METHOD FOR MANUFACTURING A COMPOSITE PART AND COMPOSITE PART

Abstract

A method for manufacturing a composite part (100) for covering, sealing, trimming, or retaining a component of a vehicle, wherein the composite part (100) has a main body (110) with a vehicle side surface (111) and is made of a first polymer, and has a mounting pin (130) configured to engage in a form fitting manner and is made of a second polymer, wherein the second polymer has a higher formability than the first polymer, comprises the steps of extrusion molding of the main body (110) and injection molding of the mounting pin (130). This is done in such a manner that the mounting pin (130) is being integrally bonded to the main body (110) on the side of the vehicle side surface (111).

Claims

1. A method for manufacturing a composite part for covering, sealing, trimming, or retaining a component of a vehicle, the composite part comprising: a main body having a shape and comprising a central portion and at least one wing portion having an end portion, the central portion and the wing portion defining a vehicle side surface, the end portion being configured to abut against the component of the vehicle in a mounted state; and a mounting pin disposed on the central portion or the wing portion and being configured to engage the component of the vehicle in a form fitting manner, thereby pressing the end portion towards the component of the vehicle in the mounted state by a force resulting from bending elasticity of the main; wherein the method comprises the steps of: 1.1 extrusion molding of the main body from a first polymer so as to form the central portion and the at least one wing portion, and 1.2 injection molding of the mounting pin from a second polymer having a higher formability than the first polymer so as to integrally bond the mounting pin to the main body on the side of the vehicle side.

2. The method according to claim 1, characterized in that the main body comprises a first wing portion and a second wing portion, wherein the central portion is adjacent to the first wing portion and the second wing portion, wherein preferably the central portion comprises a recessed portion configured to accommodate a trimming strip, wherein preferably the first wing portion is adjacent to the recessed portion, wherein preferably the central portion comprises a flat portion, wherein preferably the second wing portion is adjacent to the flat portion, wherein preferably the mounting pin is disposed between the first wing portion and the second wing portion, in particular between the recessed portion and the second wing portion, wherein preferably the mounting pin is disposed on the flat portion and/or on the second wing portion.

3. The method according to claim 1, characterized in that the composite part further comprises a supporting portion, wherein, before step 1.2, the supporting portion is injection molded, so as to integrally bond to the main body, wherein step 1.2 comprises integrally bonding the mounting pin to the supporting potion, wherein preferably the supporting portion and the main body are formed as a unitary member using the same polymer.

4. The method according to claim 3, characterized in that the composite part further comprises a supporting cavity defined by the supporting portion and the main body, wherein preferably the supporting portion includes a first leg and a second leg, wherein preferably the first leg is being integrally bonded to the 10 central portion, in particular the flat portion, wherein preferably the second leg is being integrally bonded to the wing portion, wherein preferably the first leg and the second leg are being formed as a unitary member using the same polymer, wherein preferably the supporting cavity is defined by the first leg, the second leg, and the main body, in particular the flat portion and/or the wing portion.

5. The method according to claim 1, characterized in that the composite part further comprises a wing sealing, wherein, simultaneously with or after step 1.2, the wing sealing lip is injection molded, so as to integrally bond the wing sealing lip to the main body (330, 430), in particular to the end.

6. The method according to claim 5, characterized in that the wing sealing lip is additionally integrally bonded to the vehicle side surface and/or the mounting pin, wherein preferably the wing sealing lip and the mounting pin are integrally formed as a unitary member using the same polymer.

7. The method according to claim 1, characterized in that the first polymer has any one of the following features: 7.1 the first polymer includes a thermoplastic, such as ABS, PS, PP, or PE; and/or 7.2 the first polymer includes a polymer blend comprising a thermoplastic, such as ABS, PS, PP, or PE; and/or 7.3 the first polymer has a Shore-D hardness between 40 and 100, preferably between 65 and 85, more preferably between 70 and 80.

8. The method according to claim 1, characterized in that the second polymer has any one of the following features: 8.1 the second polymer includes a thermoplastic elastomer or a thermoplastic vulcanisate; 8.2 the second polymer includes a polymer blend; 8.3 the second polymer has a Shore-A hardness between 40 and 100, preferably between 45 and 80, more preferably between 50 and 75.

