Panel element for a vehicle

Abstract

Panel element, for example, a loading floor (1) for a vehicle, comprising a first panel segment (2) made of plastic and at least one further panel segment (3) made of plastic, articulated to the first panel segment (2) by means of a film hinge (4, 4.1), each panel segment (2, 3) having a core layer and, on at least one of their two flat sides, a fiber-reinforced outer layer (8, 8.1) molded onto it, wherein the flat side of the panel segments (2, 3) pointing in the same direction is equipped with such an outer layer (8) and the film hinge (4) connects the panel segments (2, 3) in the area of ​​these outer layers (8), characterized in that the panel element (1) with its panel segments (2, 3) is made of a curable plastic carrier material as a plastic body (5) into which the fiber reinforcements are integrated, and that in the area of ​​the panel segments (2, 3) connecting film hinge (4, 4.1) a fiber reinforcement (4) with fibers (23) extending at least over the width of the film hinge (4) is provided so that tensile forces can be transferred from one panel segment (2, 3) to the other panel segment (3, 2) via these fibers (23), that these fibers (23) of the fiber reinforcement (9) have a break-free bending radius in their state embedded in the plastic body (5) which is smaller than the bending radius of the film hinge (4, 4.1) in the area of ​​its fiber reinforcement (9), and that the mutually facing side surfaces (14, 15) of the core layer of the panel segments (2, 3), when located in a common plane with their edge layer (8), are spaced apart from each other by a gap (16, 16.1) adjacent to the film hinge (4, 4.1) connecting these panel segments (2, 3).

Description

[0001] The invention relates to a panel element, for example a loading floor for a vehicle, comprising a first panel segment made of plastic and at least one further panel segment made of plastic, which is articulated to the first panel segment by means of a film hinge, each panel segment having a core layer and a fiber-reinforced edge layer molded onto it on at least one of the two flat sides, wherein the flat side of the panel segments pointing in the same direction is equipped with such an edge layer and the film hinge connects the panel segments in the area of ​​these edge layers.

[0002] Panel elements comprising at least two pivotable panel segments are used, for example, as load floors in motor vehicles, especially passenger cars. These panel elements are used to adapt the trunk floor, provided by such a load floor, to different trunk configurations. Such a load floor typically extends within the trunk of a motor vehicle between the rear trunk wall and the back of the rear seat backrest. Sometimes it is desirable to position such load floors at different heights within the trunk. Due to the angle of the rear seat backrests in such a vehicle, the effective length of the load floor must be adjusted to accommodate these different heights.For this purpose, loading floors have been developed in which two panel segments are articulated together by means of a film hinge. The bending axis of the film hinge runs in the direction of the vehicle width (y-direction). Such a loading floor is known, for example, from DE 20 2013 011 658 U1. The two panel segments (floor segments), located one behind the other in the longitudinal direction (x-direction) of the vehicle, are connected to each other by a carpet covering extending over the surface of both panel segments. This carpet covering also forms the film hinge. To transfer forces from one panel segment to the other, a suitable support is required on which the panel segments rest in the area of ​​the film hinge.

[0003] In DE 10 2015 201 054 A1 another such loading floor is described, in which the two mutually pivotable panel segments, which are also coated on the upper side with a carpet forming the film hinge, overlap in their mutually facing edge section, so that the loading floor can also bear loads in the area of ​​the film hinge, and that weight forces can also be introduced into the supporting structure of the motor vehicle via the area of ​​the film hinge.

[0004] These previously known panel elements are composed of different materials. This applies particularly to the construction of the film hinge, which uses a carpet-like backing that differs from the other panel segments. This makes recycling impractical, as the different materials must be separated.

