CA2094285A1 - Panel or shell-like structural component - Google Patents
Panel or shell-like structural componentInfo
- Publication number
- CA2094285A1 CA2094285A1 CA002094285A CA2094285A CA2094285A1 CA 2094285 A1 CA2094285 A1 CA 2094285A1 CA 002094285 A CA002094285 A CA 002094285A CA 2094285 A CA2094285 A CA 2094285A CA 2094285 A1 CA2094285 A1 CA 2094285A1
- Authority
- CA
- Canada
- Prior art keywords
- component
- accordance
- fact
- layers
- glass fibre
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/04—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a layer being specifically extensible by reason of its structure or arrangement, e.g. by reason of the chemical nature of the fibres or filaments
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
- B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/024—Woven fabric
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/0809—Fabrics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/0854—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns in the form of a non-woven mat
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/10—Cords, strands or rovings, e.g. oriented cords, strands or rovings
- B29K2105/101—Oriented
- B29K2105/108—Oriented arranged in parallel planes and crossing at substantial angles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2277/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as reinforcement
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2309/00—Use of inorganic materials not provided for in groups B29K2303/00 - B29K2307/00, as reinforcement
- B29K2309/08—Glass
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0253—Polyolefin fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0261—Polyamide fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0276—Polyester fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/101—Glass fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/08—Reinforcements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/708—Isotropic
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/726—Permeability to liquids, absorption
- B32B2307/7265—Non-permeable
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/08—Cars
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Textile Engineering (AREA)
- Laminated Bodies (AREA)
- Reinforced Plastic Materials (AREA)
Abstract
ABSTRACT
The invention relates to a panel or shell-like structural component which can be subjected to high static and dynamic loads. The component consists of a reaction plastic like polyurethane and a reinforcement embedded therein with the structure: a first and a second outer layer (10, 18) of an elastically extensible organic fibre fabric; a first and a second stiffening glass fibre layer on the inner surface of the first and second outer layers (10,18); and a compressible spacer layer of polyamide fibres inside between the two glass fibre layers (12,16). The reinforcing structure is porous enough in the region of all the layers so that is can be impregnated with a low-viscosity reaction mixture formed on the foaming of the reaction plastic.
The invention relates to a panel or shell-like structural component which can be subjected to high static and dynamic loads. The component consists of a reaction plastic like polyurethane and a reinforcement embedded therein with the structure: a first and a second outer layer (10, 18) of an elastically extensible organic fibre fabric; a first and a second stiffening glass fibre layer on the inner surface of the first and second outer layers (10,18); and a compressible spacer layer of polyamide fibres inside between the two glass fibre layers (12,16). The reinforcing structure is porous enough in the region of all the layers so that is can be impregnated with a low-viscosity reaction mixture formed on the foaming of the reaction plastic.
Description
W() 9~/06~5 2 ~ ~ ~ 2 ~ ~ P~T/EP91/01419 PANEL OR SHELL-LIKE STRUCTURAL COMl?ONENT
The invention relates to a panel or shell-like structural component which can be subjected to high loads.
In automobiles, there is often the need to expand the tmnk temporarily into the passenger compartment, in order to transport unwieldy objects. In order to make it possible to through-load, it is necessary to have a hinged rear seat back which is separate from the self-bearing bodywork construction and therefore requires additional stabilization in order to meet safety standards in the seat back area. For example, one of the safety standards prescribes that, at a relative velocity of 40 km/h, a test dummy with a weight of 18 kg andgeometrically prescribed shape and edge measurements may not break through the upright seat backs from the truck space into the passenger compartment. In order to meet this standard, to date the proposals have been one or two panel constructions of crimped or corrugated sheet metal which are given a decorative waU facing the trunk compartment.
The effective wall strength of these components lies between about 22 to 35 mm with a total weight of about l0 kg for two hinged seat backs. Attempts have also been made to produce the seat backs of a therrnoplastic synthetic material (polypropylene) with glass fibre reinforcement in a one-shel1 construction. However, under the stated conditions of the standard, this construction proved to be inadequate.
