Molded body component and method for manufacturing a molded body component

Abstract

The invention relates to a molded component for a vehicle with a predetermined breaking point, wherein the molded component has fibers for reinforcement, wherein the molded component has two first areas which have a first proportion of fibers, and a second area which is arranged between the two first areas and has a second proportion of fibers, wherein the second proportion is smaller than the first proportion to form a predetermined breaking point.

Description

[0001] The invention relates to a molded body component for a vehicle with a predetermined breaking point, wherein the molded body component has fibers for reinforcement.

[0002] The invention further relates to a method for producing a fiber-reinforced molded body component for a vehicle with a predetermined breaking point.

[0003] Although generally applicable to any molded body components, the present invention is described with reference to fiber-reinforced molded body parts for vehicles.

[0004] Fiber-reinforced molded body components in vehicles can be used both inside and outside the vehicle, for example, in the area of ​​the radiator grille or bumper. These have predetermined breaking points that break in the event of a collision between the vehicle and a pedestrian, thus reducing the risk of injury to pedestrians. Another purpose is the cost-effective protection of other, particularly higher-quality, vehicle components in the event of low-speed vehicle collisions or for targeted vehicle deceleration. Used inside, these components reduce the risk of injury to the vehicle's occupants in the event of a collision.

[0005] DE 10 2013 215 199 A1 discloses a molded component in the form of an interior trim part, in particular an instrument panel, for a vehicle. This molded component is a multi-layer structure with a natural fiber-reinforced plastic part facing away from the visible side, in which natural fibers are embedded in a plastic matrix. The interior trim part has an area with reduced component rigidity, in particular a predetermined breaking point. Furthermore, the area with reduced component rigidity is formed by a material weakening in the natural fiber-reinforced plastic carrier part.

[0006] The disadvantage here is that although a predetermined breaking point can be formed due to the weakening of the material, this can only be partially or incompletely severed due to the fiber reinforcement, since although the matrix material is separated at the predetermined breaking point, fibers can still provide a connection, albeit loose, between the separated components.

[0007] An object of the present invention is therefore to provide an improved separation of fiber-reinforced molded body components at predetermined breaking points.

[0008] A further object of the present invention is to provide an alternative molded body component and an alternative method for producing a molded body component.

[0009] In one embodiment, the present invention achieves the above-mentioned objects in a molded body component for a vehicle with a predetermined breaking point, wherein the molded body component has fibers for reinforcement, in that the molded body component has two first regions which have a first proportion of fibers, and a second region which is arranged between the two first regions and has a second proportion of fibers, wherein the second proportion is smaller than the first proportion for forming a predetermined breaking point.

[0010] In one embodiment, the present invention also achieves the above-mentioned objects with a method for producing a fiber-reinforced molded body component for a vehicle with a predetermined breaking point, comprising the steps - introducing a first material with fibers into a first region of two regions of a molding tool, wherein the second region is separated from the first region by a separating element, in particular a slide, - Removing the separating element, - introducing a second material with fibers into the second area, and - curing the first and second materials, in particular wherein the first and second materials are substantially the same material.

[0011] In particular, the first material is partially cured before the separating element is removed, so that it is suitable for introducing, in particular injection molding, the second material.

[0012] One of the advantages achieved is that the molded component can be completely broken through under appropriate stress at the predetermined breaking point, meaning the component can be separated into two separate fragments. A further advantage is that the manufacturing process allows a corresponding second region to be easily produced between the two first regions without additional elements of the molding tool, with no or significantly less fiber material being arranged in the second region.

[0013] The terms “fiber” and “fiber material” are to be understood, particularly in the claims, preferably in the description, as generally linear and / or elongated elementary objects consisting of biogenic, mineral, organic and / or inorganic fiber materials, or any mixtures thereof, for example - glass fibers, ceramic fibers or the like, - Carbon elements, such as carbon fibers, carbon nanotubes or the like, - Natural fibres, such as plant or animal fibres, for example linen, cotton, hemp, silk or the like, - Chemical fibres, for example made from natural or artificial polymers or the like.