9. The method according to claim 1, characterized in that the mounting pin extends in a mounting direction and further comprises a base portion and a head portion, the base portion being integrally bonded to the main body on the side of the vehicle side surface, in particular to the vehicle side surface, wherein preferably the head portion is configured to engage in a form fitting manner, wherein preferably the mounting pin, in particular the head portion, includes a mounting cavity, wherein preferably the mounting pin, in particular the base portion, includes a fastening disc.

10. The method according to claim 9, characterized in that the head portion includes an engaging surface extending substantially annularly and orthogonally with respect to the mounting direction, wherein preferably the head portion further includes a guiding surface extending substantially with an angle with respect to the mounting direction, wherein preferably the head portion further includes a front surface extending substantially orthogonally to the mounting direction and being spaced apart from the engaging surface in the mounting direction, wherein preferably the head portion is substantially shaped as a truncated cone or a mushroom.

11. The method according to claim 1, characterized in that the composite part further comprises an annular sealing lip being integrally bonded to the mounting pin, in particular to the base portion, wherein preferably the annular sealing lip is biased away from the vehicle side surface, in particular towards the head portion, wherein preferably the annular sealing lip is integrally formed as a unitary member with the mounting pin using the same polymer.

12. The composite part for covering, sealing, trimming, or retaining a component of a vehicle, the composite part being manufactured by the method according to claim 1 and comprising: a main body being formed by extrusion molding using a first polymer, the main body having a shape and comprising a central portion and at least one wing portion having an end portion, the central portion and the wing portion defining a vehicle side surface, the end portion being configured to abut against the component of the vehicle in a mounted state; and a mounting pin disposed on the central portion or the wing portion and being configured to engage the component of the vehicle in a form fitting manner, thereby pressing the end portion towards the component of the vehicle in the mounted state by a force resulting from bending elasticity of the main, the mounting pin being integrally bonded to the main body on side of the vehicle side surface by injection molding using a second polymer having a higher formability than the first polymer.

13. The composite part according to claim 12, characterized in that the first polymer has any one of the following features: 13.1 the first polymer includes a thermoplastic, such as ABS, PS, PP, or PE; and/or 13.2 the first polymer includes a polymer blend comprising a thermoplastic, such as ABS, PS, PP, or PE; and/or 13.3 the first polymer has a Shore-D hardness between 40 and 100, preferably between 65 and 85, more preferably between 70 and 80, wherein preferably the second polymer has any one of the following features: 13.4 the second polymer includes a thermoplastic elastomer or a thermoplastic vulcanisate; 13.5 the second polymer includes a polymer blend; 13.6 the second polymer has a Shore-A hardness between 40 and 100, preferably between 45 and 80, more preferably between 50 and 75.

Description

DESCRIPTION OF THE FIGURES

[0019] FIG. 1 depicts a vehicle including preferred composite parts;

[0020] FIG. 2 depicts a cross section of a composite part obtained by a first embodiment of the manufacturing method;

[0021] FIG. 3 depicts a cross section of a composite part obtained by a second embodiment of the manufacturing method;

[0022] FIG. 4 depicts a cross section of a composite part obtained by a third embodiment of the manufacturing method;

[0023] FIG. 5 depicts a cross section of a composite part obtained by a fourth embodiment of the manufacturing method;

[0024] FIG. 6 partially depicts an example of a mounting pin obtained by a fifth embodiment of the manufacturing method;

[0025] FIG. 7 partially depicts an example of a mounting pin obtained by a sixth embodiment of the manufacturing method;

[0026] FIG. 8 depicts a cross section of a composite part obtained by a seventh embodiment of the manufacturing method; and

[0027] FIG. 9 depicts a cross section of a composite part obtained by an eighth embodiment of the manufacturing method.

SUMMARY OF THE INVENTION

[0028] FIG. 1 depicts a vehicle 10. The vehicle 10 comprises a trunk lid 11 which is an example of a component of the vehicle 10. The trunk lid 11 is provided with a composite part 100 obtained by a method according to a first embodiment acting as a cover. The composite part 100 extends in a longitudinal direction and is disposed at the left or right side of the trunk lid 11, for example.

