WINDING ASSEMBLY AND METHOD FOR PRODUCING SUCH A WINDING ASSEMBLY

Abstract

A winding assembly for a protective device of a motor vehicle, and a method for producing such a winding assembly. Such a winding assembly includes a form-stable winding shaft and a flexible winding web held on the winding shaft such that it can be wound up and unwound. The winding shaft is formed by a form-stabilized wound-up first portion of a flexible sheet-form material and the flexible winding web is formed by a second portion of the flexible sheet-form material adjoining the first portion, whereby the winding shaft and the winding web are in continuous one-piece form.

Claims

1. A method for producing a winding assembly for a protective device of a motor vehicle, comprising a form-stable winding shaft and a flexible winding web which is held on the winding shaft such that it can be wound up and unwound, comprising the following steps: winding up a first portion of a flexible sheet-form material; carrying out form stabilization of the wound-up first portion; wherein the form-stable winding shaft is formed by the form-stabilized wound-up first portion of the flexible sheet-form material, and wherein the flexible winding web is formed by a second portion of the flexible sheet-form material adjoining the first portion, whereby the winding shaft and the winding web are in continuous one-piece form.

2. The method as claimed in claim 1, wherein form stabilization comprises: joining together winding layers of the wound-up first portion lying one on top of the other by substance-to-substance bonding.

3. The method as claimed in claim 1, wherein form stabilization comprises: adhesively bonding, welding and/or fusing together winding layers of the wound-up first portion lying one on top of the other.

4. The method as claimed in claim 1, wherein form stabilization comprises: pressing the wound-up first portion.

5. The method as claimed in claim 1, wherein form stabilization comprises: applying a polymerizable substrate to the first portion and curing the wound-up first portion provided with the polymerizable substrate.

6. The method as claimed in claim 5, wherein curing comprises: exposing the wound-up first portion provided with the polymerizable substrate to light, in particular to UV light.

7. The method as claimed in claim 1, comprising the step: cutting the flexible sheet-form material, wherein the first portion is cut to form a first basic shape which has non-parallel sides, in particular is trapezoidal, and/or wherein the second portion is cut to form a second basic shape which has non-parallel sides, in particular is trapezoidal.

8. The method as claimed in claim 1, wherein the first portion is wound onto a cylindrical winding core, wherein the winding core is removed from the winding shaft after form stabilization.

9. A winding assembly for a protective device of a motor vehicle, comprising a form-stable winding shaft and a flexible winding web which is held on the winding shaft such that it can be wound up and unwound, wherein the winding shaft is formed by a form-stabilized wound-up first portion of a flexible sheet-form material and wherein the flexible winding web is formed by a second portion of the flexible sheet-form material adjoining the first portion, whereby the winding shaft and the winding web are in continuous one-piece form.

10. A protective device for a motor vehicle having a winding assembly as claimed in claim 9.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1 shows, in a schematic perspective view, an embodiment of a protective device according to the invention for a motor vehicle which is provided with an embodiment of a winding assembly according to the invention;

[0017] FIGS. 2 to 5 show schematically simplified diagrams illustrating an embodiment of a method according to the invention for producing the winding assembly according to FIG. 1;

[0018] FIG. 6 shows, in a schematic perspective view, the winding assembly produced by means of the method according to FIGS. 2 to 5; and

[0019] FIG. 7 shows a further schematic diagram illustrating the production method.

DETAILED DESCRIPTION

[0020] According to FIG. 1, a protective device S is provided for shading a roof opening, not designated specifically, arranged in a roof region D of a passenger car P. The protective device S can in this respect also be referred to as a shading device. In embodiments not shown in the drawings, the shading device is adapted to shade a side window opening or a rear window opening of the passenger car P. In further embodiments which are not shown, the protective device can be configured as a luggage compartment cover or luggage compartment separating net of the passenger car P.

