STRUCTURAL COMPONENT HAVING A PLURALITY OF ORGANIC SHEET PIECES, AND METHOD FOR THE PRODUCTION THEREOF

Abstract

A structural component, comprising at least two organo-sheet pieces which at least sectionally lie one on top of the other and which each include a fiber layer, wherein at least in the fiber layers of the organo-sheet pieces at least one pair of mutually aligned holes is formed, at which the organo-sheet pieces are positively connected to each other. There is furthermore proposed a method for manufacturing a structural component.

Claims

1. A structural component comprising: at least two organo-sheet pieces at least partially lying one on top of another and each including a fiber layer, wherein at least two of the fiber layers define a pair of holes, wherein each of the holes are aligned with one another, wherein the at least two organo-sheet pieces are positively connected to each other in a region surrounding or defining the pair of holes.

2. The structural component of claim 1, wherein the positive connection is formed between the at least two fiber layers.

3. The structural component of claim 1, wherein a filling extends through the at least one pair of holes.

4. The structural component of claim 3, wherein at least one of the at least two organo-sheet pieces includes a matrix formed by a first material, and the filling is formed by the first material.

5. The structural component of claim 4, further comprising: a holding part having a first diameter, wherein the filling extends through the pair of holes and is disposed on both sides of overlapping portions of the at least two organo-sheet pieces and is integrally connected to the holding part, wherein each of the holes of the pair of holes defines a second diameter, and wherein the second diameter is less than the first diameter.

6. The structural component of claim 1, wherein each of the at least two fiber layers defines a plurality of holes, wherein the plurality of holes includes the pair of holes, and wherein each of the holes defined by a first fiber layer of the at least two fiber layers are aligned with each of the holes defined by a second fiber layer of the at least two fiber layers.

7. The structural component of claim 1, wherein each of the at least two fiber layers define a plurality of holes, wherein the plurality of holes includes the pair of holes, and wherein each of the holes defined by a first fiber layer of the at least two fiber layers are aligned with each of the holes defined by a second fiber layer of the at least two fiber layers, wherein a reinforcing rib is formed between the pair of holes and another pair holes of the plurality of holes, and wherein the other pair of holes are aligned with one another.

8. The structural component of claim 1, wherein each of the at least two fiber layers define a plurality of holes, wherein the plurality of holes includes the pair of holes, and wherein each of the holes defined by a first fiber layer of the at least two fiber layers are aligned with each of the holes defined by a second fiber layer of the at least two fiber layers, wherein a reinforcing rib is formed on each side of the at least two organo-sheet pieces and is between the pair of holes and another pair holes of the plurality of holes, and wherein the other pair of holes are aligned with one another.

9. A method of manufacturing a structural component, the method comprising: providing a first organo-sheet and a second organo-sheet; arranging the first and second organo-sheets so that at least a portion of the first organ-sheet lies along the second organo-sheet; and forming a through hole through the first and second organo-sheets to form a positive connection between the first and second organo-sheets at a region surrounding or defining the through hole.

10. The method of claim 9, further comprising: heating the first and second organo-sheets, wherein the forming step includes forming the one through hole through heated first and second organo-sheets.

11. The method of claim 9, wherein the forming step includes punching a spike through the first and second organo-sheets.

12. The method of claim 9, further comprising: molding an injection molding material to the first and second organo-sheets and; filling the through hole with the injection molding material.

13. The method of claim of 12, wherein the forming step includes forming another through hole extending through the first and second organo-sheets.

14. The method of claim 13, wherein the molding step includes forming a reinforcing rib formed of the injection-molded material to the first and second organo-sheets, so that the first and second organo-sheets are connected.

15. (canceled)

16. A method of manufacturing a structural component, the method comprising: arranging a first organo-sheet over top of a second organo-sheet; and while the first and second organo-sheets are overlapped, inserting a puncturing member, located under the second organo-sheet, completely through the first and second organo-sheets to create coaxial holes therethrough such that a fiber layer of the second organo-sheet extends through the hole of the first organo-sheet to create a mechanically interlock between the organo-sheets.

17. The method of claim 16, wherein the holes of the first and second organo-sheets cooperate to define a through hole, and wherein the second organo-sheet defines a complete periphery of the through hole.

18. The method of claim 17, further comprising: molding an injection molding material to the first and second organo-sheets; and filling the through hole with the injection molding material.

19. The method of claim 18, further comprising: while the first and second organo-sheets are overlapped, inserting a second puncturing member, located under the second organo-sheet, completely through the first and second organo-sheets to create additional coaxial holes therethrough such that the fiber layer of the second organo-sheet extends through the additional hole of the first organo-layer to create a another mechanically interlock between the organo-sheets, wherein the molding step includes forming a reinforcing rib, formed of the injection-molded material, between the holes and the additional holes.