[0029] As may be gathered from FIG. 2, the composite part 100 comprises a main body 110. The main body 110 is formed as a single member using a first polymer or polymer blend. The first polymer includes a thermoplastic, for instance ABS. The main body 110 in general exhibits a vehicle side surface 111 and an exposed surface 112. When the composite part 100 is mounted to the trunk lid 11, the vehicle side surface 111 is facing towards the trunk lid 11, whereas the exposed surface 112 is facing away from the trunk lid 11. It should be noted that the exposed surface 112 is not necessarily visible for a spectator.

[0030] The main body 110 further comprises a central portion 113 extending substantially flat. The central portion 113 can include a recessed portion 114 for accommodating a trimming strip and a flat portion 115 adjacent to the recessed portion 114. The recessed portion 114 can be configured accommodate the trimming strip, so as to allow for an overall flush surface.

[0031] The main body 110 has a first curved portion 116. The first curve portion 116 is adjacent to the central portion 113, more precisely the recessed portion 114. The first curved portion 116 bends towards the side of the vehicle side surface 111. The main body 110 further has a second curved portion 117. The second curved portion 117 is also adjacent to the central portion 113, more precisely the flat portion 115. The second curve portion 117 bends towards the side of the vehicle side surface 111. The first curved portion 116 and the second curved portion 117 can have the same bending radius, but do not need to be bent in a circular arcuate shape.

[0032] The main body 110 is provided with a first wing portion 118 which exhibits the first curved portion 116 and a first end portion 119. The first wing portion 118 is adjacent to the recessed portion 114. The main body 110 is further provided with a second wing portion 118 which exhibits the second curved portion 117 and a second end portion 119. The second wing portion 119 is adjacent to the flat portion 115. Thus, the main body 110 can encompass a certain bending elasticity.

[0033] The composite part 100 further includes a mounting pin 130 for mounting the composite part 100 to the vehicle 10, in particular the trunk lid 11. The mounting pin 130 is formed as a single member using a second polymer or polymer blend. The second polymer includes a thermoplastic elastomer, for example EPDM. In this embodiment the mounting pin 130 is disposed on the flat portion 115. The mounting pin 130 extends in a mounting direction, which is substantially perpendicular to the flat portion 115. The mounting pin 130 has in general a cylindrical shape and is not necessarily circular.

[0034] The mounting pin 130 comprises a base portion 131. The base portion 131 is bonded to the flat portion 115. The base portion 131 can be elastically deformed, in particular along the mounting direction.

[0035] The mounting pin 130 further comprises a head portion 133. The head portion 133 is configured to engage in a form fitting manner. The head portion 133 exhibits an engaging surface 134 extending substantially orthogonal to the mounting direction and substantially annularly in a circumferential direction of the mounting pin 130. The engaging surface 134 is configured to engage, that is, when in a mounted state, come in to contact with, a surface portion of the trunk lid 11, so as to prevent a movement of the composite part 100 parallel to the mounting direction.

[0036] Furthermore, the head portion 133 can include a guiding surface 135. The guiding surface 135 forms an oblique angle with the mounting direction, thereby substantially generating the shape of a frustrated cone. The guiding surface 135 allows for an initial engagement of the mounting pin 130 and subsequently a reliable fastening by pushing.

[0037] Additionally, the head portion 133 may comprise a front surface 136. The front surface 136 is substantially orthogonal with respect to the mounting direction and spaced apart from the engaging surface 134 along the mounting direction.

[0038] When mounted to the trunk lid 11, the mounting pin 130 engages with a portion of the trunk lid 11. The main body 110 and the mounting pin 130 are configured to cooperate, so as to cause a force urging the composite part 100 towards the trunk lid 11. Due to the mounting pin 130 being elastically deformable, in particular along the mounting direction, the force is generated and the main body 110 is pulled towards the trunk lid 11. Thereby the first end portion 119 and the second end portion 121 are pressed towards the trunk lid 11 and are in contact with the trunk lid 11.

[0039] The composite part 100 is manufactured by molding of at least two different polymers. The main body 110 is formed by extrusion molding. Consequently, the main body 110 extends in a longitudinal direction and can be cut to pieces of desired length. The extrusion molding is done using a first polymer having high Shore-D-hardness. The first polymer can be a polymer blend and includes a thermoplastic, for example ABS.

