DE102017006751A1 - Composite component, assembly with such a composite component, and vehicle with such an assembly - Google Patents

Abstract

The invention relates to a composite component (7) having a first cover layer (9), a second cover layer (11), and a core (13) arranged between the first cover layer (9) and the second cover layer (11), wherein the first cover layer (9) and the second cover layer (11) are spaced apart by the core (13), wherein only the second cover layer (11) has recesses (17), the first cover layer (9) and the core (13) being free from Incisions, wherein the incisions (17) are formed linearly and form a polygonal pattern, and wherein on the second cover layer (11) adhesive strips (19) are applied, which are seen along their longitudinal extent everywhere - perpendicular to their longitudinal extent - spaced apart.

Description

The invention relates to a composite component, an assembly with such a composite component and a component to be reinforced, and a vehicle having such an assembly.

From the European patent application EP 2 712 790 A1 is an assembly in the form of a curved vehicle roof made of sheet metal, plastic or composite material with a vehicle inside glued to the vehicle roof roof reinforcement element known as a composite component of a composite panel consisting of a foam core and on both sides with the foam core firmly connected cover layers. The roof reinforcement element is planar and provided exclusively on the side facing the vehicle roof with a pattern of linear cuts with a depth of cut of at least 55% of a thickness of the roof reinforcement element, the cuts completely cut through a cover layer and also cut a portion of the foam core. The curved vehicle roof is thus reinforced on its underside by means of the roof reinforcement element as a composite component. The linear cuts are used in particular to achieve an adaptation to the contour, in particular the curvature thereof, when the composite component is glued to the vehicle roof and thereby prevent restoring forces during the adhesion to the vehicle roof, which can otherwise lead to optical impairments, in particular bumps , For bonding such composite components to vehicle roofs typically Kleberaupen be used having a thickness of 1 cm to 2 cm.

Since the line-shaped cuts extend not only over the upper cover layer but also far into the foam core, the composite component is susceptible to cracking. The with 1 cm to 2 cm comparatively strong adhesive beads can easily lead to air inclusions when sticking, which in turn have optical impairments result.

The invention has for its object to provide a composite component, an assembly with such a composite component and a vehicle with such an assembly, said disadvantages do not occur.

The object is achieved by providing the subject matters of the independent claims. Advantageous embodiments emerge from the subclaims.

The object is achieved in particular by providing a composite component which has a first cover layer and a second cover layer, wherein a core is arranged between the first cover layer and the second cover layer, and wherein the first cover layer and the second cover layer are spaced apart by the core are. It is provided that only the second cover layer has incisions, wherein the first cover layer and the core are free of incisions. The incisions are linear and form a polygonal pattern. Adhesive sheets are applied to the second cover layer, which are seen from one another along their longitudinal extent everywhere, that is seen in each section of its longitudinal extent, perpendicular to its longitudinal extent. Due to the fact that the line-shaped incisions penetrate only the second cover layer and in particular not the core-and already thereby certainly not the first cover layer-the composite component has high crack stability. The adhesive webs, which are spaced apart from one another along their longitudinal extent, can be applied with a small thickness, so that the risk of air inclusions is significantly reduced, which in turn helps to avoid optical impairments when gluing the composite component to a component to be reinforced. At the same time, therefore, the composite component has a high crack stability and enables a backlash-free adaptation to the contour of the component to be reinforced without air pockets during adhesion. At the same time, the stability of the composite component is increased by the fact that the incisions have a small depth of cut and only extend into the second cover layer. In particular, the polygonal pattern, which form the line-shaped incisions, contributes to the fact that the composite component can be adapted without any recesses to the - in particular curved - contour of a component to be reinforced, for example a vehicle roof.

By virtue of the fact that the adhesive webs are spaced from one another along their entire longitudinal extension, when the composite component is adhesively bonded to the component to be reinforced, the air located therebetween can be pushed out, wherein it can escape along the longitudinal extent of the adhesive webs. The spacing of the adhesive webs provided along the longitudinal extent thus ensures, in particular, that virtually channels are provided for the air, along which these can then escape - seen in the longitudinal direction of the adhesive webs. The adhesive strips thus preferably all extend in parallel along one direction, in particular either in the width direction or in the longitudinal direction of the composite component. Thus, air pockets that affect the component with regard to its appearance and functionality, in particular as a result of changing heat loads, can be avoided.

