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

Abstract

A component (100) for a vehicle is proposed. At least some sections of the component comprise two layers. A first layer (S1) is produced by a three-dimensional winding process from at least one yarn-shaped and / or strand-shaped winding material (10). A second layer (S2) comprises at least one sheet made of a shaped fiber material (20), wherein the fiber material (20) is formed of fibers (22) oriented perpendicularly to a surface of the fiber material (20). The first layer (S1) and the second layer (S2) are partially fused to one another.

Description

[0001] 24-0888 PIF

[0002] 1

[0003] Component for a vehicle, method for manufacturing a component, and vehicle

[0004] The invention relates to a component for a vehicle and a method for manufacturing a component for a vehicle. Furthermore, the invention relates to a vehicle comprising at least one such component.

[0005] Components of the type mentioned above are used as trim parts, especially as interior trim parts, in vehicles to achieve a higher-quality appearance.

[0006] The requirements for the structure, function, surface, feel, and appearance of a component are typically met through the use of various materials. However, this leads to limited possibilities for adapting functionality and shape to the given form. To achieve high strength, fillers and reinforcing materials such as glass, natural, or carbon fibers are frequently used. The use of such material composites, however, impairs material recycling and the desired weight optimization. Additionally, it may be necessary to equip cladding components with fastening and / or reinforcing elements.

[0007] The present invention is based on the objective of providing a component that exhibits improved adaptability and flexibility with regard to functionality, stiffness and tensile strength.

[0008] The invention is defined in the independent claims. Advantageous embodiments of the invention are described in the dependent claims and the following description.

[0009] A first aspect of the present disclosure relates to a component for a vehicle. The component has at least two layers in sections. A first layer is produced in a three-dimensional winding process from at least one yarn- and / or strand-shaped winding material. A second layer has at least one sheet structure made of a formed fiber material, wherein the fiber material comprises fibers oriented substantially perpendicular to a surface of the fiber material. The first layer and the second layer are partially fused together. 24-0888 PIF

[0010] 2

[0011] A component for a vehicle is proposed that can incorporate different material and / or semi-finished product concepts of the same material type. The component has two layers: the first layer uses a wound material, and the second layer uses a formed fiber material as a sheet structure. The fiber material can be composed of fibers oriented perpendicular to a surface of the fiber material.

[0012] The winding material can differ in at least some of its material properties. Using such a winding material allows for the production of a first layer with high tensile strength using a comparatively small amount of material. Strength-enhancing fillers and reinforcing materials such as glass, natural fibers, or carbon fibers can be omitted in this case. Consequently, the first layer can be lighter while maintaining the same functionality. The layup pattern of the yarn enables the creation of high-quality component surfaces with a textile-like appearance. Furthermore, due to the absence of fillers, reinforcing materials, and composite materials, such a first layer can be recycled. Moreover, its high strength makes the first layer well-suited for use in crash-relevant components.

[0013] The strand-shaped winding material can be a thin, long continuous fiber, also known as a filament. The strand-shaped winding material can have a round or angular cross-section. The yarn-shaped winding material can consist of continuous fibers or length-limited fibers, also known as staple fibers. The fibers can have a round or angular cross-section. The winding material preferably consists of a single material.

[0014] In the three-dimensional winding process, the second layer, which, for example, has the desired three-dimensional component geometry, can be wrapped with at least one yarn- or strand-shaped winding material of the first layer. Alternatively, a fiber carrier can be wrapped with at least one yarn- or strand-shaped winding material. Permanent component strength can be achieved by fusing the winding material of the first layer. Alternatively, a movable surface can be created by partially fusing the winding material, for example, at specific points. This enables functions such as shading or light control when used as a trim component in vehicle interiors. 24-0888 PIF

[0015] 3

[0016] The winding material can have at least two twisted threads, one of which has a first material property and the other a second material property. This allows for the creation of a yarn made of at least two twisted threads that are made of the same material but have different material properties.

[0017] Advantageously, prefabricated elements can be integrated into the winding material during the winding process. Furthermore, the shape of the wound part can be modified after winding, but before final solidification, by forming and / or trimming. For example, the second layer can simply be a pre-form of the component.