[0014] Further features, advantages and further embodiments of the invention are described below or will become apparent thereby.

[0015] According to an advantageous development of the invention, at least one local density and / or material reduction is arranged in a transition region between at least one of the first regions and the second region. The advantage of this is that the molded component can thus break in a defined manner at the predetermined breaking point, which allows for more flexible dimensioning and arrangement of the predetermined breaking point. Furthermore, it is possible for the local density and / or material reduction to extend from one first region across the second region into the other first region.

[0016] According to a further advantageous development of the invention, the local material reduction is designed in the form of a recess. This enables the formation of a defined predetermined breaking point in a particularly simple and cost-effective manner.

[0017] According to a further advantageous development of the invention, the at least one recess is at least triangular in cross-section. This design of the recess enables, on the one hand, easy bending or folding of the two regions lateral to the predetermined breaking point and, on the other hand, a defined force introduction to the connection between the two first regions.

[0018] According to a further advantageous development of the invention, the two recesses are arranged on different sides of the molded body component, in particular, the recesses are arranged symmetrically in cross-section to the transition region. One of the advantages achieved is a reliable introduction of force for the predetermined breaking point from different sides of the molded body component.

[0019] According to a further advantageous development of the invention, at least two openings, in particular elongated ones, are arranged, extending from one first region through the second region into the other first region. The openings allow the fracture or separation behavior of the molded component into two fragments to be easily adjusted. Furthermore, material costs can be reduced because less material is required.

[0020] According to a further advantageous development of the invention, the at least two openings are of identical shape. The advantage of this is that they can be easily manufactured and the fracture or separation behavior is easier to define and predict.

[0021] According to a further advantageous development of the invention, a web is formed between the first regions through the two openings, which web has at least a height offset relative to the plane of the openings, in particular wherein the web is roof-shaped. One of the advantages achieved is the easy adaptability of the fracture or separation behavior through the design of the corresponding web. Furthermore, the web can be used to easily influence the force introduction to the predetermined breaking point from different sides.

[0022] According to a further advantageous development of the invention, the molded component has two webs arranged at a distance from one another, with at least the second region being arranged on the two webs. This allows the fracture or separation behavior of the molded component to be influenced in a particularly flexible manner.

[0023] According to a further advantageous development of the invention, a local density and / or material reduction, in particular a recess, is arranged on each of the two webs, in particular wherein the local density and / or material reductions are arranged vertically one above the other in cross-section, in particular centrally on each of the two webs. This enables a particularly reliable separation of the molded component at the predetermined breaking point.

[0024] According to a further advantageous development of the invention, the shaped body component has a rectangular base which extends along a defined direction and comprises two legs arranged on the base along the direction and at an angle, in particular at an angle of 90 degrees, and wherein a first local density and / or material reduction is formed in the base, which extends substantially perpendicular to the direction of extension of the base, and wherein a second local density and / or material reduction is arranged on each of the two legs, which extends from the side of the legs facing away from the base in the direction of the base, and wherein the first and the two second local density and / or material reductions are arranged in a common plane perpendicular to the direction of extension of the shaped body component.One of the advantages achieved is a particularly high buckling stiffness of the molded component outside the area of ​​density and / or material reductions, while at the same time enabling reliable separation along the predetermined breaking point of the molded component.

[0025] According to a further advantageous development of the invention, the first local density and / or material reduction has a greater width than the second local density and / or material reduction, and / or the first local density and / or material reduction has a smaller depth than the second local density and / or material reduction. Thus, the fracture or separation behavior of the molded component at the predetermined breaking point can be easily influenced by adjusting the width or depth.

[0026] According to a further advantageous development of the invention, the base and the legs have the same thickness. The advantage of this is particularly simple production of the molded component.

[0027] According to a further advantageous development of the invention, the molded body component is formed in one piece. This eliminates the need for a complex connection of two subcomponents to form the molded body component. Furthermore, the molded body component thus exhibits high stability.

