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US20030037500A1 - Roof module and method of producing a roof module - Google Patents

Roof module and method of producing a roof module Download PDF

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Publication number
US20030037500A1
US20030037500A1 US10/225,970 US22597002A US2003037500A1 US 20030037500 A1 US20030037500 A1 US 20030037500A1 US 22597002 A US22597002 A US 22597002A US 2003037500 A1 US2003037500 A1 US 2003037500A1
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US
United States
Prior art keywords
outer shell
cut
roof module
rim
shell
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
Application number
US10/225,970
Inventor
Horst Bohm
Rainer Grimm
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
ArvinMeritor GmbH
Original Assignee
Individual
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Assigned to ARVINMERITOR GMBH reassignment ARVINMERITOR GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BOHM, HORST, GRIMM, RAINER
Publication of US20030037500A1 publication Critical patent/US20030037500A1/en
Priority to US10/795,906 priority Critical patent/US7146732B2/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B62D29/002—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material a foamable synthetic material or metal being added in situ
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/14—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining
    • B29C44/143—Means for positioning the lining in the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/06—Fixed roofs
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49616—Structural member making
    • Y10T29/49622—Vehicular structural member making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4998—Combined manufacture including applying or shaping of fluent material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4998—Combined manufacture including applying or shaping of fluent material
    • Y10T29/49988—Metal casting

Definitions

  • the invention relates to a roof module comprising an outer shell and a foamed inner shell.
  • the invention further relates to a method of producing such a roof module.
  • the roof module has been produced by placing the outer shell, the rim of which is configured with an excess width, into a foaming mold and subsequently applying the inner shell onto the inner side of the outer shell by foaming.
  • the inner shell extends as far as to the rim of the outer shell.
  • the rim of the outer shell together with the inner shell applied by foaming is cut to size. Cutting to size of the outer shell provided with the inner shell is a difficult operation during which a lot of dirt occurs.
  • that part of the inner shell which is on the cut-off rims of the outer shell represents cuttings, this increasing the production costs.
  • the roof module has exposed edges of cut after it has been cut to size.
  • a roof module which comprises an outer shell and a foamed inner shell.
  • the outer shell has a rim including an edge of cut and the inner shell extends as far as on the edge of cut.
  • a roof module may be obtained by the following method: firstly, an outer shell is made available. Then the rims of the outer shell are cut to size. As a next step, the outer shell is placed in a foaming tool and a curable material is applied onto the outer shell. Subsequently the foaming tool is closed, a seal in the foaming tool pressing against the rim of the outer shell from outside towards inside. The curable material hardens, it reaching the edges of cut on the rim of the outer shell.
  • the roof module produced in this way does not have to be cut to size after the foaming operation. Consequently, only so much of the material for the inner shell has to be introduced as is actually required for it; no loss occurs. As the inner shell extends as far as on the edges of cut at the rim of the outer shell, the edges of cut—which have been produced prior to foaming on cutting the outer shell to size—are sealed.
  • the outer shell is configured with an undercut on its rim. This can be obtained in that, on producing the roof module, the seal is pressed elastically against the outer shell when the foaming tool is being closed and plastically deforms the outer shell in this process. It is not required in this procedure to provide slider elements in the foaming tool which usually are required for producing the undercut on foaming. It is not required either that the outer shell has the undercut already before foaming. This, in fact, could be managed during production of the outer shell only with large expenditure.
  • FIG. 1 shows in a broken sectional view a foaming tool in the open state, with an inserted outer shell according to a first embodiment
  • FIG. 2 shows the foaming tool of FIG. 1 in the closed state, an inner shell being applied to the outer shell by foaming
  • FIG. 3 shows a detail of FIG. 2 on an enlarged scale
  • FIG. 4 shows in a broken sectional view a foaming tool in the closed state, with an outer shell and an inner shell applied by foaming, according to a second embodiment
  • FIG. 5 shows a detail of FIG. 4 on an enlarged scale.
  • FIGS. 1 to 3 there is schematically shown a foaming tool 10 which consists of an upper part 12 and a lower part 14 .
  • an outer shell 16 Received in the lower part 14 is an outer shell 16 which will be a part of the roof module and which may consist of aluminum or plastics, for instance.
  • the outer shell 16 has a rim 18 that ends at an edge of cut 20 . The edge of cut is produced in the course of cutting the outer shell 16 to size.
  • seal 22 which has a base section 24 anchored in the lower part 14 and a head section 26 associated to the rim 18 of the outer shell 16 .
  • the seal 22 is made of a material which on the one hand has sufficient resistance to pressure and temperature with regard to the foaming operation and which is elastically deformable, on the other.
  • the upper part 12 of the foaming tool 10 has a sealing section associated to the rim 18 of the outer shell 16 and the head section 26 of the sealing 22 .
  • the sealing section consists of an end surface 30 and a pressure surface 32 .
  • the end surface 30 extends approximately perpendicular to the direction along which the upper part 12 and the lower part 14 of the foaming tool 10 are movable relative to each other.
  • the pressure surface 32 extends obliquely to the end surface.
  • the inner shell Prior to closing the foaming tool 10 , there has been applied onto the outer shell 16 a foamable material which cures when the foaming tool has been closed, so that it forms an inner shell 34 on the inner side of the outer shell 16 .
  • the inner shell extends along the rim 18 as far as on the edge of cut 20 which is covered by the material of the inner shell 34 .
  • the inner shell extends away from the edge of cut in extension of the outer surface of the outer shell. The material which is present there, seals the edge of cut 20 .
  • the rim 18 of the outer shell 16 rests at the head section 26 of the seal 22 with a sufficiently high force, so that the material of the inner shell 34 can not enter the region between the rim 18 of the outer shell 16 and the head section 26 of the seal 22 and, hence, can not emerge from the foaming tool.
  • the rims of the roof module formed by the outer shell 16 and the inner shell 34 are smooth after foaming, without the need of a subsequent cutting operation.
  • FIGS. 4 and 5 there is shown a roof module according to a second embodiment.
  • the same reference numerals will be used for the components known from the first embodiment, and reference is made to the above explanations.
  • the difference between the first and the second embodiment is that in the second embodiment the pressure surface 32 is inclined more, so that upon closing the foaming tool the head section 26 of the seal 22 is moved to the left to a greater extent.
  • the rim 18 of the outer shell 16 is moved to the middle of the outer shell 16 so far that the outer shell is undercut, i.e. the edge of cut lying further inwardly than does the rim 18 in the region of the transition to the horizontally extending middle section of the outer shell 16 .
  • the deformation of the rim 18 on closing the foaming tool is preferably a plastic one, so that after opening the foaming tool only a slight spring-back occurs which does not impose an exceed load on the fit of the inner shell 34 on the outer shell 16 . It is e.g. in the region of the rear flap of a vehicle provided with the roof module where the undercut can be of advantage.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Seal Device For Vehicle (AREA)
  • Roof Covering Using Slabs Or Stiff Sheets (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Molding Of Porous Articles (AREA)