[0005] Such panel elements, when configured as a cargo floor, can be made of plastic, as described in US 2005 / 0189674 A1. This previously known cargo floor is designed as a sandwich component and comprises a cellular, dimensionally stable core formed from tubes or a honeycomb structure. This core is a polypropylene sheet. The longitudinal extent of these structures corresponds to the thickness of the core. Both sides of this core layer are covered with an outer fiber-reinforced thermoplastic layer. The components of this stacked layer arrangement are bonded together under pressure in a mold. The outer layers may be preheated for this purpose.After the production of this sandwich component, a cut is made from one flat side of the sandwich element through the outer layer forming that flat side and the core layer to the opposite second outer layer to create the hinge between the two panel segments. This second outer fiber-reinforced thermoplastic layer then forms the film hinge, extending from the cut, which allows the two panel segments to pivot relative to each other. Even though this panel element is made of plastic and thus simplifies recycling, making the necessary cut to divide the panel segment into its segments and to create the film hinge is not without its challenges. For one thing, the polypropylene sheet is usually pressed in at the edges during the cutting process.Secondly, the cut must extend completely through the core layer of the panel, but must not damage the outer layer on the opposite side, which acts as a film hinge. Therefore, manufacturing such a panel element as intended is not entirely straightforward. Furthermore, the fiberglass embedded in the thin thermoplastic outer layers of the fiber reinforcement can break if the bending radius is small. It is therefore essential to ensure that the pivotable panel segments can only be pivoted relative to each other with a bending radius larger than the smallest break-free bending radius of the embedded fiberglass. Consequently, bending radii of less than 5 mm cannot be achieved with such a panel element.

[0006] US Patent 2013 / 0278018 A1 discloses another panel element designed as a cargo floor. In this cargo floor, one of the two panel segments is constructed as a sandwich component and features a projecting mounting flange on its side facing the adjacent panel segment. This flange is thinner than the actual floor section. The mounting flange rests on its underside on a shoulder of the second panel segment and is bolted to it. A constriction or narrowing is located within the mounting flange. This constriction acts as a hinge. Both panel segments are supported below the hinge formed by the shape of the flange by a beam when both panel segments are in the same plane.The panel segment, which features a thin section as a bending zone, is manufactured by stacking the outer edge layers and a thermoplastic cellular, dimensionally stable core in a mold. Under the influence of heat, the outer fiber-reinforced thermoplastic layers are bonded to the core. As with the panel element previously disclosed in US 2005 / 0189674 A1, the individual components of the sandwich structure in this panel element are also initially manufactured separately and then joined together in a mold.

[0007] Based on this discussed prior art, the invention aims to propose a panel element with at least two panel segments that can be pivoted relative to each other, which not only has improved properties with regard to recycling, but can also be manufactured in a simple manner and wherein the panel element is also suitable for absorbing weight forces (loads) without requiring continuous underside support in the area of ​​the bending zone.

[0008] According to the invention, this problem is solved by a panel element having the features of claim 1.

[0009] When fiber reinforcement is mentioned in these explanations, unless otherwise specified, this may refer to nonwoven material, woven material, or even grids, nets, braids or the like.

[0010] This panel element is characterized by the fact that, with respect to its at least one fiber-reinforced outer layer and its core layer, it is manufactured from one and the same plastic carrier material forming a plastic body. The fiber reinforcements are embedded in this plastic carrier material, which serves as the plastic body. The fiber reinforcements themselves are typically made of a different material than the plastic body. The fiber reinforcements in the outer layers of the panel segments, as well as those of the film hinge, form sufficiently large cavities so that the cavity created by these components, when placed in a stacked arrangement in a mold, can be impregnated with an uncured plastic raw material. Once this plastic material has cured, it forms the plastic carrier body of the panel element or its panel segments. Thus, the panel segment has a carrier body made of a single material.In a preferred embodiment, the plastic raw material is a polyurethane compound that is not yet fully cross-linked and is typically uncross-linked. This means that only a single manufacturing process is required to produce such a panel element. This is advantageous both with regard to the manufacturing process and for subsequent recycling.