Another method used in RD~/I technology (Reaction-~njection-Molding - reaction foams) with polyurethane is to insert flat reinforcing materials, such as glass fibre mats, into the forming tool and to impregnate them with reaction mixture during the injection process.
The purpose of the invention is to develop a panel or shell-like structural component which can be subjected to high static and dynamic loads.
,~
In order to acllieve this purpose in accordance with the invention, a structural component is proposed which is made of a reaction plastic with a layer of stiffening of the following construction embedded in it:
- a first and second outer layer of elastically extensible organic fibre fabric,- a first and second glass fibre layer on the inner surface of the f1rst and second outer layers, and - a compressible spacer layer placed between the two glass fibre layers, all of the layers being impregnated with a low-viscosity reaction mixture formed upon the foaming of the reaction plastic.
The primary purpose of the two outer layers, which will preferably consist of a weave or hotley-colllbed fabric of elastically extensible organic fibres, such as polyethylene or polyester fibres, will be to absorb shock loads elastically or plastically and thereby prevent formation of a fracture or fissure. For this reason, for example, the organic fibres exhibit a diameter of 0.3 to 0.8 mm, or in the case of polyethylenes, preferably from 0.5 mm up.
The glass fibre layers bordering on the inner surface of the outer layers have primarily a stiffening function to absorb static loads. In order to be able to absorb high tension, at least one of the two glass ~Ibre layers is made of two unidirectional mats sewn together crosswise, a so-called Roving mat. If there is little demand made on the tensile forces, a glass fibre t`abric can be used for this as well. On the other hand, on the side of the component exposed mainly to compressive load, a glass fibre mat with an essentially isotropic (irregular) glass fibre arrangement is used as the glass fibre layer.
The compressible spacer layer, composed of synthetic fibres advantageously bonded to each other poiult-by-point as a loose fleece-like mat and preferably fused together, has the purpose, especially during the manufachlre of the component, of holding the layer structure against the form wall with a certain degree of frictional connection, so that it is not displaced .
within the forming tool by the fluid reaction mixture during the form-filling process. In addition, it is intended to hold the statically and dynamically operating outer and glass fibre layers outside the neutral flexing fibres of the component. As well, the component can be varied by a greater or lesser compacting of the compressible spacer layer in its wall strength, without a compensating loss of stability over a wide area, by corresponding construction of the cavity of the forming tool. The compressible spacer layer is preferably composed of polyamide fibres in a loose, irregular pattern, in which the fibres exhibit an effective diameter of 0.5 to 1.3 mm, and preferably between 0.8 and 1 mm.
In order to obtain a high level of component stability, it is important that the reaction mixhlre which forms the reaction plastic thoroughly impregnate the reinforcing layers. For this purpose, the viscosity of the reaction mixture should not rise above 5,000 mPs initially, alld preferably be between 100 and 1,000 mPs. This is the case for polyol and isocyanate as raw products of polyurethane, for exarnple. It would be more advantageous to select a reaction plastic from the polyurethane group, polyurea, epoxy resin, polyisocyanurate.
In accordance with an advantageous embodiment of the invention, at least one of the outer layers is bordered on the exterior by a decorative layer which is imperrneable to the liquid reaction material. This decorative layer can be constructed as a synthetic foil, for example, or as a textile carpeting layer which is coated to be water-tight on the inner side or impregnated with a water-tight sealant.
For installation purposes, it is advantageous if at least one supporting structure is embedded in the area of the glass fibre layers in the component, running parallel to the layers and projectillg over the edge of the component. For example, the supporting structure can be constMcted as a metal corrugation projecting over both sides of the edge of component, \vhich in the case of a hinged seat back can be used as a storage well.
;: ~ , .
Other advantageous installation possibilities emerge from the fact that one of the outer layers, together with the glass fibre layer abutting it, overlaps the remaining layers on the side edge, in which the overlapping edge of the outer and glass fibre layers can be bent away from the other layers, leaving an open channel at the edge. The decorative layer placed on the exterior of the other layers can then overlap the layers to hook onto the channel, while in the channel a decorative or cushion cover can be wedged in the channel by means of an elastomer piping on the side edge.
