U.S. patent application number 10/574793 was filed with the patent office on 2007-01-11 for component, especially a hybid carrier for a vehicle, and method for the production of said type of component, and use of said type of component.
Invention is credited to Martin Derleth, Jochen Schmitz, Walter Wolf.
Application Number | 20070006986 10/574793 |
Document ID | / |
Family ID | 34436312 |
Filed Date | 2007-01-11 |
United States Patent
Application |
20070006986 |
Kind Code |
A1 |
Derleth; Martin ; et
al. |
January 11, 2007 |
Component, especially a hybid carrier for a vehicle, and method for
the production of said type of component, and use of said type of
component
Abstract
The invention relates to a component (1), especially a hybrid
carrier for a carrier in a vehicle. Said component comprises a base
body (2) provided with a cavity (H), and said base body is provided
with at least an inner plastic covering. The plastic covering is
formed by a film channel (3, 3a) which is made of plastic and which
is arranged in the cavity (H) of the base body (2).
Inventors: |
Derleth; Martin;
(Schonungen, DE) ; Schmitz; Jochen; (Leonberg,
DE) ; Wolf; Walter; (Oppenweiler-Zell, DE) |
Correspondence
Address: |
FOLEY AND LARDNER LLP;SUITE 500
3000 K STREET NW
WASHINGTON
DC
20007
US
|
Family ID: |
34436312 |
Appl. No.: |
10/574793 |
Filed: |
October 8, 2004 |
PCT Filed: |
October 8, 2004 |
PCT NO: |
PCT/EP04/11280 |
371 Date: |
August 16, 2006 |
Current U.S.
Class: |
162/234 |
Current CPC
Class: |
B62D 25/142 20130101;
B62D 29/004 20130101; B62D 25/14 20130101; B62D 29/005 20130101;
B62D 25/145 20130101; B60H 1/0055 20130101; B62D 29/001 20130101;
B60H 1/242 20130101; B60H 1/00564 20130101 |
Class at
Publication: |
162/234 |
International
Class: |
D21C 7/00 20060101
D21C007/00 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 8, 2003 |
DE |
103-47-230.4 |
Mar 2, 2004 |
DE |
10-2004-010-615.0 |
Claims
1. A component, particularly a hybrid carrier for a carrier in a
vehicle, comprising a base body exhibiting a cavity (H) with at
least an inner plastic covering, in conjunction with which the
plastic covering is formed by a film channel which is made of
plastic and which is arranged in the cavity (H) of the base
body.
2. The component as claimed in claim 1, in which the base body is
formed from at least two elements (E), in particular a half shell
with a lid or two half shells.
3. The component as claimed in claims 1, in which the base body
exhibits a wall thickness of 0.7 mm to 1.2 mm.
4. The component as claimed in claim 1, in which the film channel
is made from a thermoplastic, in particular from polyethylene or
polypropylene.
5. The component as claimed in claim 1, in which the film channel
is formed and produced from physically or chemically foamed and
extruded plastic, in particular in single-layer or multiple-layer
form.
6. The component as claimed in claim 1, in which the film channel
is formed from a compact, thin plastic, in particular from a
single-layer or multiple-layer plastic.
7. The component as claimed in claim 1, in which the wall thickness
of the film channel is 0.2 mm to 0.5 mm, and the density of the
plastic is 60 g/l to 200 g/l or 300 g/l.
8. The component as claimed in claim 1, in which the film channel
is formed from at least two layers of plastic.
9. The component as claimed in, claim 1, wherein the film channel
is attached in a thermally adhesive fashion and/or by bonding to
the base body.
10. The component as claimed in claim 1, in which the film channel
is arranged on the base body by means of securing elements.
11. The component as claimed in claim 1, in which the film channel
is provided with a partition wall.
12. The component as claimed in claim 1, in which the film channel
exhibits a smaller cross section than the cross section of the base
body and is arranged inside the base body in such a way that at
least two chamber channels are formed.
13. The component as claimed in claim 1, in which the base body is
lined additionally on the internal wall, at least partially, with
plastic applied by spraying.
14. The component as claimed in, in which the film channel is
provided with reinforcing elements on its outer side facing towards
the base body.
15. The component as claimed in claim 1, in which a plurality of
film channels assembled inside one another are arranged in the base
body.