[0011] Particular attention is paid to the design of the film hinge in this panel element. The fiber reinforcement of the film hinge is designed such that, on the one hand, tensile forces can be transferred from one panel segment to the adjacent panel segment, and on the other hand, that the fibers of the reinforcement spanning the width of the film hinge, when embedded in the plastic body, exhibit a break-free bending radius that is smaller than the bending radius of the film hinge in the area of ​​its fiber reinforcement. Suitable fibers for forming the fiber reinforcement of the film hinge include polyester fibers, Kevlar fibers, and polyamide fibers, which are held together as a nonwoven fabric, woven together, or held together as a grid, net, or braided structure. Of course, other fiber materials that have a correspondingly break-free bending radius when embedded can also be used.Preferably, the fiber reinforcement of the film hinge is designed such that a first set of fibers in the fiber reinforcement, which in the case of a woven fiber reinforcement are the warp fibers, forms a larger angle with the longitudinal axis of the film hinge than at least a further set of fibers, which in the case of a woven fiber reinforcement are the weft fibers. In such a design, the fibers of this set forming a larger angle with the longitudinal axis of the film hinge serve as tensile force-transmitting fibers under a weight load, while the fibers running transversely to it primarily serve to hold the fibers of the first set together and to space them apart from one another.In the design of the fiber reinforcement of the film hinge, the fibers of the fiber bundle whose fibers form a larger angle with the longitudinal axis of the film hinge can exhibit higher tensile strength than the fibers of at least one other fiber bundle, for example, because they have a larger diameter than the fibers of the other fiber bundle. Two panel segments connected by a film hinge designed in this way can be pivoted relative to each other with a tight bending radius, and thus even with a very narrow film hinge, for example, with a bending radius of the fiber reinforcement in the fiber-reinforced edge layer of 1.5 mm to 2.0 mm. For panel elements designed as loading floors, a pivoting range of 90° to 145° is generally desired. Therefore, the film hinge only needs to be 3 mm wide for this type of panel element.

[0012] Manufacturing the panel element in a mold, into which an uncrosslinked plastic raw material is introduced to form the plastic carrier material (the plastic body for the necessary crosslinking and curing process), has the further advantage that the panel segments can be easily separated from one another within or through the mold, while retaining the film hinge, as long as the plastic raw material introduced into it has not yet cured. This is indeed carried out in a preferred embodiment of the manufacturing process. Therefore, unlike when performing a cutting operation, there is no risk of damaging the film hinge. This process simultaneously determines the thickness of the film hinge and thus the material thickness of the plastic body in the area of ​​the film hinge.Such a gap, and thus a separation of the two panel segments to be formed in a mold, can be easily created by a mold strip that follows the longitudinal extent of the film hinge and is pressed into the still uncured plastic raw material. According to one embodiment, such a mold strip is located on the mold half that closes the other mold half, which has a recess for receiving one or more fiber reinforcements and the plastic raw material.

[0013] A special feature of this design of the separation gap between the facing side surfaces of the panel segments is that the contour of this gap can be freely shaped. This gap is therefore also referred to as a forming gap. The forming strip is designed according to the desired geometry of the gap. Unlike with a cut, this allows, for example, a rounded groove to be formed on the tension side of the film hinge, i.e., on its side facing the forming gap, thus avoiding or at least reducing a notch effect. The film hinge of such a panel element is correspondingly durable, even if its panel segments are frequently adjusted relative to each other. Pressing a forming strip into the still-soft plastic raw material also allows for designs with other cross-sectional geometries, for example, a forming gap with a keyhole-shaped cross-sectional geometry.In this case, despite the narrow gap being provided, the rounded groove is designed with a correspondingly large radius, further reducing the risk of cracking and thus the risk of breakage. In such a design, where undercuts are created by the mold strip in the gap, it is designed so that it is removed from the mold along with the cured panel element and then pulled or pushed out of the created mold gap. Alternatively, the cured panel element can be demolded by a corresponding sliding movement relative to the mold part carrying the mold strip.

[0014] Such plastic bodies, for example those made of polyurethane, tend to crack in a near-surface layer under bending stress, specifically on the tension side. To control this cracking—that is, to ensure that such cracking occurs at predetermined locations on the tension side of the film hinge—one embodiment provides for one or more small, shallow indentations at the end of the mold gap facing the film hinge, following the longitudinal extent of the film hinge. These indentations can be continuous along the entire length of the film hinge or provided by several sections arranged in a row. These indentations serve to initiate cracking, cleverly exploiting the fact that such cracking only develops in the near-surface layer under tensile stress.

