• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    The invention relates to a method for manufacturing a motor vehicle part (1) comprising a shaped sheet (10). The method comprises the following steps: - Provision of a shaping tool having a relief, - Preconditioning of an initial sheet on the shaping tool so that the sheet conforms to the shape of the relief, the precoated sheet obtained after preconditioning having a first relief projecting from a given face and defining a recess in an opposite face. The method then comprises a step of reversing the first relief, the shaped sheet (10) obtained after inversion then having a second relief (4) projecting from a first face (12) of the shaped sheet (10) corresponding to the opposite side and defining a recess in a second face (14) of the shaped sheet (10) corresponding to the given face.
    公开号:FR3021579A1
    申请号:FR1454795
    申请日:2014-05-27
    公开日:2015-12-04
    发明作者:Michel Langiny
    申请人:Faurecia Automotive Industrie SAS；
    IPC主号:
    专利说明:

    [0001] The present invention relates to a method for manufacturing a motor vehicle part comprising a shaped sheet, the method comprising the following steps: providing a conformation tool; the shaping tool having a relief, - pre-forming of an initial sheet, comprising the application of a face of the initial sheet on the shaping tool so that the sheet matches the shape of the relief of the shaping tool , the preformed sheet obtained after preconformation having a first relief projecting from a given face of the preformed sheet and defining a recess in an opposite face of the preformed sheet. Such a method is intended to form a motor vehicle part having a relief, in particular a hump or a hollow. The vehicle part is for example an element of an acoustic complex covering a sheet separating the engine compartment from the interior of a vehicle, so as to reduce noise. Alternatively, the vehicle part is a soundproofing sub-carpet complex or a soundproofing complex trunk side trim or the like. An acoustic complex frequently used in the automotive field consists of the combination of a heavy mass layer and a "decoupling" layer or spring layer, for example made of a polyurethane foam (PU). The acoustic principle of such an acoustic complex is generally called "mass / spring". The document FR 2 989 305 A1 describes a method of manufacturing an acoustic assembly by conformation of a heavy mass. The heavy mass, based on thermoplastic material, is heated to the softening temperature of the material and then "lapped" on a shaper having reliefs identical to those of the part of the vehicle to be covered. Under the effect of its own weight and suction through openings in the shaper, the heavy mass sheet flue and marries the reliefs of the shaper. After a few seconds, the heavy mass has cooled down and can be handled.
    [0002] Such a room is intended to match the shape of the part of the vehicle to be covered so as to reduce the noise nuisance. The reliefs of the parts to be covered are multiple. For example, it is sometimes necessary to form a large hollow including, at a through body. The through members are, for example, the steering column, for the parts covering the aprons or the gear lever and the handbrake for the underlayers. Indeed, the acoustic complex is intended to marry part of the through member, which 3021579 2 is reflected on average by a hollow 10 to 15 cm deep for a width of 10 cm to 20 cm. However, some reliefs are more difficult to manufacture during the conformation. In fact, the heavy mass does not adopt perfectly the shape of the mold, for example when the hollow to be formed is too deep or too narrow. In such a case, the development of the hollow to be made by the heavy mass is obtained by the prior flat surface of the heavy mass deposited at the time of the coating corresponding to the area of the base of the hollow. Indeed, the heavy mass does not slip once in contact with the shaper, in this case once in contact with the edges of the hollow. The stretching in this area will therefore be very high. The formed part is then likely to have manufacturing defects, to be pierced or torn. These defects can affect the strength of the part or the functionality of the part, for example, by reducing its acoustic performance or, in the case of presence of tears, to annihilate them.