16. The component as claimed in claim 1, in which at least one film
channel is executed as a deep-drawn half shell.
17. A method for the production of a component as claimed in claim
1, having a base body exhibiting a cavity with at least an inner
plastic covering, in conjunction with which a film channel made of
plastic is introduced as a plastic covering in the cavity of the
base body.
18. The method as claimed in claim 17, in which the film channel is
assembled in the base body itself or is pre-assembled in a separate
forming tool and is then introduced into the base body.
19. The method as claimed in claim 17, in which at least two layers
of plastic are arranged one above the other and are compressed or
welded at their lateral edges running in a longitudinal direction,
in conjunction with which, following thermal pre-heating, the edges
are then pushed together so as to cause the two layers of plastic
to arch outwards in a mutually opposing direction.
20. The method as claimed in claim 17, in which, in order to cause
the layers of plastic to arch outwards, warm air is caused to flow
between these until the layers of plastic arch outwards in a
mutually opposing direction.
21. The method as claimed in claim 17, in which air is led away via
at least one recess in the base body or in the forming tool.
22. The method as claimed in claim 17, in which a negative pressure
is applied in order to cause arching outwards of the layers of
plastic to take place outside the recess.
23. The method as claimed in, in which the layers of plastic harden
in the outward-arched state or adhere to the internal wall of the
base body.
24. The method as claimed in claim 17, in which the film channel is
formed from at least two deep-drawn half shells, which are
introduced into the base body.
25. The method as claimed in claim 24, in which at least one
additional layer of plastic is applied between the inserted,
deep-drawn half shells.
26. The method as claimed in claims 24, in which at least two flat
layers of plastic, in particular plastic films, are applied
additionally between the inserted, deep-drawn half shells, between
which at least one outward curve is produced by means of the inward
flow of warm air.
27. The method as claimed in claim 17, in which the film channel,
in addition to the self-adhesion, is retained by means of a
securing element on the base body.
28. The method as claimed in claim 17, in which the base body is
sprayed additionally, at least partially, with compact or foamed
plastic.
29. The method as claimed in claim 17, characterized in that a
single-layer or multiple-layer plastic film is used as the layer of
plastic.
30. The use of a component as claimed in claim 1 as an instrument
panel carrier in a vehicle with a film channel, in particular with
at least one air-guiding channel and/or a cable channel.
31. The use of a component as claimed in claim 1 as a structural
component in a vehicle, in particular as a hollow structural
element, as a longitudinal member, sill, center tunnel structure,
front, longitudinal or transverse member, vertical structural
element, A-, B-, C-, D-pillar, or roof structural element.
32. Use of a component as claimed in claim 1 as a structural
component in a vehicle, in particular as a hollow structural
component, through which air for a heating, cooling, air
conditioning or ventilation device is conducted.
Description
[0001] The invention relates to a component, especially a hybrid
carrier for a vehicle. The invention also relates to the production
and use of a component of this kind.
[0002] Already familiar from the automobile construction industry
are transverse carriers formed from tubes, which consist of metal
and exhibit appropriately heavy wall thicknesses. The wall
thicknesses in this case are of appropriately heavy execution for
adequate dimensional, bending, bursting and torsional stability and
for adequate load-bearing capacity. The transverse carrier executed
as a tubular or hollow profile is suitable in principle for guiding
air, for example from an air conditioning system arranged centrally
in the front area of the vehicle, to lateral discharge outlets.
[0003] The stipulated rigidity of the component, in particular the
carrier and a cross section resulting therefrom, leads to a
correspondingly high weight of the component. In addition, the
space required for installation is large, while the space available
for installation is restricted by the body of the vehicle. A
reduction in the size of the component would involve a reduction in
the size of the channel cross section, which, although associated
with a reduction in weight, Confirmation copy nevertheless causes
an increase in the flow velocity. This would lead to increased
noise generation and to an associated impairment of comfort.
[0004] Moreover, the cost of logistics and production of the
component with an air channel is high, because prefabricated
blow-molded or injection-molded parts are involved. In the event of
accidents involving impact by the head, costly safety measures are
also required, which call for the lowering of the outlet nozzles
from the air channel, for example.