The component in accordance with the invention can be used to great advanlage as a combined trunk barrier and hinged rear seat back of a motor vehicle, in which case the decorative layer should face the trunk side to fulfil its purpose and the shock-absorbing Roving mat or glass fibre fabric would face the passenger compartment.
The component in accordance with the invention can also be used as a roll-protection motor vehicle roof, as an undercarriage protective panel or roof spoiler of a truck, as the flexing base of a bumper, or as a bumper with an integrated flexible base for motor vehicles.
The invention is explained in greater detail below on the basis of an explanatory example illustrated schematically in the drawing:
The single figure shows a section through the reinforcing $tructure of a component for folding seat backs in motor` vehicles. In the upright position, folding seat backs of this type simultaneously have the function of a trunk compartment barrier wall, which ensures that the loose articles found in the trunk are kept from penetrating into the passenger compartment even in the case of an accident.
The reinforcing structure of the component exhibits the following construction:
. .
~a3~2~
- an outer layer 10 that, when the seat back is installed, fa~es the passenger compartment and ;s constructed of a honey-combed fabric made of polyethylene ~Ibres with a fibre diameter of about O.S mm, which can absorb shock loads -flexibly because of the elastic characteristics of the polyethylene;
- a glass flbre layer 12 constructed as a Roving mat which, because of the unidirectional orientation of its fibre bundles, sewn together crosswise, can tolerate high tensile loads in the direction of the fibres;
- a spacer layer 14, composed of polyamide fibres in a fleece-like pattern and placed in the centre, which permits the installation of various wall strengths in the component and assumes a spacing function within the layered structure;
- a second glass fibre layer 16 with an essentially isotropic (irregular) arrangement of the glass fibres, for stiffening, especially on the pressure side of the component;
- a second outer layer 18 constructed as a honey-combed fabric from polyethylene fibres with elastic shock-absorbing properties;
- a decorative layer 20, placed on the exterior of the outer layer 18 on the trunk compartment side, which may be constructed, for example, as a synthetic film or as a carpet provided with a water-tight coating or a corresponding impregnation.
In all the layers, the reinforcing structure exhibits sufficient porosity so that it can be ssltul~ted with a low-viscosity reaction mixhlre which forms when the reaction plastic is foamed.
Embedded additionally in the area of the first glass fibre layer is a metallic corrugation layer 22, the ends of which project over the component and form a storage well for the folding seat back.
6 2~ 285 The edges of the first outer layer 10 and the first glass fibre layer 12 together overlap the remaining layers 14, 16, and 18 and are vertically bent toward the tmnk compartment in such a way that an open channel 26 runs all the way around.
To manufacture the component, the reinforcing structure is set into the cavity of a forming tool (not illustrated) in the described order and acted upon by a iiquid reaction mixture, composed of polyol and isocyanate, for example, conducted through a spme located in the central area of the outer layer 10, for example. This process saturates the layer structure in the reaction mixture, so that during the subsequent foaming process a close bond with the resulting reaction plastic is created. The wall strength of the component typically is about 12 to 14 mm, so that a total weight of about 6 kg results for the two folding seat backs.
E~periments llave shown that the component can withstand an acceleration of the standard test dummy (18 kg) to 32 kg. The channel 26 remains open and can be used as a piping channel to secure a covering or cushion overlapping the component on the side of outer layer 10, with the help of an elastomer piping.
The invention relates to a panel or shell-like structural component which can be subjected to high loads.
In automobiles, there is often the need to expand the tmnk temporarily into the passenger compartment, in order to transport unwieldy objects. In order to make it possible to through-load, it is necessary to have a hinged rear seat back which is separate from the self-bearing bodywork construction and therefore requires additional stabilization in order to meet safety standards in the seat back area. For example, one of the safety standards prescribes that, at a relative velocity of 40 km/h, a test dummy with a weight of 18 kg andgeometrically prescribed shape and edge measurements may not break through the upright seat backs from the truck space into the passenger compartment. In order to meet this standard, to date the proposals have been one or two panel constructions of crimped or corrugated sheet metal which are given a decorative waU facing the trunk compartment.