[0018] The use of a formed fiber material as a sheet structure for the second layer, in which the fibers are oriented substantially perpendicular to the surface, can lead to high stiffness of the second layer and thus of the component. In the context of this disclosure, the term "substantially perpendicular" can describe an angle between 87° and 93°. Furthermore, the fiber material, with its fibers oriented perpendicular to the surface, is suitable as a replacement for polyurethane foams as an acoustic, haptic, comfort, or filling material in cladding and acoustic components. A wide range of surface finishes is also possible, from smooth to fabric-like surfaces.

[0019] By combining the two layers, the respective strengths of each layer can be utilized selectively. This makes it possible to provide a component with optimized properties without having to integrate additional material types. Preferably, the component only has two layers in certain sections. For example, the first layer can be used as a reinforcement layer at specific points on top of the second layer. By including the first layer in a predefined section, a locally increased tensile strength can be achieved. Sections of the component can also be provided that consist only of the second layer. Such sections can exhibit high strength at a (relatively) small thickness. The second layer can have a low material density. Furthermore, the component can include a section in which only the first layer is present.Such a section can exhibit a high degree of mobility.

[0020] It should be noted that the component may have more than two layers, at least in sections. For example, the component may have four layers, with the first two being 24-0888 PIF.

[0021] 4

[0022] Layers and two second layers are arranged alternately on top of each other, at least in sections. The component may, for example, have four layers in one section and two or even one layer in another section. In principle, any combination of the first and second layers is conceivable. In the context of the present disclosure, a component that has more than two layers, e.g., more than four layers, at least in sections, is not excluded.

[0023] The two layers can be joined together in their respective sections. To join the two layers, they can, for example, be fused together over a predefined thickness. For this purpose, the two layers can be subjected, at least partially, to a pressing process, whereby they are pressed together under the influence of heat. The two layers preferably consist predominantly of the same material. The component can be a monomaterial component. The material can exhibit different material properties.

[0024] The component can be a trim component, for example, for a vehicle interior. It can be used to cover a C-pillar and / or a headliner. Furthermore, the component can be a load-bearing component or structure for a vehicle.

[0025] Such a component can advantageously fulfill rigid, movable and / or decorative requirements.

[0026] According to one embodiment, the winding material has a first cross-sectional area and a second cross-sectional area. The first cross-sectional area has a first melting temperature range, and the second cross-sectional area has a second melting temperature range. The winding material can therefore form a hybrid filament from a single material, such as a type of plastic, exhibiting two different material properties, such as two different melting temperature ranges. A first cross-sectional area can serve as a low-melting area, and a second cross-sectional area can serve as a high-melting area. Advantageously, the low-melting area serves to bond the first layer to the second layer. The high-melting area can contribute to the strength and appearance of the first layer.A cross-sectional area is preferably understood to be an area within a cross-section, that is, in a sectioning plane perpendicular to a longitudinal axis or perpendicular to a longitudinal extension of the thread. 24-0888 PIF.

[0027] 5

[0028] According to one embodiment, the fiber material comprises fibers with different melting point ranges. Thus, the fiber material can contain fibers with a low melting point range and fibers with a high melting point range. Fibers with a low melting point range can serve both to fix the second layer to the first layer and vice versa.

[0029] In the context of this disclosure, the low melting point range can extend between 160°C and 180°C. The low-melting cross-sectional area of ​​the winding material can therefore melt at least partially within this low melting point range. It should be noted that, in the context of this disclosure, the term "melting point range" can refer to a region around the corresponding melting point. Preferably, the corresponding melting point is the lower limit of the melting point range. The melting point range preferably does not extend to the corresponding boiling point.

[0030] According to one embodiment, the winding material of the first layer and the fiber material of the second layer share a common melting temperature range. For example, the first cross-sectional area of ​​the winding material can have a common melting temperature range as the fibers of the fiber material. This means that the first melting temperature range of the winding material can overlap with a melting temperature range of the fiber material. This allows the two layers of the component to be easily joined and fused together, for example, by heating the component. When the component is heated, the first cross-sectional area of ​​the winding material and the corresponding fibers of the fiber material can at least partially fuse together, creating a metallurgical bond between the two layers. The second cross-sectional area can remain unchanged during this process.The remaining fibers of the fiber material can also remain unchanged in their properties.