[0015] The fiber reinforcement of the film hinge typically extends into the edge layers of the panel segments connected by the film hinge and preferably overlaps a certain section with the fiber reinforcement of the edge layers, for example over 5 to 10 cm. This serves the purpose of ensuring that tensile forces can be reliably transferred from one panel element to another when the film hinge is subjected to a load.

[0016] It is entirely possible to design a panel segment in which the fiber reinforcement of the film hinge simultaneously serves as the fiber reinforcement of the edge layers of both panel segments. In this case, the fiber reinforcement extends over the entire surface of the panel element.

[0017] To enable cost-effective production of such a panel element, a preferred embodiment provides for the use of a different fiber reinforcement for the edge layers of the panel segments than for that of the film hinge. While a woven textile plastic material with the aforementioned flexural properties, such as a woven polyester mat, is preferably used for the fiber reinforcement of the film hinge, fiberglass fleece mats are used for the fiber reinforcement in the edge layers of the panel segments. Of course, other fiber reinforcements can also be used instead of fiberglass fleece mats to form the desired fiber-reinforced edge layers.

[0018] Such a panel element can, for example, be further developed by adding a cover layer to the side where the film hinge is located. In the case of a loading floor, this is typically the top surface. This cover layer is preferably made of the same material as the plastic substrate, i.e., for example, also from polyurethane. This can, but does not necessarily have to, be produced separately as a skin and then inserted into the mold; it can also be prepared or produced directly within the mold. The fiber reinforcements are then positioned onto this plastic raw material, which has already been introduced into the mold to form the cover layer.

[0019] Such a panel element can also be equipped with a fiber-reinforced edge layer on its other flat side. In this case, open support structures are inserted into the areas of the panel segment to be produced before the plastic raw material is introduced into the mold or mold part. These open support structures serve to space the two fiber reinforcements. Such an open support structure is sufficiently dimensionally stable, although it may be intended that such an open support structure will be compressed to a certain extent during the manufacturing process. The open support structure acts as a spacer to provide sufficient cavity for the plastic raw material introduced or to be introduced into the mold to form the plastic body.The support structure is open so that the raw plastic compound introduced into the mold can easily fill the cavity provided by the support structure completely or at least partially. The desired dimensional stability of such a support structure relates to the process of introducing the raw plastic compound, ensuring that the support structure is not excessively deformed during this process and the filling of its cavities, which would impair its place-holding function. If at least one of the panel segments is also to be equipped with a fiber-reinforced edge layer on its other flat side, a fiber reinforcement mat simply needs to be placed on the top surface of the support structure, which is positioned in the mold's recess, before the still-cured plastic compound is introduced into the mold. Therefore, no additional manufacturing step is required in this respect either.In such an open support structure, the material used could be, among other suitable materials, a dimensionally stable foam board, typically made from the same plastic material as the plastic body.

[0020] Such an open support structure can also be used if no fiber reinforcement is to be formed on the flat side opposite the film hinge of the panel segments connected by the film hinge.

[0021] Considering the manufacturing process described above and the use of a mold strip for pressing into the plastic raw material to create a mold gap in the mold, it is advantageous if the facing side surfaces of the panel segments connected by the film hinge are formed by the cross-linked plastic carrier material – the plastic body – and thus an open support substrate integrated into the core layer terminates with its side surfaces before the actual lateral end of the panel segments. In this way, these surfaces can be freely shaped, for example with a curve or an incline, even when using such support substrates.

[0022] Such a panel segment can be covered with carpet on one or both sides, for example. However, unlike previously known panel elements, this covering then does not function as a film hinge, even though the carpet covering is also bent in the area where it bridges the film hinge. Accordingly, such an additional covering needs to be designed to withstand less tensile loads.

