Mounting frame for use in motor vehicle construction and method for manufacturing the mounting frame

Abstract

Mounting frame for use in motor vehicle construction for defining a recess of a sunroof and for fastening and / or clamping a material of a headliner around the recess and / or a covering towards the recess, characterized in that the mounting frame is manufactured in one piece from rigid polymeric material, namely dicyclopentadiene (DCPD) or poly-dicyclopentadiene (PDCPD), using the Reaction Injection Moulding (RIM) process.

Description

[0001] The present invention relates to a mounting frame for use in motor vehicle construction for defining a recess and for attaching and / or clamping a material and / or a covering towards the recess, in particular for clamping a headliner around the recess of a sunroof. The invention further relates to a method for manufacturing such a mounting frame.

[0002] The invention relates generally to mounting frames in motor vehicles, such as those used for roof windows or sunroofs. The mounting frame forms the connection between the headliner, i.e., the fabric stretched on the inside of the roof, and the roof itself. The invention can also be used for any other recesses, cutouts, and openings in motor vehicles that require a frame, such as a recess on the back of the front seat for installing a screen.

[0003] In practice, sunroof frames are currently manufactured from steel, usually in four sections. The formation of the curved frame shape, as well as connecting elements, clamping lugs, recesses, and / or bores, requires individual machining steps. The individual frame sections, typically four frame legs, must be joined together by welding and / or bolting before installation. Conventional steel frames weigh approximately 1.4 kg. The complex manufacturing process and the material itself represent significant time and cost factors. Given the increasing importance of weight reduction in vehicle construction, the weight of the metal frames negatively impacts the overall weight of the vehicle.

[0004] The present invention therefore aims to design and further develop a mounting frame of the generic type in such a way that it can be manufactured simply, cost-effectively, and in a few production steps while achieving sufficient stability and reduced weight. The same applies to a method.

[0005] DE 38 09 846 A1 discloses a vehicle door with a door frame and a window guide frame, as well as a method for mounting a window guide frame. The door frame comprises an anchoring groove, approximately U- or V-shaped in cross-section, which runs around the upper part of the vehicle door and is open to the outside or inside of the vehicle.

[0006] The article “Materials for the Future of Lightweight Construction” by Klaus Dallner in Kunststoffe, Vol. 102 / 2012, No. 3, pages 60-67 - ISSN 0023 - 5563 reveals materials for the future of lightweight construction. This document teaches how to manufacture short- or long-fiber-reinforced vehicle components from polyurethane.

[0007] Furthermore, the company publication of BASF Polyurethanes GmbH, “Lightness in the Automobile”, Lemförde, September 2, 2013, reveals: Short- or long-fiber reinforced composite components, especially in the form of polyurethanes.

[0008] Ultimately, DE 37 12 358 A1 discloses a sunroof for vehicles, consisting of an outer frame, an inner frame, and a cover frame attached to this frame unit on the inside of the vehicle. These individual parts are screwed together.

[0009] The aforementioned problem is solved according to the invention by the features of claim 1. According to this claim, the generic mounting frame is characterized in that the mounting frame is manufactured in one piece from plastic by the reaction injection molding (RIM) process. Claim 12 solves the problem with respect to a method.

[0010] According to the invention, it has been recognized that it is particularly advantageous to manufacture the mounting frame in one piece from a lightweight material, namely plastic, using the Reaction Injection Moulding (RIM) process, thus reducing material costs, production time, and weight. The RIM process is a primary forming process for manufacturing plastic molded parts. In this process, two components, and possibly other additives, are intensively mixed in a mixer and immediately injected as a reaction mass into a molding tool, for example, an aluminum foam mold. Reinforced Reaction Injection Moulding (RRIM) is also conceivable. This ideally utilizes the properties of plastics, such as high strength and chemical resistance, combined with their low weight compared to metals. Furthermore, all areas and elements of the mounting frame can be integrally formed in a single manufacturing step.The one-piece construction ensures the necessary stability of the mounting frame. Furthermore, the mounting frame can be recycled by type.

[0011] Consequently, the mounting frame according to the invention is a mounting frame which can be manufactured easily, cost-effectively and in a few production steps while achieving sufficient stability and reduced weight.

[0012] Advantageously, the mounting frame is made of a rigid polymeric material. Particularly advantageously, the polymeric material is dicyclopentadiene (DCPD). This material can be processed into a solid using the DCPD reaction injection molding (RIM) process.

