VEHICLE OUTER SURFACE COMPONENT AND METHOD FOR PRODUCING A VEHICLE OUTER SURFACE COMPONENT

Abstract

The invention relates to a vehicle outer surface component with a layer structure with an SMC layer forming an outer shell layer and a reinforcement structure connected to the SMC layer and having a core layer, wherein it is provided according to the invention that an IMC-TOPcoat-layer is mounted on the outside on the SMC layer, which together with the SMC layer forms the outer shell layer.

Claims

1. A vehicle outer surface component with a layer structure with an SMC layer forming an outer shell layer and a reinforcement structure connected to the SMC layer and having a core layer, wherein an IMC-TOPcoat-layer is mounted on the outside on the SMC layer, which together with the SMC layer forms the outer shell layer.

2. The vehicle outer surface component according to claim 1, wherein the IMC-TOPcoat layer has a thickness of 60 to 140 m (0.060 to 0.140 mm).

3. The vehicle outer surface component according to claim 1, wherein the core layer of the reinforcement structure is made of a honeycomb or a foam, especially wherein the honeycomb is made of paper, aluminum or a plastic such as phenolic resin.

4. The vehicle outer surface component according to claim 1, wherein the reinforcement structure has an inner plastic cover layer, which is made of polyurethane and is mounted to the core layer on its inside opposite the outer shell layer.

5. The vehicle outer surface component according to claim 1, wherein the outer shell layer is mounted by means of an outer plastic cover layer, which is made of polyurethane, to the outside of the core layer facing the outer shell layer.

6. The vehicle outer surface component according to claim 4, characterized in that the inner plastic cover layer and/or the outer plastic cover layer has a fiber reinforcement or a fiber mat.

7. A method of making a vehicle outer surface component, in particular according to claim 1, comprising the steps of: a) producing an SMC layer including an IMC-TOPcoat layer as a semi-finished product forming an outer shell layer, in a standard production method for SMC components, b) inserting the outer shell layer in a tool half of a composite tool, c) injecting a reinforcement structure bearing the outer shell layer having a core layer covered by at least one plastic cover layer, with still non-crosslinked adhesive or polyurethane in the SMC layer of the outer shell layer with molding the vehicle outer surface component, and d) demolding the vehicle outer surface component produced with high-quality finished outer shell.

8. The method according to claim 7, wherein, following the demolding of the vehicle outer surface component (step d), performing at least one further method step such as trimming or cutting the edges of the vehicle outer surface component.

9. A method of producing a vehicle outer surface member in particular according to claim 1, comprising the steps of: a) producing an SMC layer as a semi-finished product in a standard production method for SMC components, b) inserting the SMC layer in a first tool half of a molding tool and pressing the SMC layer by means of a second tool half, c) applying an IMC-TOPcoat layer on the SMC layer facing the first tool half to form an outer shell layer, d) replacing the second tool half with a tool half having an enlarged mold cavity, e) inserting a reinforcement structure bearing the outer shell layer, the reinforcement structure having a core layer covered by at least one plastic cover layer, in the enlarged mold cavity, f) injecting the reinforcement structure having still non-crosslinked adhesive or polyurethane in the SMC layer of the outer shell layer with molding the vehicle outer surface component, and g) demolding the vehicle outer surface component produced with high-quality finished outer shell.

10. The vehicle outer surface component according to claim 1, wherein the IMC-TOPcoat layer is a layer which is made of a polyurethane or a 2K polyurethane paint or the like in Class A surface quality and which replaces a primer and/or a subsequent paint.

Description

[0040] Below, the invention will be explained in more detail with reference to an exemplary embodiment of a vehicle outer surface component with reference to the drawing.

[0041] FIG. 1 shows in a sectional view a vehicle outer surface component according to the invention;

[0042] FIG. 2 shows in a sectional view an outer shell layer of the vehicle outer surface component of FIG. 1;

[0043] FIG. 3 shows in a sectional view a molding tool with two closed tool halves and an SMC semi-finished product of the vehicle outer surface component disposed therein during a first production step; and

[0044] FIG. 4 shows in a sectional view the molding tool with a second replaced tool half and a vehicle outer surface component disposed therein during a second production step.

[0045] A vehicle outer surface component 1, which is, e. g., a cover of a roof module or an openable roof, such as a sliding roof, has a reinforcement structure 2 with a core layer 3 that is made of a honey comb, for example a paper honey comb (PHC), or is made of a foam. Preferably, the core layer 3 is provided on both sides, i. e. facing the outside 4 of the component and also facing the inside 5 of the component of the vehicle outer surface component 1, with a plastic cover layer 6 and 7, respectively. The outer plastic cover layer 6 as well as the inner plastic cover layer 7 contain a thin adhesive layer or are formed by such layer that consists in particular of polyurethane, and contain in particular a reinforcing fiber layer or fiber mat, made, e. g., of a fiber material having basalt fibers, carbon fibers, natural fibers or glass fibers.