Abstract

A roof module comprises an outer shell and a foamed inner shell. The outer shell has a rim including an edge of cut and the inner shell extends as far as on the edge of cut. There is also proposed a method of producing such a roof module.

Description

    TECHNICAL FIELD
  • The invention relates to a roof module comprising an outer shell and a foamed inner shell. The invention further relates to a method of producing such a roof module. [0001]
    • BACKGROUND OF THE INVENTION
  • Hitherto, the roof module has been produced by placing the outer shell, the rim of which is configured with an excess width, into a foaming mold and subsequently applying the inner shell onto the inner side of the outer shell by foaming. In the process, the inner shell extends as far as to the rim of the outer shell. After foaming, the rim of the outer shell together with the inner shell applied by foaming is cut to size. Cutting to size of the outer shell provided with the inner shell is a difficult operation during which a lot of dirt occurs. Moreover, that part of the inner shell which is on the cut-off rims of the outer shell, represents cuttings, this increasing the production costs. Finally, the roof module has exposed edges of cut after it has been cut to size. [0002]
  • It is the object of the invention to improve a roof module of the type initially mentioned as well as a method of its production to the effect that fewer cuttings and, hence, lower production costs are produced and that the roof module does not have edges of cut which are exposed. [0003]
    • BRIEF SUMMARY OF THE INVENTION
  • According to the invention, a roof module is provided which comprises an outer shell and a foamed inner shell. The outer shell has a rim including an edge of cut and the inner shell extends as far as on the edge of cut. Such a roof module may be obtained by the following method: firstly, an outer shell is made available. Then the rims of the outer shell are cut to size. As a next step, the outer shell is placed in a foaming tool and a curable material is applied onto the outer shell. Subsequently the foaming tool is closed, a seal in the foaming tool pressing against the rim of the outer shell from outside towards inside. The curable material hardens, it reaching the edges of cut on the rim of the outer shell. The roof module produced in this way does not have to be cut to size after the foaming operation. Consequently, only so much of the material for the inner shell has to be introduced as is actually required for it; no loss occurs. As the inner shell extends as far as on the edges of cut at the rim of the outer shell, the edges of cut—which have been produced prior to foaming on cutting the outer shell to size—are sealed. [0004]
  • According to a preferred embodiment it is provided for that the outer shell is configured with an undercut on its rim. This can be obtained in that, on producing the roof module, the seal is pressed elastically against the outer shell when the foaming tool is being closed and plastically deforms the outer shell in this process. It is not required in this procedure to provide slider elements in the foaming tool which usually are required for producing the undercut on foaming. It is not required either that the outer shell has the undercut already before foaming. This, in fact, could be managed during production of the outer shell only with large expenditure. [0005]
  • Advantageous designs of the invention will be apparent from the subclaims.[0006]
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 shows in a broken sectional view a foaming tool in the open state, with an inserted outer shell according to a first embodiment; [0007]
  • FIG. 2 shows the foaming tool of FIG. 1 in the closed state, an inner shell being applied to the outer shell by foaming; [0008]
  • FIG. 3 shows a detail of FIG. 2 on an enlarged scale; [0009]
  • FIG. 4 shows in a broken sectional view a foaming tool in the closed state, with an outer shell and an inner shell applied by foaming, according to a second embodiment; and [0010]
  • FIG. 5 shows a detail of FIG. 4 on an enlarged scale.[0011]
    • DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