The first cover layer essentially serves the rigidity of the composite component and may therefore have no cuts, cracks or other weakenings. Rather, the first cover layer is preferably unhurt, homogeneous and continuous.

The second covering layer is preferably that covering layer which is adhesively bonded as intended to a component to be reinforced, that is to say facing the component to be reinforced. The first cover layer is preferably that cover layer which faces away from the component to be reinforced in the intended installation position.

The composite component is in particular designed to reinforce a curved component, in particular a vehicle roof.

The core is preferably inherently rigid, whereby the composite component can have particularly favorable reinforcing properties. At the same time, however, the core is preferably designed to be flexible, in particular flexible and inherently rigid.

The linear incisions form in particular patterns of polygonal, adjoining partial surfaces. In particular, this allows a return-free adaptation of the composite component to the component to be reinforced.

The adhesive webs are preferably flat, and more preferably have an application height of less than 1 cm, preferably less than 0.5 cm. The adhesive sheets are preferably applied parallel to one another on the second cover layer, which in particular serves for easier application of the adhesive to the composite component.

According to a development of the invention, it is provided that the second cover layer is in an intended installation position of the composite component in an assembly, in particular in a vehicle, an upper cover layer of the two cover layers. In particular, the second cover layer is preferably facing a vehicle roof of a vehicle and thus - seen in the vehicle vertical direction - arranged above the first cover layer and above the core. Thus, the second cover layer closes the composite component upwards, while the first cover layer preferably delimits the composite component downward.

According to one embodiment of the invention, it is provided that the incisions delimit hexagonal or polyhexagonal partial surfaces at least in regions of the second cover layer which are remote from the edges. In this case, the incisions can themselves run along edges of individual hexagons, or they can run along edges of polyhexagonal structures, wherein the polyhexagonal structures are composed of a plurality of hexagons, which in turn are not formed by incisions, but by otherwise structuring the second covering layer, for example by an embossing or the like, are formed. In particular, regions remote from the center are understood as meaning centrally and / or centrally arranged regions of the second cover layer. However, it is also possible for the incisions along an entire surface of the second cover layer to delimit hexagonal or polyhexagonal partial surfaces. It is possible that the cuts in certain areas of the second cover layer limit hexagonal and in other areas of the cover polyhexagonal faces. Such hexagons form, as it were, a honeycomb-like structure which, in a particularly favorable manner, permits a non-return adaptation of the composite component to a particularly curved shape of a component to be reinforced. Depending on the degree of curvature of the component to be reinforced, the partial surfaces may be composed of a plurality of hexagons, so that a partial surface geometry arises which has a polyhexagonal shape locally. Such a shape provides particularly high rigidity. Polyhexagonal partial surfaces are provided in particular for flatter places of the component to be reinforced, ie for those locations which have a smaller curvature. For areas with a higher curvature, ie greater curvature, individual hexagons are preferably provided, since they allow an even better and locally more accurate adaptation of the composite component even to strong curvatures. Hexagons have proven to be the optimum geometry in terms of stiffness and flexibility of the composite component. An edge length of such a hexagon or a hexagonal or polyhexagonal partial area is preferably 30 mm.

According to one embodiment of the invention, it is provided that the adhesive strips extend at least in sections along the incisions.

The adhesive sheets are preferably applied in such a way that they cover collinear cutting sections, ie regions of the cuts. In particular, the adhesive sheets may be applied so that these portions of the incisions are in the width direction of the composite component or in the length direction of the same. This can be done in particular so that only the incisions are exposed to adhesive. However, it is easier for the application and for an improved hold of the composite component on the component to be reinforced to form the adhesive webs continuously - in particular in the manner of a flat, long noodle. The adhesive webs then extend, in particular along their longitudinal extent, partially over cut-in regions of the second cover layer, in some cases also on non-recessed areas are positioned, in particular when the incisions do not extend continuously along one direction, but for example in the manner of a zig-zag pattern, a hexagonal pattern, discontinuous or the like. As a result of the adhesive webs, the composite component is virtually repaired at the locations of the incisions when the adhesive webs are arranged on the incisions. The adhesive sheets form a sort of film hinge, which covers the cut edges.

