Vehicle Body Part and Method for Producing a Vehicle Body Part

Abstract

The present disclosure relates to a vehicle body part of a motor vehicle having at least one frame component and at least one trim part which is arranged thereon, wherein the trim part has at least one cutout which is closed off in an essentially airtight and watertight fashion and has at least one solar cell which is arranged therein and has the purpose of generating electrical energy, and wherein the outer side of the trim part has, at least in a region adjacent to the at least one solar cell, an outer shape which is curved three-dimensionally and which is provided for forming a part of the external contour of the motor vehicle in the installed position on said motor vehicle. Furthermore, the present disclosure relates to a method for producing a vehicle body part.

Claims

1. Vehicle body part of a motor vehicle with at least one frame component and at least one trim part arranged thereon, wherein: the trim part has at least one cutout, closed in an essentially airtight and in a substantially watertight fashion, with at least one solar cell arranged in the same for generating electrical energy; and the outer side of the trim part has a three-dimensionally curved outer shape at least in an area adjacent to the at least one solar cell, which is provided in such a way that it forms part of an outer vehicle contour in its installed position on the motor vehicle.

2. The vehicle body part according to claim 1, wherein the trim part comprises a plurality of substantially planar solar cells, which are electrically connected with each other.

3. The vehicle body part according to claim 1, wherein the outer side of the trim part follows on from an outer side of the frame component substantially flush.

4. The vehicle body part according to claim 1, wherein the trim part comprises a support element curved according to the curved external contour at least in some areas, in or on which the at least one solar cell is arranged.

5. The vehicle body part according to claim 4, wherein the support element is formed of at least two discs, wherein an outer one of the discs forms the outer side of the trim part and an inner one of the discs an inside facing away from the outer side, wherein the cutout is formed between the two discs.

6. The vehicle body part according to claim 4, wherein a gap between the at least one solar cell and respective walls of the trim part delimiting the associated cutout is filled with a silicone gel.

7. The vehicle body part according to claim 4, wherein the cutout is delimited by two films arranged on the support element, in particular thermoplastic polyurethane films, which are connected with each other for sealing the cutout.

8. The vehicle body part according to claim 1, wherein the frame component has a receiving area with a step, wherein the trim part is arranged in the receiving area.

9. The vehicle body part according to claim 8, wherein the step of the frame component is substantially Z-shaped, wherein an upper leg of the Z-shaped step forms the outer side of the frame component, which follows on from the trim part substantially flush, and wherein a lower leg of the step forms a support surface for the trim part.

10. A method for producing a vehicle body part of a motor vehicle, comprising the steps of: providing a trim part blank; deforming the trim part blank; generating at least one essentially airtight and substantially watertight closeable cutout, in which at least one solar cell is arranged, by means of which electrical energy may be generated from the finished vehicle body part; closing the at least one cutout of the trim part blank with the at least one solar cell arranged in or on the same for forming a finished trim part; providing a frame component with a receiving area for the trim part; arranging the trim part in the receiving area of the frame component; and wherein an outer side of the trim part has a three-dimensionally curved outer shape at least in an area adjacent to the at least one solar cell which is designed in such a way that it forms part of an outer vehicle contour in its installed position on the motor vehicle.

11. The method according to claim 10, further comprising the steps of: arranging a plurality of substantially planar solar cells on the trim part blank by means of a matrix; and electrically connecting the plurality of solar cells.

12. The method according to claim 10, wherein a gap between the at least one solar cell and respective walls of the trim part delimiting the associated cutout is filled with a silicone gel, wherein a filler opening for the silicone gel preferably lies at a lower end defined by gravity during filling, and a ventilation opening lies at an upper end defined by gravity.

13. The method according to claim 10, further comprises the steps of arranging of at least one plastic film on the trim part blank for closing the cutout, and wherein the plastic film is sealed for closing the cutout.

14. The method according to claim 10, wherein the trim part blank has two discs, between which the at least one solar cell is arranged, and wherein the discs are deformed.

