METHOD FOR MANUFACTURING AN ELEMENT FOR A BODYWORK COMPONENT COMPRISING IMPROVED DEICING MEANS

Abstract

A method for manufacturing an element for a bodywork component is provided. The method, characterized in that a rough form made of plastic and comprising at least one housing on a first face is manufactured, a connection member comprising a first end accessible from the side of the first face of the rough form and a second end accessible from the side of a second face of the rough form is pre-positioned with respect to the rough form, a heating track is positioned on the first face of the rough form, a connection part of the track is affixed to the first end of the connection member, the first end of the connection member and the connection part of the track are squeezed together and welded by the input of electrical energy, the first end of the connection member is positioned in the housing, and an additional layer of plastic is over molded.

Claims

1. Method for manufacturing an element for a bodywork component, characterized in that: a rough form made of plastic and comprising at least one housing on a first face of the rough form, said housing comprising at least one orifice extending between a bottom of the housing and a second face of the rough form opposite the first face is manufactured, an electrically conductive connection member comprising a first end accessible from the side of the first face of the rough form and a second end extending through the orifice in the rough form so as to be accessible from the side of the second face of the rough form is pre-positioned with respect to the rough form, an electrically conductive heating track is positioned on the first face of the rough form, the heating track comprising a connection part which is free with respect to this first face, the connection part of the track is affixed to the first end of the connection member, the first end of the connection member and the connection part of the track are squeezed together, the first end of the connection member and the connection part of the track are welded together by the input of electrical energy, the first end of the connection member is positioned in the housing, an additional layer of plastic is overmolded on the first face of the rough form so as to cover the heating track, the first end of the connection member, the housing and the orifice in the rough form.

2. Method for manufacturing an element for a bodywork component according to claim 1, wherein the connection part of the track is affixed to the first end of the connection member by forming at least one coil of the connection part of the track around the first end of the connection member.

3. Method for manufacturing an element for a bodywork component according to claim 1, wherein the welding energy is supplied via a tool squeezing the first end of the connection member with the connection part of the track, this tool preferably being used in the squeezing step.

4. Method for manufacturing an element for a bodywork component according to claim 1, wherein the first end of the electrical connection member is formed by a tab bent in a hook shape comprising a web connecting a first free branch and a second branch intended to be in contact with the bottom of the housing, and wherein the second end of the connection member is formed by an extension of the second leg, bent with respect to the second leg.

5. Method for manufacturing an element for a bodywork component according to claim 1, wherein the additional layer of plastic completely covers the heating track.

6. Method for manufacturing an element for a bodywork component according to claim 1, wherein the heating track is positioned on the plastic rough form in an arrangement compatible with the passage of electromagnetic waves through the plastic element, these waves being intended to be emitted by a sensor intended to be mounted perpendicularly to the element.

7. Method for manufacturing an element for a bodywork component according to claim 1, wherein the heating track further comprises a serpentine deicing portion.

8. Method for manufacturing an element for a bodywork component according to claim 1, wherein, prior to the welding step, a layer of insulation covering the heating track is locally destroyed by inputting electrical energy via a tool squeezing the first end of the connection member with the connection part of the track, preferably used in the squeezing step.

9. Method for manufacturing an element for a bodywork component according to claim 1, wherein the heating track is fixed on the first face of the rough form by welding by heating the track to a temperature allowing local melting of the plastic of the rough form.

10. Method for manufacturing an element for a bodywork component according to claim 1, wherein the connection member is held in position in the housing with the aid of complementary snap-in means carried on the second end of the connection member and the second face of the rough form, for example by means of a snap-in tab carried by the second end and cooperating with the second face of the rough form.

11. Element for a bodywork component, characterized in that it comprises: a rough form made of plastic and comprising at least one housing on a first face of the rough form, said housing comprising at least one orifice extending between a bottom of the housing and a second face of the rough form opposite the first face, an electrically conductive heating track positioned on the first face of the rough form, the heating track comprising a connection part, an electrically conductive connection member comprising a first end positioned in the housing of the rough form and a second end extending through the orifice in the rough form so as to be accessible from the side of the second face of the rough form, the connection part of the heating track being affixed to the first end of the connection member, the first end and the connection part of the track being squeezed and welded together, an additional layer of plastic, overmolded on the first face of the rough form, covering the heating track, the first end of the connection member, the housing and the orifice of the rough form.

