Protective barrier for reinforcing a section of a vehicle wheel arch lining

Abstract

Protective barrier for reinforcing a section of a vehicle wheel arch lining (12), comprising: the wheel arch liner (12) with an arc-shaped cast main body with opposing ends (14, 16) configured to provide a barrier between a tire and a wheel arch cavity, wherein the wheel arch liner includes a contact side (13) of the vehicle structure (20); a ballistic material patch (22) that is integrally formed with a predetermined section of the cast main body to create a protective barrier between the tire and a vehicle structure (20) by the ballistic material patch (22) reinforcing the contact side (13) of the wheel arch liner (12) of the vehicle structure (20) so that, if the tire exceeds the casing limits in this area, tire damage can be prevented, wherein a wheel casing (18) illustrates all positions that the tire can assume during driving, wherein the section of the formed main body is at least one of the opposite ends (14, 16) on the contact side (13) of the vehicle structure (20) of the wheel arch lining (12), wherein the ballistic material patch (22) is formed from an oxidized polyacrylonitrile fiber material and bonding fibers, wherein the ballistic material patch (22) further comprises a middle layer formed from a thermoplastic polyurethane film material between two layers of oxidized polyacrylonitrile fiber material and binding fibers, wherein the ballistic material patch (22) further comprises a middle layer formed from a thermoplastic polyurethane film material between two layers of a para-aramid fiber material and binding fibers.

Description

TECHNICAL AREA

[0001] The present disclosure relates to vehicle wheel liners and in particular to a protective barrier arranged on a wheel arch liner. BACKGROUND

[0002] It is a known practice in engineering to equip the outer wheel arch of vehicles with a trim piece or cover, also known as an outer wheel arch cover, fender liner, or wheel arch liner. These wheel arch liners can be mounted on the front and / or rear wheel arch opposite the wheel to protect the vehicle body.

[0003] These wheel arch liners can reduce the transmission of noise generated while driving into the vehicle's interior. This noise is primarily caused by the wheel rotating on the road surface, as well as by the sound of water and stones being thrown up by the tires against the wheel arch. The wheel arch liner also serves as protection against particles such as sand and gravel, which are accelerated against the wheel arch by the rotating wheel, and against water and mud.

[0004] Wheel arch liners are shaped to follow the contours of the vehicle's wheel housing. Therefore, they are designed as three-dimensional, semicircular structural components. The physical properties of wheel arch liners, such as structural stiffness and durability, are important for protecting components within (e.g., tires) or the surfaces of components that form the vehicle's wheel arch.

[0005] In the absence of wheel arch liners, these components can be exposed to stone chips, dirt, road debris, heat, cold, and / or moisture, and may collide with obstacles under the vehicle during use. In some cases, for example, due to architectural space constraints, a vehicle tire may have a minimal clearance to prevent contact with a critical interface (e.g., the vehicle structure) when tire failure thresholds are exceeded, particularly when exposed to certain road hazards such as potholes. This contact can lead to damage to the tire or the vehicle structure if no adequate protection is provided.

[0006] DE 100 01 313 A1 discloses a wheel arch lining for a motor vehicle with an injection-molded support area and a noise-reducing area made of mechanically bonded plastic fleece, wherein the support area forms a frame that surrounds the fleece area and the plastic of which only penetrates the edge zones of the fleece during injection molding in order to connect both areas with low weight and optimized sound-absorbing effect.

[0007] US 2015 / 0273739 A1 discloses a lining device and a manufacturing process in which one or more inserts and one or more frames are combined. The frames can be made of plastic or a foam-like plastic produced using supercritical fluid and can be overmolded over the inserts. The inserts can be made of nonwoven material and include a hinged area, allowing the device to be flexibly designed for various operating environments and materials.

[0008] DE 199 30 762 A1 a wheel arch lining with a shell element adapted to the wheel arch contour, consisting of a plastic frame structure and covered on the outside facing the wheel by a tear-resistant, impact-resistant plastic film, resulting in lower weight and effective damping of stone chip and spray noise with easy installation.

