Method for manufacturing a longitudinal member cladding, and a longitudinal member cladding

Abstract

A longitudinal cladding member for a motor vehicle, a method for manufacturing the longitudinal cladding member, and a motor vehicle having such a longitudinal cladding member. The longitudinal cladding member is to be fixedly connectable to a body of the motor vehicle, and in an assembled state covers a longitudinal member at least on the visible side of the motor vehicle.

Claims

1. A method for manufacturing a longitudinal cladding member from a plastic material, the method comprising: on-demand punching of light-permeable regions from a film; arranging the film on a plastic injection-moulding tool; introducing and pressing a die onto the film and into a position of punchings; injection-moulding the punched-out regions of the film within the die, using a first plastic material; retracting the die; and filling and back injection-moulding a volume around the punched-out regions of the film, using a second plastic material.

2. The method of claim 1, wherein the film is formed in the plastic injection-moulding tool.

3. The method of claim 1, wherein retracting the die comprises retracting the relative to a plane of the plastic injection-moulding tool.

4. The method of claim 1, further comprising arranging lighting elements in the die.

5. The method of claim 1, wherein the first plastic material is dissimilar to the second plastic material.

6. The method of claim 1, wherein the second plastic material comprises polypropylene.

7. The method of claim 1, wherein the second plastic material comprises acrylonitrile butadiene styrene.

8. The method of claim 1, wherein the first plastic material comprises a light-permeable material.

Description

DRAWINGS

(1) Embodiments will be illustrated by way of example in the drawings and explained in the description below.

(2) FIGS. 1(a) to 1(e) illustrate a schematic illustration of the manufacturing method, in accordance with embodiments.

(3) FIG. 2 illustrates a schematic illustration of a longitudinal cladding member, in accordance with embodiments.

(4) FIG. 3 illustrates an isomeric view of a longitudinal cladding member, in accordance with embodiments.

DESCRIPTION

(5) FIGS. 1(a) to 1(e) schematically illustrate the method for manufacturing a longitudinal cladding member. A plastic injection-moulding tool 6 is illustrated schematically in FIG. 1(a). In order for the illustration to the simplified, no periphery of the lower tool and also no upper part of the tool are depicted here. However, it is evident that a cavity, that is to say a hollow space to be filled, must be available for manufacturing the longitudinal cladding member. The surfaces of these components must have properties in terms of external appearance and also in terms of impact resistance and weather resistance, these properties being expected by customers and met by way of complex painting methods, for example. In order for these time and cost consuming methods to be avoided, films which, post back moulding, form the surface of the finished component are employed. Typically, these films are initially moulded in a thermo-tool and subsequently post cooling are back injection-moulded, using back-moulding materials, typically duroplastic or thermoplastic materials.

(6) In a first variant of the method, clearances 4 are introduced into a film 7 already outside the injection-moulding tool 6, and the cut-out material is removed.

(7) The film 7 is arranged or otherwise positioned on the tool 6 or is arranged in a clearance of the tool 6, respectively. In accordance with embodiments, although the film 7 is arranged in a planar manner and is not pre-moulded in the illustration, this however, does not correspond to the reality in the manufacture of a longitudinal member. That is to say, that another method step, i.e., thermoforming of the film 7 in the tool 6, would have to be provided here.

(8) The film 7 is composed of an extruded material which is employable for an external application on a vehicle. This step is eliminated if the film 7 prior to back injection-moulding is pre-moulded and painted.

(9) As illustrated in FIG. 1(b), in the next operational step, a die 8 is pressed onto the film 7 from spatially above. In terms of shape and size, the die 8 is adapted to the clearance 4 and by way of the periphery of said die 8 urges the periphery of the clearance 4 into the tool 6. The frame forms the periphery of the transparent region. As a result, the die 8 is intended to be the frame that represents a delimitation in the manufacture of the light-permeable region.

(10) The die 8 is configured as a hollow space and assumes the role of a frame. An injector 9 is introduced into the interior of the die 8, and the region of the clearance is injected-moulded, using a first plastic material 10.