15. The method according to claim 14, further comprising the steps of: arranging a first plastic film on a first side of a first disc of the two discs; arranging the at least one solar cell on the first plastic film; arranging a second plastic film on at least one of the at least one solar cell and the first plastic film; arranging the second disc on the second plastic film (48) and arranging the second plastic film on the second disc; connecting the first plastic film with the second plastic film at least in one part area for closing the at least one cutout.

16. The method according to claim 11, wherein the step of electrically connecting the plurality of solar cells further comprises the step of soldering the plurality of solar cells.

17. The method according to claim 13, wherein the at least one plastic film is a TPU film and wherein the plastic film is sealed for closing the cutout with at least one of underpressure, overpressure and heating.

18. The method according to claim 14, further comprising the steps of: arranging a first plastic film on a first side of a first disc of the two discs; arranging the at least one solar cell on the first plastic film; arranging a second plastic film on at least one of the at least one solar cell and the first plastic film; arranging the second disc on the second plastic film or arranging the second plastic film on the second disc; connecting the first plastic with the second plastic film, at least in one part area for closing the at least one cutout, in particular through autoclaving.

19. The method according to claim 18 wherein the first plastic film is connected with the second plastic film through autoclaving.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0068] The above and other aspects of the present disclosure will become more apparent by describing exemplary embodiments in detail below with reference to the accompanying drawings, wherein:

[0069] FIG. 1 shows a motor vehicle with several vehicle body parts in a side view;

[0070] FIG. 2 shows the motor vehicle according to FIG. 1 in a top view;

[0071] FIG. 3 shows a vehicle body part of the motor vehicle according to FIG. 1 in a side top view;

[0072] FIG. 4 shows a vehicle body part according to FIG. 3 in a section view;

[0073] FIG. 5 shows the vehicle body part according to FIG. 3 in a perspective view;

[0074] FIG. 6 schematically illustrates a part of a production process of the vehicle body part according to FIG. 3;

[0075] FIG. 7 illustrates a construction of the vehicle body part according to FIG. 3 in a schematic section view;

[0076] FIG. 8 schematically shows the connection between a frame component and a trim part of the vehicle body part according to FIG. 3 arranged thereon;

[0077] FIG. 9 illustrates a further part of a production process of the vehicle body part according to FIG. 3 in a schematic section view.

DETAILED DESCRIPTION

[0078] As used throughout the present disclosure, unless specifically stated otherwise, the term or encompasses all possible combinations, except where infeasible. For example, the expression A or B shall mean A alone, B alone, or A and B together. It is stated that a component includes A, B, or C, then, unless specifically stated otherwise or infeasible, the component may include A, or B, or C, or A and B, or A and C, or B and C, or A and B and C. Expressions such as at least one of do not necessarily modify an entity of a following list and do not necessarily modify each member of the list, such that at least one of A, B, and C should be understood as including only one of A, only one of B, only one of C, or an

[0079] An exemplary arrangement is set out in FIG. 1 which shows a motor vehicle 10 in a side view, which has several vehicle body parts 12. Vehicle body parts according to the present disclosure may for example be one or more doors, a bonnet, a roof, a tailgate, a bumper (front and/or rear) and/or one or more fenders (front and/or rear). Individual random sub-combinations or even all of these vehicle body parts may be designed as vehicle body parts according to the present disclosure. A multitude of solar cells 14 each is arranged in these vehicle body parts 12, which may convert incoming sunlight radiation into electrical energy. A respective outer side of the vehicle body part 12 is designed transparently at least in some areas for this purpose, so that respective sunbeams may reach the solar cells 14 and excite these to generate energy.

[0080] FIG. 2 shows the motor vehicle 10 according to FIG. 1 in a top view, wherein respective vehicle body parts 12 are also recognizable on the roof and the bonnet of the motor vehicle 10.

[0081] It is further recognizable in FIGS. 1 and 2 that respective vehicle body parts 12 have a three-dimensionally curved outer shape at least in some areas. The vehicle body parts 12 form a curved external contour of the motor vehicle in the installed position on the motor vehicle 10 as well in this way. The motor vehicle 10 may consequently be designed aerodynamically and have an elegant appearance.