20. The method of claim 16, wherein the puncturing member includes a spike.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The idea underlying the invention will be explained in detail below with reference to the exemplary embodiments illustrated in the Figures. There are shown in:

[0034] FIGS. 1A to 1C show schematic cross-sectional views of two organo-sheet pieces that are jointly pierced with a spike and are connected to each other;

[0035] FIGS. 2A to 2D show schematic top views of two organo-sheet pieces in various stages of the manufacture of a structural component;

[0036] FIG. 3 shows a perspective view of three organo-sheet pieces for manufacturing a structural component for a vehicle door;

[0037] FIGS. 4A and 4B show top views of two sides of a partly superimposed arrangement of the three organo-sheet pieces of FIG. 3;

[0038] FIGS. 5A and 5B top show views of two sides of a structural component manufactured with the arrangement of FIGS. 4A and 4B;

[0039] FIGS. 5C and 5D show perspective views of two sides of the structural component of FIGS. 5A and 5B; and

[0040] FIGS. 6A and 6B show top views of two sides of a vehicle door inner panel with the structural component of FIGS. 6A and 6B.

DETAILED DESCRIPTION

[0041] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

[0042] From DE 10 2013 213 711 A1 it is known to manufacture a structural component from an organo-sheet. Here, an organo-sheet piece is subjected to a hot forming process for manufacturing the structural component.

[0043] To the applicant it is internally known from practice to manufacture structural components from several organo-sheet pieces. To ensure that the individual organo-sheet pieces are securely fastened to each other in the finished structural component, the organo-sheet pieces are usually placed one beside the other with a relatively large overlap and hot pressed. In order to ensure that the organo-sheet pieces securely adhere to each other, it is necessary to provide comparatively large overlap areas. However, such large overlap areas are often not necessary for the stability of the structural component. However, since the manufacture of organo-sheet is very expensive, its efficient use on the structural component is desirable. It has also been found that the hot pressing of the organo-sheets must take place within a relatively small optimum temperature window. Thus, the exact monitoring of the temperature can make the manufacturing method comparatively expensive.

[0044] FIG. 1A shows two organo-sheet pieces 10A and 10B, which in the area shown in FIG. 1A lie one on top of the other, here in flat abutment. The organo-sheet pieces 10A, 10B each include a fiber layer 100 in the form of a fiber mat, e.g. as a scrim or knitted fabric. The fiber layer 100 each is embedded in a matrix 102 of a thermoplastic material. The organo-sheet pieces 10A, 10B in particular are each made of a thermoplastic woven or laid glass fiber fabric.

[0045] FIG. 1A furthermore shows a spike 2 with a tip 20 adjacent to the organo-sheet pieces 10A, 10B. For example, the organo-sheet pieces 10A, 10B are clamped into a tool, e.g. an injection molding tool. The spike 2 can be mounted, e.g. shiftably mounted, on the injection molding tool. The spike 2 for example has a diameter of 3 to 4 mm.

[0046] FIG. 1B shows the organo-sheet pieces 10A, 10B of FIG. 1A after the spike 2 has been shifted perpendicularly to the surface of the organo-sheet pieces 10A, 10B and thus has pierced holes 101 (with the diameter of the spike 2) into the organo-sheet pieces 10A, 10B. By means of the spike, the organo-sheet pieces 10A, 10B thus are (in particular jointly) pierced or punched.

[0047] The holes 101 of the two organo-sheet pieces 10A, 10B are aligned coaxially relative to each other. The holes 101 are in register with each other, hence are arranged in alignment with each other. The holes jointly form a through hole DL through both organo-sheet pieces 10A, 10B.

[0048] The piercing of the organo-sheet pieces 10A, 10B in particular can be performed after heating the organo-sheet pieces 10A, 10B. In the region of the holes 101, fibers of the fiber layers 100 of the organo-sheet pieces 10A, 10B have been pushed aside by the tip 20 of the spike 2. Due to the (joint) piercing of the holes 101, the organo-sheet pieces 10A, 10B enclose each other in the region of the holes 101. Between the (needled) organo-sheet pieces 10A, 10B a form fit exists, by which the organo-sheet pieces 10A, 10B are fastened to each other.

[0049] The organo-sheet pieces 10A, 10B fastened to each other form a structural component 1. The structural component 1 for example is a trim part or a body part of a motor vehicle.

[0050] After piercing the organo-sheet pieces 10A, 10B by way of the spike 2, the spike 2 is again withdrawn from the through hole DL. Thereupon, a filling is introduced into the through hole DL, e.g. injected by way of injection molding.

[0051] The through hole DL serves as a flow channel for injection molding material.