[0005] DE 100 64 522 A1 describes a component, especially a
transverse carrier intended to be arranged between the A-pillars of
a motor vehicle, having an essentially tubular base body, in which
at least one channel is provided, in conjunction with which the
base body is lined internally with plastic to form channel walls
consisting of plastic. The component in this case is covered with
plastic by an injection or molding process, in conjunction with
which this forms channel walls. A process of this kind requires a
large number of working operations and is thus associated with a
high production cost. This component also exhibits a high
weight.
[0006] Previously disclosed in DE 200 21 556 U1 is an airtight hose
made from a flexible material used as a fluid or flow channel. A
hose of this kind can also be connected by gluing or welding, which
is a very intricate operation if accurate positioning is to be
achieved, in view of the small space that is available for
installation. Here, too, the simultaneous conveyance of several
fluids is not possible.
[0007] The object of the invention is thus to make available a
component of particularly simple construction, which is especially
suitable for a channel for a medium, for example air. A
particularly simple process for producing the component and uses
for the component are described in addition.
[0008] The object is achieved in accordance with the invention with
regard to the component by the characterizing features of claim 1.
With regard to the process, the object is achieved by the
characterizing features of claim 17, and with regard to the uses
for a component of this kind, the object is achieved by the
characterizing features of claims 30 to 32.
[0009] Advantageous further developments of the invention are the
subject of the dependent claims.
[0010] The invention in this case is based on the notion that a
component, in particular a hybrid component used as a carrier and
intended for the distribution of air in the interior of a vehicle,
should be simplified in such a way as to afford particularly simple
production and easy replacement, and in such a way as to provide an
air-guiding channel offering a significant reduction in the weight
of the component. In addition to the simplification of the channel,
the weight in particular should also be significantly reduced. For
this purpose, the base body of the component exhibiting a cavity is
provided at least in some areas with a plastic lining situated at
least internally and/or is executed with perforations at least in
some areas. In order to achieve the greatest possible reduction in
weight, the plastic lining is formed by a film channel made of
plastic arranged in the cavity of the base body.
[0011] The base body is made appropriately from at least two
elements, for example a half shell with a lid or two half shells.
With the component in its closed state, a flow channel, in
particular an air-guiding channel, is formed in a simple manner by
the cavity in the closed base body and the film channel arranged
therein. The base body is executed from a metal, a light metal or
its alloys, in particular from aluminum, magnesium, titanium or
refined steel, and exhibits a wall thickness from 0.4 mm up to 2.0
mm or even up to 3.0 mm, and in particular from 0.7 mm up to 1.2
mm. The wall thickness in this case can remain largely constant,
however, or may vary in the longitudinal and/or transverse extent
of the base body depending on the strength or rigidity
requirements. With a thin-walled metal base body of this kind
consisting of a plurality of elements, for example half shells, and
a film channel made of plastic, it is possible to replace the
customary thick, compact walls of a hybrid carrier with a thin,
compact wall with an easily applied lightweight insulation. The
hybrid carrier in its entirety is significantly lighter in weight
and can be produced at a lower cost. In conjunction with this, a
film channel can be used at the same time for a plurality of, or
for all the outflow points, whereby a delayed use of the film
channel for the conveyance of different fluids to different outflow
points is also possible. In the event of deformation, the discharge
nozzles can retract into the film channel or the film channels, in
conjunction with which the film channel, which is made in
particular from a plastic film, will offer only little resistance.
In addition, the base body made from sheet metal half shells with
low wall thickness contributes to the high stability of the
component.
[0012] The film channel is preferably made from a thermoplastic
material, in particular polyethylene plastic or polypropylene
plastic. For example, the film channel can be formed and produced
from a plastic material that has been foamed and extruded by
physical or chemical means, in particular in a single layer or in
multiple layers. In one preferred embodiment, for example, a foam
film made of polypropylene or polyethylene can be provided. The
plastic in this case is preferably foamed and extruded, as a result
of which a smaller thickness with a high load-bearing capacity is
achieved. Alternatively, the film channel can be executed from a
compact film provided, where appropriate, with a woven fabric made
from plastic fibers or metal fibers. Examples of this are films
made of polyvinyl chloride, polypropylene, polyethylene,
thermoplastic polyolefin and thermoplastic polyurethane. The use of
a compact plastic film of this kind permits a small film thickness
in conjunction with high stability and rigidity, in particular
resistance to bursting. A very low weight for the film channel can
be achieved with polyethylene or polypropylene plastic.
