Component for a vehicle, method for manufacturing a component, and vehicle

Abstract

The invention relates to a component (12) for a vehicle (10), comprising at least one planar structure (16) made of a formed fiber material (18), wherein the fiber material (18) is formed from fibers oriented perpendicular to a surface (20) of the fiber material (18). Furthermore, the invention relates to a method for manufacturing such a component (12) and to a vehicle with such a component (12) and / or at least one component (12) manufactured by such a method.

Description

[0001] The invention relates to a component for a vehicle, comprising at least one sheet-like structure made of a formed fiber material. Furthermore, the invention relates to a method for producing such a component and to a vehicle having such a component and / or having at least one component produced using such a method.

[0002] In automotive construction, many components, especially trim components, are made of different materials that form composites. Examples of composite materials include a back-injected textile, a laminated textile, a foam-laminated outer fabric on a glass-fiber-reinforced polyurethane substrate with bonded metal attachments, injection molding, or foams of varying densities.

[0003] For aesthetic reasons, cladding components often have a decorative layer, which is often made of a nonwoven fabric. An example of such a nonwoven fabric is known from EP 3 385 422 A1. The nonwoven fabric comprises needle-punched thermoplastic fibers. The nonwoven fabric is provided with thermally embossed indentations.

[0004] The materials of the composites are usually glued together and therefore inseparable. Recycling these composites is very difficult or even impossible. Additionally, the cladding components may be equipped with fastening and / or reinforcement elements. Finally, composites require multiple manufacturing and assembly steps.

[0005] The present invention is based on the object of creating a component and a vehicle that have improved rigidity and recyclability. Furthermore, the invention is based on the object of creating a method that has a reduced number of manufacturing and assembly steps.

[0006] To solve the problem, a component having the features of claim 1, a method having the features of claim 8 and a vehicle having the features of claim 10 are proposed.

[0007] Advantageous embodiments of the component and the method are the subject of the respective dependent claims.

[0008] According to a first aspect of the invention, a component for a vehicle is proposed. The component comprises at least one sheet-like structure made of a formed fiber material, wherein the fiber material is formed from fibers oriented perpendicular to a surface of the fiber material.

[0009] By using a formed fiber material as a sheet for a component, whose fibers are aligned perpendicular to a surface of the fiber material, the component exhibits high rigidity. Furthermore, components can be produced without further processing steps. Because the component consists of a single material, it is recyclable and recyclable. Furthermore, the fiber material, with its fibers aligned perpendicular to a surface of the fiber material, is suitable as a replacement for polyurethane foams as an acoustic, haptic, comfort, or filling element in cladding and acoustic components. Depending on the tool parameters, a wide range of surface designs is also possible. For example, a surface ranging from smooth to fabric-like can be created.

[0010] The component can be a trim component, such as a headliner, a C-pillar trim, a supporting structure or an acoustic component.

[0011] In an advantageous embodiment, the fiber material comprises fibers with different material properties. Advantageously, the fibers have different melting points. Thus, the fiber material can comprise fibers with a low melting point and fibers with a high melting point.

[0012] In an advantageous embodiment, the sheet-like structure has at least one uncompacted region and at least one compacted region. The at least one compacted region can be achieved by pressing the fiber material, for example with the aid of steam, expansion or isothermal pressing and / or compression. The at least one compacted region ensures sufficient stability of the component. The pressing advantageously takes place in a forming tool. By designing the tool parameters, compacted or densified regions or densified, hard zones as well as soft, uncompacted or uncompacted regions or soft, slightly uncompacted zones are created. This enables a wide range of surface designs, for example from smooth to fabric-like, depending on the setting of the tool parameters.Advantageously, the compacted area has a lower height than the uncompacted area.

[0013] In an advantageous embodiment, the compacted area forms a supporting structure. This supporting structure ensures sufficient stability of the component.