[0028] According to a further advantageous development of the invention, the molded body component is formed in two pieces, comprising a first component and a second component, which can be secured to one another via a positive connection. The positive connection is designed in the form of a dovetail connection, the dovetail connection having at least two different depths in the cross-sectional plane of the connection between the two components, in particular a variable depth perpendicular to the connection direction between the two components. One of the advantages achieved is a simple and reliable separation of the two components along the dovetail connection in addition to the predetermined breaking point.

[0029] According to a further advantageous development of the invention, a local reduction in density and / or material, in particular a recess for forming a predetermined breaking point, is produced by means of a projection of the molding tool, in particular wherein the projection is arranged in the area between the separating element and the first area. The advantage of this is that the local reduction in density and / or material is thus provided in a particularly simple manner for a more precisely metered introduction of force to the predetermined breaking point.

[0030] Further important features and advantages of the invention emerge from the subclaims, from the drawings and from the associated description of the figures with reference to the drawings.

[0031] It is understood that the features mentioned above and those to be explained below can be used not only in the combination specified in each case, but also in other combinations or on their own, without departing from the scope of the present invention.

[0032] Preferred embodiments and embodiments of the present invention are illustrated in the drawings and are explained in more detail in the following description, wherein the same reference numerals refer to the same or similar or functionally identical components or elements.

[0033] It shows in schematic form Fig. 1 a shaped body component according to an embodiment of the present invention in cross section; Fig. 2 shows a molded body component according to an embodiment of the present invention in an oblique view from above; Fig. 3 shows a molded body component according to an embodiment of the present invention in an oblique view from above; Fig. 4 the molded component according to Fig. 3 in a side view; Fig. 5 shows a molded body component according to an embodiment of the present invention in an oblique view from above; Fig. 6 a molded body component according to an embodiment of the present invention in an oblique view from above; and Fig. 7 steps of a method according to an embodiment of the present invention.

[0034] Fig. 1 shows a molded body component according to an embodiment of the present invention in cross section.

[0035] In Fig. 1 shows a molded component 1. The molded component 1 has two first regions B1-1, B1-2 on the left and right, which have a second region B2 between them in a transition region 2. The two regions B1-1, B1-2 are formed, for example, by a resin matrix which has fibers, in particular glass or carbon fibers, for structural reinforcement. However, no fibers, or fewer fibers, are arranged in region B2 than in the first regions B1-1, B1-2. Furthermore, in the transition region 2, in particular in the region of the second region B2, a triangular recess 3a, 3b is arranged on an upper side 4a and on a lower side 4b of the molded component 1, the tip of the respective triangle being aligned with the second region B2 running perpendicular to the upper and lower sides 4a, 4b.

[0036] In order to produce the molded body component 1 according to Fig. 1, the following steps can be performed: - Producing the right first region B1-2 by injecting the castable resin matrix with fiber material through a first nozzle D1. A separating element T prevents the left first region B1-1 from also being exposed to the resin material. - Then the separating element T is placed along the connecting line between the first two areas B1-1, B1-2, in Fig. 1 upwards, pulled out. - Subsequently, for example, castable resin matrix with fiber material is injected into the left area B1-1 via a second nozzle D2, so that the first two areas B1-1, B1-2 are connected to each other.

[0037] As a result, a low-fiber region B2 is formed between the first regions B1-1, B1-2, which enables easier separation of the molded body component 1 along the region B2.

[0038] Fig. 2 shows a molded body component according to an embodiment of the present invention in an oblique view from above.