The adhesive strips thus extend at least in sections along the incisions. In particular, they are arranged at least partially on the incisions.

According to one development of the invention, it is provided that a planar expansion of the partial surfaces delimited by the incisions varies over the surface of the second cover layer. The partial surfaces are therefore not the same size everywhere along the surface of the second cover layer, but have locally different expansions. The areal extent of the partial surfaces is smaller, especially where the composite component is more curved in the intended installation position, in particular on a curved component to be reinforced. As already explained above, the composite component can better adapt to stronger curvatures where it has locally smaller partial surfaces which are delimited by the cuts. Where the composite component is provided locally for less strongly curved regions of the component to be reinforced, on the other hand larger partial surfaces with a larger areal extent can be bounded by the incisions, which does not detract from the adaptability of the composite component to the lower curvature prevailing there, but in an advantageous manner Increases the stability of the composite component compared to a configuration in which the composite component has smaller partial areas everywhere. In this way, the composite component can locally be designed so that on the one hand the need for a flexible and non-return adaptation to the curvature of the reinforcing member and on the other hand for the highest possible rigidity and stability of the composite component is taken into account. In particular, the faces for areas of greater curvature may have a simple hexagonal shape, ie consist of individual hexagons, where they may have a polyhexagonal shape for locally smaller curvatures, which may have several, for example, by embossing or impressions forms. Also, the size of each hexagon can vary locally.

According to a development of the invention, it is provided that at least one incision selected from the linear incisions has a discontinuous cutting profile. Unlike the adhesive webs, this at least one incision then does not extend continuously along one direction, but preferably also does not extend continuously along a zig-zag line delimiting a hexagonal structure. Rather, the incision is partially interrupted by non-incised areas and thus deviates over its width or length direction from the patency of the uniform zigzag course. In this way, the crack resistance of the composite component can be significantly increased. Preferably, a plurality of incisions, particularly preferably all incisions, have such a discontinuous sectional profile. Furthermore, the cuts preferably do not extend along a single, continuous direction, but rather follow a polygonal structure of boundary edges of polygonal faces, so that they change direction locally in some sections. So they are in particular formed locally linear.

According to one embodiment of the invention, it is provided that the core comprises a foam material or consists of a foam material, in particular a foam. In this way, the core can be both flexible and intrinsically stiff. Alternatively or additionally, the core preferably has a column honeycomb structure or is formed from a column honeycomb structure. Such a column honeycomb structure can likewise be hexagonal, in particular honeycomb-shaped, and gives the composite component a particularly high stability. Apart from a foam, the core may also comprise a material having similar or equivalent properties as a foam. In addition to stiffening properties, the core material preferably also has damping properties, in particular in order to compensate for the vibrations. Preferably, the material of the core also has heat-insulating properties.

Alternatively or additionally, it is preferably provided that the first cover layer and / or the second cover layer has / have a fiber material or consists / consist of a fiber material. As fiber materials are in particular paper, cardboard or textile materials as well as fiber-reinforced plastics in question. Alternatively or additionally, it is also possible for the first cover layer and / or the second cover layer to comprise at least one plastic or to consist of at least one plastic or a plastic mixture.

Alternatively or additionally, it is preferably provided that the second cover layer comprises a fiber material or consists of a fiber material, wherein the line-shaped incisions preferably at least partially, particularly preferably completely extend along a fiber longitudinal direction of the fiber material. In this way, damage to the second cover layer can be kept small by the incisions, so that the strength of the second cover layer is maintained as much as possible. This can be achieved, in particular, by arranging the second cover layer on the core in such a way that the incisions can extend along the fiber longitudinal direction. This is possible in a particularly favorable manner if the second cover layer has as a fibrous material paper, cardboard or a textile material.