[0013] The use of such materials for the film channel permits the
selection of acoustic and/or thermal characteristics, such as
acoustically and or thermally insulated characteristics, as
required, for example in sections, by executing the layer
construction of the plastic used for the film channel accordingly.
The film channel preferably exhibits a channel wall with an
ultimate tensile strength of at least 1 bar positive pressure and a
temperature resistance of 85.degree. C. to at least 120.degree. C.
It is possible in this way to ensure that the film channel remains
dimensionally stable and functionally stable, both in the presence
of positive pressure, for example with the outflow nozzles of the
flow channel closed and with the fan switched on, and in the
presence of particularly high thermal loadings, for example due to
solar radiation.
[0014] In one possible embodiment, the film channel exhibits a wall
thickness from 0.2 mm to 0.5 mm and a density of the plastic from
60 g/l to 200 g/l or 300 g/l. In this case, the film channel
exhibits a stable wall structure. For example, the skin or the
deformable material is executed with corresponding flexibility, and
in particular elasticity, so that wrinkling is reliably avoided and
with it adhesion of the channel wall of the film channel. At the
same time, the generation of noise is suppressed and the traveling
comfort is increased accordingly by the use of an elastic, in
particular rubber-like material with particularly good acoustic
damping characteristics.
[0015] In one simple embodiment, the film channel is formed from at
least two layers of plastic or plastic films, which are
superimposed as far as possible one on top of the other to form a
cavity. The film channel is expediently attached in a thermally
adhesive fashion and/or by bonding to the base body, and in
particular to its inner wall. Alternatively or additionally, the
film channel can be retained on the base body by securing
elements.
[0016] In order to execute the flow channel as a so-called
multiple-chamber channel, the film channel is provided with a
partition wall, in particular an elastic, formable and/or folding
partition wall. Variable cross sections can be set for the
individual channels of the chamber by means of a flexibly formable
partition wall of this kind. The partition wall in this case can be
formed by a separate plastic film, which is arranged between the
two layers of plastic of the film channel. By using a plurality of
chamber channels, which are separated from one another in each case
by at least one partition wall in the form of a plastic film,
different flow media, for example warm air, cold air, fresh air,
can be conducted to different outflow points.
[0017] Alternatively or additionally to the partition wall, for the
purpose of forming a multiple-chamber channel in the base body, the
film channel can exhibit a smaller cross section than the cross
section of the base body. At least one two-chamber channel can be
formed by the appropriate arrangement of the film channel with a
smaller cross section. For this purpose, the film channel makes
contact with at least one internal wall of the base body. More than
two chamber channels can be formed in the case of an arrangement of
the film channel without making contact with the base body. An
additional partition wall or separating film can be dispensed
with.
[0018] For the best possible rigidity, in particular resistance to
bursting, buckling and/or torsional stability of the base body,
this can also be lined on its inner wall, at least in parts, with
plastic applied by spraying. Additional insulation and/or improved
force transmission and force stability are achieved in this
way.
[0019] Furthermore, the film channel can be provided with
reinforcing elements, for example ribs or burls, on its outer side
facing towards the base body. In this way, the film channel has a
greater load-carrying capacity and is of more stable execution.
[0020] In a further embodiment, a plurality of film channels can be
arranged in the base body. These can be assembled inside one
another or adjacent to one another, for example, to form a
multiple-chamber channel. In this way, the insulation of the
channel and the chambers can be improved in relation to one
another. Additionally or alternatively, in the case of a flexible
film channel, its surface can be provided with a structure which
prevents adhesion of the channel walls.
[0021] In a further embodiment, the film channel can be executed,
instead of as a blown film, as at least two deep-drawn half shells,
which are arranged one above the other to form the film channel.
The deep-drawn half shells are made from compact plastic of a
similar kind to the plastic used in a box of chocolates, for
example, and exhibit sufficiently good inherent stability and
inherent strength.
[0022] Various methods are available for the simple forming and
introduction of the film channel.
[0023] For example, the film channel made of plastic may be
introduced into a cavity in the base body, in particular by
mechanical and/or thermal means with or without the use of
pressure.
[0024] In conjunction with this, the film body can be assembled in
the base body itself. Alternatively, the film channel can be
pre-assembled in a separate forming tool and then introduced into
the base body.