[0039] In Fig. 2 shows a flat molded body component 1. The molded body component 1 according to Fig. 2 shows in cross section the structure of the molded body component 1 according to Fig. 1. Furthermore, two elongated openings 5a, 5b are shown, which extend essentially along the longest extension direction R of the molded body component 1. Between the two openings 5a, 5b, a web 6 is formed, which extends from the plane of the molded body component 1 in Fig. 2 extends upwards, essentially resulting in a "roof shape" or triangular connection through the web 6. In this respect, the web 6 has a height offset 7. Corresponding recesses 3a, 3b can also be arranged in the web 6. The highest point of the web 6 relative to the plane of the molded body component 1 is aligned with the corresponding recesses 3a, 3b on the upper side 4a of the molded body component 1. It is also conceivable to arrange the web 6 asymmetrically to the openings 5a, 5b and / or the recesses 3a, 3b in order to influence the fracture or separation behavior of the molded body component 1 depending on the planned location and purpose of use.

[0040] Fig. 3 shows a molded body component according to an embodiment of the present invention in an oblique view from above and Fig. 4 the molded component according to Fig. 3 in a side view.

[0041] In the Fig. 3 and Fig. 4 shows a flat molded component 1 which has two first regions B1-1, B1-2 and a second region B2 between the first two regions B1-1, B1-2. In the first two regions B1-1, B1-2, the molded component 1 has two sections 30, 31 lying perpendicular to the direction of extension R. The first section 30 extends in the plane of the molded component 1, i.e. in the plane of the regions B1-1, B1-2, and is provided with a triangular recess 3b on the upper side 4a. The section 31 arranged adjacent to it perpendicular to the direction of extension R of the molded component 1 has a height offset 7 from the section 30 and runs partially parallel to the first section 30 in the transition region 2, in particular in the second region B2, and ultimately merges back into the common plane of extension of the molded component 1 via corresponding straight flanks 32.The second section 31 also has a recess 3a, which is aligned with the recess 3b of the first section 30. In the side view of the . Fig. 4, these are spaced apart from one another in the respective sections 30, 31. In this way, a horizontal web 6a - section 30 - and a trapezoidal web 6b are formed. Region B2 is arranged on each of the two webs 6a, 6b in the area of ​​the recesses 3a, 3b, thus creating a corresponding predetermined breaking point.

[0042] It is also conceivable to design the first section 30 or the web 6a in a mirror image to the web 6b, so that instead of the horizontal course of the web 6a, it Fig. 4 extends upwards and downwards, corresponding to the upward and downward extension of the web 6b. The recess can then either be designed like the recess 3a or also be mirror-symmetrically open downwards.

[0043] Fig. 5 shows a molded body component according to an embodiment of the present invention in an oblique view from above.

[0044] In Fig. 5 shows a molded body component 1 which has a U-shaped cross-section with a base 8 and two legs 9a, 9b arranged perpendicularly (at a perpendicular angle W) thereto. The thicknesses 12a, 12b of the legs 9a, 9b and of the base 8 are the same, but can also be selected to be different. The U-shaped cross-section extends in the direction of extension R. Extending perpendicularly to the direction of extension R in the base 8 is a recess 3c with a width 10a which is smaller than the recesses 3a, 3b which are aligned on the legs 9a, 9b and also extend perpendicularly to the direction of extension R. The depth 11a, 11b of the recesses 3a, 3b is greater than the depth 11c of the recess 3c in the base 8. The width 10b of the recesses 3a, 3b on the legs 9a, 9b is smaller than the width 10a of the recess 3c in the base 8. The widths 10a, 10b are measured parallel to the extension direction R.

[0045] Fig. 6 shows a molded body component according to an embodiment of the present invention in an oblique view from above.

[0046] In Fig. 6 shows a molded body component 1, which is formed in two parts with two parts 21, 22. The molded body component 1 has a U-shaped cross-section. The two parts 21, 22 are connected to each other by a dovetail joint 23, wherein the dovetail joint 23 has a depth 11c in the cross-sectional plane Q of the connection between the two parts 21, 22 that decreases in direction R2, which is oriented perpendicular to the direction R.

[0047] In other words, the lateral regions of the dovetail joint 23 are oriented obliquely in the cross-sectional plane Q. A predetermined breaking point can also be provided by means of the dovetail joint 23 thus formed. The low-fiber region can then be formed in the area of ​​the dovetail joint 23, so that the fracture or separation behavior can be adapted both via the formation of the dovetail joint 23 and via the low-fiber region in the area of ​​the dovetail joint 23.