[0014] In an advantageous embodiment, the at least one compacted region is created by forming the fiber material under pressure and / or temperature. The compacted region can be created by pressing the fiber material using steam, expansion, or isothermal pressing and / or compression. The fiber material is advantageously pressed at a temperature between 150°C and 250°C. Furthermore, the use of temperature enables a broad range of surface finishes, from smooth to fabric-like.

[0015] In an advantageous embodiment, at least one structure is injection-molded onto the sheet-like structure. The structure can be a fastening means. This allows fastening points to be integrated into the component. The at least one structure is advantageously produced by back-injection molding of the sheet-like structure. The back-injection molding can be integrated into the forming process step, in particular the pressing process. This reduces the number of manufacturing steps. The structure is advantageously injection-molded onto the compacted area. Furthermore, the injection-molded structure is advantageously made of the same material as the fibers. The structure can be provided with fibers, such as glass fibers, thermoplastic fibers, or natural fibers.

[0016] In an advantageous embodiment, the at least one structure is designed as a rib and / or as a receiving frame for attachments surrounding the sheet-like structure. The rib can be produced by back-injection molding of the formed fiber material to form a structure.

[0017] In an advantageous embodiment, the pressing of the fiber material and the injection molding of at least one rib and / or a receiving frame surrounding the sheet-like structure can take place during the pressing.

[0018] In an advantageous embodiment, the fibers are made of a thermoplastic. The fibers are also advantageously made of polyethylene (PET).

[0019] According to a further aspect of the invention, a method for producing a component according to the invention is proposed. In the method, a mat of fiber material is placed into a forming tool, wherein the fiber material consists of fibers oriented perpendicular to a surface of the fiber material. The fiber material is then formed under pressure and / or temperature and with the formation of at least one compacted region into a sheet-like structure forming the component.

[0020] The method makes it possible to create a component into which a supporting structure in the form of at least one compacted region is already integrated and which has an attractive surface. The fiber material is advantageously pressed at a temperature between 150°C and 250°C. To produce the compacted region, the shaping tool can have at least one elevation which compresses the fiber material during pressing and creates the compacted region by melting the fibers, in particular the fibers with the low melting point. Furthermore, the sheet-like structure can have at least one uncompacted region in addition to the compacted region. In addition, the sheet-like structure can have a plurality of compacted regions and uncompacted regions.

[0021] In an advantageous embodiment, at least one structure is injection-molded onto the sheet during the forming process. The structure can be a rib and / or a support frame for attachments surrounding the sheet. This allows attachment points to be integrated into the component. The at least one structure is advantageously produced by back-injection molding of the sheet.

[0022] According to a further aspect of the invention, a vehicle is proposed. The vehicle has at least one component according to the invention and / or at least one component manufactured using a method according to the invention.

[0023] Below, a vehicle, a component for the vehicle, a method for manufacturing the component, and other features and advantages are explained in more detail using an exemplary embodiment. Here: Fig. 1 a vehicle with a component; Fig. 2 a plan view of the component; and Fig. 3 an enlarged view of a section of a section through the component along the line III-III in Fig. 2.

[0024] In Fig. 1 shows a vehicle 10 having a drive unit configured as an internal combustion engine and / or an electric motor. The vehicle 10 has a component 12 which is Fig. 2 is shown.

[0025] The component 12 is in the present case a trim component in the form of a roof lining 14. The component 12 has a sheet-like structure 16 made of a fiber material 18, wherein the fiber material 18 is formed from fibers 22 aligned perpendicular to a surface 20 of the fiber material 18, as in Fig. 3 is evident.

[0026] The fibers 22 are made of a thermoplastic, in particular polyethylene (PET), and have different material properties. The fibers 22 differ, in particular, in their melting point. In particular, the fiber material 18 comprises fibers 22 with a low melting point and fibers 22 with a high melting point.

[0027] As also in Fig.As can be seen in Figure 2, the sheet 16 has compacted regions 24 and uncompacted regions 26. The compacted regions 24 are created during the compression of the fiber material 18 in a forming tool, as will be explained in more detail below. As a result, the compacted regions 24 have a lower height than the uncompacted regions 26. Thus, the sheet 16 has compacted, hard zones and soft, less compacted zones, with the compacted zones, i.e., the compacted regions 24, ensuring sufficient stability of the sheet 16.