The effective wall strength of these components lies between about 22 to 35 mm with a total weight of about l0 kg for two hinged seat backs. Attempts have also been made to produce the seat backs of a therrnoplastic synthetic material (polypropylene) with glass fibre reinforcement in a one-shel1 construction. However, under the stated conditions of the standard, this construction proved to be inadequate.
Another method used in RD~/I technology (Reaction-~njection-Molding - reaction foams) with polyurethane is to insert flat reinforcing materials, such as glass fibre mats, into the forming tool and to impregnate them with reaction mixture during the injection process.
The purpose of the invention is to develop a panel or shell-like structural component which can be subjected to high static and dynamic loads.
,~
In order to acllieve this purpose in accordance with the invention, a structural component is proposed which is made of a reaction plastic with a layer of stiffening of the following construction embedded in it:
- a first and second outer layer of elastically extensible organic fibre fabric,- a first and second glass fibre layer on the inner surface of the f1rst and second outer layers, and - a compressible spacer layer placed between the two glass fibre layers, all of the layers being impregnated with a low-viscosity reaction mixture formed upon the foaming of the reaction plastic.
The primary purpose of the two outer layers, which will preferably consist of a weave or hotley-colllbed fabric of elastically extensible organic fibres, such as polyethylene or polyester fibres, will be to absorb shock loads elastically or plastically and thereby prevent formation of a fracture or fissure. For this reason, for example, the organic fibres exhibit a diameter of 0.3 to 0.8 mm, or in the case of polyethylenes, preferably from 0.5 mm up.
The glass fibre layers bordering on the inner surface of the outer layers have primarily a stiffening function to absorb static loads. In order to be able to absorb high tension, at least one of the two glass ~Ibre layers is made of two unidirectional mats sewn together crosswise, a so-called Roving mat. If there is little demand made on the tensile forces, a glass fibre t`abric can be used for this as well. On the other hand, on the side of the component exposed mainly to compressive load, a glass fibre mat with an essentially isotropic (irregular) glass fibre arrangement is used as the glass fibre layer.
The compressible spacer layer, composed of synthetic fibres advantageously bonded to each other poiult-by-point as a loose fleece-like mat and preferably fused together, has the purpose, especially during the manufachlre of the component, of holding the layer structure against the form wall with a certain degree of frictional connection, so that it is not displaced .
within the forming tool by the fluid reaction mixture during the form-filling process. In addition, it is intended to hold the statically and dynamically operating outer and glass fibre layers outside the neutral flexing fibres of the component. As well, the component can be varied by a greater or lesser compacting of the compressible spacer layer in its wall strength, without a compensating loss of stability over a wide area, by corresponding construction of the cavity of the forming tool. The compressible spacer layer is preferably composed of polyamide fibres in a loose, irregular pattern, in which the fibres exhibit an effective diameter of 0.5 to 1.3 mm, and preferably between 0.8 and 1 mm.
In order to obtain a high level of component stability, it is important that the reaction mixhlre which forms the reaction plastic thoroughly impregnate the reinforcing layers. For this purpose, the viscosity of the reaction mixture should not rise above 5,000 mPs initially, alld preferably be between 100 and 1,000 mPs. This is the case for polyol and isocyanate as raw products of polyurethane, for exarnple. It would be more advantageous to select a reaction plastic from the polyurethane group, polyurea, epoxy resin, polyisocyanurate.
In accordance with an advantageous embodiment of the invention, at least one of the outer layers is bordered on the exterior by a decorative layer which is imperrneable to the liquid reaction material. This decorative layer can be constructed as a synthetic foil, for example, or as a textile carpeting layer which is coated to be water-tight on the inner side or impregnated with a water-tight sealant.
For installation purposes, it is advantageous if at least one supporting structure is embedded in the area of the glass fibre layers in the component, running parallel to the layers and projectillg over the edge of the component. For example, the supporting structure can be constMcted as a metal corrugation projecting over both sides of the edge of component, \vhich in the case of a hinged seat back can be used as a storage well.
;: ~ , .
Other advantageous installation possibilities emerge from the fact that one of the outer layers, together with the glass fibre layer abutting it, overlaps the remaining layers on the side edge, in which the overlapping edge of the outer and glass fibre layers can be bent away from the other layers, leaving an open channel at the edge. The decorative layer placed on the exterior of the other layers can then overlap the layers to hook onto the channel, while in the channel a decorative or cushion cover can be wedged in the channel by means of an elastomer piping on the side edge.