[0040] Subsequently, a plurality of mounting pins 130 are bonded to the main body 110 by injection molding at predetermined intervals. The injection molding is done using a second polymer being more deformable than the first polymer. The second polymer can be a polymer blend and includes a thermoplastic elastomer, for example EPDM.

[0041] During the injection molding small portions of the main body 110 are reheated. This usually causes indentations on the exposed surface 112, which is undesirable. Using a softer, easier deformable material for the injection molding, allows for a reduction of the depth indentations and in turn a smoother exposed surface 112. Also the manufacturing method is highly adaptable for different kinds composite parts, such as sealing strips for window shafts, windows (both movable and static), and the like.

[0042] For the sake of brevity further embodiments are merely described in so far, as they differ from previously discussed embodiments.

[0043] Referring again to FIG. 1, the vehicle 10 further comprises a vehicle door 12 which is another example of a component of the vehicle 10. The vehicle door 12 has a window shaft 13 provided with a composite part 200 obtained by a method according to a second embodiment. The composite part 200 extends in a longitudinal direction substantially in parallel to the window shaft 13 and is disposed on the inside of the vehicle 10.

[0044] As may be gathered from FIG. 3, the composite part 200 comprises a main body 210 which substantially has the same design as the main body 110. The composite part 200 further includes a mounting pin 230 for mounting the composite part 200 to the vehicle 10. The mounting pin 230 is formed as a single member using a second polymer or polymer blend. The second polymer includes a thermoplastic vulcanisate. The mounting pin 230 extends in a mounting direction.

[0045] The mounting pin 230 comprises a base portion 231. The base portion 231 is bonded to the flat portion 115. The base portion 231 can be elastically deformed, in particular along the mounting direction. The base portion 231 further includes a fastening disk 232 for fastening the mounting pin 230. The fastening disk 232 extends substantially orthogonal with respect to the mounting direction. The mounting pin 230 further comprises a head portion 233 which is configured in substantially the same manner as the head portion 133.

[0046] According to FIG. 3, the composite part 200 further comprises a supporting portion 240. The supporting portion 240 is bonded to the main body 210. The supporting portion 240 supports the mounting pin 230. The supporting portion 240 comprises a first leg 241 and a second leg 242, which are integrally bonded to each other. The first leg 241 and the second leg 242 can be arranged orthogonally. The first leg 241 is integrally bonded to the main body 210, in particular to the central portion 113 or the flat portion 115. The second leg 242 is integrally bonded to the first wing portion 118 or the second wing portion 120. The mounting pin 230 is fastened to the second leg 242, for example via the fastening disk 232.

[0047] The composite part 200 further includes a supporting cavity 243. The supporting cavity 243 allows for a vibrational damping of relative movements between the main body 210 and the mounting pin 230. The supporting cavity 243 is presently defined by the main body 210 and supporting portion 240. This can be particularly advantageous when the composite part 200, as in the present embodiment, is provided on the inside of the vehicle in the passenger area.

[0048] When mounted to the vehicle door 12 the composite part 200 hast similar effects as the composite part 100. The composite part 200 is manufactured by molding of at least two different polymers as described before. Additionally, the supporting portion 240 is injection molded to the main body 210. The supporting portion 240 is preferably only formed at positions, where a mounting pin 230 is to be provided.

[0049] The mounting pin 230 and the supporting portion 240 can be injection molded simultaneously or subsequently. During the injection molding small portions of the main body 210 are reheated. Using a supporting portion 240 between the main body 210 and the mounting pin 230, in particular when the supporting portion 240 is formed using the same material as for the main body 210, allows for a smoother exposed surface 112.

[0050] Referring back to FIG. 1 the vehicle door 12 is provided with a composite part 300 obtained by a method according to a third embodiment for trimming and sealing on the outside of the vehicle 10. As may be gathered from FIG. 4, the composite part 300 comprises a main body 310. The main body 310 is similar to the main body 110. However the main body 310 is formed as a single member using a polymer blend. The polymer blend includes a mixture of thermoplastics, for instance PE and PP.

