Plastic component for a motor vehicle

Abstract

Plastic component (2) for a motor vehicle, which is arranged in a standard installation state in the area of ​​a vehicle interior, and has a base body (4) with an inner surface (6) facing the vehicle interior, - wherein the base body (4) is at least partially made of a plastic material (10) containing odorants, and - wherein an odor-impermeable top layer (12) is applied to the base body (4) to cover the inner surface (6).

Description

[0001] The invention relates to a plastic component for a motor vehicle, which in its intended installation state is arranged in the area of ​​a vehicle interior. The invention further relates to a door module for a motor vehicle, comprising a plastic component designed as a component carrier.

[0002] A vehicle door typically has a door frame or door shell as its framework or basic structure. Such a door shell usually comprises an outer door panel (outer door sheet) forming the outer skin of the vehicle door and an inner door panel (inner door sheet) connected to the outer door panel on the inside of the vehicle. A cavity is formed between the outer and inner door panels, serving as a mounting space in which functional elements or door components, such as a window regulator, a door lock, an airbag, or the like, can be installed.

[0003] The door components of the vehicle door are conventionally inserted from the inside of the door into the cavity or assembly space between the outer door panel and the inner door panel through an assembly opening located in the inner door panel and brought into their functional positions (final assembly positions).

[0004] To simplify the installation of door components in a vehicle door, these components can be pre-assembled on a plate-like carrier, also known as a door module carrier or carrier plate. The assembled carrier is then referred to as a door module (door system) and is subsequently placed onto the mounting opening of the vehicle door. The door module, or carrier, covers the mounting opening and typically also provides a wet / dry compartment separation within the vehicle door.

[0005] The mounting bracket can be made of a metal, for example, steel or an aluminum alloy. Preferably, the mounting bracket is made at least partially of a composite or plastic material. This means, for example, that part or several parts of the mounting bracket are made of a plastic material, such as glass fiber reinforced polyamide (PA-GF) or glass fiber reinforced polypropylene (PP-GF). Preferably, a large proportion of the mounting bracket, i.e., more than 40% or 50% of the mounting bracket, is made of the plastic material.

[0006] The term "post-consumer plastic" (also called post-consumer recycled plastic or PCR plastic) refers, in the following, to a plastic material that is collected, processed, and recycled after use by the end consumer. This includes all plastic products that originate from the household or commercial waste stream after they have completed their original lifespan, such as plastic packaging or household products.

[0007] To improve sustainability and environmental protection, it is desirable to use recycled plastic material, especially PCR plastic materials, in the manufacture of plastic components, such as an aggregate carrier, in order to reduce the need for new, petroleum-based raw materials and to minimize the amount of plastic waste.

[0008] Unfortunately, such recycled plastic materials often contain undesirable odors that cannot usually be completely masked or absorbed by the granules. This makes the use of recycled plastic materials or PCR plastics in the production of plastic components more difficult, as plastic components located near a vehicle interior, such as a door panel, must not have such a noticeable odor to avoid negatively impacting the comfort of the vehicle occupants.

[0009] The invention is based on the objective of providing a particularly suitable plastic component for a motor vehicle. In particular, a plastic component located near the vehicle interior is to be provided, which is at least partially made of a plastic material containing odorants, and from which the odorants do not enter the vehicle interior. The invention is further based on the objective of providing a particularly suitable door module.

[0010] With regard to the plastic component, the problem is solved according to the invention by the features of claim 1, and with regard to the door module by the features of claim 9. Advantageous embodiments and further developments are the subject of the dependent claims. The advantages and embodiments mentioned with regard to the plastic component are also transferable to the door module and vice versa.

[0011] The plastic component according to the invention is intended for, suitable for, and configured for use in a motor vehicle. In its intended installation state, the plastic component is arranged near or within the vehicle interior. The term "within the vehicle interior" also includes arrangements where the plastic component is located completely or only partially within the vehicle interior.

[0012] The term "vehicle interior" here and in the following refers specifically to the passenger compartment, i.e., the area of ​​a motor vehicle located inside and intended for the (vehicle) occupants. The vehicle interior includes all areas and components provided for the driver and passengers, including the cockpit, seats, dashboard, center console, door panels, and all other equipment and controls. The vehicle interior also specifically includes the dry-room side of the vehicle door(s) connected to the vehicle interior.

[0013] The plastic component has a base body. Here and in the following, a "base body" refers specifically to a structure that serves as the foundation for further functional or decorative elements. A base body has a specific shape or geometry and forms the foundation upon which additional components, reinforcements, or coatings are attached.

