Modular component made of plastic

Abstract

The invention relates to a modular component (1) made of plastic, having a component body (2), at least one first plastic layer (3) and at least one second plastic layer (4), wherein at least partially between the first plastic layer (3) and the second plastic layer (4) a heating wire (5) is arranged, and to a method for producing such a modular component (1) made of plastic.

Description

[0001] This application is a divisional application, with its parent application having application number 201980035943.9, an application date of July 11, 2019, and an invention titled "Modular Components Made of Plastic". Technical Field

[0002] The present invention relates to a heatable modular component made of plastic, particularly a modular component for a vehicle, preferably a visible body panel. Background Technology

[0003] Currently, vehicle body panels that must be heated are achieved, for example, using overmolded heating films. This manufacturing process results in a high workload with numerous operational steps. Components manufactured in this way may become unusable and thus be excluded if damaged or wrinkled. Furthermore, on vehicle body panels or modular components made of plastic manufactured in this way, the area to be heated is often located inside the component rather than on the outer surface due to the overmolding of the film used, limiting heating efficiency. Additionally, the use of heating films generally does not allow for any optically visible molding (mise en formme) in areas located below or behind the heating film.

[0004] German patent DE 10 2016 212 763 B4 generally describes a method for depositing filaments on a substrate. Summary of the Invention

[0005] The object of the present invention is therefore to provide a modular component made of plastic, and a method for manufacturing the modular component, wherein the defects of the prior art are avoided, and to provide a feasible method for simple and reliable heating of the modular component made of plastic obtained in a structurally simple manner.

[0006] Modular components made of plastic according to the invention, intended to achieve the above-mentioned objectives, are particularly suitable for vehicle components, such as body panels. The modular components made of plastic according to the invention comprise a component body, at least one first plastic layer, and at least one second plastic layer. According to the invention, heating wires are arranged at least partially between the first and second plastic layers. According to the invention, a modular component made of plastic capable of being heated can be reliably heated in a structurally simple manner with low energy consumption, wherein the possibility of heating is virtually invisible.

[0007] According to the invention, the second plastic layer thereby enables reliable protection of the heating wire, especially when the second plastic layer is relatively thinner than, for example, the first plastic layer. The second plastic layer can also be used to create a visible and particularly smooth outer surface of the modular plastic component according to the invention, which does not need to be coated with paint.

[0008] Since the heating wire according to the invention can preferably be arranged with a relatively thinner second plastic layer near the visible outer surface, defrosting of the outer surface can also be achieved particularly easily, because in this area, relatively little material of the second plastic layer should preferably be heated.

[0009] Preferably, a decorative or functional layer may be arranged at least partially between the main body of the modular component made of plastic and the first plastic layer. This layer is preferably transparent to radar systems and is particularly preferably based on colored or coated polycarbonate, especially in the form of a film material. This allows for the integration, in a structurally simple manner, of visible decorative elements, such as graphics, into the heatable modular component made of plastic, which are optically attached to the corresponding visible outer surface of the modular component made of plastic.

[0010] Since, according to the invention, the decorative or functional layer is preferably separated from the heating wire by a first plastic layer, the properties of the material of the decorative or functional layer can be prevented from being damaged by heat, for example, due to accelerated aging of the material, in a particularly effective manner.

[0011] In order to ensure the visibility of, in particular, the graphic decorative elements in a particularly simple manner, the first and / or second plastic layers of the modular components made of plastic according to the invention are preferably transparent, translucent, or transparent for radar systems.

[0012] The main body of the component, the first and second plastic layers, and the decorative or functional layer (if present) are made transparent to the radar system, allowing the radar system to be easily arranged behind the modular component made of heatable plastic in a suitable manner.

[0013] Preferably, the individual elements or layers of the modular plastic component according to the invention are arranged in a complementary manner with adjacent shapes, without forming any cavities within the individual elements or layers—this is also achieved by the manufacturing method according to the invention described further below—to further improve the transparency to radar systems due to the plastic used. The preferred relatively fine heating wires also ensure that the modular plastic component according to the invention has particularly good transparency to radar systems.

[0014] In order to obtain a feasible heating method that is preferably as simple as possible, especially in the corresponding surface area of ​​the modular component made of plastic according to the invention, the heating wire can be connected to a connecting terminal and thereby powered through the connecting terminal, which preferably extends through the component body and the first plastic layer.

[0015] In order to protect the modular components made of plastic in particular effectively from environmental impacts (especially humidity), the second plastic layer may be implemented to at least partially cover the body of the component and the first plastic layer in the edge side region of the modular components made of plastic.

[0016] Using polycarbonate as the first plastic layer in modular components made of plastic according to the present invention provides a particularly stable and economical solution.

[0017] Preferably, the second plastic layer may be made of flowable plastic, particularly preferably polyurethane.

[0018] The construction of modular components made of plastic according to the invention is particularly stable when the main body of the component is preferably made of polycarbonate or a mixture of polycarbonate-based materials (e.g., PC+ABS).