[0031] According to one embodiment, the first layer forms at least part of the visible surface of the component. The arrangement of the strand and / or yarn-shaped winding material allows, for example, the creation of high-quality surfaces that have a textile-like appearance.

[0032] According to one embodiment, the component consists of a single material. Since the component consists of a single material, it can advantageously be recyclable and circular. The single material is preferably a type of plastic, such as a thermoplastic. 24-0888 PIF

[0033] 6

[0034] According to one embodiment, the first layer is arranged section by section on the second layer according to a pattern. Alternatively or additionally, the second layer is arranged section by section on the first layer according to a pattern. This allows for the provision of an improved, property-optimized component.

[0035] A second aspect of the present disclosure relates to a method for manufacturing a component for a vehicle. The method comprises the following steps:

[0036] • Pre-positioning a first layer on a second layer, wherein the first layer is positioned at least sectionally on the second layer and wherein the first layer is produced in a three-dimensional winding process from at least one yarn- and / or strand-shaped winding material and

[0037] the second layer comprises at least one planar structure made of a transformed fiber material, wherein the fiber material is formed from fibers oriented perpendicular to a surface of the fiber material, and

[0038] • Heating the first layer and the second layer so that the two layers partially fuse together.

[0039] Heating the first and second layers can cause certain areas, such as a cross-sectional area of ​​the first layer and fibers of the second layer's fibrous material, to partially melt. This melting process can create a metallurgical bond between the two layers.

[0040] The first layer can be pre-positioned on the second layer in such a way that the first layer forms a pattern. In particular, the first layer can be intended as a decorative layer and therefore positioned at specific points on the surface of the second layer. The first layer can also or alternatively serve as a reinforcing layer to increase the tensile strength of the component. Therefore, it can be positioned at specific points on the second layer.

[0041] According to one embodiment of the method, the method for manufacturing a component is set up as described above and / or below.

[0042] A third aspect of the present disclosure relates to a vehicle. The vehicle comprises at least one component as described above and / or below. Alternatively or additionally, the vehicle comprises at least one component manufactured by a process as described above and / or below. 24-0888 PIF

[0043] 7

[0044] All benefits, revelations and / or explanations described above and / or below in relation to one aspect of the present revelation apply equally to all other aspects of the present revelation.

[0045] Further advantages, features, and details of the invention will become apparent from the following description, in which exemplary embodiments of the invention are described in detail with reference to the drawings. The features mentioned in the claims and in the description can each be essential to the invention individually or in any combination.

[0046] Exemplary embodiments of the invention are described below with reference to the figures. The figures show:

[0047] Fig. 1 shows a component for a vehicle according to an exemplary embodiment;

[0048] Fig. 2 shows a component for a vehicle according to an exemplary embodiment;

[0049] Fig. 3 shows a cross-section through the strand-shaped winding material of the first layer according to an exemplary embodiment;

[0050] Fig. 4 shows a schematic representation of the fiber material of the second layer according to an exemplary embodiment; and

[0051] Fig. 5 shows a schematic representation of a yarn-shaped winding material formed from two threads twisted together to form a yarn.

[0052] Similar, similar-looking, identical, or equivalent elements are identified by the same reference symbols in the figures. The figures are shown schematically and not to scale.

[0053] Fig. 1 shows a component 100 for a vehicle, in particular in a top view, according to an exemplary embodiment. The component 100 has two layers in sections. The first layer S1 is produced in a three-dimensional winding process from at least one yarn- and / or strand-shaped winding material 10 (see, for example, Fig. 3). The second layer S2 has at least one planar structure made of a formed fiber material 20. The fiber material 20 is formed from fibers 22 oriented perpendicular to a surface 21 of the fiber material 20 (see Fig. 4). In the top view of Fig. 1, both the first 24-0888 PIF

[0054] 8

[0055] The first layer S1 and the second layer S2 are clearly visible. Some sections of component 100, such as section B, can consist exclusively of the second layer S2 and thus of the fiber material 20. Component 100 in Fig. 1 also has at least one first section A, which has both a first layer S1 and a second layer S2. In section A of component 100 in Fig. 1, three yarns 16 of the winding material 10 form the first layer S1 (see Fig. 5). The winding material 10 of the first layer S1 is bonded to the second layer S2, for example, by fusion. In a further third section C of component 100, the component 100 has only the first layer S1. Such a section C can serve to functionalize component 100.

