REINFORCEMENT PART FOR ROUTING CABLES, AS WELL AS VEHICLE COMPONENT COMPRISING SUCH A REINFORCEMENT PART, AND VEHICLE COMPRISING SUCH A VEHICLE COMPONENT

Abstract

The invention relates to a reinforcement part (1) for reinforcing a vehicle component, comprising a structural wall (3) enclosing walls of a ribbing structure (5), the reinforcement part having a first side region (6) allowing a first load portion to pass through and a second side region (7) allowing a second load portion to pass through, wherein the first load portion represents the largest load portion, characterized in that at the second side region, the walls of the ribbing structure are provided with cut-outs (8), the structural wall at the second side region being shaped to at least partially cover the contours (9) of the cut-outs, wherein a continuously shaped cut-out (10) is formed in the structural wall for cabling (11), whereas the walls of the ribbing structure at the first side region are free from cut-outs.

Claims

1. Reinforcement part (1) for reinforcing a vehicle component (2), comprising a structural wall (3) extending along a longitudinal axis (X) of the reinforcement part, wherein the structural wall at least partly encloses walls (4) of a ribbing structure (5) for supporting structural strength of the reinforcement part, the reinforcement part, when viewed in cross-section, having a first side region (6) configured for allowing a first load portion to pass through and a second side region (7) configured for allowing a second load portion to pass through, wherein the first load portion represents the largest load portion occurring at the cross-section, wherein the ribbing structure is at least provided at the first side region and the second side region, characterized in that at the second side region, when viewed along the longitudinal axis, the walls of the ribbing structure are provided with cut-outs (8), the structural wall at the second side region being shaped to at least partially cover the contours (9) of the cut-outs, in such a way, that a continuously shaped cut-out (10) is formed in the structural wall for routing cabling (11), whereas the walls of the ribbing structure at the first side region are free from cut-outs to keep the ribbing structure at the first side region intact.

2. Reinforcement part (1) according to claim 1, wherein the second load portion represents the smallest load portion occurring at the cross-section.

3. Reinforcement part (1) according to claim 1, wherein, when viewed in cross-section, the structural wall (3) has an open side (12), the first side region comprising the open side, the walls (4) of the ribbing structure (5) at the open side being free from cut-outs.

4. Reinforcement part (1) according to claim 3, the structural wall (3) comprising a base wall (13) and side walls (14) connected to the base wall, the base wall and side walls enclosing the ribbing structure (5), wherein the second side region (7) is located at the base wall and/or at least one of the side walls.

5. Reinforcement part (1) according to claim 4, wherein the structural wall (3) has a U-shape, comprising a base (15) and legs (16) connected to the base, the legs forming the side walls (14) of the structural wall and the base forming the base wall (13) of the structural wall.

6. Reinforcement part (1) according to claim 1, wherein the walls (4) of the ribbing structure (5) at the first side region (6) have a larger thickness than the walls of the ribbing structure at the second side region (7).

7. Reinforcement part (1) according to claim 1, wherein the ribbing structure (5) comprises a cross-ribbing structure (17), wherein the walls (4) of the cross-ribbing structure (17) are arranged at an angle with respect to each other.

8. Reinforcement part (1) according to claim 1, wherein the cut-outs (8) have a partly circular, oval or elliptical shape.

9. Reinforcement part (1) according to claim 1, wherein a width (W) of the cut-outs (8), when viewed along the longitudinal axis (X), is 10-30 mm and/or wherein a height (H) of the cut-outs is 10-20 mm.

10. Reinforcement part (1) according to claim 1, wherein the structural wall (3) has a thickness of 1-6 mm.

11. Reinforcement part (1) according to claim 1, comprising cabling (11) arranged in the continuously shaped cut-out (10).

12. Vehicle component (2) comprising a reinforcement part (1) according to claim 1.

13. Vehicle component (2) according to claim 12, wherein the vehicle component is a tailgate (19), a front end module or a door module.