The component in accordance with the invention can be used to great advanlage as a combined trunk barrier and hinged rear seat back of a motor vehicle, in which case the decorative layer should face the trunk side to fulfil its purpose and the shock-absorbing Roving mat or glass fibre fabric would face the passenger compartment.
The component in accordance with the invention can also be used as a roll-protection motor vehicle roof, as an undercarriage protective panel or roof spoiler of a truck, as the flexing base of a bumper, or as a bumper with an integrated flexible base for motor vehicles.
The invention is explained in greater detail below on the basis of an explanatory example illustrated schematically in the drawing:
The single figure shows a section through the reinforcing $tructure of a component for folding seat backs in motor` vehicles. In the upright position, folding seat backs of this type simultaneously have the function of a trunk compartment barrier wall, which ensures that the loose articles found in the trunk are kept from penetrating into the passenger compartment even in the case of an accident.
The reinforcing structure of the component exhibits the following construction:
. .
~a3~2~
- an outer layer 10 that, when the seat back is installed, fa~es the passenger compartment and ;s constructed of a honey-combed fabric made of polyethylene ~Ibres with a fibre diameter of about O.S mm, which can absorb shock loads -flexibly because of the elastic characteristics of the polyethylene;
- a glass flbre layer 12 constructed as a Roving mat which, because of the unidirectional orientation of its fibre bundles, sewn together crosswise, can tolerate high tensile loads in the direction of the fibres;
- a spacer layer 14, composed of polyamide fibres in a fleece-like pattern and placed in the centre, which permits the installation of various wall strengths in the component and assumes a spacing function within the layered structure;
- a second glass fibre layer 16 with an essentially isotropic (irregular) arrangement of the glass fibres, for stiffening, especially on the pressure side of the component;
- a second outer layer 18 constructed as a honey-combed fabric from polyethylene fibres with elastic shock-absorbing properties;
- a decorative layer 20, placed on the exterior of the outer layer 18 on the trunk compartment side, which may be constructed, for example, as a synthetic film or as a carpet provided with a water-tight coating or a corresponding impregnation.
In all the layers, the reinforcing structure exhibits sufficient porosity so that it can be ssltul~ted with a low-viscosity reaction mixhlre which forms when the reaction plastic is foamed.
Embedded additionally in the area of the first glass fibre layer is a metallic corrugation layer 22, the ends of which project over the component and form a storage well for the folding seat back.
6 2~ 285 The edges of the first outer layer 10 and the first glass fibre layer 12 together overlap the remaining layers 14, 16, and 18 and are vertically bent toward the tmnk compartment in such a way that an open channel 26 runs all the way around.
To manufacture the component, the reinforcing structure is set into the cavity of a forming tool (not illustrated) in the described order and acted upon by a iiquid reaction mixture, composed of polyol and isocyanate, for example, conducted through a spme located in the central area of the outer layer 10, for example. This process saturates the layer structure in the reaction mixture, so that during the subsequent foaming process a close bond with the resulting reaction plastic is created. The wall strength of the component typically is about 12 to 14 mm, so that a total weight of about 6 kg results for the two folding seat backs.
E~periments llave shown that the component can withstand an acceleration of the standard test dummy (18 kg) to 32 kg. The channel 26 remains open and can be used as a piping channel to secure a covering or cushion overlapping the component on the side of outer layer 10, with the help of an elastomer piping.
Claims (26)
1. Panel or shell-like structural component made of a reaction plastic with a reinforcing structure of the following construction, embedded in it:
- a first and second outer layer (10; 18) made of an elastically extensible organic fibre fabric, - a first and a second glass fibre layer (12, 16) on the inner surface of the first and second outer layers (10; 18), respectively and - a compressible spacer layer (14) located inside between the two glass fibre layers (12, 16), all the layers being impregnated with a low-viscosity reaction mixture formed on the foaming of the reaction plastic.