(11) As illustrated in FIG. 1(c), thereafter, the die 8 is moved from the plane E1 of the film 7 and from the first plastic material 10 upwardly and away until said die 8 is located approximately on the plane E2 of the finished component. On account thereof, it is prevented that the second plastic material comes to lie along the plane E2, behind the light-permeable component.

(12) Thereafter, the cavity around the first plastic material 10, above the film 7, is back injection-moulded and filled, using a second plastic material 11.

(13) The second plastic material 11 here may completely wet the side walls 12 of the first plastic material 10 and the walls of the clearance of the film 13, and establish an optimal connection and a joint-free surface.

(14) The resulting joint-free design configuration of the light-permeable region may be seen in the enlargement in FIG. 1(d).

(15) As illustrated in FIG. 1(d), depending on the design embodiment, a step 14 is created between the sidewall 12 and the wall 13 of the film in that the light-permeable plastic material 10 is injected to just a few millimeters beyond the clearance.

(16) In accordance with embodiments, the plastic material employed for the clearance is a light-permeable material. The light-permeable material here may be transparent in the visible region, such as is meaningful for a surround light. Above all, PMMA is employed here. However, it is also possible for a material which is transparent in the infrared range or in the ultraviolet range to be selected. The employment of these wavelength ranges for illuminating the surroundings of the vehicle is conceivable in conjunction with sensors.

(17) Since materials which are transparent, particularly in the visible range, are often brittle, it is meaningful for the employment of the plastic material to be limited to the region of the clearance. The longitudinal cladding member per se is manufactured using a second plastic material which is more flexible than the light-permeable material and may be used in a more cost-effective manner.

(18) Here, plastic materials such as ABS or PP may be employed. The use of the solution in accordance with embodiments is, however, not limited to these plastic materials.

(19) As illustrated in FIGS. 2 and 3, longitudinal cladding member 1 is provided in accordance with embodiments. The longitudinal cladding member 1 is divided into three regions, i.e. a first region, a central region 5, and an end region which extends in a direction of the rear of the vehicle.

(20) A plurality of the light-permeable clearances 4 which are disposed in the central region 5 are illustrated in the example of FIG. 2. The front doors of the vehicle open in this region, so that the light-permeable clearances 4 illuminate the carriageway there so as to be convenient for the driver or occupant of the vehicle. Alternatively, the clearances 4 may also extend along the entire longitudinal axis L of the longitudinal cladding member 1.

(21) A lower region 3 in which the light-permeable clearances 4 are located is illustrated in FIG. 3. The longitudinal cladding member 1 moreover has fastenings 2 by way of which the longitudinal cladding member 1 is attached to a longitudinal member of the vehicle.

(22) Since the light-permeable clearances 4 are so close to the carriageway so as to efficiently illuminate the carriageway F in the surroundings of the vehicle, a lighting device which has a lower output, and are thus, able to be installed in a cost-effective manner are employable. The lighting device here is either adhesively bonded in a suitable manner or are fastened in another manner behind the light-permeable clearances 4. Since the longitudinal cladding member 1 is located in the region of heavy spray water, debris, and dirt ingress, it is, however, also meaningful for the lighting device to be integrated at the outset during injection-moulding.

(23) To this end, the lighting device is laid up in the die 8, such that the lighting device by way of the injector 9 is insert-moulded.

(24) The term coupled or connected may be used herein to refer to any type of relationship, direct or indirect, between the components in question, and may apply to electrical, mechanical, fluid, optical, electromagnetic, electromechanical or other connections. In addition, the terms first, second, etc. are used herein only to facilitate discussion, and carry no particular temporal or chronological significance unless otherwise indicated.

(25) This written description uses examples to disclose the invention, including the preferred embodiments, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of embodiments is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. Aspects from the various embodiments described, as well as other known equivalents for each such aspects, may be mixed and matched by one of ordinary skill in the art to construct additional embodiments and techniques in accordance with principles of this application.

LIST OF REFERENCE SIGNS

(26) 1 Longitudinal cladding member 2 Fastenings 3 Lower sides 4 Light-permeable regions/clearances 5 Central region 6 Plastic injection-moulding tool 7 Film 8 Die 9 Injector 10 First plastic material 11 Second plastic material 12 Side wall 13 Wall 14 Step E1, E2 Planes F Carriageway