14. Vehicle (18) comprising a vehicle component (2) according to claim 12.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The present subject matter will be explained hereafter with reference to exemplary embodiments of the reinforcement part according to the present subject matter and with reference to the drawings. Therein:

[0027] FIG. 1 shows a schematic view of a vehicle with a vehicle component comprising a reinforcement part;

[0028] FIGS. 3-5 show a prior art reinforcement part with top apertures;

[0029] FIG. 6 shows a schematic perspective view of an exemplary embodiment of a reinforcement part according to the present subject matter, with bottom apertures;

[0030] FIG. 7 shows a cross-sectional view of the reinforcement part according to FIG. 6;

[0031] FIG. 8 shows a schematic perspective view of an exemplary embodiment of a reinforcement part according to the present subject matter, with side apertures;

[0032] FIG. 9 shows a cross-sectional view of the reinforcement part according to FIG. 8;

[0033] FIG. 10 shows a schematic perspective view of an exemplary embodiment of a reinforcement part according to the present subject matter, with partial side apertures;

[0034] FIG. 11 shows a first comparative example of relative stiffnesses for several aperture configurations of a beam-shaped reinforcement part, for several loading conditions; and

[0035] FIG. 12 shows a second comparative example of relative stiffnesses for several aperture configurations of a beam-shaped reinforcement part, for several loading conditions.

DETAILED DESCRIPTION

[0036] FIGS. 1-11 will be discussed in conjunction. FIG. 1 shows a portion of a vehicle 18 provided with a vehicle component 2 comprising a reinforcement part 1, for instance according to the present subject matter (FIGS. 6-10). The vehicle component 2 could be formed by a tailgate 19 as shown in FIG. 1, but can also be formed by other vehicle components, like doors and side panels (not shown) that are made of thermoplastics with reinforcement ribs. Optimal use of such reinforcement parts 1, for instance near highly loaded areas, reduces vehicle weight significantly. The reinforcement part 1 can for instance be integrated in the vehicle component 2 by injection molding, overmolding, or adhesion by welding or gluing. The reinforcement part 1 may comprise a composite material laminate with a layer of a composite tape having a thermoplastic matrix material with continuous fibers embedded in the matrix material. The matrix material is preferred to be a thermoplastic material, such as a polyolefin.

[0037] The vehicle component may comprise a polybutylene terephthalate (PBT); acrylonitrile-butadiene-styrene (ABS); polycarbonate; polycarbonate/PET blends; polycarbonate/ABS blends; acrylic-styrene-acrylonitrile (ASA); phenylene ether resins; blends of polyphenylene ether/polyamide; blends of polycarbonate/polyethylene terephthalate (PET)/polybutylene terephthalate (PBT); polyamides; phenylene sulfide resins; polyvinyl chloride PVC; (high impact) polystyrene; polyolefins such as polypropylene (PP), expanded polypropylene (EPP) or polyethylene; polysiloxane; polyurethane and thermoplastic olefins (TPO), as well as combinations comprising at least one of the foregoing. The vehicle component may comprise a fiber filled thermoplastic material, in particular from the list above. For example, a fiber-filled polyolefin can be used. The fiber material may include glass fiber, long or short, carbon fiber, aramid fiber, or any plastic fiber. In particular, long glass fiber filled polypropylene may be used. Long fibers are defined as fibers with an initial, e.g. pre-molding, length of greater than or equal to 3 mm. International patent publication WO 2018/100146 A1 discloses further advantageous techniques and materials for fabricating the reinforcement part 1.

[0038] Generally speaking, FIGS. 2-5 show a prior art elongated, beam-like reinforcement part 1, such as a composite or injection-molded reinforcement part 1, for reinforcing a vehicle component 2, comprising a structural wall 3 extending along a longitudinal axis X of the reinforcement part 1. The reinforcement part 1 can be made of Long glass fiber reinforced PP (PP-LGF). The structural wall 3 at least partly encloses walls 4 of a ribbing structure 5 for providing structural strength of the reinforcement part 1, with the walls 4 of the ribbing structure 5 extending in a vertical direction with respect to a first side region 6, e.g. perpendicular to the top side. The structural wall 3 may comprise one or more flanges 20 for attachment purposes.

[0039] The reinforcement part 1, when viewed in cross-section, has the first side region 6 configured for (during its intended use) allowing a first load portion to pass through and a second side region 7 configured for allowing a second load portion to pass through. The first load portion represents the largest load portion occurring at the cross-section (e.g. for the intended loading conditions during use). The ribbing structure 5 is at least provided at the first side region 6 and the second side region 7. The ribbing structure 5 may comprise a cross-ribbing structure 17, wherein the walls 4 of the cross-ribbing structure 17 are arranged at an angle with respect to each other, such as at an angle of larger than 0° and up to 90°, optionally between 20° to 70°, or between 30 to 60°. However, this depends on the specific design of the ribbing structure 5.