[0082] The solar cells 14 are preferably rigid and planar solar cells here, preferably with respective identical dimensions and characteristics, in particular a respective identical irradiated surface. The solar cells 14 themselves are not adapted to the curved external contour of the motor vehicle 10 or the trim part 20 here, as correspondingly shaped solar cells are very complex and expensive to manufacture. Instead substantially identical planar solar cells 14 are used for all vehicle body parts 12. In order to nevertheless be able to form a three-dimensionally curved external contour with the vehicle body parts 12, the solar cells 14 are arranged in respective cutouts 16, which are for example recognizable in FIGS. 4, 6, 7 and 9. Respective parts of the vehicle body part 12 may have a substantially constant thickness and three-dimensionally curved outer shape thanks to the cutouts 16, wherein sufficient installation space is nevertheless available for arranging of the planar solar cells 14. This means that the planar solar cells 14 may for example be arranged closer to one end of an outer side wall of the cutout 16 than to another end, as they do not follow the curvature of the external contour across a width of the cutout 16. The solar cells 14 do not need to be arranged parallel to respective walls of the cutout 16 either here, which also allows the same to be adapted especially well at an incline to a probable irradiation angle of the sunlight.

[0083] In the side view according to FIG. 3 an example of a vehicle body part 12 of the motor vehicle 10 according to FIG. 1 is shown, wherein this is the left front door of the motor vehicle 10. It is recognizable here that the vehicle body part 12 is a frame component 18 and has a trim part 20 arranged thereon. The frame component 18 may adopt a structurally supportive function here and hold the trim part 20 on the rest of the motor vehicle 10. The frame component 18 is preferably designed as a CFRP component here, which is especially light and rigid. The frame component 18 encloses the trim part 20 in the way of a frame around its outer circumference here. In this way the trim part 20 may support the frame component 18 at least on its main expansion level and additionally reinforce the same. Overall the vehicle body part 12 may therefore be especially light.

[0084] The trim part 20 is preferably held on the frame component 18 on a step 22 here, which is for example schematically shown in the section view according to FIG. 8. The frame component 18 has a Z-shaped step 22 here, on the lower leg 24 of which the trim part 20 lies. The lower leg 24 extends below the trim part 20 only some areas here, and a through opening 26 may otherwise be provided in the frame component 18 in the centre of a receiving area for the trim part 20 for reducing weight. The upper leg 28 of the Z-shaped step 22 follows the trim part 20 flush on a level here. This is of particular aerodynamic advantage.

[0085] An adhesive 32 may be arranged in a gap 30 between the trim part 20 and the frame component 18, for example an acrylic adhesive. This adhesive 32 may serve not only for fixing the trim part 20 on the frame component 18 but may also enable a compensation of different thermal expansion coefficients. The frame component 18 may for example be made of a carbon fiber reinforced plastic and the trim part 20 substantially of polycarbonate discs. Different thermal expansion coefficients must be compensated for in this case. This is especially easy thanks to the gap 30 and the adhesive 32. Alternatively or additionally a double-sided adhesive tape (such as a double-sided vehicle body adhesive tape between the lower leg 24 and the trim part 20) may be provided.

[0086] The trim part 20 may be painted on the back of a side facing the interior of the motor vehicle 10, in particular in color, in order to make the motor vehicle 10 colorful on the outer side for respective observers. The trim part 20 may however for example be equipped with a clear lacquer on the outer side on a side facing incoming light in order to protect respective components, but nevertheless not to hinder light falling onto the solar cells 14. A corresponding color or a corresponding clear lacquer may also be applied to the frame component 18 for a consistent appearance.

[0087] The cutout 16 of the trim part 20 is preferably closed in a substantially airtight and substantially watertight fashion. Respective solar cells 14 may be protected against environmental influences in this way.