[0013] The following information pertains to the chemical structure and processing of DCPD: Dicyclopentadiene is a byproduct of the cracking process in gasoline production. At a purity of 99%, it becomes liquid when mixed with norbornene at temperatures above -2°C to 0°C. In the presence of catalysts such as alkaline aluminum, polymerization to a cross-linked DCPD occurs through the cleavage of double bonds and ring openings. Mixed with additives, DCPD can be processed in the form of two-component systems using conventional RIM equipment. DCPD exhibits extremely high toughness, stiffness, and dimensional stability at high temperatures. Its operating temperature range is between -40°C and 110°C. Therefore, DCPD is particularly well-suited for the production of mounting frames that require sufficient rigidity for secure fastening. Simple, single-material production and disposal are ensured.

[0014] In a further advantageous manner, clips and / or clamping studs protrude outwards on the outside of the mounting frame and serve, based on tension and positive locking, to clamp into a recess or frame.

[0015] Ideally, the clips or clamping studs are designed as an integral part of the mounting frame, meaning they are manufactured in the same production step as the mounting frame itself. It is particularly advantageous if the mounting frame is made of solid material and, unlike conventional steel frames, the clips or clamping studs are fully or partially backfilled with material.

[0016] Ideally, the required clamping force results solely from the material-specific stiffness or strength of the mounting frame material.

[0017] Secure mounting of the installation frame is ensured in particular by the fact that the clips or clamping studs are formed all around, preferably equidistantly, on the edge of the installation frame.

[0018] Advantageously, the surface of the mounting frame is sealed at least in some areas to protect against outgassing and also to protect the surface itself, in particular by being primed and / or painted before installation.

[0019] It is particularly advantageous if the wall thickness of the mounting frame is at least 2 mm in some areas. A progression or variation in wall thickness from the top to the bottom of the mounting frame is conceivable.

[0020] Recesses or bores in the mounting frame for fastening the mounting frame itself and / or for fastening a material and / or a covering are advantageously formed in the clamping or recess direction – i.e., in the Z-direction. These recesses and / or bores are preferably equidistant on the mounting frame. They can be formed during the manufacturing process of the mounting frame or in an additional step.

[0021] There are now various ways to advantageously elaborate and further develop the teaching of the present invention. For this purpose, reference should be made, on the one hand, to the claims subordinate to claim 1 and, on the other hand, to the following explanation of a preferred embodiment of the invention with reference to the drawing. In conjunction with the explanation of the preferred embodiment of the invention with reference to the drawing, generally preferred embodiments and further developments of the teaching are also explained. The drawing shows Fig. 1 in a schematic view an embodiment of a mounting frame according to the invention, Fig. 2. In a schematic top view, the object is... Fig. 1, Fig. 3. In a schematic side view, the object is shown from the Fig. 1 and Fig. 2, Fig. 4 in a schematic side view, opposite Fig. 3. Rotated 90°, remove the object from the Fig. 1, Fig. 2 to Fig. 3, Fig. 5 in a schematic view, enlarged, a section of the object from the Fig. 1, Fig. 2, Fig. 3 to Fig. 4, Fig. 6. schematically depict the cross-section of the object from the Fig. 1, Fig. 2, Fig. 3, Fig. 4 to Fig. 5 at one in Fig. 5 corner point shown, Fig. 7 in a schematic view a mounting frame made of metal, known from practice and Fig. 8 a schematic top view of the object Fig. 7.

[0022] Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5 to Fig. Figure 6 shows different schematic views of a preferred embodiment of a mounting frame according to the invention. The mounting frame is made in one piece. A key component of the mounting frame is a rectangular frame 1 with four frame legs, which is shaped such that it can be positioned from the inside into a recess of a motor vehicle roof. From the lower end 2 to the upper end 3, the mounting frame narrows conically, so that the inner diameter at the upper end 3 of the mounting frame is smaller than that at the lower end 2 of the mounting frame. Fig. 1, Fig. 3 and Fig. 4) The upper end 3 of the mounting frame projects into the center of the frame, the lower end 2 of the mounting frame projects outwards away from the scaffold 1 (especially). Fig. 6).

[0023] The mounting frame has elongated clips 4 on its outer side, which project outwards and serve to clamp into a frame fixed in the recess of a vehicle roof. The clips 4 are an integral part of the mounting frame and, like the frame itself, are made of solid material or completely backfilled with material ( Fig. 6) The required clamping force results exclusively from the material-specific stiffness or strength of the material of the mounting frame or the clips 4.