[0056] The first layer S1 is preferably arranged in a pattern on the surface of the second layer S2. The tensile strength of the component 100 can be increased section by section and / or at specific points by the first layer S1. Furthermore, a patterned arrangement of the first layer S1 on the second layer S2 can create a predetermined appearance for the component 100.

[0057] Fig. 2 shows a component 100 for a vehicle according to an exemplary embodiment. Fig. 2 shows, in particular schematically, the component 100 of Fig. 1 in the first section A. The component 100 has two layers S1, S2, wherein both layers S1, S2 are fused together over a predefined thickness D, in particular a predefined average thickness D. Preferably, the thickness D of the second layer S2 is greater than the thickness of the first layer S1. Both layers have the same material type, such as polyethylene (PET). This can facilitate easier categorization within the framework of recycling.

[0058] Fig. 3 shows a cross-section through the strand-like winding material 10 of the first layer S1 according to an exemplary embodiment. The winding material 10 has a centrally arranged first cross-sectional area 12 and a second cross-sectional area 13 enclosing the first cross-sectional area 12. The second cross-sectional area 13 is preferably a circular ring, which is arranged coaxially around the first cross-sectional area 12.

[0059] The strand-shaped winding material 10 of Fig. 3 is a hybrid thread made of a monomaterial. The monomaterial is preferably a type of plastic, namely a thermoplastic, in particular a polyester, with different material properties. These different material properties differ in at least one mechanical property. 24-0888 PIF

[0060] 9

[0061] Specifically, the two cross-sectional areas 12 and 13 differ at least in their differing melting temperature ranges. The first cross-sectional area 12 preferably has a higher melting temperature range than the second cross-sectional area 13.

[0062] To produce cross-sectional areas 12 and 13 with different material properties, the strand-shaped winding material 10 can be stretched. Stretching causes the strand-shaped winding material 10 to work-harden in the first cross-sectional area 12, so that the first cross-sectional area 12 has a higher melting point than the second cross-sectional area 13 and thus high strength.

[0063] A three-dimensional winding process is used to produce the first layer S1 from the strand-shaped winding material 10. The winding material 10 can be wound onto or around the second layer S2. By fusing the winding material 10 across the second cross-sectional area 13, which has a lower melting point, the winding material 10 can be bonded to the second layer S2. Thus, the second cross-sectional area 13 of the strand-shaped winding material 10 serves for fixation. The first cross-sectional area 12, which has a higher melting point, contributes to the strength and appearance of the first layer S1, or of the component 100. By partially fusing the winding material 10, movable surfaces can be created for the first layer S1. This allows for shading and / or light control when used as a trim component for the vehicle interior.

[0064] Instead of a thermoplastic, the winding material can be made of cellulose, for example paper, with an adhesive, for example glue.

[0065] Fig. 4 shows a schematic representation of the fiber material 20 of the second layer S2 according to an exemplary embodiment. In particular, Fig. 4 shows an enlarged view of a section of the second layer S2 of a component 100, such as a vehicle headliner. The second layer S2 has a planar structure made of a fiber material 20, wherein the fiber material 20 is formed from fibers 22 oriented perpendicular to a surface 21 of the fiber material 20. The fibers 22 are preferably made of a thermoplastic, in particular polyethylene (PET), and have different material properties, in particular different melting temperature ranges. In particular, the fiber material 20 has fibers 22 with a low melting temperature range and fibers 22 with a high melting temperature range. 24-0888 PIF

[0066] 10

[0067] To increase the stability of the second layer S2, the sheet structure can be compacted in certain areas. A compacted area can be created by compressing the fiber material 20 under the influence of heat. The compression of the fiber material 20 can be carried out in the temperature range of 150°C to 250°C and can be performed using steam, expansion, or isothermal pressing. The temperature range for compressing the fiber material preferably overlaps with the melting temperature range of the second cross-sectional area 13 and / or with the melting temperature range of some fibers 22 of the fiber material 20. During compression of the fiber material 20, the fibers 22 of the fiber material 20 with the lower melting temperature range can melt. It is conceivable that the sheet structure of the second layer S2 is compacted in areas where the component 100 has a first layer S1.By pressing at a temperature between 150°C and 250°C, the surface structure can be compacted in one step, and the first layer S1 can be joined with the second layer S2.