[0021] The protective device S comprises a winding assembly 1 having a form-stable winding shaft 2 and a flexible winding web 3 which is held on the winding shaft 2 such that it can be wound up and unwound. In the present case, the winding shaft 2 is rotatably mounted, secured to the vehicle, about an axis of rotation oriented parallel to a vehicle transverse axis. In the embodiment shown, the winding shaft 2 is arranged in the region of a rear edge, not designated specifically, of the roof opening. The winding web 3 can be wound up and unwound by rotating the winding shaft 2 and in this way is displaceable between a protecting position and an uncovering position. The protecting position can in the present case also be referred to as a shading position and is shown by means of FIG. 1. In the shading position, the unwound winding web 3 covers the roof opening so that the interior of the passenger car P is thus shaded. In the uncovering position, the winding web 3 is wound on the winding shaft 2.

[0022] In order to achieve particularly simple production and a particularly simple construction of the winding assembly 1, the winding shaft 2 is formed by a form-stabilized wound-up first portion A1 of a flexible sheet-form material 4 (see in particular FIG. 2, 6). The flexible winding web 3 is formed by a second portion A2 of the flexible sheet-form material 4 adjoining the first portion A1. The winding shaft 2 and the winding web 3 are thus in continuous one-piece form. With reference to FIG. 2, the first and second portions A1, A2 are depicted as being separated from one another by means of a dot-and-dash line. It will be appreciated that the first and second portions are nevertheless continuous in one piece.

[0023] A method for producing the winding assembly 1 comprises a plurality of steps illustrated by means of FIGS. 2 to 5 and 7:

[0024] In the present case, cutting Z of the flexible sheet-form material 4 is first carried out. Cutting Z can be carried out, for example, starting from rolled or piece goods. Alternatively, the flexible sheet-form material 4 can be acquired in already prefabricated form, so that cutting Z is not necessarily required. In this respect, the step of cutting Z is advantageous but not essential with regard to the solution according to the invention.

[0025] The (cut) flexible sheet-form material 4 shown in FIG. 2 is tailored in terms of its dimensions and with regard to its basic shape to the geometric properties of the winding shaft 2 on the one hand and of the winding web 3 on the other hand that are to be achieved or produced.

[0026] In the embodiment shown, the flexible sheet-form material 4 with its two portions A1, A2 has a rectangular basic shape with a width b and a length 1. The width b of the flexible sheet-form material 4 is tailored to a length, not designated specifically, of the winding shaft 2 along its longitudinal axis L (FIG. 6) that is to be achieved. The length 1 of the flexible sheet-form material 4 comprises a first length 11 of the first portion A1 and a second length 12 of the second portion A2. The first length 11 is tailored to a diameter of the winding shaft 2 that is to be produced. The second length 12 is tailored to a length of the flexible winding web 3 in the unwound state that is to be produced.

[0027] In the embodiment shown, the first portion A1 has a first basic shape G1. The second portion A2 has a second basic shape G2. The first and second basic shapes G1, G2 are each configured or cut in a rectangular shape in the embodiment shown.

[0028] Alternatively, the two portions A1, A2 can each be cut to form a non-parallel, in particular trapezoidal, basic shape. This is illustrated by means of the alternative second basic shape G2′ depicted by a broken line. By correspondingly cutting the second portion A2, the winding web can easily be adapted on the production side to different installation situations in a motor vehicle with different geometries to be covered and/or separated. By cutting the first portion A1 in a non-parallel manner, a conical winding shaft can easily be formed. The reference numeral G1′ is also to be understood in this context.