[0046] An outer shell layer 8 of the vehicle outer surface component 1 is connected to reinforcement structure 2 or core layer 3 by means of the plastic or polyurethane of the outer plastic cover layer 6. Outer shell layer 8 is formed of an inner layer and an outer layer. The inner layer is a thin SMC layer 9 having a thickness of preferably about 1.0 mm to 2.5 mm. The outer layer is an IMC-TOPcoat layer 10 (IMC In Mold Coat) of a thickness of preferably about 60 to 140 m (0.060 to 0.140 mm).

[0047] The IMC-TOPcoat layer 10 is a high-quality layer, so that a subsequent painting is not provided and is not necessary. Rather, high-gloss, matt or structured component surfaces can be generated according to the tool surface in the molding tool, wherein the IMC-TOPcoat layer 10 itself can have a coloring e. g. in car color or also can have contrast colors.

[0048] The SMC layer 9 coated with IMC-TOPcoat layer 10 is then injected with the PHC support or the reinforcement structure. This gives a lightweight Class A component without additional painting.

[0049] A high-gloss surface is obtained either by a corresponding high-gloss surface in the tool or by subsequent polishing of the component. Appropriately, then a larger layer thickness of about 120 m (0.120 mm) to 140 m (0.140 mm) is provided.

[0050] The outer plastic cover layer 6 may also be omitted as a fibrous layer, if SMC layer 9 takes over the structural properties of the outer plastic cover layer 6. The bonding of SMC layer 9 directly to core layer 3 is then carried out only by plastic such as, e. g., polyurethane.

[0051] A method of producing such a vehicle outer surface component 1 provides for producing first an SMC layer 9 including an outer high quality IMC-TOPcoat layer 10 as a semi-finished product in a standard production method for SMC components.

[0052] Subsequently, the semi-finished product (SMC layer 9 with IMC-TOPcoat layer 10) is inserted in a tool half of a composite tool. If necessary, the semi-finished product is drawn to the tool half with vacuum.

[0053] In a further downstream method step, the reinforcement structure 2 is injected into the semi-finished product with still non-crosslinked adhesive (z. B. polyurethane). In this method step the shaping of the reinforcement structure 2 at the surface facing SMC layer 9 is carried out.

[0054] Optionally, following the demolding of the composite component or vehicle outer surface component 1 further method steps take place, such as trimming or cutting the edges of vehicle outer surface component 1. In any case, the need for a subsequent painting is eliminated.

[0055] A further alternative method (see FIGS. 3 and 4) provides the combination of an SMC process with a composite process. A molding tool 11 has a first or upper tool half 12 and a second or lower tool half 13. SMC layer 9 is pressed first in a mold cavity 14 between the two tool halves 12 and 13, and then flooded with an IMC-TOPcoat layer 10 by means of the first or upper tool half 12 (Class A tool half) on the subsequent outside of the component. In contrast to the first-mentioned method, the semi-finished product or the outer shell layer 8 (SMC layer 9 with IMC-TOPcoat layer 10) is not removed from molding tool 11, rather the counterpunch of molding tool 11, i. e., the lower tool half 13, is replaced by a second tool half 13 for producing the final composite geometry. This can be done by exchanging the counterpunch or by a shuttling or displacing tool half 13 or 13, wherein SMC layer 9 remains at the upper tool half 12. The replaced lower tool half 13 has an enlarged mold cavity 14 in which reinforcement structure 2 is disposed. This is followed by the composite process, in which the reinforcement structure 2 is pressed against SMC layer 9 of outer shell layer 8 and connected thereto.

[0056] Alternatively, the lower tool half 13 may also be the Class A tool half, and both the lower tool half 13 and the upper tool half 12 may be shuttled. Optionally, SMC layer 9 may also remain on the lower tool half 13 and the process for attaching the reinforcement structure 2 may be done in a second pressing tool.

[0057] Great advantage of this method is the elimination of additional handling steps for moving the semi-finished product, avoiding damage to the later surface, and avoiding of contamination of the composite tool with impurities.

[0058] The individual features of the invention disclosed in the description and by the exemplary embodiment as well as in the figures may be combined in any technically appropriate arrangements and configurations with the subject matter of the invention in its general form.

LIST OF REFERENCE NUMERALS

[0059] 1 vehicle outer surface component [0060] 2 reinforcement structure [0061] 3 core layer [0062] 4 outside of the component [0063] 5 inside of the component [0064] 6 outer plastic cover layer [0065] 7 inner plastic cover layer [0066] 8 outer shell layer [0067] 9 SMC layer [0068] 10 IMC-TOPcoat layer [0069] 11 molding tool [0070] 12 first tool half [0071] 13 second tool half [0072] 13 replaced second tool half [0073] 14 mold cavity [0074] 14 enlarged mold cavity