[0052] FIG. 1C shows the organo-sheet pieces 10A, 10B after introducing the filling 11 into the through hole DL, i.e. into both holes 101 of the organo-sheet pieces 10A, 10B. The filling 11 secures the organo-sheet pieces 10A, 10B in the form-fitting position in the region of the holes 101.

[0053] Furthermore, it is not only the interior of the through hole DL that is filled up with the filling 11. In addition, the material of the filling 11 is expanded beyond the edges of the holes 101 on both sides of the organo-sheet pieces 10A, 10B resting against each other. On both sides of the organo-sheet pieces 10A, 10B a holding part 13 is formed thereby, which provides a particularly secure positive connection of the organo-sheet pieces 10A, 10B at the through hole DL.

[0054] FIG. 1C furthermore schematically shows an (open) injection molding tool 4 for overmolding the injection molding material and optionally for shaping the organo-sheet pieces 10A, 10B, on which the spike 2 is shiftably mounted.

[0055] With reference to FIGS. 2A to 2D, the method for manufacturing a repeatedly needled structural component 1 will now be explained in detail.

[0056] In a first step, the two organo-sheet pieces 10A, 10B (also referred to as organo-patches) are provided, see FIG. 2A, which can include (e.g. cutting or punching) out of a larger organo-sheet plate. Both organo-sheet pieces 10A, 10B each are flat and even, and it is also possible to connect uneven organo-sheet pieces in the way described here. In one embodiment, the steps of punching, shaping and injection molding are carried out in the same tool.

[0057] In a further step, the organo-sheet pieces 10A, 10B are arranged such that they sectionally lie one on top of the other, see FIG. 2B. In the present case, the organo-sheet pieces 10A, 10B lie one on top of the other in an overlap area UB, concretely in flat abutment. Arranging the organo-sheet pieces 10A, 10B sectionally one on top of the other can be effected in particular by placing the organo-sheet pieces 10A, 10B in the tool, e.g. in the injection molding tool.

[0058] In a further step, a plurality of through holes DL is incorporated through both organo-sheet pieces 10A, 10B, see FIG. 2C. Incorporating each of the through holes DL can be effected as explained in detail in connection with FIGS. 1A and 1B for an individual through hole DL.

[0059] On the one hand, it is possible to incorporate several or all of the through holes DL (one after the other) by way of the same spike 2. On the other hand, a separate spike 2 can also be provided for each through hole DL to be made, so that all through holes DL can be made at the same time.

[0060] In the example of FIG. 2C a raster, more exactly a matrix, of several rows and columns of through holes DL is incorporated into the organo-sheet pieces 10A, 10B.

[0061] By punching or needling the organo-sheet pieces 10A, 10B, the same already are fastened to each other and jointly form the structural component 1.

[0062] In a next step, ribbings, namely stiffening ribs 11, are injected through the needled through holes DL, concretely by injection molding by means of the injection molding tool, see FIG. 2D.

[0063] An injection molding material for example a long glass fiber-reinforced material, in particular a long glass fiber-reinforced injection molding material can be used.

[0064] The stiffening ribs 11 as shown in FIG. 2D serve as holding parts (like the holding parts 13 of FIG. 1C). In addition, the stiffening ribs 11 stiffen the structural component 1, e.g. against torsions.

[0065] In the example of FIG. 2D, each through hole DL is connected to at least two adjacent through holes DL by way of the stiffening ribs 11. In the present case, a group of mutually parallel stiffening ribs 11 extend across several through holes DL. Another group of mutually parallel stiffening ribs 11 extends perpendicularly to the first-mentioned group of stiffening ribs 11.

[0066] By injecting through the through holes DL, a particularly good stability is provided to the injection-molded stiffening ribs 11.

[0067] Optionally, stiffening ribs 11 can be formed (injection-molded) on both sides of the organo-sheet pieces 10A, 10B connected to each other, which can further increase the stability of the structural component 1.

[0068] The injection molding of the organo-sheet pieces 10A, 10B through the needled through holes DL can also be referred to as injection sewing. It has a similar effect as sewing, e.g. by means of a thread. The injection molding material injected through the through holes DL uniformly extends through the through holes DL and, due to the stiffening ribs 11, across several through holes DL. There is achieved a particularly secure connection of the two organo-sheet pieces 10A, 10B.

[0069] Because the organo-sheet pieces 10A, 10B are fastened to each other securely, the overlap area UB can be comparatively small. This reduces the amount of organo-sheet needed to form the secure connection. In addition, this provides for an improved, needs-oriented adaptation of the stability of the structural component 1 with the lowest possible weight.

[0070] Optionally, the organo-sheet pieces 10A, 10B (e.g. at the same time as injection sewing) are hot-pressed (in particular in a molten state) in order to achieve an even further improved fastening of the organo-sheet pieces 10A, 10B to each other.

