UNDERBODY PANEL HAVING MOUNTING POINTS

Abstract

Moulded underbody panel for shielding the underside of a motor vehicle, comprising a consolidated fibrous layer comprising at least one mounting point for mounting the moulded underbody panel to the vehicle by means for mounting, the means for mounting comprising at least a rod shape element, and a fixing element, whereby the mounting point consists at least of a through-hole extending through the moulded underbody panel for hosting the rod shape element, and a contact area on the moulded underbody panel surface, provided around the through-hole, for contacting and supporting the fixing element in the mounting position, wherein the mounting point further comprises a blocking element which is formed integrally with the moulded underbody panel, whereby the blocking element is raised above at least the plane of the contact area and formed around the through-hole and whereby the distance between the foot of the blocking element facing the through hole and the centre of through-hole is 5 to 20 mm.

Claims

1. A moulded underbody panel for shielding the underside of a motor vehicle, comprising: a consolidated fibrous layer with at least one mounting point for mounting the moulded underbody panel to the vehicle by a mount comprising: at least a rod shape element, a fixing element, and wherein the at least one mounting point consists at least of a through-hole extending through the moulded underbody panel for hosting the rod shape element, and a contact area on the moulded underbody panel surface, provided around the through-hole, for contacting and supporting the fixing element in the mounting position; wherein the at least one mounting point further comprises a blocking element formed integrally with the moulded underbody panel, whereby the blocking element is raised above at least the plane of the contact area and formed around the through-hole and whereby the distance between the foot of the blocking element facing the through hole and the centre of through-hole is 5 to 20 mm.

2. The moulded underbody panel according to claim 1, wherein the consolidated fibrous layer consists of fibres and a thermoplastic or thermoset binder.

3. The moulded underbody panel according to claim 2, wherein the fibres are at least one of mineral fibers, glass fibers, polyester fibers, and recycling fibers.

4. The moulded underbody panel according to claim 2, wherein the thermoset binder is epoxy resin or phenolic resin.

5. The moulded underbody panel according to claim 2, wherein the thermoplastic binder is polyamide, polypropylene, or a copolymer of polyester or a bicomponent fiber with one component working as a binder.

6. The moulded underbody panel according to claim 1, whereby the blocking element is at least 2 mm and not higher than 6 mm raised above the plane of the contact area.

7. The moulded underbody panel according to claim 1, whereby the blocking element is formed as a ridge and aligned around the border of the contacting area.

8. The moulded underbody panel according to claim 7, whereby the ridge segment has an apex angle between 30 and 360, wherein 360 corresponds to a full circular ring shaped raised area.

9. The moulded underbody panel according to claim 2, wherein the blocking element is configured in a U shape.

10. The moulded underbody panel according to claim 1, whereby the at least one mounting point is situated along the outer rim of the panel.

11. The moulded underbody panel according to claim 1, whereby the width of the foot of the blocking element is between 5 and 20 mm.

Description

DESCRIPTION OF EMBODIMENTS

[0030] FIG. 1 shows schematic the underside of a vehicle.

[0031] FIG. 2 shows examples of underbody panels.

[0032] FIG. 3A and B shows schematically the mounting of an underbody panel to a vehicle chassis according to the prior art.

[0033] FIG. 4A and B show schematically the mounting of an underbody panel to a vehicle chassis according to the invention.

[0034] FIG. 5 shows defines the apex angle

[0035] FIG. 6 I to V show examples of the blocking elements according to the invention

[0036] FIG. 1 shows the underside of a vehicle with examples of underbody panels 1, 10 mounted to the chassis 5 of the vehicle, for instance to the cross beams of the steel carrying body of a vehicle. The panel 1 in front, also known as under engine panel is the most exposed to the forces during driving or for instance water wading.

[0037] FIG. 2 shows additional underbody panels and a layout for such panelling, with the front or under engine panel 20, the main underbody panel 30, in this case divided in 2 parts, a centre panel 40 and the back panel 50, situated under the boot or trunk of the vehicle.

[0038] FIG. 3A and B show an example of a fastening of the moulded underbody panel or panel 1 to the chassis of a vehicle 5. The moulded underbody panel has a through-hole 6 for inserting a rod shape element 3. An underbody panel normally contains at least one through-hole 3 for each mounting point. This through-hole is either punched through the material after the moulding of the part or integrated in the moulding tool as material free areas.

[0039] The mounting is achieved by inserting a rod shape element through the through-hole. The rod shaped element 3 might be permanently fixed to the vehicle chassis 5. The part will then be mounted by placing the through-hole over the rod shaped element and fixing it with at least a fixing element 4 which is able to clamp the material of the underbody panel in its place preventing or at least hindering any in plane or out of plane movement of the part, for instance a screw or clipping device, bolt and nut, or a punch clip system. A possible counter element when needed, for instance a nut may be integrated in the mounting area of the vehicle chassis or body. The rod shape element and the fixing elements together form the means for mounting.