[0025] In one possible production process, at least two layers of
plastic are arranged one on top of the other and are attached to
one another at their lateral edges running in a longitudinal
direction, in particular by compression or welding. Instead of two
flat layers or films of plastic, a simple blown film which
initially lies flat can also be used, which is also attached at two
edges. Following thermal preheating, the edges are then pushed
together so as to cause the two layers or films of plastic to arch
outwards in mutually opposing directions or the blown film to arch
outwards. This process is also known as the so-called "Twin Sheet
Process". Alternatively or additionally, outward arching of the two
layers of plastic can be achieved by shortening spring elements
applied to the outside of the layer of plastic in each case.
[0026] The arching apart of the layers of plastic can thus be
performed very easily and efficiently in a variety of ways: for
example, by causing the compressed edges to slide towards one
another, or by allowing warm air to flow in between at least two
layers or to be introduced into a single blown film lying flat,
until the layers or the blown film arch outwards and become
attached to the internal wall of the base body or the forming tool
(=restriction).
[0027] The arching process will be easier and more precise if air
is led away via at least one recess in the base body or the forming
tool. Alternatively or additionally, arching outwards can be caused
to take place outside the recess in the base body or the forming
tool by the application of a negative pressure, in conjunction with
which the precision is increased if the expansion of the plastic
layers or the blown plastic film is restricted to the recesses.
[0028] Depending on the production process, and the nature of the
plastic used, the layer of plastic in the outward-curved state may
harden and form the film channel, in conjunction with which this
may lead to adhesion at points of contact with the internal wall of
the base body. In the case of an essentially flexible and soft
plastic, this will adhere to the internal wall of the base body in
such a way that the film channel is formed.
[0029] In an alternative embodiment, the film channel is produced
from at least two deep-drawn half shells, which are introduced into
the base body. Depending on the production process, the base body
in this case is used as a forming tool to produce the two
deep-drawn half shells. In this case, the film channel is formed
from at least two deep-drawn plastic layers or plastic films
inserted into at least one element of the base body and secured
there. Furthermore, at least one additional plastic layer or
plastic film can be applied between inserted, deep-drawn half
shells, thereby enabling a division of the film channel into two
chamber channels, in which various fluids, for example fresh air or
warm air, can be conveyed at the same time. By the additional
application of at least two flat plastic films between inserted,
deep-drawn half shells, between which at least one outward curve is
produced by means of the inward flow of warm air, it is possible to
produce a film channel with three or more chamber channels by
simple means.
[0030] In addition to the self-adhesion of the film channel to the
base body, the film channel can be retained on the base body by
means of a securing element. An additional attachment of the film
channel to at least one element of the base body increases the
stability, in particular in respect of displacements of the film
channel in relation to the base body in service as a flow
channel.
[0031] In order to achieve the best possible supporting structure
and supporting construction of the component, the base body can be
coated additionally by the plastic, at least partially and in
particular along its longitudinal extent, and in particular
extrusion-coated. The base body is preferably provided with plastic
internally and/or externally. The plastic is also preferably
applied in one or more layers and/or with a thickness that varies
in different areas. In order to achieve the best possible bending,
buckling and torsional stability of the component, the plastic
should preferably be applied with positive engagement and over the
entire surface. In addition to providing good structural rigidity,
the plastic layer also offers thermal insulation and/or acoustic
insulation in a plastic structure that is executed as a channel,
through which a medium flows in the form of a gas or a liquid. In
addition, one of the layers of plastic can be provided with a
reinforcement, and in particular with a reinforcing woven fabric,
with fibers, spheres or other materials, for example a fiberglass
cloth. For better thermal and acoustic insulation, the layer of
plastic can be executed as a foam. PU foam, hard or soft foam,
integral foam, can be caused to foam by physical or chemical means
for this purpose (TSG thermoplastic foam extrusion molding, Mucell
process, etc.), or can be applied in a multiple-layer form, in
conjunction with which individual layers can exhibit different
thicknesses.