[0009] DE 10 2017 129 086 A1 discloses a profile arrangement for reducing disruptive spray formation from a vehicle wheel, which is arranged parallel to the tread and perpendicular to the direction of travel and consists of a polymeric material. It comprises a base, at least one profile element projecting at an acute angle, and at least one damping element facing the tire tread. The profile element has a damping element integrally connected to it, which is made of a soft-elastic polymeric material with a Shore A hardness of approximately 50 to 95.

[0010] DE 20 2016 008 324 U1 shows a nonwoven component with at least one nonwoven structure made of nonwoven material and a reinforcement structure which has several reinforcement elements made of or comprising a reinforcement material, which are arranged at least partially on or in the nonwoven structure in order to improve its mechanical properties in particular.

[0011] CN 1 07 757 723 A describes a reinforced woven wheel arch liner with base layers and a reinforcing layer, which consist at least partially of thermoformable textile material. The reinforcing layer is bonded to a section of the base layers. In some embodiments, the base and reinforcing layers are manufactured separately; in others, the reinforcing layer can be formed as part of the base layer in a single molding operation and subsequently separated if necessary.

[0012] US 2016 / 0288747A1 describes an energy management system for a vehicle with a load-bearing component located in the wheel well behind a tire-wheel module. This component is designed to limit the movement of the tire / wheel module within the wheel well when a load acts in front of the wheel and laterally to the vehicle's longitudinal axis. SUMMARY

[0013] The object of the invention is to prevent such damage. This object is achieved by the subject matter according to claim 1. Further developments are described in the dependent claim. One or more exemplary embodiments solve the aforementioned problem by providing a protective barrier arranged on a wheel arch liner. In particular, a protective barrier arranged on a wheel arch liner and a method for its manufacture. According to aspects of one exemplary embodiment, a protective barrier for reinforcing a section of a vehicle wheel arch liner comprises the wheel arch liner with an arc-shaped main body having opposing ends configured to provide a barrier between a tire and a wheel arch cavity, wherein the wheel arch liner includes a contact face of the vehicle structure.And a further aspect according to the exemplary embodiment includes a ballistic material patch that is integrally cast with a predetermined section of the molded main body, configured to provide a protective barrier between the tire and a vehicle structure. And in yet another aspect, wherein the predetermined section of the cast main body is at least one of the opposite ends on the contact side of the vehicle structure of the wheel arch liner. And in yet another aspect, wherein the ballistic material patch is formed from an oxidized polyacrylonitrile fiber material and bonding fibers.

[0014] Further aspects are disclosed as exemplary embodiments, wherein the ballistic material patch is formed from a para-aramid fiber material and bonding fibers, or wherein the ballistic material patch further comprises a middle layer of a thermoplastic polyurethane film material between two layers of oxidized polyacrylonitrile fiber material and bonding fibers. Another embodiment further comprises a middle layer formed from a thermoplastic polyurethane film material between two layers of para-aramid fiber material and bonding fibers. Still further embodiments further comprise a reinforcing layer of a thermoplastic polyurethane film material arranged on the contact side of the vehicle structure of the wheel arch liner.And another aspect, in which the vehicle structure of the articulated column crimp welding flange is.

[0015] A method for manufacturing a wheel arch liner arranged with a protective barrier comprises adhering a ballistic material patch to a predetermined section of a raw material of the wheel arch liner; heat forming the raw material of the wheel arch liner and the adhering ballistic material patch together to form a wheel arch liner with an arc-shaped main body having opposite ends, wherein the wheel arch liner is configured to provide a barrier between a tire and a wheel arch cavity, and wherein the wheel arch liner includes a contact face of a vehicle structure; and removing the formed wheel arch liner and the ballistic material patch from the mold, wherein the ballistic material patch is configured to provide a protective barrier between the tire and a vehicle structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The present embodiment will be better understood from the following description with reference to the associated drawings, in which the following applies: Fig. Figure 1 is a representation of a vehicle wheel arch. Fig. 2 is an example of a wheel arch lining in physical contact with a vehicle structure. Fig. Figure 3 is a representation of a wheel arch liner with a ballistic material patch located on a contact side of the vehicle structure. Fig. 4 is a representation of the wheel arch lining of Fig. 3 in physical contact with the vehicle structure of Fig. 2. The Fig. 5A and Fig. 5B are representations of ballistic material patches. Fig. Figure 6 is a description of a method for producing the protective barrier on a wheel arch lining, not covered by the scope of protection of the patent claims, according to the aspects of the exemplary embodiment. Fig. 7 is a representation of an algorithm for carrying out the procedure of Fig. 6 according to the aspects of the exemplary embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0017] The following description is merely exemplary and is not intended to limit the present disclosure, application or uses thereof in any way.