[0014] The base body is at least partially made of a plastic material containing an odorant. Preferably, a large proportion of the base body, i.e., more than 40% or 50% of the base body, is made of the odorant-containing plastic material. Particularly preferably, the base body is made essentially entirely, i.e., to more than 90%, preferably to about 100%, of the odorant-containing plastic material.

[0015] In the following, the terms "odor-containing plastic material" or "odor-suppressing plastic material" refer specifically to a plastic material containing one or more odor-suppressing substances that cause gaseous substances (e.g., odor molecules) to escape from the resulting product, thus producing odors. These odor-suppressing substances can be present in the plastic granules as liquid or solid additives. An "odor-containing plastic material" or "odor-suppressing plastic material" is, in particular, a strongly scented plastic that causes an unpleasant or unwanted odor in its environment. The plastic material, or the product made from it, is therefore odor-emitting. In other words, the plastic material, or the product, has its own inherent odor.

[0016] The base body has an inner surface facing the vehicle interior, which, according to the invention, is covered with an odor-impermeable coating. In other words, an odor-impermeable coating is applied to the base body in such a way that it covers the inner surface. For example, the coating is applied to the entire surface of the inner surface.

[0017] Alternatively, the top layer is only attached in sections, for example at a (circumferential) edge or perimeter of the base body, or is designed as an edge coating.

[0018] In this and the following, an "odor-impermeable topcoat" refers specifically to a boundary layer or odor barrier layer, i.e., a material or coating that prevents odor-causing gases (odorants) from passing through the topcoat. The odor-impermeable topcoat (blocking layer) has a structure or composition that completely blocks or at least minimizes the diffusion of odor molecules. For example, the odor-impermeable topcoat is essentially gas-impermeable. For this purpose, the topcoat has a sufficient thickness and consists of an odorless or odor-neutral primary material. Additionally or alternatively, it is conceivable, for example, that odor-binding substances, such as oxides in various forms, are integrated into the topcoat.The composition of the top layer is preferably designed in such a way that chemical changes to the top layer due to contact with the odorants are avoided.

[0019] This results in a particularly suitable plastic component for motor vehicles. Applying an odor-impermeable coating to the base material ensures that odors caused by the base material or its plastic components are largely prevented from entering the vehicle interior. This reduces or completely eliminates unwanted odors from the base material within the vehicle. Consequently, the use of strongly scented plastics for interior components is made possible without negatively impacting user comfort.

[0020] In a preferred embodiment, the base body is at least partially made from a recycled plastic material, for example, a PCR plastic material. In other words, the plastic material containing the fragrance is a recycled plastic material, particularly a PCR plastic material. Preferably, a large proportion of the base body, i.e., more than 40% or 50% of the base body, is made from the recycled plastic material. This means that a large proportion of the plastic granules used to manufacture the base body is a recycled material. Particularly preferably, the base body is made essentially entirely, i.e., to more than 90%, preferably to about 100%, from the recycled plastic material or recycled material.The odorous substance of the plastic material is therefore primarily a remaining impurity of the recycled plastic material, which was caused during the previous use of the recycled plastic.

[0021] In a particularly suitable advanced design, the odor-impermeable top layer and the base body are manufactured from the same material matrix. Here and in the following, a "material matrix" refers specifically to a composite consisting of a base material that provides structure and in which additional substances or components are embedded. This matrix can consist of a polymeric material that serves as a carrier material for reinforcing fibers, fillers, additives, or functional particles. The material matrix ensures the cohesion and spatial arrangement of the embedded elements and significantly determines the mechanical, thermal, and chemical properties of the overall composite.

[0022] The base material and the cover layer differ only in terms of additional substances or components embedded in the matrix material (e.g., PA or PP). The base material contains, in particular, odor-causing substances as embedded materials, while the cover layer contains, for example, odor-blocking, odor-impermeable, or odor-binding substances as embedded materials. Alternatively, the cover layer can also consist solely of the matrix material without any embedded substances or components.

[0023] In one conceivable embodiment, the plastic component is manufactured as an injection-molded part, with the top layer being a coating or material layer applied to the injection mold. This layer adheres to the inner surface of the base body after the mold is opened. To apply the top layer, an odor-impermeable coating or material layer is applied to at least one half of the mold part that forms the (injection) cavity and thus the inner surface of the base body. Preferably, the edges of the mold half that do not directly form the cavity are also covered with the coating or material layer. The injection mold is then closed, and the plastic material is injected to produce the base body. When the base body is demolded, the coating layer applied to the mold half remains adhered to the base body as a top layer.