The object is also achieved by providing an assembly which has a component to be reinforced, preferably curved, as well as a composite component according to one of the embodiments described above, wherein the composite component is glued to the component to be reinforced via the adhesive sheets. In connection with the assembly, in particular, the advantages that have already been explained in connection with the composite component arise. In particular, the composite component can follow the contour of the component to be reinforced without jump-back and flexibly and at the same time has high crack stability and high rigidity, whereby the risk of air inclusions when gluing the composite component to the component to be reinforced is markedly reduced.

According to a development of the invention, it is provided that the adhesive webs are glued to the component to be reinforced, in particular pressed with the component to be reinforced, a width, which is measured in particular perpendicular to the longitudinal extent of the adhesive sheets, of at least 6 mm to at most 10 mm , preferably of 8 mm. Alternatively or additionally, the adhesive webs in this state have a height measured locally along a surface normal of the second cover layer, that is to say perpendicular to the second cover layer, of at least 0.8 mm to at most 1.2 mm, preferably 1 mm. Alternatively or additionally, the adhesive webs in this state have a distance measured perpendicularly to the longitudinal extension of the same from one another of at least 10 mm to at most 15 mm, preferably of 13 mm. This distance is in particular measured between adhesive webs immediately adjacent to each other. The adhesive webs are thus formed flat in any case in glued and in particular compressed state, wherein their height over the second cover layer is significantly lower than their measured in the plane of the second cover layer width. The distance between the adhesive sheets to each other is again significantly greater than the height, and in particular greater than the width of the adhesive sheets. In particular, in this way it can be ensured that the adhesive sheets are spaced apart from each other along their longitudinal extent, so do not touch anywhere.

When glued to the component to be reinforced, the composite component is preferably pressed against this in order to achieve a particularly strong and stable adhesive bond. Therefore, it is also spoken of a compressed state of the adhesive sheets.

Due to the fact that the adhesive webs do not overlap, when the composite component is adapted to the component to be reinforced, the intervening air can escape, so that air inclusions that would lead to optically undesired impressions on the component to be reinforced are avoided.

Finally, the object is also achieved by providing a vehicle having an assembly according to one of the previously described embodiments. The component to be reinforced is preferably a planar body component of the vehicle, in particular a vehicle roof. But it can also be another, in particular expansive, sheet-metal body part, for example, a bonnet, a trunk lid, a side wall, or a vehicle door. In connection with the vehicle, in particular, the advantages that have already been explained in connection with the assembly and the composite component arise.

The vehicle is designed in particular as a motor vehicle, particularly preferably as a passenger car. But it is also possible that the vehicle is a commercial vehicle or a truck.

The invention will be explained in more detail below with reference to the drawing. Showing:

Showing:

1 a schematic detail of an embodiment of a vehicle with an embodiment of an assembly and an embodiment of a composite component, and

2 a schematic detail of the composite component according to 1 ,

1 shows a schematic detail of an embodiment of a vehicle 1 , in particular a passenger car, with an assembly 3 , which is a component to be reinforced 5 and a composite component 7 having. The composite component 7 is to reinforce the component to be reinforced 5 glued to this. That too reinforcing component 5 is preferably curved and in particular a flat body component of the vehicle 1 , In particular, it may be in the component to be reinforced 5 to act around a vehicle roof. But it is also possible that the component to be reinforced 5 a bonnet, a trunk lid, a side wall, a vehicle door, or another, in particular expansive, flat body part of the vehicle 1 is.

The composite component 7 has a component to be reinforced 5 facing away, first cover layer 9 and a component to be reinforced 5 facing, in particular with the component to be reinforced 5 bonded second cover layer 11 on, being between the first cover layer 9 and the second cover layer 11 - In the vertical direction of the composite component 7 seen - a core 13 is arranged, through which the first cover layer 9 and the second cover layer 11 spaced apart from each other. As will be explained below, only the second cover layer has 11 Cuts on, with the core 13 and the first cover layer 9 are free from cuts. As a result, the stability of the composite component 7 compared to a design in which cuts deep into the core 13 penetrate, increased, at the same time the crack stability of the composite component 7 is significantly increased.