12. Element for a bodywork component according to claim 11, wherein the connection part of the heating track is affixed to the first end of the connection member, forming at least one coil of the connection part of the heating track around the first end of the connection member.

13. Element for a bodywork component according to claim 11, wherein the first end of the electrical connection member is formed by a tab bent in a hook shape comprising a web connecting a first free branch and a second branch intended to be in contact with the bottom of the housing, and wherein the second end of the connection member is formed by an extension of the second leg, bent with respect to the second leg.

14. Element for a bodywork component according claim 11, wherein the connection member is held in position in the housing by means of complementary snap-in means carried on the second end of the connection member and the second face of the rough form, for example by means of a snap-in tab carried by the second end and cooperating with the second face of the rough form.

15. Element for a bodywork component according to claim 11, wherein the heating track is positioned on the plastic rough form in an arrangement compatible with the passage of electromagnetic waves through the plastic element, which waves are to be emitted from a sensor to be perpendicularly mounted on the element.

16. Element for a bodywork component according to claim 11, wherein the heating track further comprises a serpentine deicing portion.

17. Element for a bodywork component according to claim 11, wherein the heating track comprises an electrically conductive material selected from copper, tungsten or an alloy comprising copper or tungsten.

18. Element for a bodywork component according claim 11, wherein the heating track is covered with an insulating layer.

19. Element for a bodywork component according to claim 18, wherein the insulation is selected from enamel or insulating paint.

20. Element for a bodywork component according to claim 11, wherein the heating track is fixed on the first face of the rough form by local melting of the plastic of the rough form.

Description

[0061] The invention will be better understood by reading the following description given by way of example and made with reference to the drawings, in which:

[0062] FIG. 1 is a schematic cross-sectional view along the plane I-I of FIGS. 2 and 3, showing a part of an element for a bodywork component according to the invention, this Figure showing a connection member in a housing on a first face of a rough form;

[0063] FIG. 2 is a schematic perspective view showing a part of the element for a bodywork component during a step of the manufacturing method according to the invention, this Figure showing the connection member pre-positioned with respect to the rough form, around which two coils of a connection part of a heating track are formed;

[0064] FIG. 3 is a schematic perspective view showing the element for a bodywork component during a manufacturing step according to the invention, this Figure showing a rough form on which a heating track is positioned;

[0065] FIG. 4 is a schematic sectional view along the plane I-I of FIGS. 2 and 3, showing a part of an element for a bodywork component according to the invention, this Figure showing the placement of a squeezing tool prior to the step of squeezing the first end of the connection member and the turns of the connection part of the track between them;

[0066] FIG. 5 is a schematic cross-sectional view along the plane I-I of FIGS. 2 and 3, showing a part of an element for a bodywork component according to the invention, this Figure showing the removal of the squeezing tool after the step of squeezing the first end of the connection member and the turns of the connection part of the track between them.

[0067] FIG. 1 shows part of a component 10 that is intended to be connected to a bodywork component of a motor vehicle, such as a tailgate, door side, front or rear bumper, or roof, to protect and conceal a sensor C on the vehicle. Specifically, the element 10 has a radome function for the sensor C.

[0068] The element 10 for a bodywork component comprises a plastic rough form 11, a heating track 12, an additional plastic layer 13 and an electrically conductive connection member 14.

[0069] The plastic rough form 11 has at least one housing 15. The housing 15 is located on a first face 16 of the rough form 11.

[0070] The housing 15 comprises an orifice 17 that extends between a bottom 18 of the housing 15 and a second face 19 of the rough form 11 opposite the first face 16.

[0071] In the example described, the rough form 11 has two housings 15, as shown in FIG. 3, each with an orifice 17.