    [0003] In order to avoid tearing, the intervention of a dedicated operator who tries to homogenize the drawing of the heavy mass at the sensitive places is often required. If this intervention reduces the tear drop rate, it is not very effective. In other cases, the part to be made has slight undercuts. The conventional methods are unsuitable for this type of parts. The processes adapted to this type of parts are slow and require complicated and expensive molds and formers where removable systems with drawers are added. The object of the invention is to provide a reliable, reproducible, automated and inexpensive method for obtaining good quality parts adopting the desired complex shape. For this purpose, the subject of the invention is a method of the aforementioned type, characterized in that the method then comprises a step of reversing the first relief, the shaped sheet obtained after inversion then having a second relief projecting from a first face of the shaped sheet corresponding to the opposite face 30 and defining a recess in a second face of the shaped sheet corresponding to the given face. The method according to the invention can comprise one or more of the following characteristics, taken alone or in any technically possible combination: the method comprises the provision of a substantially flat initial sheet, the first relief being formed by deformation of the substantially planar sheet deposited on the shaping tool; the method comprises the following steps: heating of the initial sheet before the application of the initial sheet to the shaping tool; cooling of the preformed sheet after formation of the first relief, preferably before the reversal step; relief ; the initial sheet is a layer of heavy mass; The method comprises the following steps: providing a hump for constituting the raised shape on the shaping tool; arranging the hump on the shaping tool at the location provided for forming the first relief; The reversal step is carried out by gravity and / or by pushing on the first relief; the method comprises a step of forming a spring layer on the second face of the shaped sheet, after the step of reversing the relief. The invention also relates to a motor vehicle part comprising a shaped sheet having a first face, a second face and a relief, projecting from the first face and defining a recess in the second face, the relief being susceptible to be obtained by inverting a first relief of a preformed sheet protruding from a given face of the preformed sheet corresponding to the first face and defining a recess in an opposite face of the preformed sheet corresponding to the second face .
    [0004] The motor vehicle part according to the invention may comprise one or more of the following characteristics, taken in isolation or in any technically possible combination: the relief at the periphery of its base, a peripheral fold resulting from a reversal of the first relief; The relief has a height greater than 100 times the thickness of the shaped sheet. The invention will be better understood on reading the description which will follow, given solely by way of example, and with reference to the appended drawings, in which: FIG. 1 is a top view of a piece of motor vehicle having a relief formed by a manufacturing method according to the invention; FIG. 2 is a view taken in section of an initial sheet and of a shaping tool for carrying out the method, before a first step of implementing the method according to the invention; FIG. 3 is a view similar to FIG. 2, after the first step of implementing the method according to the invention; - Figure 4 is a view similar to Figure 2 of a foaming mold for carrying out a next step of the method. FIG. 5 is a view similar to FIG. 2 of an acoustic complex produced by the method according to the invention. - Figure 6 is a view similar to Figure 2 of a variant of shaping tool for the implementation of the method. A vehicle part 1 formed by the process according to the invention is illustrated in FIG. 1. Part 1 is for example an element of an acoustic complex designed to cover an apron. The piece 1 has an area 2 of large size relative to its thickness. The piece 1 has a rough surface, having various recesses and at least one relief 4, here recessed. The vehicle part 1 comprises a shaped sheet 10 and a base layer 52, in particular a layer of foam on which the shaped sheet 10 is assembled. The shaped sheet 10 has a first face 12 and a second face 14 and a thickness e between the faces. The shaped sheet 10 additionally has the relief 4. In FIG. 1, the first face 12 of the shaped sheet 10 of the part 1 is invisible. In the example described here, the relief 4 protrudes with respect to the first face 12 of the shaped sheet 10 and defines a recess in the second face 14 of the shaped sheet 10. The relief 4 is advantageously delimited at its base by a Fold mark 30 device. The mark is a peripheral fold formed during the manufacturing process of the part, as will be described below. The relief 4 has a height h, taken with respect to the main plane of the shaped sheet 10, advantageously greater than 100 times the thickness e of the shaped sheet 10.
    [0005] The shaped sheet 10 is formed from an initial sheet 30 of conformable material. The initial sheet 30 is shown in FIG.
    [0006] The initial sheet 30 is for example a heavy mass layer. The heavy-mass layer is formed based on a charge-containing polymer matrix. The polymer is advantageously a thermoplastic polymer. It has a weight per unit area of between 0.5 kg / m 2 and 7 kg / m 2 and a density of between 5 1200 kg / m 3 and 1700 kg / m 3. The polymer is preferably an elastomer. The heavy mass is for example made based on polyolefin and / or Ethylene Propylene Diene Monomer (EPDM) polymer. The fillers are for example chosen from chalk or barium sulfate.