[0023] The invention is described below with reference to an exemplary embodiment and the accompanying figures. These show: Fig. 1: A schematic longitudinal section through a panel element designed as a loading floor with two hinged floor segments, Fig. 2: an enlarged view of a section of the loading floor of the Fig. 1 in the area of ​​its film hinge connecting the two bottom segments, Fig. 2a: a representation corresponding to that of the Fig. 2 with a different contour of the gap located between the facing side surfaces of two floor segments, Fig. 3: the loading floor of the Fig. 1 in a position in which one bottom segment is pivoted relative to the other bottom segment about the bending axis of the film hinge and Fig. 4a - 4f: a schematic sequence of figures produced by a mold for manufacturing the loading floor of the Fig. 1.

[0024] A panel element designed as a loading floor 1, intended for insertion into the trunk of a passenger vehicle, comprises two floor segments 2, 3 as panel segments. The two floor segments 2, 3 are connected to each other by a film hinge 4. The longitudinal extent of the film hinge 4, which simultaneously defines the bending axis of the two floor segments 2, 3 relative to each other, runs in the transverse direction of the vehicle (y-direction). The plane of section through the loading floor 1 is in the direction of the longitudinal extent of a vehicle (x-direction). The vertical direction is indicated in this figure as the z-direction.

[0025] In the illustrated embodiment, the loading floor 1 is a polyurethane panel in which the polyurethane raw material has been cured or cross-linked in a mold. Fig. 1 The plastic carrier material provided by the polyurethane material – the plastic body 5 – is identified by a dot matrix. In the illustrated embodiment, the film hinge 4 is aligned with the flat sides of the bottom segments 2, 3, which point upwards in the z-direction.

[0026] In the plastic body 5, a fiber reinforcement 6, 7 is integrated into the upward-facing flat side of each of the floor segments 2, 3, thus providing the loading floor 1 with a fiber-reinforced edge layer 8 on its upper surface. In the illustrated embodiment, the fiber reinforcements 6, 7 are each a glass fiber fleece. The two fiber reinforcements 6, 7 are separated from each other in the area of ​​the film hinge 4. At this point, there is another fiber reinforcement 9, which is a woven polyester mat. The fiber reinforcement 9 of the film hinge 4 extends beneath the fiber reinforcements 6, 7 of the two floor segments 2, 3 and overlaps them over a section that is typically between 5 and 10 cm.In the fiber reinforcement 9 of the film hinge 4, the warp fibers, as the first fiber set, run in the x-direction and thus extend from the fiber reinforcement 6 across the film hinge 4 to the fiber reinforcement 7. The weft fibers, as the second fiber set, run in the y-direction. The figures show the fiber reinforcements 6, 7, 9 schematically. This applies particularly to the angular shape of the fiber reinforcement 9 shown in the figures, which is intended to fill the gap between the fiber reinforcements 6 and 7. In reality, these transitions are not angular but rounded, or a gradual transition occurs.

[0027] In the illustrated embodiment, the flat sides of the bottom segments 2, 3 opposite the two fiber reinforcements 6, 7 are also equipped with a fiber reinforcement 10, 11. The fiber reinforcements 10, 11 are made of the same material as the fiber reinforcements 6, 7. Between the fiber reinforcements 6, 10 and 7, 11, which each form an edge layer 8, 8.1, an open support structure is located within the plastic body 5 in each bottom segment 2, 3. This structure acts as a spacer between the fiber reinforcements 6, 10 and 7, 11, respectively. In the illustrated embodiment, this support structure consists of open-pored, dimensionally stable foam panels 12, 13. In the illustrated embodiment, this foam panel is a polyurethane foam panel, for example, one used for filter purposes. These foam panels 12, 13 define the area of ​​the core layer to be formed.Therefore, commercially available components can be used to form the loading floor 1.