[0072] Referring to FIGS. 2 and 3, it can be seen that the heating track 12 is positioned and fixed by local melting of the plastic on the first face 16 of the rough form 11, that is to say a melting at the periphery of the heating track 12 which is deposited on the first face 16 of the rough form 11. This track 12 comprises, for each housing 15, a part referred to as a connection part 20c, extending at the level of the housing 15 of the rough form 11. The track 12 also comprises a serpentine deicing portion 20s intended to be placed on the area of the element 10 which serves as a radome. The serpentine deicing portion 20s of the heating track 12 is positioned on the rough form 11 in an arrangement compatible with the passage of electromagnetic waves through the plastic element 10. These waves are intended to be emitted by the sensor C to be mounted on the element 10. In the example described, the serpentine deicing portion 20s of the heating track 12 follows a boustrophedon path.

[0073] The heating track 12 comprises an electrically conductive material. In the example described, the heating track 12 comprises copper covered with an insulating enamel layer. It should be noted that the heating track 12 can, for example, comprise tungsten or an alloy based on copper or tungsten. In addition, the insulating layer may, for example, comprise an insulating paint instead of enamel. When a current flows through the heating track 12, it releases calories by the Joule effect. Lastly, in the example described, the heating track 12 has a diameter between 300 and 500 μm.

[0074] As can be seen in FIG. 1, the electrically conductive connection member 14 has a first end 21 positioned in the housing 15 of the rough form 11. The connection member 14 also has a second end 22 extending through the orifice 17 in the rough form 11 and intended to be connected to a standard connector S. The second end 22 of the connection member 14 is thus accessible from the side of the second face 19 of the rough form 11. In addition, the connection part 20c of the track 12 is affixed to the first end 21 of the connection member 14 by forming at least one coil around the first end 21 of the connection member 14. The first end 21 of the connection member 14 and the coil of connection part 20c are squeezed and welded together. In the described example, the connection part 20c of the track 12 forms two turns around the first end 21 of the connection member 14. The insulating enamel layer of the heating track 12 is locally destroyed at a contact area between the first end 21 of the connection member 14 and the connection part 20c of the heating track 12.

[0075] In the example described, the first end 21 of the electrical connection element 14 is formed by a tab bent in a hook shape comprising a web 23 connecting a first free branch 24 and a second branch 25 intended to be in contact with the bottom 18 of the housing 15. The second end 22 of the connection member 14 is formed by an extension 26 of the second branch 25, bent with respect to the second branch 25, for example at right angles. In addition, the connection member 14 comprises a silver-copper alloy.

[0076] The connection member 14 may also comprise a snap-in tab 27 carried by the second end 22 of the connection member 14 so as to be held in position in the housing 15. This snap-in tab 27 cooperates with the second face 19 of the rough form 11.

[0077] Lastly, the additional plastic layer 13 overmolds the first face 16 of the rough form 11. Thus, in the example described, the additional layer 13 covers the heating track 12, the first end 21 of the connection member 14, the housing 15 and the orifice 17 in the rough form 11.

[0078] A method according to the invention for manufacturing the element 10 for a bodywork component will be described below.

[0079] First of all, the rough form 11 made of plastic is manufactured. In the example described, the rough form 11 comprises two housings 15, each with an orifice 17.

[0080] Then, as shown in FIGS. 2, 4 and 5, the electrically conductive connection member 14 is pre-positioned with respect to the rough form 11. The first end 21 of the connection member 14 is accessible from the side of the first face 16 of the rough form 11. The second end 22 of the connection member 14 extends through the orifice 17 in the rough form 11 so as to be accessible from the side of the second face 19 of the rough form 11. The second end can thus be connected, directly or not, to a standard connector S.

[0081] The electrically conductive heating track 12 is then positioned on the first face 16 of the rough form 11, for example with the aid of a sonotrode. The heating track 12 comprises a connection part 20c at the housing 15 of the rough form 11, which connection part is free with respect to the first face 16 of the rough form 11 so as to facilitate its connection to the connection member 14. As shown in FIG. 3, the serpentine deicing portion 20s of the heating track 12 is positioned on the rough form 11 following a boustrophedon path.