[0088] It may for example be envisaged to fill a gap in the cutout 16 between the solar cell 14 and the respective walls of the cutout 16 with a silicone gel for this purpose. A silicone rubber may be filled into the cutout 16 after arranging the solar cells 14 for this purpose, which then vulcanizes there. The silicone rubber is preferably inserted into the cutout 16 via one or more lower filler openings 34 against gravity hereas shown in FIG. 6. The insertion against gravity may prevent for formation of air bubbles especially reliably. At least one ventilation opening 36 should be provided here, preferably at an upper end, through which respective air located in the cutout 16 may exit during filling. These respective filler openings 34 and ventilation openings 36 may also be closed after filling, or may be sealed by the vulcanized silicone gel itself.

[0089] As shown in FIG. 7 the trim part 20 may for example have two discs here, which together form a support element 38. The solar cell 14 is for example fitted to a first inside polycarbonate disc 42 by means of its double-sided acrylic adhesive tape 40. In addition a second polycarbonate disc 44 is arranged in the direction of the outer side of the vehicle body part 12, which is fitted to the first polycarbonate disc 42 with respective double-sided acrylic adhesive tapes 46. The acrylic adhesive tapes 46 not only serve as distancers here, but may also seal the cutout 16 at least in part, in particular at the side. The polycarbonate discs 42, 44 may for example have a thickness of 1 mm to 4 mm here, preferably 2 mm to 3 mm or 2.5 mm, and the cutout 16 may for example have a height of 1 mm to 4 mm, preferably 1 mm to 3 mm, for example approximately 2 mm, in the section view according to FIG. 7.

[0090] Additionally or alternatively the trim part 20 may also have a layer construction, which is demonstrated in FIG. 9. A thermoplastic polyurethane film 50 or 48 is arranged on the respective inside on the side of the first polycarbonate disc 42 and the second polycarbonate disc 44 facing the cutout 16 here. Respective cutouts 16 with solar cells 14 located therein may be encapsulated in an airtight and watertight fashion by means of these TPU films 50, 48. The trim part 20 is for example inserted into a vacuum bag and autoclaved for 3 hours at 120 for this. In respective part areas in which no cutout 16 is arranged and the first and the second TPU films 50, 48 contact each other, these melt together and close the cutout 16 in this way. The two polycarbonate discs 42, 44 are simultaneously connected with each other by means of the TPU films 50, 48 here.

[0091] In an example of the production process the polycarbonate discs 42, 44 are made available as planar discs. Both of these planar discs are deformed into the three-dimensionally curved shape according to the external contour of the motor vehicle 10 by means of a molding tool, and optionally by means of additional heating. With this deformation respective domes are inserted are simultaneously introduced into the polycarbonate discs 42, 44. One of the two TPU films 50, 48 is subsequently for example laid onto the associated polycarbonate disc 42, 44 and the respective solar cells 14 arranged thereon with the aid of a matrix. In line with a predetermined circuitry the solar cells 14 are then electrically connected with each other and at least one electric output is provided at the trim part 20, by means of which electrical energy may be supplied to respective energy stores of the motor vehicles 10. The other one of the two TPU films 50, 48 is then applied, followed by the other one of the two polycarbonate discs 42, 44. This layer construction preferably continues to be held on at least one of the molding tools of the molding process of the polycarbonate discs 42, 44. The entire layer construction may then be introduced into a vacuum bag and autoclaved, for example for 3 hours at 120. The solar cells 14 are then sealed in the cutouts 16 in an air- and watertight fashion and protected against environmental influences, and the respective polycarbonate discs 42, 44 are firmly connected with each other. The trim part 20 produced in this way may then be glued into the Z step of the frame component 18. Thanks to the sealing of the solar cells 14 the assembly is especially easy here, as the solar cells 14 are now already protected against damage and contamination and may be inserted into the frame component 18 in the way of a module without particular precaution measures.

[0092] The solar cells 14 may for example be provided as solar cell strings that are already electrically connected with each other here. A string may equal a series of solar cells 14 in one trim part 20 here. Such a string may then be inserted together into a respective common cutout 16 of the trim part 20, so that several solar cells 14 are directly arranged in a correct arrangement in the trim part 20. Several strings may then be electrically connected with each other.

[0093] Have described aspects of the present disclosure in detail, it will be apparent that further modifications and variations are possible without departing from the scope of the present disclosure. All matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.