[0032] A base body executed from a metal or a light metal, in
particular aluminum, magnesium or refined steel, with a wall
thickness from 0.4 mm to 1.5 mm, to 2.0 mm or even to 3.0 mm is
preferably used. Depending on the nature and the function of the
component, the base body can be formed with a varying wall
thickness in different areas. For example, in the event that the
component is used as a transverse member, this can be executed with
a greater wall thickness in the vicinity of mountings and force
application points in the vehicle, for example in the vicinity of a
connection to an A-pillar, in the vicinity of the steering, in the
area of the connection of an air conditioning system, or, in the
case of so-called front-end structural members, in the vicinity of
the longitudinal members, engine mountings or the bonnet lock, than
in the area in which the component serves only as an air channel,
as an assembly support or for other functions. The metal sheets
used for the base body are available under the designations
"tailored blanks" (assembled by welding in certain areas),
"tailored rolled blanks" (rolled with a different thickness in the
direction of rolling), "profiled strip" (e.g. thick edge, thin
center), or as "patch-work sheets" (as in a puzzle, although each
part attached to the blank has a different wall thickness). A metal
base body of this kind or a sheet component of this kind is
particularly economical and is particularly suitable for use in the
automobile construction industry in a lightweight assembly designed
to achieve a reduction in weight.
[0033] The component described above is preferably used as an
instrument panel carrier in a vehicle, in conjunction with which
the plastic core or the plastic structure forms one or more
channels, in particular an air-guiding channel and/or a cable
channel. Alternatively, a component of this kind can be used as a
transverse carrier in a vehicle, in particular as a transverse
carrier between the A-pillars of a vehicle.
[0034] The advantages achieved with the invention are in particular
that, by means of a base body with a film channel, an essentially
lightweight component with a particularly small installation volume
is obtained. In addition, the component can be produced with a
particularly simple forming tool. A component is thus particularly
cost-advantageous as an air-guiding channel due to the low material
and component costs. The component also has a particularly low
weight. Various flow channels are possible through the flexible
design of the film channel.
[0035] Illustrative embodiments of the invention are explained in
more detail with reference to a drawing, in which:
[0036] FIG. 1 illustrates schematically an overall view of a
component, in particular a hybrid carrier;
[0037] FIGS. 2A to 2D illustrate schematically the production of a
component with a film channel as a cross section in a forming
tool;
[0038] FIGS. 3A to 3B illustrate schematically the insertion of a
film channel into a base body of a component as a cross
section;
[0039] FIGS. 4A to 4C illustrate schematically the production and
arrangement of a film channel in a base body of a component as a
cross section;
[0040] FIGS. 5A to 5B illustrate schematically two components, in
particular hybrid carriers with a film channel as two chamber
channels as a cross section.
[0041] Corresponding component parts are provided with identical
designations in all the Figures.
[0042] Represented in perspective view in FIG. 1 is a component 1,
in particular a hybrid component for a carrier for arrangement
between the A-pillars (not shown here in greater detail) of a motor
vehicle (not shown here in greater detail).
[0043] The component 1 comprises, for example, a base body 2 formed
from two connected elements E, which base body is lined with a film
channel 3. The component 1 also comprises, for the ventilation of
the interior of the vehicle, a plurality of openings O, which serve
as air inlets and/or air outlets. An opening O for the supply of
air from an air conditioning system and/or heating and an opening O
for a central outlet opening are provided in the central area.
Openings O for the outer outlet nozzles are present at the ends of
the carrier 1.
[0044] The film channel 3 serves as a flow channel for the purpose,
for example, of conducting air or routing cables. The film channel
3 is in the form of a foamed or extruded polypropylene foam film in
one possible embodiment. The film channel 3 preferably exhibits a
wall thickness of 0.4 mm to 0.5 mm for a density of 60 g/l to 200
g/l or 300 g/l. In addition, the film channel 3 can be provided
with a thermally insulated covering layer.
[0045] The base body 2 is preferably made from a metal sheet, in
particular a light metal sheet, for example from aluminum sheet,
magnesium sheet, or fine steel sheet. The base body 2 in the
illustrative embodiment is executed as a hollow profile, and in
particular as a tubular hollow profile. Alternatively, the base
body can also be executed as a hollow profile with a box-like cross
section. In this case, one of the elements E of the base body 2
forms a U-profile or a half shell or an under shell, and the other
element E is executed as a lid. The base body 2 exhibits a wall
thickness of 0.7 mm to 1.2 mm. The base body 2 can be provided
internally with plastic in addition. The plastic is attached in the
form of a plastic lining by joining, insertion or extrusion.