[0018] Fig. Figure 1 shows a representation of a vehicle wheel housing 10, which is essentially the underside of a vehicle's fender. The main purpose of the wheel housing 10 is to prevent sand, mud, stones, liquids, and other debris from being thrown into the air by the rotating tire. To protect the underside of the vehicle fenders and other undersides, a wheel housing cover is arranged between the vehicle tire and the wheel housing cavity.

[0019] Besides acting as a barrier against projectiles caused by the rotating wheels, wheel arch liners can serve additional functions, including acoustic and aesthetic ones. Furthermore, wheel arch liners can conceal some of the vehicle's less attractive components and / or structure from the exterior. Some wheel arch liners have an exposed outer edge. Other vehicles incorporate an additional molded piece to cover the edge so that it is not visible.

[0020] With reference to Fig. 2 is a wheel arch liner 12, generally shaped to match the wheel arch 10. In this case, the wheel arch liner 12 has a domed, shaped main body with opposing ends (14, 16) configured to form a barrier between a tire and a wheel arch cavity. The wheel arch liner 12 includes a contact face 13 of the vehicle structure that can abut sections of the vehicle body, such as a body hinge-pillar pinch weld flange 20. A wheel casing 18 illustrates all the positions a tire can assume during driving.

[0021] This process takes into account the maximum impact and rebound caused by the suspension system and the maximum rotation and pitch angles allowed by the steering mechanism. This casing 18 is compared with the wheel arch 10 and other components in the area, such as the body pivot or the fender perimeter, to perform an interference / collision analysis. The results of this analysis can indicate whether this vehicle tire will contact the casing and components under driving conditions. In some cases, due to design space limitations, a tire may have a minimum clearance to make contact with a problematic interface (e.g., the vehicle structure) because it exceeds the limits for the tire casing, especially when exposed to certain road hazards such as speed limits and potholes.This contact can lead to damage to a vehicle tire or the vehicle structure if no suitable protection is provided.

[0022] Fig. Figure 3 illustrates a wheel arch liner 12 with a ballistic material patch 22 arranged on a contact side 13 of the vehicle structure according to the aspects of an exemplary embodiment. The ballistic material patch 22 is integrally cast with a predetermined section, e.g., at least one opposite end (14, 16) or extending to the entire contact side 13 of the vehicle structure of the molded main body of the wheel arch liner 12. The ballistic material patch 22 is configured to provide a protective barrier between the tire and a vehicle structure when the limits of the tire casing are exceeded. Fig. Figure 4 illustrates the wheel arch lining 12 of Fig. 3 in physical contact with the vehicle structure of Fig. 2 according to the aspects of the exemplary embodiment. In this case, the ballistic material patch 22 would reinforce the contact side 13 of the wheel arch lining 12 of the vehicle structure, so that if the vehicle tire exceeds the turning limits in this area, tire damage can be prevented.

[0023] With reference to the Fig. 5A and Fig. Figure 5B illustrates exemplary embodiments of ballistic material patches (22A, 22B). The ballistic material patch 22 can be formed from several materials designed for maximum durability, heat resistance, abrasion resistance, and penetration resistance, such as Kevlar®. Preferred materials include, but are not limited to, the following: A para-aramid fiber material and binding fibers, and a glass fiber fabric with binding fibers, as shown in the illustrations of exemplary embodiments of ballistic material patches with binding fibers. The binding fibers according to the aspects of the exemplary embodiment are preferably polypropylene fibers having a lower melting point than the casting material, e.g., polyethylene terephthalate.