[0024] In another conceivable embodiment, the plastic component is designed as a two-component injection molded part (2K injection molded part), in which the base body and the top layer are made of different plastic materials. The two components of the 2K injection molded part are thus formed by the plastic material of the base body and the plastic material of the top layer.

[0025] In an equally conceivable version, the top layer is designed as an odor-impermeable film, which is bonded to the inner surface of the base body.

[0026] In another conceivable embodiment, the top layer is an odor-impermeable coating applied to the inner surface of the base body. In other words, the top layer, or rather the odor-impermeable coating, is applied as a boundary layer in a subsequent production step. This means that the base body is first manufactured, for example, by injection molding, and then the top layer is applied at a later stage.

[0027] In a preferred application, the plastic component is designed as a carrier for a door module. Here and in the following, a "carrier" is understood to be, in particular, a flat component on which door components or functional elements of the vehicle door can be (pre-)mounted. The carrier has at least one support or mounting surface for arranging the door components.

[0028] In its assembled state, the door carrier acts as a wet / dry compartment divider for the vehicle door, thus featuring a dry compartment side facing the vehicle interior and a wet compartment side facing away from the interior and towards the vehicle environment. The dry compartment side of the carrier forms the inner surface onto which the top layer is applied. This results in a particularly suitable door carrier. Specifically, the carrier's base body is thus sealed off from the vehicle interior by both the top layer and the seals that create the wet / dry compartment separation, ensuring an odor-tight seal. This results in a particularly sustainable and environmentally friendly door carrier.

[0029] The door module according to the invention is specifically designed, suitable, and configured for use in a vehicle door of a motor vehicle. The door module comprises a plastic component as described above, which serves as a carrier (door module carrier, carrier plate). At least one door component, i.e., a functional component of the vehicle door (for example, window regulator, speaker, etc.), is pre-mounted on the plastic component or the carrier. In its assembled state, the carrier provides, in particular, a wet-dry compartment separation for the vehicle door, and has an inner surface covered with a coating layer: a wet-compartment side facing away from the vehicle interior and a dry-compartment side facing the vehicle interior. This results in a particularly suitable door module.

[0030] Exemplary embodiments of the invention are explained in more detail below with reference to a drawing. The drawing shows: Fig. 1. Top view of a plastic component designed as a carrier for a door module, Fig. 2 in schematic and simplified sectional view the plastic component, and Fig. 4, Fig. 5, Fig. 6 to Fig. 7. Various methods for manufacturing the plastic component are shown in schematic and simplified representations.

[0031] Corresponding parts and sizes are always marked with the same reference symbols in all figures.

[0032] The Fig. Figure 1 shows a plastic component 2, which is designed as a plate-shaped carrier for a door module of a vehicle door (not shown in detail). Door components of the vehicle door can be pre-mounted on the plastic component 2, or on the carrier, to form the door module.

[0033] The plastic component 2 has a base body 4 as a support plate for the aggregate carrier. The base body 4 has two opposing flat faces 6, 8 as mounting surfaces for the door components. The in Fig. The plan side 6 shown in Figure 1 is hereinafter also referred to as the inner surface of the base body 4. The inner surface 6 is hereinafter also referred to as the dry room side of the door module or the unit carrier, since in the intended installation state it faces a dry room TR of the vehicle door or the vehicle interior. The opposite side, shown in Figure 1, is also referred to as the dry room side. Fig. 2 shown, plan page 8 also referred to as the exterior surface or wet room side, as it faces a wet room NR.

[0034] In its intended installation state, the plastic component 2 is thus located near or within the vehicle interior of the vehicle door.

[0035] The base body 4 is at least partially made of a plastic material 10 containing a fragrance. The plastic material 10 is a recycled plastic material, for example, a PCR plastic material. In particular, the fragrance is incorporated into the plastic material due to its previous use prior to the recycling process. The base body 4 is largely, preferably substantially entirely, made of the recycled plastic material or recyclate.

[0036] As especially in the Fig. As can be seen in Figure 2, an odor-impermeable cover layer 12 is applied to the inner surface 6 of the base body 4, which essentially completely covers the inner surface 6 facing the vehicle interior. The cover layer 12 is therefore made of a plastic material 14. Preferably, the cover layer 12 is not a recycled plastic material, in particular not a PCR plastic material. The plastic materials 10, 14 of the base body 4 and the cover layer 10 thus differ only with regard to additional substances or components that are embedded in the matrix material (for example, PA or PP).