[0040] Generally for the mounting of these panels following types of fixing or means for mounting might be used: punch or screw clips, or screws in combination with a nut or a clip; however other more elaborate solutions are possible as well. In particular the use of washers 2 are favourable to increase the clamped area and thereby the friction force of the panel.

[0041] The panel is directly after mounting, fixed on the vehicle such that the panel cannot move particularly not in in-plane direction, however after a certain time of use the material might slightly loose its thickness and/or rigidity and the original friction force between the fastener means and the moulded underbody panel may decrease such that the panel is able to move in-plane. This situation is shown in FIG. 3B. A force F, for instance induced during driving at speed or driving through water, pushes the underbody panel able to move against the rod shape element shown in the circled area A in FIG. 3B. As the rod shape element is permanently fixed and not able to move, the force is transferred into the material causing a local stress. The rod shape element will ride into the material. This might eventually lead to a breaking or tearing of the material at this point, causing the mounting point and or the part to fail during use. Such defaults are more often in the mounting points that are arranged on the rim area of the panel, particularly on the area situated at the front of the panel, pointing to the front of the vehicle.

[0042] FIG. 4A and B show an underbody panel with a mounting area according to the invention. By introducing a blocking element 7 at least partly along the contact area and in a distance D of between 5 and 20 mm measured from the centre of the through hole, the panel will move until stopped by the fixing element or optionally the washer element, hitting the side of the blocking element, shown in the circled area Y. As the blocking element is touched by a large area of the fixing or washer element the force is divided over a larger area. As the blocking element has a larger area of resistance, it allows redistributing the stress and reducing it. In this example given the rod shape element is not able to reach the rim of the moulded material of the panel in the through hole, shown in the circled area X, however even if it would be able to merely touch the rim the blocking element would still be able to redistribute the force and prevent the failure of the mounting point.

[0043] FIG. 5 shows schematically simplified the underbody panel 1 with a through hole and a contact area 2 for the fixing element of the washer element (not shown). In this example there is only a partial blocking element 3d placed along the contact area 2. The length the blocking element extends along the border of the contact area can be defined by the apex angle, whereby the angle is given by two imaginary line through the centre of the through-hole and following the ends of the blocking as shown in the drawing.

[0044] FIG. 6 I to V show schematically simplified the underbody panel 1 with a through hole and a contact area 2 for the fixing element of the washer element (not shown) as already shown in FIG. 5. FIG. 6 I to V show different possible solutions for the blocking element 7a-d and 7-7. With F the force direction is given that is expected to work on the part mounted on a vehicle in use, for instance during driving at speed and or through water.

[0045] In FIG. 6 I. a circular ring-shaped blocking section 7a comprises a single circular ring-shaped blocking element, being an embossing integrally formed with moulded underbody panel 1 and aligned to extend along the border of contact area of the contact area 2. The blocking element is a single element forming substantially the whole blocking section. Having an apex of 360 according to the definition given in FIG. 5.

[0046] In FIG. 6 II. a semi-circular ring-shaped blocking section 7b, respectively a circular ring-segment with apex angle =180 is shown. Blocking section 7b comprises a single semi-circular ring-shaped blocking element 7b, being an embossing integrally formed with the moulded underbody panel 1 and aligned to extend along a border segment of contact area 2.

[0047] FIG. 6 III. shows the moulded underbody panel 1 with an U-shaped blocking section 7c comprises a single U-shaped blocking element 7c, being an embossing integrally formed with moulded underbody panel 1 and aligned to extend along a border segment of contact area 2. The straight flanks of the U-shaped embossing 7c act as anchors, which are pulled under the load F and which additionally enhance the mechanical resistance of the moulded underbody panel 1.

[0048] FIG. 6 IV. shows the moulded underbody panel 1, a circular ring-segment 7d with apex angle =60. Blocking section 3d comprises a single circular ring-segment 7d with apex angle =60 forming the blocking element 7d, being an embossing integrally formed with moulded underbody panel 1 and aligned to extend along a border segment of the contact area 2.

[0049] FIG. 6 V. shows the moulded underbody panel 1. A blocking section 7 formed as circular ring-segment with apex angle =180 comprises three circular ring-segments 7, 7 and 7, being separated by a void space respectively between them, with apex angles of the ring-segments of about =40, each ring-segment forming a blocking element being an embossing integrally formed with moulded underbody panel 1 and following the contact area 2.

[0050] Although the examples in FIGS. 5 and 6 are showing a circular contact area the contact area might also be elliptical or irregular in shape, depending on the means for mounting in particular the fixing element and or washer element and on the available space around the mounting point.

[0051] The examples of mounting systems are not exhaustive; in particular the different elements of the systems shown can be mixed among the systems as known by the skilled person.