- a first and second outer layer (10; 18) made of an elastically extensible organic fibre fabric, - a first and a second glass fibre layer (12, 16) on the inner surface of the first and second outer layers (10; 18), respectively and - a compressible spacer layer (14) located inside between the two glass fibre layers (12, 16), all the layers being impregnated with a low-viscosity reaction mixture formed on the foaming of the reaction plastic.
2. Component in accordance with Claim 1, characterized by the fact that at least one of the outer layers (10, 18) is constructed as a textile fabric, preferably as a honey-combed fabric.
3. Component in accordance with Claims 1 and 2, characterized by the fact that the organic fibres of the outer layers (10, 18) consist of polyethylene or polyester.
4. Component in accordance with Claims 1 through 3, characterized by the fact that the diameter of the organic fibres measures 0.3 to 0.8 mm, and preferably about 0.5 mm.
5. Component in accordance with Claims 1 through 4, characterized by the fact that at least one of the glass fibre layers (12) is composed of two unidirectional mats laid crosswise to each other and preferably sewn together (roving mat).
6. Component in accordance with Claims 1 through 5, characterized by the fact that at least one of the glass fibre layers (12) is constructed as a glass fibre fabric.
7. Component in accordance with Claims 1 through 6, characterized by the fact that at least one of the glass fibre layers (16) is formed by a mat with essentially isotropic glass fibre distribution.
8. Component in accordance with Claims 1 through 7, characterized by the fact that the spacer layer (14) consists of a loose fleece-like mat made of synthetic fibres bonded to each other at points, and preferably fused together.
9. Component in accordance with Claims 1 through 8, characterized by the fact that the compressible spacer layer (14) is composed of polyamide fibres in a loose, irregular pattern.
10. Component in accordance with Claim 9, characterized by the fact that the polyamide fibres exhibit a diameter of 0.5 to 1.3 mm, and preferably 0.8 to 1 mm.
11. Component in accordance with one of the Claims 1 through 10, characterized by the fact that the reaction mixture exhibits a viscosity of initially 100 to 1,000 mPs.
12. Component in accordance with one of the Claims 1 through 11, characterized by the fact that the reaction mixture contains polyol and isocyanate.
13. Component in accordance with one of the Claims 1 through 12, characterized by a reaction plastic composed of the group of polyurethane, polyurea, epoxy resin, polyisocyanurate.
14. Component in accordance with one of the Claims 1 through 13, characterized by the fact that a water-tight decorative layer (20) is located on the exterior side of at least one of the outer layers (18).
15. Component in accordance with Claim 14, characterized by the fact that the decorative layer (20) is constructed as a synthetic film or as a textile carpet with a water-tight coating on the inside or impregnated with a water-tight substance.
16. Component in accordance with one of the Claims 1 through 15, characterized by the fact that at least one supporting structure (22) is embedded in the area of the glass fibre layers (12) parallel to the layers and projecting over the edge of the component.
17. Component in accordance with Claims 16, characterized by the fact that the supporting structure is constructed as a metallic corrugation (22) projecting on both sides over the edge of the component.
18. Component in accordance with one of the Claims 1 through 17, characterized by the fact that one of the outer layers (10), together with the glass fibre layer next to it, overlaps the remaining layers (14,16, 18) on the side edge.
19. Component in accordance with Claim 18, characterized by the fact that the overlapping edge of the outer and glass fibre layers (10, 12) is bent away from the remaining layers (14, 16, 18), leaving an open-edged channel (26).
20. Component in accordance with Claim 19, characterized by the fact that the decorative layer (20) located on the exterior side of the remaining layers (14, 16, 18) interlocks in the channel (26).
21. Component in accordance with Claim 19 or 20, characterized by the fact that a decorative or cushioned cover can be wedged in the channel (26) on the side edge by means of an elastomer piping.
22. Use of the component in accordance with one of the Claims 1 through 21 as a combined trunk compartment barrier wall and a fold-down seat back of a motor vehicle.
23. Use of the component in accordance with Claims 1 through 22, characterized by the fact that the decorative layer (20) is located on the trunk compartment side and the Roving mat or glass fibre fabric is located on the passenger compartment side.