    [0007] The initial sheet 30 is substantially planar. It has a first face 32 and a second face 34. The thickness of the initial sheet 30 is advantageously between 100% and 150% of the thickness e of the shaped sheet 10. The spring layer 52 is disposed on the second face 12 of the shaped sheet 10.
    [0008] The spring layer 52 advantageously constitutes an acoustic decoupling layer. It is, for example, made from polyurethane foam. The piece 1 is made by a method according to the invention using a manufacturing device visible in FIGS. 2 to 4. The manufacturing device comprises a thermoforming station of the sheet 20 visible in FIGS. 3 and a station for producing the spring layer 52 and assembling this layer 52 on the shaped sheet 10, visible in Figure 4. It advantageously comprises a relief turning tool (not shown). The thermoconforming station comprises a heating assembly 54 of the initial sheet 30 and a shaping tool 60 on which the heated sheet 30 is intended to be deposited. It further comprises a tool (not shown) for moving the sheet 30, to place it successively facing the heating assembly 54 and on the shaping tool 60. The heating assembly 54 is able to heat the initial sheet up to a softening temperature allowing its conformation. It is, for example, formed by a convection heater or infrared heater. The shaping tool 60 having a shape generally corresponding to the shape of the shaped sheet 10. The shaping tool 60 further comprises a boss 62 projecting. In the embodiment shown in FIGS. 2 and 3, the shaping tool 60 is integral with the boss 62.
    [0009] In a variant, shown in FIG. 6, the shaping tool 60 comprises a standard mold 64 and a boss 66 attached to the mold 64. Such a boss 66 is removable and movable. This variant makes it possible to use a standard mold 64 in order to carry out the method according to the invention. The turning tool is, for example, a member for applying a pressure on the relief 46 to return it.
    [0010] The embodiment of the spring layer 52 comprises, for example, a foaming assembly 70 shown in FIG. 4. This foaming assembly 70 comprises a first half-mold 72 having a hollow 74, a second half-mold 76 and a foam injection device 78. The hollow 74 of the first half-mold 72 is substantially complementary to the second relief 10 4 of the shaped sheet. A production method for manufacturing the motor vehicle part 1 according to the invention in the manufacturing device of FIGS. 2 to 4 will now be described. Initially, a sheet as described above is provided.
    [0011] The initial sheet 30 is cut beforehand to a format close to the final piece 1 to be formed. The initial sheet 30 is heated by means of the heating assembly 54 to a softening temperature prior to the application of the sheet 30 to the shaping tool 60. The softening temperature is advantageously 80 ° C. and 250 ° C. The first face 32 of the initial sheet 30 is applied to the shaping tool 60 so that the sheet 32 conforms to the shape of the shaping tool 60. Because of its own weight and a suction effect, the sheet 32 comes to conform to the reliefs of the shaping tool 60. In a variant, a pressure is applied to the sheet 32. At the end of this first step, a preformed sheet 40 is obtained from the initial sheet 30. 3. The preformed sheet 40 has, after application to the shaping tool 60, a first relief 46 defining a recess in a first face 42 of the preformed sheet 40 and projecting from a second The end of the first process step is shown in FIG. 3. The preformed sheet 40 after formation of the first embossment 46 is then cooled to reach a hardening temperature. The curing temperature is advantageously between 10 ° C and 70 ° C. At this temperature, the preformed sheet 40 has a stiffness sufficient to be manipulated in keeping its shape. In addition, this temperature allows the bonding of the sheet 10 with the spring layer 52 in a subsequent step. In a second step, the shaped sheet 10 is obtained from the preformed sheet 40. According to the invention, the first relief 46 of the preformed sheet 40 is returned, for example by means of a tool of FIG. flipping or by hand. The shaped sheet 10 then has the second relief 4 protruding from the first face 12 and defining a recess in the second face 14. The upturn is, for example, carried out by pushing on the first relief 46. Alternatively or in addition the reversal takes place under the effect of gravity.