  • In FIGS. [0012] 1 to 3 there is schematically shown a foaming tool 10 which consists of an upper part 12 and a lower part 14. Received in the lower part 14 is an outer shell 16 which will be a part of the roof module and which may consist of aluminum or plastics, for instance. The outer shell 16 has a rim 18 that ends at an edge of cut 20. The edge of cut is produced in the course of cutting the outer shell 16 to size.
  • In the [0013] lower part 14 of the foaming tool 10, there is received a seal 22 which has a base section 24 anchored in the lower part 14 and a head section 26 associated to the rim 18 of the outer shell 16. The seal 22 is made of a material which on the one hand has sufficient resistance to pressure and temperature with regard to the foaming operation and which is elastically deformable, on the other.
  • The [0014] upper part 12 of the foaming tool 10 has a sealing section associated to the rim 18 of the outer shell 16 and the head section 26 of the sealing 22. The sealing section consists of an end surface 30 and a pressure surface 32. The end surface 30 extends approximately perpendicular to the direction along which the upper part 12 and the lower part 14 of the foaming tool 10 are movable relative to each other. The pressure surface 32 extends obliquely to the end surface.
  • When the [0015] foaming tool 10 is transferred from the open position shown in FIG. 1 into the closed position shown in FIG. 2, the obliquely extending pressure surface 32 engages the head section 26 of the elastic seal 22 and moves this head section to the left due to a wedge effect. In so doing, the rim 18 resting at the head section 26 of the seal 22 is likewise moved to the left. When the foaming tool is in the closed state, the end surface 32 rests tightly on the upper side of the head section 26 of the seal 22. The edge of cut 20 of the rim 18 of the outer shell 16 lies opposite the end surface 30 at a small distance (see in particular FIG. 3).
  • Prior to closing the [0016] foaming tool 10, there has been applied onto the outer shell 16 a foamable material which cures when the foaming tool has been closed, so that it forms an inner shell 34 on the inner side of the outer shell 16. As can be taken in particular from FIG. 3, the inner shell extends along the rim 18 as far as on the edge of cut 20 which is covered by the material of the inner shell 34. In the region where the material of the inner shell 34 rests at the head section 26 of the seal 22, namely between the edge of cut 20 of the outer shell 16 and the end surface 30 of the upper part 12 of the foaming tool, the inner shell extends away from the edge of cut in extension of the outer surface of the outer shell. The material which is present there, seals the edge of cut 20. As the head section 26 of the seal has moved the rim 18 of the outer shell 16 towards inside on closing the foaming tool, the rim 18 of the outer shell 16 rests at the head section 26 of the seal 22 with a sufficiently high force, so that the material of the inner shell 34 can not enter the region between the rim 18 of the outer shell 16 and the head section 26 of the seal 22 and, hence, can not emerge from the foaming tool. With this, the rims of the roof module formed by the outer shell 16 and the inner shell 34 are smooth after foaming, without the need of a subsequent cutting operation.
  • In FIGS. 4 and 5 there is shown a roof module according to a second embodiment. The same reference numerals will be used for the components known from the first embodiment, and reference is made to the above explanations. [0017]
  • The difference between the first and the second embodiment is that in the second embodiment the [0018] pressure surface 32 is inclined more, so that upon closing the foaming tool the head section 26 of the seal 22 is moved to the left to a greater extent. In the process, the rim 18 of the outer shell 16 is moved to the middle of the outer shell 16 so far that the outer shell is undercut, i.e. the edge of cut lying further inwardly than does the rim 18 in the region of the transition to the horizontally extending middle section of the outer shell 16. The deformation of the rim 18 on closing the foaming tool is preferably a plastic one, so that after opening the foaming tool only a slight spring-back occurs which does not impose an exceed load on the fit of the inner shell 34 on the outer shell 16. It is e.g. in the region of the rear flap of a vehicle provided with the roof module where the undercut can be of advantage.