[0046] In order to permit the best possible utilization of the film
channel 3 for guiding a medium, for example air, for the air
conditioning of a vehicle interior or, alternatively, for routing
lines or cables, the two elements E must be secured to one another
sufficiently via the edges R. The edges R in this case form the
parting plane between two elements E. For this purpose, with the
base body 2 in its closed state, the elements E are attached to one
another at their edges R that are superimposed one on top of the
other by mechanical means and/or with positive bonding between the
materials. To this end, the base body 2 can be attached by caulking
to the mutually opposing edges R of the elements E by riveting,
screwing, welding, gluing, folding, caulking, clinching or in some
other way. In addition, the base body 2, and in particular its two
elements E, can be held together via the plastic at the edges R at
openings, for example projections, that are not illustrated here in
greater detail.
[0047] The plastic lining on the internal wall formed from the
plastic serves the purpose, among other things, of increasing the
rigidity of the base body 2. When air flows through it, the base
body 2 of particularly thin-walled execution gives rise to the
generation of noise, which is damped to particularly great
advantage by lining the base body 2 with the plastic. That is to
say, the plastic assumes an acoustic insulation function and, if
appropriate, a thermal insulation function, too.
[0048] FIGS. 2A, 2B and 2C illustrate the so-called Twin Sheet
process. This involves clamping two flat layers 8 of plastic or
plastic films in place in a separate forming tool 7 with a cavity H
for the purpose of forming and producing the film channel 3.
Polypropylene foam films or polyethylene foam films, for example,
are clamped in place as layers of plastic. The layers 8 of plastic
are attached to one another at their edges R by means of connecting
elements 9, for example by screwing, compressing or welding. The
forming tool 7 exhibits a plurality of recesses 10 in the form of
longitudinal bores, through which from the outside, for example, a
negative pressure can be applied, which acts on the internal space
(=cavity H) of the forming tool 7. A grille 11 is arranged on the
internal wall of the cavity H of the forming tool 7.
[0049] The layers 8 of plastic in FIG. 2A are pre-heated, whereby
they are caused to adopt a dough-like consistency and become
ductile. Warm or hot air is then blown in between the two layers 8
of plastic and a positive pressure is thereby created. The layers 8
of plastic are caused to arch outwards by means of the positive
pressure that is applied externally via the recesses 10, as shown
in FIG. 2B, and are forced or sucked into the mutually opposing
cavities in the forming tool 7.
[0050] The process is allowed to continue until the layers 8 of
plastic arch outwards as far as the internal wall of the forming
tool 7, as shown in FIG. 2C. Any expansion into the recesses 10 is
prevented by the grille 11. The nature of the material of the
forming tool 7 is such that no adhesion takes place with the film
material. After cooling and opening the forming tool 7 and removal
of the clamping devices, the sufficient inherent rigidity of the
layer 8 of plastic retains its shape of a channel which forms the
film channel 3 of the component 1, as represented in FIG. 2D. The
layers 8 of plastic may be compact, foamed and/or single-layer
and/or multiple-layer formed bodies. A blown film can also be
utilized.
[0051] In order to avoid sagging of the film channel 3, additional
reinforcing elements may be applied to the film, for example
adhesive strips, which additionally bring about adhesion to the
internal wall of the base body 2. Alternatively or additionally,
thin strips of a stronger plastic or a textile sheet material may
be used.
[0052] Instead of using positive pressure and/or negative pressure
to cause the film channel 3 to arch outwards, the attached edges R,
for example the welded or also compressed film edges, may simply be
pushed together. The arching of the plastic film or layer 8 in the
cavities of the forming tool 7, in particular in its half shells,
can be achieved in the same way by shortening spring elements
applied to the layer 8 of plastic.
[0053] FIG. 3A shows how the film channel 3 is introduced into the
elements E, for example two sheet metal half shells, of the base
body 2. After joining together the elements E, the component 1, the
hybrid carrier, is completed, and this stage is shown in FIG. 3B.
The film channel 3 is attached to the base body 2, for example by
thermal adhesion to gluing points. Alternatively, the film channel
3 can be attached at its edge R by means of a securing element 12
on the edge of the base body 2, or can be attached to this by some
other means.
[0054] As an alternative to a film channel 3 produced by the Twin
Sheet process, the layers 8 of plastic can also be inserted into
the elements E as two deep-drawn half shells made from compact thin
plastic or from foamed plastic, and can be secured there. One or
more additional plastic films or layers or deep-drawn layers can be
inserted between these deep-drawn half shells, which subdivides the
internal space of the film channel 3 into two or correspondingly
more chambers.