[0024] At the lower end 2 of the mounting frame, recesses 5 are formed in the clamping or recess direction, i.e., in the Z-direction, which are already manufactured during the mounting frame's production process. These recesses 5 serve to tension the headliner (not shown in the drawing) around the opening of a sunroof. The mounting frame thus forms a connection between the headliner (i.e., the fabric) and the roof of a motor vehicle.

[0025] Fig. Figure 5 shows a schematic view of one corner of the mounting frame. Fig. Figure 6 schematically shows the cross-section of the mounting frame in which Fig. The outermost corner point shown in Figure 5. In contrast to known mounting frames, the outer skin of the mounting frame according to the invention is thickened to 0.75 mm, at least in certain areas, towards the outside. At the upper, inwardly directed end 3 of the mounting frame, the wall thickness is 0.75 mm, and in the long, middle section and at the lower end 2 of the mounting frame, it is 2 mm. The radius at the upper edge between the upper end 3 and the long, middle section is 3.2 mm.

[0026] The mounting frame is a single piece and is made entirely of rigid polymeric material, namely dicyclopentadiene (DCPD) or polydicyclopentadiene (PDCPD) using the Reaction Injection Moulding (RRIM) process.

[0027] By using plastic, the mounting frame according to the invention achieves a weight saving of over 60% compared to conventional mounting frames. The one-piece design reduces both production time and material costs. Furthermore, the one-piece design enhances the stability of the mounting frame.

[0028] The Fig. 7 and Fig.Figure 8 shows a mounting frame as it is known from practical experience. In its basic form, it resembles the mounting frame according to the invention, but has crucial differences. The mounting frame is made of four individual frame legs 6 made of steel and is assembled by welding before installation. The clamping lugs 4 are formed from the sheet metal by cutting and bending, so that open areas are created below the clamping lugs 4 and cavities behind the clamping lugs 4. The bores 3 at the lower end 2 of the mounting frame must be produced in an additional work step.

[0029] To avoid repetition, reference is made to the general part of the description with regard to features that cannot be deduced from the figures.

[0030] Finally, it should be noted that the embodiment described above serves only as an example to illustrate the claimed teaching, but does not limit it to this embodiment. Reference symbol list 1. Frame of the mounting frame 2 lower end of the mounting frame 3 upper end of the mounting frame 4 clips / clamping studs 5 cutouts / holes 6 individual frame legs

Claims

[1] Mounting frame for use in motor vehicle construction for defining a recess of a sunroof and for fastening and / or tensioning a headliner material around the recess and / or a trim towards the recess, characterized by that the mounting frame is manufactured in one piece from rigid polymeric material, namely dicyclopentadiene (DCPD) or poly-dicyclopentadiene (PDCPD), using the Reaction Injection Moulding (RIM) process. [2] Mounting frame according to claim 1, characterized by , that clips or clamping studs protrude outwards on the outside of the mounting frame and serve to clamp into a frame based on tension and positive locking. [3] Mounting frame according to one of claims 1 or 2, characterized by that the clips or clamping studs are designed as an integral part of the mounting frame. [4] Mounting frame according to one of claims 1 to 3, characterized bythat the mounting frame is made of solid material and, in particular, that the clips or clamping studs are completely or partially backfilled with material. [5] Mounting frame according to any one of claims 1 to 4, characterized by that the required clamping force results exclusively from the material-specific stiffness or strength of the mounting frame material. [6] Mounting frame according to any one of claims 1 to 5, characterized by that the clips or clamping studs are formed all around, preferably equidistantly, at the edge of the mounting frame. [7] Mounting frame according to any one of claims 1 to 6, characterized by that the surface of the mounting frame is at least partially sealed, in particular primed and / or painted. [8] Mounting frame according to any one of claims 1 to 7, characterized by that the wall thickness of the mounting frame is at least 2 mm in some areas. [9] Mounting frame according to any one of claims 1 to 8, characterized by, that preferably equidistant recesses and / or bores are formed in the clamping or recess direction during the manufacturing process of the mounting frame and / or in an additional operation. [10] Method for manufacturing a mounting frame according to any one of claims 1 to 9, characterized by that the mounting frame is manufactured in one piece from rigid polymeric dicyclopentadiene (DCPD) or poly-dicyclopentadiene (PDCPD) using the Reaction Injection Moulding (RIM) process.

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