24. Use of the component in accordance with one of the Claims 1 through 21 as a motor vehicle roof.
25. Use of the component in accordance with one of the Claims 1 through 21 as an undercarriage protective panel.
26. Use of the component in accordance with one of the Claims 1 through 21 as a flexible base of a bumper or as a bumper with an integral flexible base for motor vehicles.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DEP4033270.5 | 1990-10-19 | ||
| DE4033270A DE4033270A1 (en) | 1990-10-19 | 1990-10-19 | PLATE OR SHELL-SHAPED COMPONENT |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2094285A1 true CA2094285A1 (en) | 1992-04-20 |
Family
ID=6416654
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002094285A Abandoned CA2094285A1 (en) | 1990-10-19 | 1991-07-29 | Panel or shell-like structural component |
Country Status (5)
| Country | Link |
|---|---|
| EP (1) | EP0553092B1 (en) |
| JP (1) | JPH06501654A (en) |
| CA (1) | CA2094285A1 (en) |
| DE (2) | DE4033270A1 (en) |
| WO (1) | WO1992006845A1 (en) |
Families Citing this family (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| BE1008585A3 (en) * | 1994-03-22 | 1996-06-04 | Kruyfhooft Christina | Method for producing a manhole cover and manhole cover obtained in this way |
| WO1998008705A1 (en) * | 1996-08-29 | 1998-03-05 | Lear Corporation | Vehicle seat assembly |
| DE19809272C2 (en) * | 1998-03-04 | 2002-05-02 | Eldra Kunststofftechnik Gmbh | Fiber composite sandwich component and manufacturing process |
| WO2000061363A1 (en) * | 1999-04-08 | 2000-10-19 | Mitsubishi Rayon Co., Ltd. | Preform for composite material and composite material |
| US6828016B2 (en) | 1999-04-08 | 2004-12-07 | Mitsubishi Rayon Co., Ltd. | Preform for composite material and composite material |
| FR2795371B1 (en) * | 1999-06-25 | 2001-09-14 | Faure Bertrand Equipements Sa | SEAT WITH VISCOELASTIC FOAM |
| US20020168531A1 (en) * | 2001-03-15 | 2002-11-14 | Markusch Peter H. | Two-ply polyurethane/geotextile composite and process for preparing the same |
| LU101019B1 (en) | 2018-11-26 | 2020-05-26 | Euro Composites | Sandwich composite component for aircraft interiors |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| ATA911273A (en) * | 1972-10-31 | 1976-08-15 | Bayer Ag | FIBER COMPOSITE SYSTEM FOR REINFORCEMENT OF HIGHLY DEMANDING FOAM SHAPED BODIES |
| DE3021428A1 (en) * | 1980-06-06 | 1982-01-07 | Lentia GmbH Chem. u. pharm. Erzeugnisse - Industriebedarf, 8000 München | Cementable, foamable laminate prodn. e.g. for ski mfr. - by pressing fibre-reinforced thermosetting resin substrate and barrier resin-coated top layer(s) |
| US4828910A (en) * | 1987-12-16 | 1989-05-09 | Reinhold Haussling | Sound absorbing laminate |
-
1990
- 1990-10-19 DE DE4033270A patent/DE4033270A1/en not_active Withdrawn
-
1991
- 1991-07-29 DE DE59103134T patent/DE59103134D1/en not_active Expired - Fee Related
- 1991-07-29 CA CA002094285A patent/CA2094285A1/en not_active Abandoned
- 1991-07-29 JP JP3512758A patent/JPH06501654A/en active Pending
- 1991-07-29 EP EP91913678A patent/EP0553092B1/en not_active Expired - Lifetime
- 1991-07-29 WO PCT/EP1991/001419 patent/WO1992006845A1/en active IP Right Grant
Also Published As
| Publication number | Publication date |
|---|---|
| WO1992006845A1 (en) | 1992-04-30 |
| DE4033270A1 (en) | 1992-04-23 |
| JPH06501654A (en) | 1994-02-24 |
| EP0553092A1 (en) | 1993-08-04 |
| EP0553092B1 (en) | 1994-09-28 |
| DE59103134D1 (en) | 1994-11-03 |
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| EEER | Examination request | ||
| FZDE | Dead |