Method for manufacturing a paneling member

Patent metadata

Field	Value
Publication number	US-9987793-B2
Application number	US-201615200822-A
Country	US
Kind code	B2
Filing date	Jul 1, 2016
Priority date	Jul 1, 2015
Publication date	Jun 5, 2018
Grant date	Jun 5, 2018

Abstract

A method for producing a panelling component for a motor vehicle. The method includes press-forming a fiber-reinforced load-bearing composite component; forming a film having a class-A surface; and joining the load-bearing composite component as a first layer and the film as a second layer via an adhesive as an interposed third layer.

First claim

What is claimed is:

1. A method for producing a paneling component for a motor vehicle, the method comprising:
forming a fiber-reinforced load-bearing composite component;
pressing the load-bearing composite component in a double-sided mould into a first shape;
forming a film having a class-A surface;
thermoforming the film, but not the load-bearing composite component, using a single-sided mould while an entire surface of the film is free of direct contact with the single-sided mould so that the film is shaped into a second shape corresponding to the first shape; and
after the pressing of the load-bearing composite component and the thermoforming of the film, joining the load-bearing composite component, that has the first shape, as a first layer, and the film, that has the second shape, as a second layer via an adhesive as an interposed third layer.

2. The method of claim 1 , wherein, before the joining, the film has already set and/or cooled, and/or already has a structure of the paneling component when the paneling component is finished.

3. The method of claim 1 , wherein the film comprises a single ply and/or is a co-extrudate.

4. The method of claim 1 , wherein the film is connected to the load-bearing composite component over a full surface area thereof via the adhesive.

5. The method of claim 1 , wherein the load-bearing composite component is formed by pressing or extruding.

6. The method of claim 1 , wherein the load-bearing composite component is produced by pressing organosheets reinforced with continuous fibers into a desired shape under heat.

7. The method of claim 1 , wherein the load-bearing composite component and the film are each produced from a thermoplastic.

8. The method of claim 1 , wherein the adhesive is applied having a thickness sufficient to ensure accommodation of component tolerances.

9. The method of claim 1 , wherein leads or cables are integrated into the load-bearing composite component and/or the adhesive.

10. The method of claim 1 ,
wherein sensors and/or lighting systems are integrated into the adhesive.

11. The method of claim 1 , further comprising:
forming at least one aperture in the load-bearing composite component and the adhesive; and
arranging a lighting system in the at least one aperture.

12. The method of claim 11 , wherein a region of the film is at an end of the at least one aperture and is transparent, and an end of the lighting system is arranged directly adjacent to the region so that the end of the lighting system faces the region.

13. The method of claim 1 , wherein the entire surface of the film that is free of direct contact with the single-sided mould is the class-A surface.

14. The method of claim 1 , wherein the pressing occurs at a temperature range of between 240 to 300 degrees Celsius, and the thermoforming occurs at a temperature range of between 175 to 190 degrees Celsius.

15. A method for producing a paneling component for a motor vehicle, the method comprising:
forming a fiber-reinforced load-bearing composite component;
pressing the load-bearing composite component in a double-sided mould into a first shape;
forming a film having a class-A surface;
thermoforming the film, but not the load-bearing composite component, in a single-sided mould so that the film is shaped into a second shape corresponding to the first shape;
after the pressing of the load-bearing composite component and the thermoforming of the film, joining the load-bearing composite component as a first layer, and the film as a second layer via an adhesive as an interposed third layer; and
before the joining, the film already has a finished shape corresponding to a shape of the paneling component when the paneling component is finished.

Assignees

• Magna Steyr Fahrzeugtechnik Ag & Co Kg

Inventors

• Hofer Bernhard
• Passegger Wolfgang

Classifications

• B29C51/082

  by shaping between complementary mould parts · CPC title

• B32B2307/414

  Translucent · CPC title

• B32B5/12

  characterised by the relative arrangement of fibres or filaments of {different layers, e.g. the fibres or filaments being parallel or perpendicular to each other} · CPC title

• B29K2055/02

  ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers · CPC title

• B32B27/365

  comprising polycarbonates · CPC title