[0029] After cutting Z, winding up W (FIG. 7) of the first portion A1 is carried out. After winding up W, the flexible sheet-form material 4 assumes a configuration which is illustrated schematically by means of FIG. 3. In the embodiment shown, the first portion A1 is wound onto a cylindrical winding core 5. The winding core 5 is longer than the width b of the flexible sheet-form material 4. In the embodiment shown, the winding core 5 is oriented parallel to a rear edge 6 of the flexible sheet-form material 4 for winding the first portion A1. This is not absolutely essential, however. “Slanted” winding is also conceivable in principle. An outer contour 7 of the winding core 5 defines an inner contour 8 of the winding shaft 2 to be formed (FIG. 6). In the present case, the winding shaft 2 is accordingly in tubular form with a cylindrical inner contour for accommodating any further components of the winding assembly 1, for example a spring motor or the like. The second portion A2 is not wound up in order to form the winding shaft 2 and the winding web 3. In the wound-up state of the first portion A1, the first portion forms a plurality of winding layers WS lying one on top of the other (FIG. 3). The number of winding layers WS is tailored to the diameter of the winding shaft 2 that is to be achieved and is additionally governed by the thickness, not designated specifically, of the flexible sheet-form material 4.

[0030] In the embodiment shown, the flexible sheet-form material 4 is a knitted fabric produced from a plastics material K. The plastics material K is in the present case polyester (PES).

[0031] In order to form the cylindrical shaft 2, the first portion A1 is stabilized in its wound-up form. In other words, form stabilization F (FIG. 7) of the wound-up first portion A1 (FIG. 3) is carried out. Form stabilization can in principle be carried out by interlocking engagement, frictional engagement and/or substance-to-substance bonding. In the embodiment shown, substance-to-substance joining of the winding layers WS of the wound-up first portion A1 lying one on top of the other is provided for this purpose.

[0032] In further embodiments, adhesive bonding, welding and/or fusion, for example, of the winding layers WS lying one on top of the other is provided.

[0033] In the embodiment shown, form stabilization F comprises a plurality of steps:

[0034] In a step F1, a polymerizable substrate PS is applied to the first portion A1. Various methods and various substrates are conceivable for this purpose. In the present case, the first portion A1 is impregnated with the polymerizable substrate PS in the wound-up state. Accordingly, the substrate PS is in flowable, preferably liquid, form. The polymerizable substrate is in the present case UV-curing epoxy resins.

[0035] In a further step F2, the wound-up portion A1 impregnated with the substrate PS is pressed (FIG. 4). Pressing F2 is carried out in the present case by means of a jaw-type mold 9, 10 having an upper molding jaw 9 and a lower molding jaw 10. By pressing F2 by means of the jaw-type mold 9, 10, improved shaping of the wound-up first portion A1 and thus improved dimensional stability of the winding shaft 2 to be produced can be achieved. The jaw-type mold 9, 10 accordingly has an inner contour, not shown in detail, which forms a negative mold to the outer contour of the winding shaft 2 that is to be achieved. Pressing F2 can be carried out under the action of heat and/or radiation.

[0036] In a further step F3, curing of the wound-up first portion A1 provided with the polymerizable substrate PS is carried out. Curing F3 is shown schematically by means of FIG. 5 and in the present case is carried out by exposing the wound-up first portion A1 impregnated with the substrate PS to light. Exposure to light is carried out by means of a light source 11, shown schematically and in a greatly simplified manner, which in the present case is a UV light source. It will be appreciated that curing F3 can be carried out after and/or during pressing F2. In order to illustrate curing F3 during pressing F2, the wound-up first portion shown in FIG. 5 is still accommodated in the jaw-type mold 9, 10 during curing. Accordingly, the light source 11 can be integrated in the jaw-type mold 9, 10, for example. Alternatively, curing F3 can be carried out after the first portion A1 has been removed from the jaw-type mold 9, 10.

[0037] During curing, a chemical reaction of the substrate PS takes place, by means of which the first portion A1 is stabilized in its wound-up form to form the winding shaft 2 (FIG. 6). In this context, stabilization can also be referred to as fixing, stiffening and/or hardening.

[0038] After curing F3 and removal from the jaw-type mold 9, 10, the winding core 5 is removed from the winding shaft 2. The winding core 5 is in the present case produced from a silicone material. This ensures that it can be removed easily and reliably. The winding core 5 produced from the silicone material additionally serves in the present case as a light guide for exposing to light or curing the polymerizable substrate PS. That is to say, the wound-up first portion A1 is exposed to light from within via the winding core 5.