[0037] The Fig. Figure 3 shows an embodiment of the plastic component 2, in which the base body 4 with a cover layer 12 designed as a structural element is designed as a 2K injection molded part (two-component injection molded part).

[0038] In a Fig. In the embodiment shown in Figure 4, the plastic component 2 is designed as an injection-molded part, wherein the top layer 12 is designed as a paint or material layer 18 applied to the injection mold 16, which adheres to the inner surface 6 of the base body 4 after the injection mold 16 has been opened.

[0039] The injection mold 16, for example, has two mold halves 20 which, when closed, form the cavity for shaping the base body 4. To apply the top layer 12, an odor-impermeable coating or material layer 18 is applied to the inner surface of the mold half 20, which forms the inner surface 6 of the base body 4. The injection mold 16 is then closed, and the odor-containing plastic material 10 is injected to produce the base body 4. During demolding of the base body 4, the coating applied to the mold half 20 adheres to the inner surface 6 of the base body 4 as the top layer 12.

[0040] In a Fig. In the embodiment shown in Figure 5, the top layer 12 is designed as an odor-impermeable lacquer 22, which is applied, for example by spraying, to the inner surface 6 of the base body 4. In other words, the top layer 12, or the odor-impermeable lacquer, is applied as a sealant or boundary layer in a production step downstream of the base body manufacturing. This means that the base body 4 is first manufactured, for example by injection molding, and then the top layer 12 is applied to the inner surface 6 of the base body 4.

[0041] The Fig. Figure 6 shows an embodiment in which the plastic component 2 is designed as a two-component injection-molded part (2K injection-molded part). Here, the plastic materials 10, 14 of the base body 4 and the cover layer 12 are injected successively into the cavity of the injection mold 16.

[0042] In the exemplary embodiment of the Fig. 7 the top layer 12 is designed as an odor-impermeable film 24, which is applied to the inner surface 6 of the base body 4 in a material-bonded manner, for example glued on.

[0043] The claimed invention is not limited to the embodiments described above. Rather, other variants of the invention can also be derived by a person skilled in the art within the scope of the disclosed claims without departing from the subject matter of the claimed invention. In particular, all individual features described in connection with the various embodiments can also be combined in other ways within the scope of the disclosed claims without departing from the subject matter of the claimed invention. Reference symbol list 2 plastic components, aggregate carriers 4 Base body, support plate 6 Interior surface, plan side 8 Exterior area, plan side 10 Plastic material with odorant 12 Top layer 14 Plastic material 16 injection molds 18 layers of paint or material 20 tool half 22 Lacquer 24 slides TR Dry Room NR wet room

Claims

Plastic component (2) for a motor vehicle, which is arranged in a vehicle interior in a state of intended installation, and has a base body (4) with an inner surface (6) facing the vehicle interior, wherein the base body (4) is made at least partially of a plastic material (10) containing odorants, and wherein an odor-impermeable cover layer (12) is applied to the base body (4) to cover the inner surface (6). Plastic component (2) according to claim 1, characterized in that the base body (4) is at least partially made from a recycled material, in particular from a PCT plastic material. Plastic component (2) according to claim 1 or 2, characterized in that the odor-impermeable cover layer (12) and the base body (4) are made from the same material matrix. Plastic component (2) according to one of claims 1 to 3, characterized in that the plastic component (2) is designed as an injection molded part, wherein the top layer (12) is designed as a paint or material layer (18) applied to the injection molding tool (16), which adheres to the inner surface (6) of the base body (4) after the injection molding tool (16) has been opened. Plastic component (2) according to one of claims 1 to 3, characterized in that the plastic component (2) is designed as a two-component injection molded part, wherein the base body (4) and the cover layer (12) are made of different plastic materials (10, 14). Plastic component (2) according to one of claims 1 to 3, characterized in that the cover layer (12) is designed as an odor-impermeable film (24) which is bonded to the inner surface (6) of the base body (4). Plastic component (2) according to one of claims 1 to 3, characterized in that the top layer (12) is designed as an odor-impermeable lacquer (22) which is applied to the inner surface (6) of the base body (24). Plastic component (2) according to one of claims 1 to 7, which is designed as an aggregate carrier for a door module. Door module for a vehicle door, comprising an aggregate carrier and at least one door component pre-mounted thereon, wherein the aggregate carrier is designed as a plastic component (2) according to one of claims 1 to 8.

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