[0055] Instead of prefabricating the film channel 3 in a separate
forming tool 7, the foil channel 3 can be formed in the base body 2
itself. As illustrated in FIG. 4A, along similar lines to the
forming tool 7, two plastic films or layers 8 are clamped in the
cavity H of the base body 2 and are attached at their edges R by
means of connecting elements 9, for example by screwing or
compression. The layers 8 of plastic are then preheated. Next, the
outward arching of the layers 8 of plastic is brought about by
positive pressure, as represented in FIG. 4B. This is allowed to
continue until the layers 8 of plastic are in contact with the
elements E, as represented in FIG. 4C. In conjunction with this, an
adhesive effect of the plastic to the insides of the elements E is
caused as a result of the heat, whereby a self-adhesive or adhesive
fixing of the film channel 3 formed in this way is brought
about.
[0056] Additional attachment by means of securing elements 12 is
possible.
[0057] In a similar fashion to the forming tool 7, the elements E
in this procedure can exhibit recesses so that, on the one hand,
the uniform extension of the layers 8 of plastic is assured and, on
the other hand, in addition to or as an alternative to the positive
pressure, a negative pressure can be applied by the inward flow of
warm air from the outside.
[0058] The film channel 3 is able, as an air-guiding channel, to
conduct a flow of fresh air, cold air or warm air in order, for
example, to bring about the drying or the rapid de-icing of a front
screen in the event of condensation water being present in the
channel.
[0059] It is fundamentally possible to cause a plurality of
chambers or chamber channels to be formed inside the film channel
3, in which different media, for example fresh air, warm air, cold
air are conducted, by a plurality of plastic films, which are
expanded and/or formed in the corresponding geometrical
relationships, or also by flat or deep-drawn plastic half
shells.
[0060] FIG. 5A illustrates in addition a component 1, in which the
film channel 3 is completely arched outwards only in the direction
of one of the elements E of the base body 2 and is joined to the
internal wall. In the direction of the other element E, however,
the outward arching is restricted by air flowing into the cavity H
between the internal wall of the element E concerned and the film
channel 3, so that, after the hardening of the plastic, a cavity H
is formed between the internal wall of the element E concerned and
the only partially outward-curved film channel 3, which can be used
as an additional chamber K, that is to say as a guiding
channel.
[0061] FIG. 5B illustrated a base body 2 with a further film
channel 3a, that is to say a plurality of film channels 3 and 3a
are arranged in the base body 2. The film channel 3a is executed
with adequately high inherent rigidity and a smaller cross section
than that of the outer film channel 3. In addition, the elements E
can be lined on the inside with plastic applied by spraying.
[0062] By spraying one of the elements E with compact or foamed
plastic, while the other element E is lined with an elastic
material or an elastic plastic shell, components such as holders,
clips or seats can also be integrated, which are also capable of
absorbing greater forces or other functions.
[0063] The film channels 3 can be used as a general rule not only
in base bodies 2 with a closed hollow profile in the form of a
hollow cylinder made of half shells, but also in any desired hollow
profiles, in particular in U-profiles with a smooth lid.
[0064] The component 1 serves, for example, as an instrument panel
carrier for an air conditioning and/or heating system.
Alternatively, the component 1 can serve as a transverse member
arranged under a windshield in a vehicle, which member is intended
as an air-guiding channel for the air conditioning of the vehicle
interior and for de-icing the windshield or front screen. The base
body 2 is provided for this purpose with a plurality of flow taps
arranged at a distance from one another viewed in the longitudinal
direction with openings O for the inlet and/or outlet of a medium
conducted in the film channel 3, for example air. The number and
arrangement of the inlets and outlets can, of course, be varied at
will. Moreover, an inlet or outlet can also be present in the
vicinity of the edges R and can extend both inside only one shell
of the base body 2 and over both shells.
[0065] Furthermore, such a structural component 1 can also be used
at other locations in a vehicle. Examples are: A-, B-, C-,
D-pillars, longitudinal members, vehicle sills, roof components,
etc. The air from an air conditioning system (abbreviated to HVAC)
can also be conducted and distributed in a space-saving manner
through these components 1, in conjunction with which the component
1 is executed as a structural component in the vehicle, and in
particular as a hollow structural component.
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