[0071] FIGS. 1A to 2D each have shown the connection of two organo-sheet pieces 10A, 10B. Of course, however, it is also possible to connect more than two organo-sheet pieces 10A, 10B to each other in the described way. It is also possible to make through holes through more than two layers of superimposed organo-sheet pieces, e.g. through three or more superimposed organo-sheet pieces.

[0072] FIG. 3 shows another exemplary embodiment of a plurality of organo-sheet pieces, here three organo-sheet pieces 10C-10E.

[0073] The organo-sheet pieces 10C-10E of FIG. 3 are pre-shaped already, i.e. each manufactured from an even organo-sheet piece by reshaping (in particular thermoforming).

[0074] The organo-sheet pieces 10C-10E are configured to jointly form a structural component 1 in the form of a part of a door inner panel of a motor vehicle. The organo-sheet pieces 10C-10E have properties different from each other. The individual organo-sheet pieces 10C-10E here are adapted to the requirements of the structural component 1 of that area which is formed by the respective organo-sheet piece 10C-10E.

[0075] In the finished structural component 1, a first organo-sheet piece 10C forms a flat portion, e.g. a part of an assembly carrier, and is made of a (thin) organo-sheet, here with a thickness of 0.6 mm for example. A second organo-sheet piece 10D in the finished structural component 1 forms part of a horizontal carrier of the door inner panel. The second organo-sheet piece 10D is manufactured from an organo-sheet of medium thickness, here with a thickness of 1.0 mm for example. A third organo-sheet piece 10E in the finished structural component 1 forms part of a holm of the door inner panel. The holm must withstand particularly strong loads. Therefore, the first organo-sheet piece 10C is manufactured from a thick organo-sheet, in the present example with a thickness of 1.5 mm for example.

[0076] FIGS. 4A and 4B show the organo-sheet pieces 10C-10E in a state in which they are arranged one on top of the other. The first organo-sheet piece 10C and the (smaller) second organo-sheet piece 10D overlap the entire surface of the second organo-sheet piece 10D. The second organo-sheet piece 10D thus reinforces the first organo-sheet piece 10C. The first organo-sheet piece 10C and the (smaller) third organo-sheet piece 10E partly overlap. The second and the third organo-sheet piece 10D, 10E do not overlap.

[0077] FIGS. 5A to 5D show the finished structural component 1. The three organo-sheet pieces 10C-10E are fastened to each other by injection sewing. A plurality of through holes DL connects the first to the second organo-sheet piece 10C, 10D and the first to the third organo-sheet piece 10C, 10E.

[0078] A network of stiffening ribs 11 is formed on both sides of the structural component 1.

[0079] The edges of the organo-sheet pieces 10C-10E are overmolded with injection molding material. The fiber layers of the organo-sheet pieces 10C-10E can be protected thereby. Optional lugs or other connecting elements are injection-molded to the structural component 1. All injection-molded portions can be formed without undercuts, which provides for an easy manufacture.

[0080] Furthermore, there are formed flatly overmolded areas 14, namely in the present example on a portion of the structural component 1 visible to the outside, here on the holm. Another flatly overmolded area is provided in the form (of at least a part) of a guide rail for a window lifter. In particular surfaces visible to the outside can be provided with a surface structure, e.g. with a grain, by a corresponding injection molding method.

[0081] FIGS. 6A and 6B show a door inner panel 3 for a vehicle door, wherein the structural component 1 of FIGS. 5A-5D forms a part of the door inner panel 3. The structural component provides a structuring function (and in the illustrated example also a supporting function).

[0082] In the example shown in FIGS. 6A and 6B, the structural component 1 is connected, e.g. screwed, to a metal sheet which forms the remaining door inner panel 3. Alternatively, the remaining parts of the door inner panel 3 also are manufactured in the form of a structural assembly as described herein.

[0083] The illustrated configuration of the structural assembly 1 as shown in FIGS. 5A-5D only is an example. For example, the structural assembly might form the entire door inner panel. For this purpose, a plurality of organo-sheet pieces can be connected to each other by injection sewing.

[0084] The following is a list of reference numbers shown in the Figures. However, it should be understood that the use of these terms is for illustrative purposes only with respect to one embodiment. And, use of reference numbers correlating a certain term that is both illustrated in the Figures and present in the claims is not intended to limit the claims to only cover the illustrated embodiment.

List of Reference Numerals

[0085] 1, 1, 1 structural component [0086] 10A-10E organo-sheet piece [0087] 100 fiber layer [0088] 101 hole [0089] 102 matrix [0090] 11 filling [0091] 12 reinforcing rib [0092] 13 holding part [0093] 14 flatly overmolded area [0094] 2 spike [0095] 3 door inner panel [0096] 4 injection molding tool [0097] 20 tip [0098] DL through hole [0099] UB overlap area

[0100] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.