[0051] The composite part 300 further includes a mounting pin 330 for mounting the composite part 300 to the vehicle 10, in particular the vehicle door 12. The mounting pin 330 is similar to the mounting pin 130.

[0052] The composite part 300 comprises a sealing portion 340 for sealing, for example against humidity. The sealing portion 340 comprises a first wing sealing lip 341 and a second wing sealing lip 342. The first wing sealing lip 341 is integrally bonded to the first end portion 119. The second wing sealing lip 342 is integrally bonded to the second end portion 121. The sealing portion 340, more precisely the first wing sealing lip 341 and the second wing sealing lip 342 are formed by injection molding using a polymer or polymer blend, in particular a thermoplastic elastomer preferably including natural rubber or EPDM.

[0053] Similar to the first embodiment, when the composite part 300 is mounted to the vehicle door 12, the main body 310 is elastically deformed, thereby pressing the first end portion 119 and the second end portion 121 towards the surface of the vehicle door 12. In turn, the first wing lip 341 and the second wing lip 342 are in contact with the vehicle door 12 and allow for forming a seal, for instance against humidity.

[0054] The composite part 300 is manufactured similar to the composite part 100 by molding of at least two different polymers. The main body 310 is formed by extrusion molding as described before. Subsequently, a plurality of mounting pins 330 are bonded to the main body 310 by injection molding at predetermined intervals as described before. Simultaneously or subsequently the sealing portion 340, that is the first wing lip 341 and the second wing lip 342, is injection molded, so as to integrally bond to the first end portion 119 and the second end portion 121, respectively. In the present embodiment the composite part 300 is formed using a total of three different polymers.

[0055] Referring now to FIG. 4, a composite part 400 obtained by a method according to a fourth embodiment comprises a main body 410. The main body 410 is similar to the main body 310. The composite part 400 further includes a mounting pin 430 for mounting the composite part 400 to the vehicle 10. The composite part 400 also comprises a sealing portion 440 for sealing, for example against humidity. The sealing portion 440 comprises a first wing sealing lip 441 which is similar to the first wing sealing lip 341. The sealing portion 440 has a second wing sealing lip 442. The mounting pin 430 and the second wing sealing lip 442 are integrally formed as a single unitary member. The composite part 400 therefore exhibits a connecting portion 431 extending between the mounting pin 430 and the second wing sealing lip 442. The connecting portion 431 is integrally bonded to the main body 410. The mounting pin 430 and the second wing sealing lip 442, consequently also the connecting portion 431, are formed by injection molding using a polymer or polymer blend, in particular a thermoplastic elastomer preferably including natural rubber or EPDM.

[0056] The composite part 400 is manufactured similar to the composite part 300 by molding of at least two different polymers. The main body 410 is formed by extrusion molding as described before. Subsequently, a plurality of mounting pins 430 and the second sealing lip 442 are bonded to the main body 410 by injection molding. The mounting pins 430 are provided at predetermined intervals as described before. The mounting pin 430 and the second wing lip 442 are simultaneously formed by injection molding, so as to integrally bond to the main body 410. In the present embodiment the composite part 400 is formed using a total of two different polymers.

[0057] Referring to FIG. 6, a composite part 500 obtained by a method according to a fifth embodiment can be any one of the previously described embodiments. The composite part 500 comprises a mounting pin 530. The mounting pin 530 extends in a mounting direction and comprises a base portion 531. The base portion 531 can be elastically deformed, in particular along the mounting direction. The mounting pin 530 further comprises a head portion 533. The head portion 533 is configured similar to the head portion 133. Additionally, the head portion 533 has a cavity 537. The cavity 537 can facilitate the overall deformation of the mounting pin 530.

[0058] Referring to FIG. 7, a composite part 600 obtained by a method according to a sixth embodiment can be any one of the previously described embodiments. The composite part 600 comprises a mounting pin 630. The mounting pin 630 is similar to the mounting pins according to the previously described embodiments. The mounting pin 630 includes a base portion 631. Additionally, the mounting pin 630 has an annular sealing disk 632, so as to seal an opening of the vehicle 10, in which the mounting pin 630 is inserted. The annular sealing disk 632 is disposed on the base portion 631.