[0028] To increase the stability of component 12, structures not shown, such as ribs, can be molded onto the sheet-like structure 16. Additionally or alternatively, attachment points and / or a support frame surrounding the sheet-like structure 16 for attachment parts can be molded onto the sheet-like structure 16 as structures.

[0029] A possible manufacturing method for component 12 is described below. To manufacture component 12, a mat of fiber material 18, which consists of fibers 22 aligned perpendicular to a surface 20 of fiber material 18, is placed in a forming tool (not shown). The fiber material 18 is then formed under pressure and / or temperature to form the sheet-like structure 16 or component 12. The fiber material 18 is pressed at a temperature between 150°C and 250°C and can be accomplished with the aid of steam, expansion, or isothermal pressing. To produce compacted regions 24, the forming tool has elevations which compress the fiber material 18 during pressing, causing the fibers 22, particularly the fibers 22 with the low melting point, to melt.During the pressing, at least one structure (not shown), such as a rib and / or a receiving frame for add-on parts surrounding the sheet-like structure 16, can be injection-molded onto the sheet-like structure 16.

[0030] The component 12 is characterized by its sheet-like structure 16, which consists of a fiber material 18 having fibers 22 aligned perpendicular to the surface 22 of the fiber material 18. By compressing the fiber material 18 under heat, compacted regions 24 are created that increase the rigidity of the component 12. Furthermore, structures such as ribs and / or a receiving frame for add-on parts surrounding the sheet-like structure 16 can be injection-molded onto the sheet-like structure 16 during forming. This reduces the number of manufacturing steps for the component 12. Since the component 12 consists of a single material, it is recyclable and recyclable. Furthermore, the fiber material 16 is suitable as a replacement for polyurethane foams as an acoustic, haptic, comfort, or filling element in cladding and acoustic components. Depending on the setting of the tool parameters, a wide range of surface designs for the component 12 is possible.For example, a surface 20 can be created from smooth to fabric-like. List of reference symbols 10 vehicles 12 components 14 headliner 16 surface structures 18 fiber material 20 Surface 22 fibers 24 compacted area 26 uncompacted area QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] EP 3 385 422 A1

[0003]

Claims

[1] Component (12) for a vehicle (10), comprising at least one sheet-like structure (16) made of a deformed fiber material (18), wherein the fiber material (18) is formed from fibers (22) aligned perpendicular to a surface (20) of the fiber material (18). [2] Component according to claim 1, characterized by that the fiber material (16) has fibers (22) with different material properties. [3] Component according to claim 1 or 2, characterized by that the sheet-like structure (16) has at least one uncompacted region (26) and at least one compacted region (24). [4] Covering part according to claim 3, characterized by that the at least one compacted region (24) is produced by deforming the fiber material (16) under pressure and / or temperature. [5] Component according to one of the preceding claims, characterized by that at least one structure is injection-molded onto the surface structure (16). [6] Covering part according to claim 5, characterized by that the at least one structure is designed as a rib and / or as a receiving frame for add-on parts surrounding the sheet-like structure (16). [7] Component according to one of the preceding claims, characterized by that the fibers (22) are made of a thermoplastic. [8] Method for producing a component (12) according to one of claims 1 to 7, comprising the following steps: a. Inserting a mat of fiber material (18) into a forming tool, wherein the fiber material (18) consists of fibers (22) oriented perpendicular to a surface (20) of the fiber material (18); and b. forming the fiber material (18) under pressure and / or temperature and forming at least one compacted region (24) into a sheet-like structure (16) forming the component (12). [9] Method according to claim 8, characterized bythat at least one structure is injected during the forming in step b). [10] Vehicle (10) comprising at least one component (12) according to one of claims 1 to 7 and / or at least one component (12) produced by a method according to one of claims 8 or 9.

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