2 shows a schematic detail of the composite component 7 according to 1 , Identical and functionally identical elements are provided with the same reference numerals, so that reference is made to the preceding description. It shows 2 in particular a view of the viewer on the second cover layer 11 from above. The component to be reinforced 5 So here is removed, or not yet with the composite component 7 glued so that the view of the viewer free on the not yet to be reinforced with the component 5 connected composite component 7 and in particular on its second cover layer 11 falls. In particular, the viewer is in 2 a surface 15 the second cover layer 11 facing.

In the composite component proposed here 7 now has the second cover layer 11 cuts 17 on, for the sake of simplicity, only an incision is indicated here by a reference numeral. The first cover layer 9 and the core 13 are free from cuts 17 , whereby the crack stability of the composite component 7 in particular compared to a composite component, in which the incisions 17 deep in the core 13 extend, is significantly increased. At the same time, the composite component 7 in this way a high rigidity.

The cuts 17 are linear and form a polygonal pattern. In particular, this allows a return-free adaptation of the composite component 7 to the contour of the component to be reinforced 5 ,

On the second cover layer 11 , especially on the surface 15 , are adhesive strips 19 applied along a, in 2 horizontal, longitudinal extent and everywhere along its longitudinal extent - seen perpendicular to the longitudinal extent - are spaced apart. In this way, air when pressing the composite component 7 against the component to be reinforced 5 along the longitudinal extent of the adhesive sheets 19 escape, so that air pockets are avoided and high optical quality and functionality - especially in changing heat loads - the composite component 7 can be guaranteed.

2 also shows that the cuts 17 - At least in edge remote areas of the second cover layer 11 - But preferably everywhere along the second cover layer 11 , hexagonal or polyhexagonal faces 21 form, of which only one is provided with a reference numeral here. Such a hexagon can have an edge length of 30 mm.

The flat extension of the incisions 17 limited patches may be over the surface 15 the second cover layer 11 vary, wherein the areal extent can be smaller, especially locally where the composite component 7 at the intended installation position on the component to be reinforced 5 is more curved, so where in particular locally to be reinforced component 5 has a greater curvature. In particular, it is possible that the hexagons are not everywhere along their edges of incisions 17 are limited, but that, for example, the incisions 17 polyhexagonal faces 21 which are composed of several contiguous hexagons, wherein the inner edges of the individual hexagons of the polyhexagonal faces are formed by impressing or embossing, but not by cutting. Especially in shallower areas of the composite component 7 That is, in such areas, which are to rest on shallower areas of the component to be reinforced 5 are provided, such polyhexagonal partial surfaces may be provided, so that the composite component 7 Here locally has increased rigidity and stability. In areas of the composite component 7 for abutment against more curved or curved areas of the component to be reinforced 5 are provided, however, the incisions 17 individual hexagons limit, so that the composite component 7 here in a particularly flexible manner to the locally increased curvature of the component to be reinforced 5 can be adjusted so that in particular a return-free adaptation and surface conditioning results.

Preferably, the cuts have 17 at least in some areas a discontinuous cutting process. In particular, they can be interrupted so that they do not consistently follow a clear direction or consistently follow a uniform zig-zag course. As a result, the crack resistance of the composite component 7 increase.

The adhesive sheets 19 extend preferably at least partially along the incisions, in particular at least partially on the incisions 17 lie. This will be through the incisions 17 caused injuries to the second cover layer 11 at least partially through the adhesive sheets 19 quasi repaired, so that these, like a film hinge, the cut edges of the cuts 17 cover.

The adhesive sheets 19 preferably in with the component to be reinforced 5 glued and in particular pressed state a width - in 2 measured in the vertical direction - from at least 6 mm to at most 10 mm, preferably 8 mm; and / or a - perpendicular to the image plane of 2 measured - height of at least 0.8 mm to at most 1.2 mm, preferably 1 mm; and / or a distance d from each other of at least 10 mm to at most 15 mm, preferably 13 mm.

The core 13 is preferably formed of foam, or of another material with similar properties. Alternatively or additionally, the core 13 also comprise a column honeycomb structure. In addition to stiffening properties, the material of the core 13 Also have damping properties to compensate for vibrations and preferably to act heat-insulating.