[0048] Fig. 7 shows steps of a method according to an embodiment of the present invention.

[0049] In Fig. 7 shows, in schematic form, steps of a method for producing a fiber-reinforced molded body component 1 for a vehicle with a predetermined breaking point.

[0050] The procedure includes the steps - introducing S1 a first material with glass fibers into a first region B1-2 of two regions B1-1, B1-2 of a molding tool, wherein the second region B1-1 is separated from the first region B1-2 by a separating element T, in particular a slide, - Removal S2 of the separating element, - Introduction S3 of second material with glass fibers into the second area B1-1, - Curing S4 of the first and second material.

[0051] Furthermore, a molded body component with a predetermined breaking point for a vehicle can comprise the following: a rectangular base which extends along a defined direction and two legs arranged on the base along the direction and at an angle, in particular at an angle of 90 degrees, wherein a first depression is formed in the base which extends substantially perpendicular to the direction of extension of the base, and wherein a second depression is arranged on each of the two legs, which extends from the side of the legs facing away from the base in the direction of the base, and wherein the first and the two second depressions are arranged in a common plane perpendicular to the direction of extension of the molded body component to form a predetermined breaking point.

[0052] The first recess may have a greater width than the second recess and / or the first recess may have a smaller depth than the second recess. Likewise, the base and the legs may have the same thickness.

[0053] Furthermore, a molded body component system with a predetermined breaking point for a vehicle can comprise the following: a first component and a second component which can be fixed to one another via a positive connection, wherein the positive connection is designed in the form of a dovetail connection, wherein the dovetail connection has at least two different depths in the cross-sectional plane of the connection between the two components to form a predetermined breaking point, in particular a variable depth perpendicular to the connection direction between the two components.

[0054] At least one of the embodiments of the present invention may have at least one of the following features and / or may realize at least one of the following advantages: - Simple, cost-effective production. - Defined force introduction into the predetermined breaking point. - Flexible adaptation of the fracture and / or separation behavior of the molded component. - Reliable and complete separation of the fiber-reinforced molded component under appropriate load in the area of ​​the predetermined breaking point.

[0055] Although the present invention has been described using preferred embodiments, it is not limited thereto but can be modified in many ways. List of reference symbols 1 molded body component 2 Transition area 3, 3a, 3b, 3c recess, cutout 4a top 4b bottom 5a, 5b openings 6, 6a, 6b Bridge 7 Height offset 8 Base 9a, 9b legs 10a, 10b Wide recess 11a, 11b, 11c Deep recess 12a Thick Legs 12b Thick Base 21 component 22 Component 23 Dovetail joint Section 30 Section 31 32 flank B1-1, B1-2 First area B2 Second Area D1, D2 nozzle Q cross-sectional plane R Extension direction R2 direction S1-S4 steps of a procedure T separating element W angle 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] DE 10 2013 215 199 A1

[0005]