    [0012] The first face 12 of the shaped sheet 10 then corresponds to the first face 42 of the preformed sheet 40 and the second face 14 of the shaped sheet 10 corresponds to the second face 44 of the preformed sheet 40. This step makes it possible to form a hollow in the second face 12 of the shaped sheet instead of the bump defined in the second face 44 of the preformed sheet 40. The reversal is generally performed out of the foaming assembly 70, by an action, manual or piloted , independent of the foam injection into the foaming assembly 70. The shaped sheet 10 is then transferred to a foaming assembly 70 as previously described. The first face 12 of the shaped sheet 10 is applied to the first half-mold 72. The raised relief 4 is inserted into the recess 74. The second half-mold 76 is put in place and the precursor material of the foam is injected between the second half-mold 76 and the second face 14 of the shaped sheet 10. The spring layer 52 is thus formed on the second face 14 of the shaped sheet 25. The foam fills the hollows of the relief. The foam is, for example, made by injecting two liquid components an isocyanate and a polyol. Alternatively, the reversal takes place under the effect of the pressure exerted by the foam formation. The turning over and filling is thus carried out simultaneously.
    [0013] The process according to the invention is therefore reliable, reproducible and inexpensive. In addition, it allows to obtain parts adopting the desired shape even if it is undercuts. For example, if a dimple is desired in the final shaped sheet, producing a protrusion with a substantially constant thickness on the preformed sheet 40 is simpler. The material is substantially homogeneously stretched. Indeed, the preliminary surface of the initial sheet 30 to be stretched to produce the projection 3021579 8 is greater than the preliminary surface of an initial sheet 30 to stretch in the case of a hollow because the material is not blocked on the sides of the protrusion. The reversal of the relief 46 makes it possible to obtain the same material distribution characteristics for a hollow as for a bump.
    [0014] The material is thus less stretched when forming depressions by this method. The coin thus has less risk of tears. Heavy weight layers of lower thickness can therefore be used, which reduces manufacturing costs and reduces the weight of the workpiece. On the other hand, the required percentage of deformation of the sheet is less, which allows for higher-laden heavy-mass formulations or those containing a higher percentage of recycled. On the other hand, the relief 4 is not weakened by the manufacture. The parts obtained 1 are strong and have good acoustic performance. In addition, the parts obtained by this process all have the same quality. This process is also automatable, which reduces the cost of manufacture. For example, it is no longer necessary for an operator to intervene to help lengthen the heavy mass during its conformation at the locations of the recesses corresponding to the steering columns, for example. In the alternative embodiment, it is possible to use an already existing mold 64, by adding a removable boss 66 to modify the shape of a shaping tool 60. The method therefore does not require changing all manufacturing tools. In a variant, the shaping tool 60 has a recessed relief 62, adapted so that the first relief 46 forms a recess in one application face of the preformed sheet 40 and forms a protrusion with respect to the other face of the preformed sheet.
    [0015] After reversal of the relief, the shaped sheet 10 has a relief 4 projecting from a face of the shaped sheet 10, corresponding to the application face of the preformed sheet 40, the relief forming a recess relative to the other face of the shaped sheet 10. Alternatively, the reversal of the relief 46 is partial. A portion of the relief 4 then protrudes from the first face 12 and another part of the relief projects from the second face 14.
    权利要求:
    Claims (10)
    [0001]
    1. A method of manufacturing a motor vehicle part (1) comprising a shaped sheet (10), the method comprising the following steps: - providing a shaping tool (60), the shaping tool (60). ) having a relief (62), - pre-forming an initial sheet (30), comprising applying a face (32) of the initial sheet (30) to the forming tool (60) so that the sheet (30) matches the shape of the relief (62) of the shaping tool (60), the preformed sheet (40) obtained after preconformation having a first relief (46) projecting from a given face (44) of the preformed sheet (40) and defining a recess in an opposite face (42) of the preformed sheet (40), characterized in that the method then comprises a step of reversing the first relief (46), the shaped sheet (10) obtained after reversal then having a second relief (4) protruding by r to a first face (12) of the shaped sheet (10) corresponding to the opposite face (42) and defining a recess in a second face (14) of the shaped sheet (10) corresponding to the given face (44) .
    [0002]
    2. A method according to claim 1 comprising providing a substantially planar initial sheet (30), the first relief (46) being formed by deformation of the substantially planar sheet (30) deposited on the forming tool (60). .