[0028] The two bottom segments 2, 3 are connected to each other by the film hinge 4 with the fiber reinforcement 9 located therein, but are otherwise spaced apart from each other with their opposing side surfaces 14, 15. Between the two bottom segments 2, 3 is a gap following the longitudinal extent of the film hinge 4, which is referred to below as the forming gap 16 (see Fig. 2) The special feature of the molded gap 16 is that the foam plates 12, 13 do not extend to the side surfaces 14, 15 of the molded gap 16, but end before them, so that the molded gap 16 is exclusively enclosed by the material of the plastic body 5. In the illustrated embodiment, the outline of the molded gap 16 is introduced into the still uncured (cross-linked) polyurethane mass within the mold used for manufacturing the loading floor 1. This allows for a contour design that ensures that tensile stresses acting on it when the two floor segments 2, 3 are folded towards each other are distributed as described in Fig. As indicated by the block arrow, the film hinge 4 does not lead to an increased notch effect or to potential tearing of the polyurethane material. In the illustrated embodiment, the film hinge 4 is limited by the forming gap 16 by a curved groove 17. This allows the two bottom segments 2 and 3 to be adjusted relative to each other by the desired pivot angle between 90° and 145° without any significant notch effect. The groove 17 can be equipped with small indentations following the longitudinal extent of the film hinge 4, which act as crack initiators.

[0029] Since the shaping of the mold gap 16 takes place in the still uncured plastic raw material, its outline contour can be shaped almost arbitrarily.

[0030] Fig. Figure 2a shows a different embodiment of the end section of a further forming gap 16.1 facing the film hinge 4.1. In this embodiment, the groove 17.1 has a larger radius. Overall, the forming gap 16 is designed in a keyhole shape. This allows the distance between the opposing side surfaces of the adjacent bottom segments to be very small, despite the relatively large radius of the groove 17.1. Other contours, such as wave-like contours, are also possible in the area of ​​such a groove.

[0031] Fig. Figure 3 shows the loading floor 1 when its floor segment 2 is pivoted relative to the floor segment 3.

[0032] The loading floor 1 has a decorative polyurethane top layer 18 on its upper surface, which also extends over the outward-facing side surfaces of the floor segments 2, 3.

[0033] The manufacturing process for producing the loading floor 1 is described below with reference to the sequence of figures 4a to 4f.

[0034] Fig. Figure 4a shows a forming tool 19 comprising a lower tool 20 and an upper tool 21. The lower tool 20 is shown in a longitudinal section to allow a view of the fixture 22 provided by the lower tool 20. The upper tool 21, on the other hand, is shown in a side view. Fig. Figure 4a shows the lower tool 20, in whose receptacle 22 the top layer 18 has already been applied. In the illustrated embodiment, the top layer 18 is a spray application on the inner surfaces of the receptacle 22. Fiber reinforcements 6, 7 are placed on the bottom of the receptacle 22, on top of the top layer 18. The two fiber reinforcements 6, 7 are spaced apart from each other. The film hinge 4 is formed in this space.

[0035] In a next step (see Fig. 4b) The fiber reinforcement 9 of the film hinge 4 is inserted into the receptacle 22 of the lower tool 20 and positioned where the film hinge 4 is to be formed. Fig. Figure 4b shows the fiber reinforcement 9 in a top view. The woven structure of this polyester material is visible. The warp fibers running in the x-direction are designated with reference numeral 23, and the weft fibers running in the y-direction with reference numeral 24. When the finished film hinge 4 is subjected to tensile stress, forces are transferred from one bottom segment to the other via the warp fibers 23.

[0036] Once fiber reinforcement 9 is positioned, foam plate 12 is placed on fiber reinforcement 6 and foam plate 13 on fiber reinforcement 7. These serve as placeholders to space the fiber reinforcements 10, 11 inserted on the other flat side from the fiber reinforcements 6, 7 already located in the lower tool 20. The lower tool 20, equipped with these components, is in Fig. 4c shown.

[0037] Next, as in Fig. As indicated by block arrows in Figure 4d, polyurethane raw material is introduced into the lower tool 20. This material fills the cavities in the fiber reinforcements 6, 7, 9, 10, 11, thus impregnating them, as well as at least largely the cavity in the foam plates 12, 13 and the gap formed by the spacing between the two foam plates 12, 13. The upper tool 21 is designed to close the lower tool 20. On its underside, the upper tool 21 carries a forming strip 25, which is pressed into the gap between the two foam plates 12, 13, filled with polyurethane raw material, when the two tool halves 20, 21 are closed. This is in Fig. 4e shown. In this closed state of the mold 19, the polyurethane mass cures as a plastic carrier material. After completion of the crosslinking process, the product manufactured in this way is removed from the mold 19. The top layer 18 is trimmed in a subsequent step, i.e., the protruding edge sections are cut off. Subsequently, the loading floor 1 is, as shown in Fig. 1 shown, completed.