[0024] Fig. Figure 5A illustrates a configuration for a ballistic material patch 22A according to aspects of exemplary embodiments, wherein the ballistic material patch 22A comprises a middle layer of a thermoplastic polyurethane film material 26 between two layers of the ballistic material 24. The layers can be bonded together by means of suitable bonding fibers, resins, and adhesives. Fig. Figure 5B illustrates an alternative configuration for a ballistic material patch 22B, wherein the ballistic material patch includes a reinforcing layer made of a thermoplastic polyurethane film material 26, which is arranged on the contact side 13 of the vehicle structure of the wheel arch liner 12. Likewise, the reinforcing layer 26 can be bonded to the ballistic material 24 using bonding fibers, resins, and suitable adhesives.

[0025] Fig. Figure 6 provides a description of a method 50 for producing the ballistic material patch 22 on a wheel arch liner 52 according to the aspects of the exemplary embodiment. In general, the method involves pre-applying the ballistic material patch 22 to a predetermined section of a wheel arch liner blank 52 and then preheating it with heating elements 53 before the workpiece is placed in a hot press molding device.

[0026] The workpiece is then placed between the lower 54 and upper 56 molds of the hot pressing device. The upper mold 56 is then moved downwards, clamping the workpiece between the core of the upper mold 56 and the cavity of the lower mold 54. In this position, heating is performed while pressure is applied to the wheel arch liner blank 52 and the ballistic material patch 22, causing melting to bond the components between the upper 16 and lower 14 molds. After the components are bonded and a cooling process is complete, the wheel arch liner, including the ballistic material patch 22, is removed from the molding device.

[0027] Fig. Figure 7 is a representation of an algorithm 100 for carrying out the procedure of Fig.6 according to the aspects of the exemplary embodiment. The method begins at 105 with the bonding of a ballistic material patch to a predetermined section of a wheel arch liner material blank and the preheating of the workpiece before insertion into the forming device. Next, the method proceeds at block 110 with the heat forming of the wheel arch liner raw material and the bonded ballistic material patch to form a wheel arch liner with an arc-shaped main body having opposite ends, wherein the wheel arch liner is configured to provide a barrier between a tire and a wheel arch cavity, and wherein the wheel arch liner includes a contact face of the vehicle structure.Finally, at block 115, the process concludes with the removal of the molded wheel arch liner and the ballistic patch from the mold, in which the ballistic patch is configured to provide a protective barrier between the tire and a vehicle structure. An alternative manufacturing method can involve inserting a ballistic patch into an injection molding device and then injecting molten wheel arch liner material into a mold. After the molten wheel arch liner material has cooled and solidified, the wheel arch liner with the integrated ballistic patch can be removed from the injection molding device.

Claims

[1] Protective barrier for reinforcing a section of a vehicle wheel arch lining (12), comprising: the wheel arch liner (12) with an arc-shaped cast main body with opposing ends (14, 16) configured to provide a barrier between a tire and a wheel arch cavity, wherein the wheel arch liner includes a contact side (13) of the vehicle structure (20); a ballistic material patch (22) that is integrally formed with a predetermined section of the cast main body to create a protective barrier between the tire and a vehicle structure (20) by the ballistic material patch (22) reinforcing the contact side (13) of the wheel arch liner (12) of the vehicle structure (20) so that, if the tire exceeds the casing limits in this area, tire damage can be prevented, wherein a wheel casing (18) illustrates all positions that the tire can assume during driving, wherein the section of the formed main body is at least one of the opposite ends (14, 16) on the contact side (13) of the vehicle structure (20) of the wheel arch lining (12), wherein the ballistic material patch (22) is formed from an oxidized polyacrylonitrile fiber material and bonding fibers, wherein the ballistic material patch (22) further comprises a middle layer formed from a thermoplastic polyurethane film material between two layers of oxidized polyacrylonitrile fiber material and binding fibers, wherein the ballistic material patch (22) further comprises a middle layer formed from a thermoplastic polyurethane film material between two layers of a para-aramid fiber material and binding fibers. [2] Protective barrier according to claim 1, wherein the vehicle structure (20) is the hinge column weld flange.

Images