[0019] To ensure sufficient stability, as well as good heating capacity and optically suitable decoration of the modular components made of plastic according to the invention, the following dimensions and characteristics are preferably provided:

[0020] - Main body of the component: 2 to 6 mm thickness;

[0021] - First plastic layer: 1 to 4 mm thick;

[0022] - Second plastic layer: 0.2 to 1.0 mm, preferably 0.3 to 0.6 mm, particularly preferably 0.4 mm thick;

[0023] - Heating wire: Diameter of heating wire = 40 µm, material: metal alloy, such as CuAg10;

[0024] - Decorative or functional layer: 0.3 to 0.6 mm, preferably 0.45 mm thick;

[0025] - Connecting terminal: Material = CuSn6.

[0026] The present invention also relates to a method for manufacturing the aforementioned modular component made of plastic to achieve the objectives of the present invention, the modular component comprising a component body and a plurality of plastic layers disposed thereon, the method comprising the following steps:

[0027] - Based on plastic, form a component body for manufacturing a component made of plastic, or provide such a component body and form a first plastic layer that at least partially covers the exposed surface of the load-bearing element by injecting a first plastic behind the exposed surface of the component body; or

[0028] - Form a first plastic layer of a component to be manufactured based on a first plastic, or provide such a first plastic layer and form a component body that at least partially covers the exposed surface of the first plastic layer by injecting plastic at least partially behind the exposed surface of the component body;

[0029] - Deposit the heating wire at least partially on the exposed surface of the first plastic layer;

[0030] - By allowing at least a portion of the flowable second plastic to flow on the exposed surface of the first plastic layer, a second plastic layer is formed that at least partially covers the exposed surface of the first plastic layer and the heating wire.

[0031] The method of the present invention is particularly capable of manufacturing modular components made of plastic according to the invention in an economical and relatively simple manner, and in a reliable manner without major operational work.

[0032] In the method according to the invention, especially when an optical effect is desired, it is particularly simple to form at least partially a decorative or functional layer between the component body and the first plastic layer, preferably by depositing a film material in the corresponding injection mold before injection from the rear.

[0033] In the method according to the invention, the connecting terminal may preferably be functionally installed before injection from the rear, and then the heating wire is connected to the connecting terminal, for example by brazing or welding. Attached Figure Description

[0034] The invention will now be better understood by reading the following description with reference to the accompanying drawings, in which:

[0035] - Figure 1 This is a schematic cross-sectional view of a modular component made of plastic according to a first embodiment of the present invention;

[0036] - Figure 2 This is a schematic top view of a modular component made of plastic according to a second embodiment of the present invention;

[0037] - Figure 3 This is a schematic top view of a modular component made of plastic according to a first embodiment of the present invention.

[0038] In the accompanying drawings, the same elements are indicated by the same reference numerals. Detailed Implementation

[0039] Figure 1 A schematic cross-sectional view of a modular component 1 made of plastic according to a first embodiment of the present invention is shown. The modular component 1 made of plastic according to the present invention includes a component body 2 (which is preferably transparent to a radar system) and at least one first plastic layer 3 and a second plastic layer 4. To enable the modular component made of plastic according to the present invention to be heated, heating wires 5 are arranged at least partially between the first plastic layer 3 and the second plastic layer 4. For additional optical decoration, optical decoration is provided in the present invention... Figure 1 In the illustrated embodiment, a decorative or functional layer 6 is arranged at least partially between the component body 2 and the first plastic layer 3. In this example, this layer is preferably transparent to the radar system, for example, made of colored polycarbonate. In particular, it can also be a material in the form of a film.

[0040] like Figure 1 As illustrated, the modular component 1 made of plastic according to the invention is constructed in an arch shape, with a first plastic layer 3 having a corresponding arch, upon which heating wires 5 are then deposited. The entire assembly is then covered by a second plastic layer 4. The first plastic layer 3 and the second plastic layer 4 are implemented to be transparent, translucent, or transparent for radar systems to ensure the visibility of decorative elements. The second plastic layer 4 is disposed on the outer surface of the modular component made of plastic according to the invention and also surrounds its entire edge. Overall, the corresponding layers or materials are arranged in a complementary manner with adjacent shapes.

[0041] The second plastic layer 4 is preferably a layer made of flowable plastic (preferably polyurethane). This material can be relatively thin and flowable, forming a relatively smooth visible surface that can also be polished if necessary.

[0042] To power the heating wire 5, it is connected to at least one connecting terminal 7, which is preferably arranged through the main body of the component and the first plastic layer 3. In this way, the connecting terminal is protected from the effects that the environment (e.g., humidity) may cause.

[0043] The first plastic layer can preferably be made of polycarbonate to ensure sufficient stability when heating is applied simultaneously in three directions. For the stability of the modular component made of plastic according to the invention, the component body 2 can be made of polycarbonate or a mixture of polycarbonate-based materials (e.g., PC+ABS).