[0038] It goes without saying that the flat sides of the loading floor 1 can be covered or coated with other materials, for example with a carpet.

[0039] In the described embodiment, the floor segments 2, 3, which serve as panel segments, are connected to one another by a film hinge 4 that separates in the transverse direction (y-direction) of the vehicle. Such a panel element can also have more than two panel segments arranged one behind the other in the x-direction and each connected to one another by a film hinge in the manner described. It is also possible for two panel segments to be connected to one another by a film hinge extending in the longitudinal direction (x-direction) of the vehicle in the case of a loading floor. A configuration is also possible in which the panel element, for example designed as a loading floor, has panel segments, at least two of which are connected to each other in the x-direction and at least two more in the y-direction.

[0040] The invention has been described with reference to exemplary embodiments. Without departing from the scope of protection described by the applicable claims, numerous further embodiments of the inventive concept would be apparent to a person skilled in the art, without these needing to be explained in more detail within the scope of these explanations. Reference symbol list 1 panel element / loading floor 2 panel segments / floor segments 3 panel segments / floor segments 4, 4.1 Film hinge 5 plastic bodies 6 Fiber reinforcement 7 Fiber reinforcement 8, 8.1 Edge layer 9 Fiber reinforcement 10 Fiber reinforcement 11 Fiber reinforcement 12 foam board 13 foam board 14 side surface 15 side surface 16, 16.1 Gap / Form gap 17, 17,1 throat 18 Top layer 19 Forming tool 20 lower tools 21 Upper tool 22nd recording 23 Warp fiber 24 weft fibers 25 Form strip QUOTES INCLUDED IN THE DESCRIPTION

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

[0000] DE 20 2013 011 658 U1

[0002] DE 10 2015 201 054 A1

[0003] US 2005 / 0189674 A1 [0005, 0006] US 2013 / 0278018 A1

[0006]

