UNDERRIDE PROTECTION DEVICE AND METHOD FOR PRODUCING AN UNDERRIDE PROTECTION DEVICE

Abstract

An underride protection device for a battery-electric vehicle, having a sandwich arrangement with a core layer arranged between an upper cover layer and a lower cover layer made of a fiber-reinforced plastic material. In order to functionally improve the underride protection device, ribs are arranged on the upper cover layer, which are materially connected to the upper cover layer, wherein the ribs arranged on the upper cover layer are surrounded by a respective top layer, which is materially connected to the upper cover layer at two retaining sections.

Claims

1. An underride protection device for a battery-electric vehicle, said underride protection device comprising: a sandwich arrangement including a core layer arranged between (i) an upper cover layer composed of a fiber-reinforced plastic material and (ii) a lower cover layer composed of the fiber-reinforced plastic material, and ribs arranged on and materially connected to the upper cover layer, wherein the ribs are surrounded by a respective top layer, wherein the respective top layer is also materially connected to the upper cover layer at two retaining sections.

2. The underride protection device according to claim 1, wherein the core layer is formed from polyurethane-reinforced glass fibers.

3. The underride protection device according to claim 1, wherein the ribs are foam ribs composed of polyurethane.

4. The underride protection device according to claim 3, wherein the ribs have a density of five hundred kilograms per cubic meter.

5. The underride protection device according to claim 3, wherein, as viewed in cross-section, the ribs each have a trapezoid shape including a base that is materially connected to the upper cover layer.

6. The underride protection device according to claim 1, wherein the upper and lower cover layers are materially connected to the core layer, and the core layer is composed of polyurethane.

7. The underride protection device according to claim 1, wherein the upper and lower cover layers and, optionally, the top layer are formed from an epoxy resin with a volume content of sixty percent glass fibers and quartz sand.

8. The underride protection device according to claim 1, wherein the core layer and the ribs are materially connected to the upper cover layer arranged therebetween as well as to the lower cover layer and the top layer in a double sandwich arrangement.

9. A vehicle comprising the underride protection device of claim 1.

10. In an underride protection device for a battery-electric vehicle, said underride protection device comprising: (a) a sandwich arrangement including a core layer arranged between (i) an upper cover layer composed of a fiber-reinforced plastic material and (ii) a lower cover layer composed of the fiber-reinforced plastic material, and (b) ribs arranged on and materially connected to the upper cover layer, wherein the ribs are surrounded by a respective top layer, wherein the respective top layer is also materially connected to the upper cover layer at two retaining sections, a method for producing the underride protection device comprises: forming the core layer from a polyurethane foam by means of long fiber injection.

11. The method according to claim 10, comprising the following steps: a) depositing a lower fiber layer into a compression mold and soaking the lower fiber layer with a resin to form the lower cover layer; b) injecting the core layer by means of long fiber injection; c) depositing an upper fiber layer on the core layer and soaking the upper fiber layer with a resin to form the upper cover layer; d) applying the ribs to the upper cover layer; e) depositing a top fiber layer on the ribs and the upper cover layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 depicts an underride protection device with a double sandwich arrangement, which is shown schematically in a sectional view.

DETAILED DESCRIPTION OF THE INVENTION

[0018] In FIG. 1, an underride protection device 1, which is also referred to briefly as an underride protection, is shown schematically in a sectional view. The underride protection 1 comprises a simple sandwich arrangement 2 with a core layer 4 arranged between a lower cover layer 3 and an upper cover layer 5. The two cover layers 3 and 5 are planar. This results in the simple sandwich arrangement 2 having the core layer 4 and the two cover layers 3 and 5 having substantially the shape of a cuboid.

[0019] A rib 6 is arranged on the upper cover layer 5. The rib 6 is one of several ribs arranged on the upper cover layer 5. The rib 6 preferably extends in a longitudinal vehicle direction, also referred to as the x direction. However, depending on the design, the rib 6 can also extend in a transverse vehicle direction, also referred to as the y direction.

[0020] When viewed in cross-section, the rib 6 has the design of an isosceles trapezoid with a base, which is materially connected to the upper cover layer 5. A top base side of the trapezoid is planar in form and extends parallel to the two cover layers 3 and 5. The upper base side of the trapezoid and two trapezoid legs angled therefrom are surrounded by a top layer 7.

[0021] The top layer 7 comprises a support section 8 and two side sections 9, 10. With its support section 8 and the side sections 9 and 10, the top layer 7 is materially connected to the rib 6. Retaining sections 11, 12 are angled from the free ends of the side sections 9, 10. The retaining sections 11 and 12 are materially connected to the upper cover layer 5.

[0022] The combination of the simple sandwich arrangement 2 with the ribs 6 surrounded by a respective top layer 7 results in a double sandwich arrangement 14, in which the ribs 6, in the sections in which they are present, represent an additional core layer to the core layer 4 of the simple sandwich arrangement 2.

[0023] The core layer 4, which is also referred to briefly as a core, is made from a polyurethane, which is reinforced by glass fibers cut by means of long fiber injection. This core 4 is fitted with polyurethane foam ribs 6, in particular with a density of five hundred kilograms per cubic meter. The two cover layers 3 and 5 are formed from a glass fiber-reinforced plastic, in particular from an epoxy resin having a volume content of sixty percent glass fibers and quartz sand.

REFERENCE NUMBERS

[0024] 1 Underride protection device [0025] 2 Sandwich arrangement [0026] 3 Lower cover layer [0027] 4 Core layer [0028] 5 Upper cover layer [0029] 6 Rib [0030] 7 Top layer [0031] 8 Support section [0032] 9 Side section [0033] 10 Side section [0034] 11 Retaining section [0035] 12 Retaining section [0036] 14 Double sandwich arrangement