[0068] Fig. 5 shows a schematic representation of a yarn-like winding material 10, which is formed from two threads 15 twisted together to form a yarn 16. The yarn-like winding material 10 has at least two threads 15 twisted together to form a yarn 16. The two threads 15 have different material properties, in particular different mechanical properties. Thus, one of the threads 15 preferably has a higher melting point range than the other thread 15. The thread 15 with the lower melting point range is used to fix the first layer S1 onto the second layer S2 by melting it. The thread 15 with the higher melting point range serves in particular to provide strength and appearance to the first layer S1, especially to the component 100.

[0069] It should be further noted that the terms "comprising" and "comprising" do not exclude other elements, and the indefinite articles "a" or "an" do not exclude a plurality. It should also be noted that features and steps described with reference to one of the above embodiments may also be used in combination with other features and steps of other embodiments described above. Reference numerals in the claims are not to be considered as limitations. 24-0888 PIF

[0070] 11

[0071] Reference symbol list

[0072] 100 components

[0073] 10 wrapping materials

[0074] 12 first cross-sectional area 13 second cross-sectional area 15 thread

[0075] 16 yarn

[0076] 20 Fiber material

[0077] 21 surface

[0078] 22 fibers

[0079] 51 first shift

[0080] 52 second shift

[0081] A first section

[0082] B second section

[0083] Section C, third section

[0084] D predefined thickness

Claims

-0888 PIF 12 Claims 1. Component (100) for a vehicle, comprising at least two layers in sections, wherein a first layer (S1) is produced in a three-dimensional winding process from at least one yarn- and / or strand-shaped winding material (10), wherein a second layer (S2) has at least one planar structure made of a formed fiber material (20), wherein the fiber material (20) comprises fibers (22) oriented substantially perpendicular to a surface of the fiber material (20), and where the first layer (S1) and the second layer (S2) are partially fused together.

2. Component (100) according to claim 1, wherein the winding material (10) has a first cross-sectional area (12) and a second cross-sectional area (13), wherein the first cross-sectional area (12) has a first melting temperature area and wherein the second cross-sectional area (13) has a second melting temperature area which differs from the first melting temperature area.

3. Component (100) according to one of the preceding claims, wherein the fiber material (20) comprises fibers (22) with different melting temperature ranges.

4. Component (100) according to one of the preceding claims, wherein the winding material (10) of the first layer (S1) and the fiber material (20) of the second layer (S2) have a common melting temperature range.

5. Component (100) according to one of the preceding claims, where the first layer (S1) forms at least part of the visible surface of the component.

6. Component (100) according to one of the preceding claims, where the component (100) consists of a single material. -0888 PIF 13 7. Component (100) according to one of the preceding claims, wherein the first layer (S1) is arranged section by section on the second layer (S2) according to a pattern and / or wherein the second layer (S2) is arranged section by section on the first layer (S1) according to a pattern.

8. Method for manufacturing a component for a vehicle, comprising the following steps: • Pre-positioning a first layer on a second layer, wherein the first layer (S1) is positioned at least sectionally on the second layer and wherein the first layer (S1) is produced in a three-dimensional winding process from at least one yarn- and / or strand-shaped winding material (10) and the second layer (S2) has at least one planar structure made of a transformed fiber material (20), wherein the fiber material (20) is formed from fibers (22) oriented perpendicular to a surface of the fiber material (20), and • Heating the first layer (S1) and the second layer (S2) so that the two layers fuse together over a predefined thickness (B).

9. Method according to claim 8, wherein the method for manufacturing a component (100) according to any one of claims 1 to 7 is set up.

10. Vehicle comprising at least one component (100) according to one of claims 1 to 7 and / or at least one component (100) manufactured using a method according to one of claims 8 to 9.

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