[0040] When for instance arranging cabling 11 or wiring 11 through the vehicle component 2, for instance lighting, radio and the like, space needs to be created in the various components where the wiring 11 goes through, e.g. also in the reinforcement part 1.

[0041] As shown in FIGS. 2-5, usually this is done at a first side region 6 at the top, e.g. the visible part, of the reinforcement part 1, that is easy to access. However, making apertures 8 in the top of the walls 4 or reinforcement ribs 4 of the ribbing structure 5 to form a continuous aperture 10 for accommodating cabling or wiring 11 can decrease the effectiveness of such ribbing and reduces the torsional and bending stiffness of the reinforcement part 1.

[0042] As shown in FIGS. 6-10, according to the present subject matter, when viewed along the longitudinal axis X, the walls 4 of the ribbing structure 5 are provided with apertures 8 at the second side region 7, e.g. in a side region 7 with smaller loading than the first side region 6 (e.g. the smallest loading at the respective cross-section). The structural wall 3 at the second side region 7 is shaped to cover and optionally follow the contours 9 of the apertures 8, in such a way, that a continuous aperture 10 is formed in the structural wall 3 for routing cabling 11 (e.g. along the longitudinal axis X). The walls 4 of the ribbing structure 5 at the first side region 6 are free from such apertures 8 or similar features harming the structural integrity of the ribbing structure 5 at the first side region 6, to keep the ribbing structure 5 at the first side region 6 as intact as possible.

[0043] As shown in FIGS. 6-10, the structural wall 3 may have an open (top) side 12, the first side region 6 comprising the open side 12. The structural wall 3 can define a channel 40 having a channel opening 38. The structural wall 3 can have an inner surface 32 and an outer surface 34. A ribbing structure 5 can be disposed in the channel 40 and coupled to the structural wall such that channel is open with the ribbing structure exposed, wherein the ribbing structure is configured to increase a rigidity of the structural wall. A portion of the outer surface 34 of the structural wall 3 can define a curvilinear plane interrupted by a wiring loom channel 36 set into the outer surface, the wiring loom channel 36 formed from material of the structural wall extending across a plurality of ribs of the ribbing structure to form an elongate smooth surface and to define a void sized to receive the wiring loom 11.

[0044] The walls 4 of the ribbing structure 5 at the open side 12 are free from apertures 8 to keep the ribbing structure 5 intact there. The structural wall 3 may have a U-shape (enclosing the ribbing structure 5), comprising a top 15 and legs 16 connected to the top 15, the legs 16 forming sidewalls 14 of the structural wall 3 and the top 15 forming a top wall 13 of the structural wall 3.

[0045] The walls 4 of the ribbing structure 5 at the first side region 6 optionally have a larger thickness than the walls 4 of the ribbing structure 5 at the second side region 7.

[0046] Advantageously, the apertures 8 have a partly circular, oval or elliptical shape, as more clearly shown in FIGS. 7 and 9 to prevent the occurrence of stress concentrations and damage to the cabling 11 due to irregular or rough edges. The width W of the apertures 8 may amount to 10-30 mm, optionally 15-25 mm, or 20 mm. The height H of the apertures may for instance amount to 10-20 mm, or 15 mm. The walls 4 of the ribbing structure 5 may have a thickness of 1-3 mm, or 2 mm. The structural wall 3 may have a thickness of 2-4 mm, or 3 mm. This, however, depends on the specific design of the reinforcement part 1. The apertures can provide a locus for mounting a fastener.

[0047] As shown in FIG. 10 partial apertures have been made in the structural wall 3. Optionally, as illustrated in FIG. 10, such partial apertures comprise (when seen in the longitudinal direction X) aperture portions 21 alternating with solid portions 22. Optionally, the solid portions 22 coincide with the areas where the ribbing structure 5 contacts the structural wall 3 at side regions 7 of the reinforcement part 1. Optionally, the surface area of the aperture portions 21 is 40-60%, such as 50%, of the surface area of the structural wall 3. An aperture can be sized to receive a fastener 42.

COMPARATIVE EXAMPLES

[0048] FIGS. 11 and 12 show comparisons (simulations) of relative stiffnesses for several aperture configurations of an example beam-shaped reinforcement part 1, for several loading conditions.