[0059] Referring again to FIG. 1, the vehicle 10 further comprises a pinch sensor 15 which is another example of a component of the vehicle 10. The pinch sensor 15 is disposed at the trunk lid 11, so as to detect an object in the movement path of the trunk lid 11. The pinch sensor 15 is retained by a composite part 700 obtained by a method according to a seventh embodiment.

[0060] As may be gathered from FIG. 8, the composite part 700 comprises a main body 710 which is configured similar to the main body 110. Different from the main body 110, however, the main body 710 does not include a recessed portion. The main body 710 is formed as a single member using a first polymer or polymer blend. The first polymer includes a thermoplastic, for instance ABS.

[0061] The composite part 700 further includes a mounting pin 730 for mounting the composite part 700 to the trunk lid 11. The mounting pin 730 is configured similar to the mounting pin 130, for example. Furthermore, the composite part 700 includes a retaining portion 740 for accommodating the pinch sensor 15. The retaining portion 740 comprises a retaining profile 741. The retaining profile 741 extends in a longitudinal direction and is manufactured separately from the main body 710. The retaining profile 741 is fastened to the exposed surface 112 by a suitable fastening member 742, preferably an adhesive strip 743.

[0062] Referring again to FIG. 1, the vehicle 10 further comprises a window pane 14 which is another example of a component of the vehicle 10. The window pane 14 is provided in the window shaft 13, so as to be movable between an open position and a closed position. The window pane 14 is also an example for a closing element. On the upper inside of the vehicle door 12, a composite part 800 obtained by a method according to an eighth embodiment is disposed. The composite part 800 can serve as a cover and/or sealing for the frame of the vehicle door 12.

[0063] As may be gathered from FIG. 9, the composite part 800 comprises a main body 810 which is configured similar to the main body 710. The main body 710 is formed as a single member using a first polymer or polymer blend. The first polymer includes a thermoplastic, for instance ABS.

[0064] The composite part 800 further includes a mounting pin 830 for mounting the composite part 800 to the vehicle door 12. The mounting pin 830 is configured similar to the mounting pin 710, for example. Additionally, the composite part 800 includes a retaining portion 840 for accommodating the pinch sensor 15. The retaining portion 840 comprises a retaining section 841. The retaining section 841 is integrally formed with the main body 810 as a single unitary member.

[0065] The composite parts 100, 200, 300, 400, 500, 600, 700, 800 described herein are composed of at least to polymer materials. The combination of hard polymer materials for the main body 110, 210, 310, 410, 510, 610, 710, 810 with the soft materials of the mounting pin 130, 230, 330, 430, 530, 630, 730, 830 allows in particular for a smoother surface. The composite parts 100, 200, 300, 400, 500, 600, 700, 800 are formed by extrusion molding and subsequent injection molding.

LIST OF REFERENCE SIGNS

[0066]

TABLE-US-00001 10 vehicle 11 trunk lid 12 vehicle door 13 window shaft 14 window pane 15 pinch sensor 100 composite part 110 main body 111 vehicle side surface 112 exposed surface 113 central portion 114 recessed portion 115 flat portion 116 first curved portion 117 second curved portion 118 first wing portion 119 first end portion 120 second wing portion 121 second end portion 130 mounting pin 131 base portion 133 head portion 134 engaging surface 135 guiding surface 136 front surface 200 composite part 210 main body 230 mounting pin 231 base portion 232 fastening disk 233 head portion 240 supporting portion 241 first leg 242 second leg 243 supporting cavity 300 composite part 310 main body 330 mounting pin 340 sealing portion 341 first wing lip 342 second wing lip 400 composite part 410 main body 430 mounting pin 431 connecting portion 440 sealing portion 441 first wing lip 442 second wing lip 500 composite part 530 mounting pin 531 base portion 533 head portion 537 cavity 600 composite part 630 mounting pin 631 base portion 632 annular sealing disk 700 composite part 710 main body 730 mounting pin 740 retaining portion 741 retaining profile 742 fastening member 743 adhesive strip 800 composite part 810 main body 818 first wing portion 819 first end portion 830 mounting pin 840 retaining portion 841 retaining section