[0044] Figure 2 A schematic top view of a modular component made of plastic according to a second embodiment of the present invention is shown. Figure 2 The second embodiment of the present invention shown generally corresponds to Figure 1 The illustration, but Figure 2 The illustrated implementation does not include any decorative or functional layers. Figure 2 In the top view (like in the following) Figure 3 (Similar to the previous example), it can effectively distinguish heating wires 5 that are visually imperceptible in certain areas due to their thinness. Preferably, as shown in the example... Figure 2 and 3 As shown, the heating wire 5 is placed in a meandering manner above the surface of the modular component made of plastic according to the invention that must be heated.

[0045] Figure 3 A schematic top view of a modular component made of plastic according to a first embodiment of the present invention is shown. Figure 3 The illustration is related to the modular component made of plastic according to the present invention. Figure 2 The only difference in the implementation shown is that: according to Figure 1 The embodiments of the present invention, Figure 3 The graphic decoration obtained through an additional decorative or functional layer 6 is shown. It can be seen that the corresponding decorative element (shown as an "X") through the heating wire 5 according to the invention is almost unchanged from an optical perspective.

[0046] The modular components made of plastic shown in the attached figure can be manufactured using the method of the present invention described above.

[0047] The above embodiments are described to illustrate possible implementations, and those skilled in the art will recognize that various variations of the forms described herein can be used without departing from the scope of the invention. It is anticipated and also contemplated that, given that the disclosed components are provided exemplarily and not restrictively, other developments of the technology in this study may occur, such that, overall, the scope of protection is limited only by the subject matter of the appended claims.

Claims

1. A method for manufacturing a modular component (1) made of plastic, the modular component comprising a component body (2) and a plurality of plastic layers (3, 4) disposed thereon or formed thereon. Its characteristics include the following steps: Based on plastic, form a component body (2) of the component (1) to be manufactured made of plastic, or provide such a component body (2) to form a decorative or functional layer (6) that at least partially covers the exposed surface of the component body (2), and form a first plastic layer (3) that at least partially covers the exposed surface of the component body (2) and the decorative or functional layer (6) by injecting a first plastic behind at least partially the exposed surface of the component body (2); or Based on the first plastic, a first plastic layer (3) is formed on the component (1) to be manufactured made of plastic, or such a first plastic layer (3) is provided, and a decorative or functional layer (6) is formed that at least partially covers the first exposed surface of the first plastic layer (3), and a component body (2) that at least partially covers the first exposed surface of the first plastic layer (3) and the decorative or functional layer (6) is formed by injecting plastic at least partially behind the first exposed surface of the first plastic layer (3). At least partially, carrier-free independent heating wires (5) are deposited on the second exposed surface of the first plastic layer (3); By allowing at least a portion of the flowable second plastic to flow on the second exposed surface of the first plastic layer (3), a second plastic layer (4) is formed that at least partially covers the second exposed surface of the first plastic layer (3) and the heating wire (5). Prior to the rear injection, the decorative or functional layer (6) is formed at least partially between the component body (2) and the first plastic layer (3) by depositing a film material in the corresponding injection mold.

2. The method as described in claim 1, characterized in that, Before the rear injection, install the connecting foot (7) and then connect the heating wire (5) to the connecting foot (7).

3. The method as described in claim 1 or 2, characterized in that, The decorative or functional layer (6) is transparent to the radar system.

4. The method as described in claim 3, characterized in that, The decorative or functional layer (6) is composed of colored or coated polycarbonate.

5. The method as described in claim 1 or 2, characterized in that, The first plastic layer (3) and / or the second plastic layer (4) are transparent, semi-transparent or transparent to the radar system.

6. The method as described in claim 2, characterized in that, The heating wire (5) can be powered through the connecting foot (7), wherein the connecting foot (7) extends through the component body (2) and the first plastic layer (3).

7. The method as described in claim 1 or 2, characterized in that, The second plastic layer (4) at least partially covers the body of the component (2) and the first plastic layer (3) in the edge side region of the modular component (1) made of plastic.

8. The method as described in claim 1 or 2, characterized in that, The first plastic layer (3) is made of polycarbonate.

9. The method as described in claim 1 or 2, characterized in that, The second plastic layer (4) is made of flowable plastic.

10. The method as described in claim 9, characterized in that, The second plastic layer (4) is made of polyurethane.

11. The method as described in claim 1 or 2, characterized in that, The main body of the component (2) is composed of polycarbonate or a mixture of polycarbonate-based materials.

12. The method as described in claim 11, characterized in that, The main body of the component (2) is composed of a mixture of PC and ABS.

13. The method as described in claim 1 or 2, characterized in that, The thickness of the second plastic layer (4) is 0.2 mm to 1.0 mm.

14. The method as described in claim 13, characterized in that, The thickness of the second plastic layer (4) is 0.3 mm to 0.6 mm.

15. The method as described in claim 14, characterized in that, The thickness of the second plastic layer (4) is 0.4 mm.

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