At least one of the cover layers selected from the first cover layer 9 and the second cover layer 11 , preferably both outer layers 9 . 11 , Has / have a fiber material, in particular paper, cardboard or a textile material, and / or a plastic, or they consist of such a material.

Particularly preferably, at least the second cover layer 11 a fiber material or consists of a fiber material, wherein the incisions 17 extend at least partially along a fiber longitudinal orientation of the fiber material to the least possible extent the second cover layer 11 damage and thus to maintain their strength as much as possible.

With the composite component proposed here 7 , the assembly 3 and the vehicle 1 it is possible, a return-free adaptation of the composite component 7 to the component to be reinforced 5 without air pockets and at the same time high rigidity of the composite component 7 to reach, which may have a high crack stability.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 2712790 A1 [0002]

Claims (10)

Composite component ( 7 ), with - a first cover layer ( 9 ), - a second cover layer ( 11 ), and - one between the first cover layer ( 9 ) and the second cover layer ( 11 ) arranged core ( 13 ), wherein - the first cover layer ( 9 ) and the second cover layer ( 11 ) through the core ( 13 ) are spaced apart, wherein - only the second cover layer ( 11 ) Cuts ( 17 ), wherein - the first cover layer ( 9 ) and the core ( 13 ) are free of incisions, and where - the incisions ( 17 ) are formed in a line shape and form a polygonal pattern, and wherein - on the second cover layer ( 11 ) Adhesive sheets ( 19 ) are applied, which are seen everywhere along its longitudinal extent - perpendicular to its longitudinal extent - spaced apart. Composite component ( 7 ) according to claim 1, characterized in that the second cover layer ( 11 ) in the intended installation position of the composite component ( 7 ) is an upper cover layer. Composite component ( 7 ) according to one of the preceding claims, characterized in that the incisions ( 17 ) at least in regions of the second cover layer which are remote from the edge ( 11 ) hexagonal or polyhexagonal faces ( 21 ) limit. Composite component ( 7 ) according to one of the preceding claims, characterized in that the adhesive webs ( 19 ) at least in sections along the cuts ( 17 ). Composite component ( 7 ) according to one of the preceding claims, characterized in that a surface extension of the incisions ( 17 ) limited areas ( 21 ) over a surface ( 15 ) of the second cover layer ( 11 ), wherein the areal extent is smaller where the composite component ( 7 ) is more curved at the intended installation position. Composite component ( 7 ) according to one of the preceding claims, characterized in that at least one of the cuts ( 17 ) has a discontinuous cutting profile. Composite component ( 7 ) according to one of the preceding claims, characterized in that a) the core ( 13 ) comprises a foam or consists of a foam, and / or that the core ( 13 ) has a column honeycomb structure; and / or that b) the first cover layer ( 9 ) and / or the second cover layer ( 11 ) comprise a fiber material and / or a plastic, or consist of a fiber material and / or at least one plastic; and / or that c) the second cover layer ( 11 ) comprises a fiber material or consists of a fiber material, wherein the incisions ( 17 ) extend at least partially along a fiber longitudinal direction of the fiber material. Assembly ( 3 ), comprising a reinforcing, preferably curved component ( 5 ), and a composite component ( 7 ) according to one of claims 1 to 7, wherein the composite component ( 7 ) with the component to be reinforced ( 5 ) over the adhesive webs ( 19 ) is glued. Assembly ( 3 ) according to claim 8, characterized in that the adhesive webs ( 19 ) in with the component to be reinforced ( 5 ) glued state a) a width of at least 6 mm to at most 10 mm, preferably 8 mm; and / or b) have a height of at least 0.8 mm to at most 1.2, preferably of 1 mm, and / or c) have a distance from one another of at least 10 mm to at most 15 mm, preferably 13 mm. Vehicle ( 1 ), with an assembly ( 3 ) according to one of claims 8 and 9, wherein the component to be reinforced ( 5 ) preferably a flat body component of the vehicle ( 1 ), in particular a vehicle roof, a hood, a trunk lid, a side wall, or a vehicle door.

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