support (1) facing away from the front cover (2).

10. The composite component (100) according to claim 9, characterized in that The support (1) and the rear cover (5) are detachably and / or media-tightly connected to one another.

11. A lighting device for a motor vehicle, comprising at least a composite component (100) according to one of the preceding claims and a light module, wherein: The front cover (2) of the composite component (2) is designed as a transparent closing plate (2a), and / or the light module is received on a bracket (1) of the composite component (100).

12. A structural unit (1000) for integration into a front or rear apron of a motor vehicle, comprising at least a composite component (100) according to one of claims 1 to 10, a lighting device, a sensor device and / or a decorative element, wherein: The composite component (100) has a plurality of front covers (2), which are configured as closing plates (2a) for the lighting device, covering baffles (2b) for the sensor device and / or decorative baffles (2c) for the decorative element, and / or the lighting device, the sensor device and / or the decorative element are received on a bracket (1) of the composite component (100).

13. A method for producing a composite component (100) according to any one of claims 1 to 10, comprising at least the following steps in an unspecified order: - injection molding the support (1) from a thermoplastic or thermosetting plastic, - Multi-component injection molding of the at least one front cover (2), wherein: In a first step, the base body is injection molded with thermoplastic plastic and in a second step, the base body (21) is over-injected with polyurethane to form a polyurethane coating (22), and - Connecting the support (1) and the front cover (2) to each other.

14. The method according to claim 13, characterized in that The support (1) and the front cover (2) are connected by means of welding, wherein the welded connection is subsequently heated for stress reduction.

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