    [0003]
    3.- Method according to one of claims 1 or 2, comprising the following steps: - heating the initial sheet (30) before the application of the initial sheet (30) on the shaping tool (60), - cooling the preformed sheet (40) after forming the first relief (46), preferably before the step of reversing the relief (46).
    [0004]
    4. A process according to any one of the preceding claims, wherein the initial sheet (30) is a heavy mass layer.
    [0005]
    5. A process according to any one of the preceding claims, comprising the following steps, - providing a boss (66) for forming the raised shape (62) on the shaping tool (60), 3021579 10 - arranging the hump (66) on the shaping tool (60) at the location provided for forming the first relief (46).
    [0006]
    6. A process according to any one of the preceding claims, wherein the reversing step is by gravity and / or by pushing on the first relief (46).
    [0007]
    7. A process according to any one of the preceding claims, comprising a step of forming a spring layer (52) on the second face (14) of the shaped sheet (10), after the step of reversing the relief ( 46). 10
    [0008]
    8. A motor vehicle part (1) comprising a shaped sheet (10) having a first face (12), a second face (14) and a relief (4) projecting from the first face (12) and defining a recess in the second face (14), the relief being obtainable by reversal of a first relief (46) of a preformed sheet (40) projecting from a given face (44) of the preformed sheet (40) corresponding to the first face (12) and defining a recess in an opposite face (42) of the preformed sheet (40) corresponding to the second face (14).
    [0009]
    9. Part (1) according to claim 8, wherein the relief (4) has at the periphery of its base, a peripheral fold resulting from a reversal of the first relief (46).
    [0010]
    10. Part (1) according to one of claims 8 or 9, wherein the relief (4) has a height greater than 100 times the thickness of the shaped sheet (10). 25
    类似技术:
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    同族专利:
    公开号 | 公开日
    FR3021579B1|2017-01-27|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    FR2325483A1|1975-09-24|1977-04-22|Upjohn Co|METHOD AND DEVICE FOR MOLDING A SHEET, IN PARTICULAR A TEXTILE ETOFFE SHEET OR A PLASTIC FILM IN A MOLD|
    EP0079682A1|1981-10-16|1983-05-25|Plastona Limited|Method of producing plastics material containers|
    WO2003041945A1|2001-11-12|2003-05-22|Manufacturing Evolutions Limited|Thermoplastic sheating of articles and moulding process|
    NL1024892C1|2003-11-27|2005-05-30|Dexter Mould Technology B V|Rapid exchange system for form parts in thermo-form matrix where no harm is caused to possible cooling in the part to be exchanged|CN108215134A|2017-11-28|2018-06-29|中国航发西安动力控制科技有限公司|Polyimides heterotype film part hot press forming technology and molding die|
    WO2020161357A1|2019-02-08|2020-08-13|Treves Products, Services & Innovation|Sound protection screen for a motor vehicle engine compartment|
    FR3094934A1|2019-04-12|2020-10-16|Treves Products, Services & Innovation|Acoustic protection screen for motor vehicle engine compartment|
    FR3100769A1|2019-09-12|2021-03-19|Treves Products, Services & Innovation|Acoustic protection screen for motor vehicle engine compartment|
    法律状态:
    2015-04-22| PLFP| Fee payment|Year of fee payment: 2 |
    2015-12-04| PLSC| Search report ready|Effective date: 20151204 |
    2016-04-22| PLFP| Fee payment|Year of fee payment: 3 |
    2017-04-21| PLFP| Fee payment|Year of fee payment: 4 |
    2018-04-23| PLFP| Fee payment|Year of fee payment: 5 |
    2019-04-18| PLFP| Fee payment|Year of fee payment: 6 |
    2020-04-22| PLFP| Fee payment|Year of fee payment: 7 |
    2021-04-21| PLFP| Fee payment|Year of fee payment: 8 |
    优先权:
    申请号 | 申请日 | 专利标题
    FR1454795A|FR3021579B1|2014-05-27|2014-05-27|METHOD FOR MANUFACTURING A PIECE OF A MOTOR VEHICLE AND PART THEREOF|FR1454795A| FR3021579B1|2014-05-27|2014-05-27|METHOD FOR MANUFACTURING A PIECE OF A MOTOR VEHICLE AND PART THEREOF|
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