Claims

[1] Moulded body component (1) for a vehicle with a predetermined breaking point, wherein the moulded body component has fibres for reinforcement, characterized by that the shaped body component (1) has two first regions (B1-1, B1-2) which have a first proportion of fibers, and a second region (B2) which is arranged between the two first regions (B1-1, B1-2) and has a second proportion of fibers, wherein the second proportion is smaller than the first proportion to form a predetermined breaking point. [2] Shaped body component (1) according to claim 1, characterized by that in a transition region (2) between at least one of the first regions (B1-1, B1-2) and the second region (B2) at least one local density and / or material reduction (3) is arranged. [3] Shaped body component (1) according to claim 2, characterized by that the local material reduction (3) is designed in the form of a recess. [4] Shaped body component (1) according to claim 3, characterized bythat the at least one recess (3, 3a, 3b) is at least triangular in cross-section. [5] Shaped body component (1) according to one of claims 3-4, characterized by that the two recesses (3a, 3b) are arranged on different sides (4a, 4b) of the shaped body component (1), in particular wherein the recesses (3a, 3b) are arranged symmetrically in cross section to the transition region (2). [6] Shaped body component (1) according to one of claims 1-5, characterized by that at least two, in particular elongated, openings (5a, 5b) are arranged which extend from the one first region (B1-1) through the second region (B2) into the other first region (B1-2). [7] Shaped body component (1) according to claim 6, characterized by that the at least two openings (5a, 5b) are of the same shape. [8] Shaped body component (1) according to one of claims 6-7, characterized bythat a web (6) is formed between the first regions (B1-1, B1-2) through the two openings (5a, 5b), which web has at least one height offset (7) relative to the plane of the openings (5a, 5b), in particular wherein the web (6) is roof-shaped. [9] Shaped body component (1) according to one of claims 1-8, characterized by that the shaped body component (1) has two webs (6a, 6b) which are arranged at a distance from one another, wherein at least the second region (B2) is arranged on the two webs (6a, 6b). [10] Shaped body component (1) according to claim 9, characterized by in that a local density and / or material reduction (3a, 3b), in particular a recess (3a, 3b), is arranged on each of the two webs (6a, 6b), in particular wherein the local density and / or material reductions (3a, 3b) are arranged vertically one above the other in cross-section, in particular in the middle of each of the two webs (6a, 6b). [11] Shaped body component (1) according to claim 2, characterized by that it has a rectangular base (8) which extends along a defined direction (R) and comprises two legs (9a, 9b) arranged on the base (8) along the direction (R) and at an angle (W), in particular at an angle (W) of 90 degrees, and wherein a first local density and / or material reduction (3c) is formed in the base (8), which extends substantially perpendicular to the direction of extension (R) of the base (8), and that a second local density and / or material reduction (3a, 3b) is arranged on each of the two legs (9a, 9b), which extends from the side of the legs (9a, 9b) facing away from the base (8) in the direction of the base (8), and that the first and the two second local density and / or material reductions (3a, 3b, 3c) are arranged in a common plane perpendicular to the direction of extension (R) of the molded body component (1) are arranged. [12] Shaped body component (1) according to claim 11, characterized by that the first local density and / or material reduction (3c) has a greater width (10a) than the second local density and / or material reduction (3a, 3b) and / or that the first local density and / or material reduction (3c) has a smaller depth (11a) than the second local density and / or material reduction (3a, 3b). [13] Shaped body component (1) according to one of claims 11-12, characterized by that the base (8) and the legs (9a, 9b) have the same thickness (12a, 12b). [14] Shaped body component (1) according to one of claims 1-13, characterized by that the shaped body component (1) is formed in one piece. [15] Shaped body component (1) according to one of claims 1-13, characterized byin that the shaped body component (1) is designed in two pieces, comprising a first component (21) and a second component (22) which can be fixed to one another via a positive connection (23), wherein the positive connection (23) is designed in the form of a dovetail connection, wherein the dovetail connection has at least two different depths (11c) in the cross-sectional plane (Q) of the connection between the two components (21, 22), in particular a variable depth (11c) perpendicular to the connection direction (R2) between the two components (21, 22). [16] Method for producing a fiber-reinforced molded body component (1) for a vehicle with a predetermined breaking point, comprising the steps - introducing (S1) a first material with fibers into a first region (B1-2) of two regions (B1-1, B1-2) of a molding tool, wherein the second region (B1-1) is separated from the first region (B1-2) by a separating element (T), in particular a slider, - Removal (S2) of the separating element (T), - introducing (S3) a second material with fibers into the second area (B1-1), - curing (S4) the first and second materials, in particular wherein the first and second materials are substantially the same material. [17] Method according to claim 16, characterized by that a local density and / or material reduction (3), in particular a recess (3a, 3b), is produced by means of a projection of the molding tool to form a predetermined breaking point, in particular wherein the projection is arranged in the region between the separating element (T) and the first region (B1-1, B1-2).

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