[0082] In the example described, the heating track 12 is welded to the first face 16 of the rough form 11 by heating the heating track 12, for example by generating an electric current or ultrasound in the heating track 12, to a temperature that allows local melting of the plastic of the rough form 11.

[0083] Subsequently, the connection part 20c of the track 12 is affixed to the first end 21 of the connection member 14 by forming at least one coil of the connection part 20c of the track 12 around the first end 21 of the connection member 14. In the example described, as shown in FIG. 2, two coils of the connection part 20c of the track 12 are formed around the web 23 of the first end 21 of the connection member 14. Thus, a large contact area is formed between the connection member 14 and the heating track 12.

[0084] Referring to FIGS. 4 and 5, the first end 21 of the connection part 14 and the two coils of the connection part 20c of the heating track 12 are then squeezed together using a squeezing tool 28. In the example described, the squeezing tool 28 comprises an anvil 28a and a squeezing member 28b, which carries electrical energy.

[0085] Then, the insulating enamel layer covering the heating track 12 is locally destroyed. In the example described, the insulating enamel layer is destroyed by inputting electrical energy via a tool that squeezes the first end 21 of the connection member 14 with the connection part 20c of the track 12. The combination of the effect of the energy input and the mechanical effect of the squeezing effectively destroys the insulation layer. It should be noted that the amount of energy input is related to the thickness and nature of the insulation and that preferably the squeezing tool 28 used during the squeezing step is used.

[0086] Next, the first end 21 of the connection member 14 and the two coils of the connection part 20c of the track 12 are welded together, for example by the input of electrical energy. In the example described, the welding energy is applied via a tool squeezing the first end 21 of the connection member 14 with the connection part 20c of the track 12. It should be noted that the intensity of the electric current or ultrasound depends on the material forming the heating track 12 and may be different from the intensity used to destroy the insulation layer. It should also be noted that the squeezing tool 28 used during the squeezing step is preferably used. The same tool can thus be used to squeeze together the first end 21 of the connection member 14 and the two coils of the connection part 20c of the heating track 12 and to destroy the enamel layer and to weld the first end 21 of the connection member 14 to the connection part 20c of the track 12. In addition, a large contact surface is formed between the connection member 14 and the heating track 12, thus ensuring a robust and quality electrical connection.

[0087] It should be noted that the pre-positioning of the connection member 14 with respect to the rough form allows free access to the first end 21 of the connection member 14 for squeezing and welding means.

[0088] The first end 21 of the connection member 14 is then positioned in the housing 15. It should be noted that, as shown in FIG. 1, the connection member 14 can be held in the housing 15 with the aid of the snap-in tab 27 carried by the second end 22 of the connection member 14 and cooperating with the second face 19 of the rough form 11.

[0089] Lastly, the additional layer 13 of plastic is overmolded on the first face 16 of the rough form 11 so as to cover the heating track 12, the first end 21 of the connection member 14, the housing 15 and the orifice 17 of the rough form 11. It should be noted that, in the example described, the additional layer 13 of plastic completely covers the heating track 12 in order to provide good protection against shocks and corrosion of the track 12 and good sealing of the assembly 10. In addition, the additional layer 13, by filling the orifice 17, improves the resistance of the connection between the connection member 14 and the heating track 12 to the vibrations of the vehicle on which the element for a bodywork component is mounted during use.

[0090] The invention is not limited to the embodiment presented, and other embodiments will clearly be apparent to a person skilled in the art. In particular, the first end 21 of the connection member 14 may have teeth and the attachment may be achieved by winding or engaging the connection part 20c of the heating track 12 around teeth formed by the first end 21 of the connection member 14. In addition, the connection member 14 can be held in position in the housing 15 by means of complementary snap-in means carried on the second end 22 of the connection member 14 and the second face 19 of the rough form 11, for example the snap-in tab 27 can be carried on the second face 19 of the rough form 11 or on a wall of the orifice 17.