[0049] In the first comparative example of FIG. 11, the beam has a height of 70 mm and a width of 60 mm.

[0050] In the second comparative example of FIG. 12, the beam has a height of 40 mm and a width of 60 mm.

[0051] The material used for both beams is SABIC® STAMAX™ 40YM240 with a density of 1.22 gram/cm3, a Young's modulus of 3092 MPa and a Poisson ratio of 0.34. These properties were taken from measurements at 85° C. under quasi-static tensile rate. The software used is Abaqus Standard V2016. The simulated material is linear elastic (with the above-mentioned parameters).

[0052] From left to right, respectively, the following loading conditions are shown:

[0053] “Bending simple constrained”;

[0054] “Bending constrained”;

[0055] “Torsion free”; and

[0056] “Torsion constrained”.

[0057] In the “bending simple constrained” loading condition, the beam is simply supported (from below) at opposite end ribs of the beam (DOF 2, 3) and at a center rib, halfway the length of the beam (DOF 1). A downward force of 1000 N is applied at the center rib.

[0058] For sake of completeness, “DOF” stands for “degree of freedom”, as commonly used to describe the state of a physical or mechanical system, with DOF 1, 2 and 3 respectively standing for translations along the X-, Y- and Z-axes and DOF 4, 5, and 6, respectively standing for rotations around the X-, Y- and Z-axes.

[0059] In the “bending constrained” loading condition, the beam is fully fixed at opposite end ribs (DOF 1-6) of the beam, but not at the center rib. Again, a downward force of 1000 N is applied at the center rib.

[0060] In the “torsion free” loading condition, the beam is fixed (DOF 1-6) at one end of the beam. A torque of 10 Nm is applied at the opposite end of the beam (around the longitudinal axis X).

[0061] In the “torsion constrained” loading condition, the beam is again fixed (DOF 1-6) at one end of the beam. Again, a torque of 10 Nm is applied at the opposite end of the beam (around the longitudinal axis X). The opposite end of the beam is now fixed though (DOF 2, 3, 5, 6).

[0062] It should furthermore be noted that for bending loads the displacements of a reference node at the bottom of the reinforcement part, where the load is applied, is shown. For torsional loads the angular rotation of the reference node to which the moment is applied is shown.

[0063] In FIGS. 11 and 12:

[0064] S1 indicates a relative stiffness simulation with top aperture (e.g. the prior art beam);

[0065] S2 indicates a relative simulation with bottom aperture and structural wall aperture, e.g. the aperture of the ribbing structure is left uncovered by the structural wall;

[0066] S3 indicates a relative stiffness simulation with bottom aperture and intact structural wall (e.g. according to the present subject matter);

[0067] S4 indicates a relative stiffness simulation with bottom aperture and partially intact structural wall (e.g. according to the present subject matter), wherein 50% of the structural wall surface area is aperture;

[0068] S5 indicates a relative stiffness simulation with side aperture and structural wall aperture; and

[0069] S6 indicates a relative stiffness simulation with side aperture and intact structural wall (e.g. according to the present subject matter).

[0070] S7 indicates a relative stiffness simulation with side aperture and partially intact structural wall (e.g. according to the present subject matter), wherein 50% of the structural wall surface area is aperture.

[0071] The relative stiffness of the prior art reinforcement part 1 with top apertures is set at 100%, as indicated by S1.

[0072] As can be clearly seen, for virtually all loading conditions the relative stiffnesses S3 and S6 for the beam according to the present subject matter are visibly higher than the relative stiffness of the prior art beam indicated by S1—with the configuration with side apertures (indicated by S6) showing the best performance for all loading conditions.

[0073] Furthermore, it can be seen that the structural wall 3 can optionally be kept fully intact at the second side region 7 (e.g. free from apertures or similar features), otherwise performance may be worse than with the prior art beam (as indicated by relative stiffnesses S2 and S5). Only with certain loading conditions a partial aperture is preferred, or at least a partial aperture with 50% of the structural wall surface area removed (such as with the “torsion free” loading condition as shown in FIG. 12). Optionally, less than 50% of the structural wall surface area is aperture, such as 5-50%, 5-40%, 5-30%, 5-20% or 5-10% of the structural wall surface area. However, according to the simulations discussed above, the inventors submit the loss of stiffness due to having partial apertures does not linearly scale with the removed surface area.