Claims

[1] Panel element, for example a loading floor (1) for a vehicle, comprising a first panel segment (2) made of plastic and at least one further panel segment (3) made of plastic, which is articulated to the first panel segment (2) by means of a film hinge (4, 4.1), each panel segment (2, 3) having a core layer and at least one of its two flat sides having a fiber-reinforced outer layer (8, 8.1) molded onto it, wherein the flat side of the panel segments (2, 3) facing in the same direction is equipped with such an outer layer (8) and the film hinge (4) connects the panel segments (2, 3) in the area of ​​these outer layers (8), characterized by, that the panel element (1) with its panel segments (2, 3) is made of curable plastic carrier material as a plastic body (5) into which the fiber reinforcements are integrated, that in the area of ​​the film hinge (4, 4.1) connecting the panel segments (2, 3) a fiber reinforcement (4) with fibers (23) extending at least over the width of the film hinge (4) is provided so that tensile forces can be transferred from one panel segment (2, 3) to the other panel segment (3, 2) via these fibers (23), that these fibers (23) of the fiber reinforcement (9) in their state embedded in the plastic body (5) have a break-free bending radius which is smaller than the bending radius of the film hinge (4, 4.1) in the area of ​​its fiber reinforcement (9), and that the mutually facing side surfaces (14, 15) of the core layer of the panel segments (2, 3), when located in a common plane with their outer layer (8), are spaced apart from each other by a gap (16, 16.1) adjacent to the film hinge (4, 4.1) connecting these panel segments (2, 3). [2] Panel element according to claim 1, characterized by , that the fiber reinforcement (9) of the film hinge (4, 4.1) extends into the edge layers (8) of the panel segments (2, 3) connected by the film hinge (4. 4.1) and preferably overlaps in an edge section of the fiber reinforcement (6, 7) present in the edge layers (8). [3] Panel element according to claim 1 or 2, characterized by , that the fiber reinforcement (9) of the film hinge (4, 4.1) is a woven, nonwoven, net-like or grid-like plastic material. [4] Panel element according to claim 3, characterized by , that the plastic material is oriented with respect to the orientation of its fibers in relation to the longitudinal extent of the film hinge (4, 4.1) such that one fiber set forms a larger angle with the longitudinal axis of the film hinge (4, 4.1) than the other fiber set. [5] Panel element according to claim 3 or 4, characterized by , that the fibers of the fiber reinforcement (9) of the film hinge (4, 4.1) are polyester fibers, Kevlar fibers and / or polyamide fibers. [6] Panel element according to claim 4 or 5, characterized by , that the fiber set whose fibers form a larger angle with the longitudinal axis of the film hinge (4, 4.1) have a higher tensile strength than the fibers of at least one other fiber set. [7] Panel element according to one of claims 1 to 6, characterized by, that the fiber reinforcement extends over the entire surface of the edge layers of the panel segments connected by the film hinge and thus simultaneously forms the fiber reinforcement of the edge layers of the panel segments separated by the film hinge. [8] Panel element according to one of claims 1 to 7, characterized by that the fiber reinforcement (6, 7) in the edge layers (8, 8.1) of the panel segments (2, 3) is of a different material than the fiber reinforcement (9) of the film hinge (4, 4.1). [9] Panel element according to claim 8, characterized by , that the fiber reinforcement (6, 7) in the edge layers (8, 8.1) of the panel segments (2, 3) is a glass fiber fleece mat. [10] Panel element according to any one of claims 1 to 9, characterized by , that in the core layer an open structural substrate for receiving curable plastic mass is integrated as a placeholder in connection with the manufacturing process. [11] Panel element claim 10, characterized by , that the structural substrate is an open-pored foam board (12, 13) that is sufficiently dimensionally stable for the purpose of serving as a placeholder, in particular a PU foam board. [12] Panel element according to claim 11, characterized by , that the open-pore foam plates (12, 13) of two panel segments (2, 3) connected by a film hinge (4, 4.1) end at a distance from the mutually facing side surfaces (14, 15) of the panel segments (2, 3), so that these side surfaces (14, 15) limiting the gap (16, 16.1) are formed by the plastic mass of the plastic body (5). [13] Panel element according to any one of claims 1 to 12, characterized by, that the open structural substrate contained in the core layer of each panel segment (2, 3) are spaced apart from each other by a gap provided for the formation of the film hinge (4, 4.1) or that such a gap has been created by a deformation process of the open structural substrate. [14] Panel element according to any one of claims 1 to 13, characterized by , that the plastic body (5) is a polyurethane body. [15] Panel element according to one of claims 1 or 14, characterized by , that the form gap (16, 16.1) in its end section pointing towards the film hinge (4, 4.1) is designed as a curved groove (17, 17.1). [16] Panel element according to any one of claims 1 to 15, characterized by , that in the end section of the form gap (16, 16.1) pointing towards the film hinge (4, 4.1) one or more notches are provided which follow the longitudinal extent of the film hinge (4, 4.1). [17] Panel element according to any one of claims 1 to 16, characterized by , that the panel segments (2, 3) also have a fiber-reinforced edge layer (10, 11) on their respective further flat sides. [18] Panel element according to any one of claims 1 to 17, characterized by , that the panel segments (2, 3) connected by the film hinge (4, 4.1) are laminated with a cover layer (18) on the side where the film hinge (4, 4.1) is located by the fiber-reinforced edge layer (8, 8.1). [19] Panel element according to claim 18, characterized by , that the top layer (18) also extends over the side surfaces of the panel segments (2, 3) connected by the film hinge (4, 4.1). [20] Panel element according to claim 18 or 19, characterized by , that the top layer (18) is a polyurethane top layer. [21] Panel element according to any one of claims 1 to 20, characterized by, that the panel element is a loading floor (1) of a vehicle, in particular a passenger car.

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