Claims (6)

1. A roof module comprising an outer shell and a foamed inner shell, said outer shell having a rim including an edge of cut and said inner shell extending as far as on said edge of cut.
2. The roof module according to claim 1, wherein said inner shell extends away from said edge of cut in an extension of an outer surface of said outer shell.
3. The roof module according to claim 1, wherein said outer shell is configured with an undercut at its rim.
4. A method of producing a roof module comprising an outer shell and a foamed inner shell by means of the following steps:
an outer shell having a rim is made available;
said rims of said outer shell are cut to size;
said outer shell is placed in a foaming tool;
a curable material is applied onto said outer shell;
said foaming tool is closed, a seal in said foaming tool pressing against said rim of said outer shell from outside towards inside;
said curable material hardens, it reaching said edges of cut on said rim of said outer shell.
5. The method according to claim 4, wherein said seal is pressed elastically against said outer shell when said foaming tool is being closed.
6. The method according to claim 5, wherein said seal plastically deforms said outer shell when said foaming tool is being closed.
US10/225,970 2001-08-23 2002-08-22 Roof module and method of producing a roof module Abandoned US20030037500A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US10/795,906 US7146732B2 (en) 2001-08-23 2004-03-08 Roof module and method of producing a roof module

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10141242.8 2001-08-23
DE10141242A DE10141242A1 (en) 2001-08-23 2001-08-23 Roof module and method for manufacturing a roof module

Related Child Applications (1)

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US10/795,906 Expired - Fee Related US7146732B2 (en) 2001-08-23 2004-03-08 Roof module and method of producing a roof module

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1342650A1 (en) * 2002-03-01 2003-09-10 Webasto Vehicle Systems International GmbH Vehicle body part and method of producing such a part
US7146732B2 (en) * 2001-08-23 2006-12-12 Arvinmeritor Gmbh Roof module and method of producing a roof module
US20150001754A1 (en) * 2012-02-13 2015-01-01 Bridgestone Corporation Mold, method for manufacturing molded foam body, and molded foam body

Families Citing this family (3)

* Cited by examiner, † Cited by third party
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EP1747977A1 (en) * 2005-07-28 2007-01-31 ArvinMeritor GmbH Method of manufacturing a foamed component and foaming mould to apply this method
US7874832B2 (en) * 2008-06-13 2011-01-25 Kimastle Corporation Assembly for producing an auto headliner with a folded-over perimeter edge
KR101428274B1 (en) 2012-12-12 2014-08-07 현대자동차주식회사 Sealing apparatus for foam-injection mold

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US4065899A (en) * 1973-01-10 1978-01-03 Kirkhuff William J Interlocking combination shingle and sheeting arrangement
US4259817A (en) * 1979-02-05 1981-04-07 Elliott Frank S Insulative roof apparatus
US4788808A (en) * 1987-03-30 1988-12-06 Slocum Donald H Building panel and method of fabrication
US5502940A (en) * 1992-08-21 1996-04-02 Oldcastle, Inc. Composite building element and methods of making and using the same
US6226944B1 (en) * 1994-03-25 2001-05-08 Mouchel Consulting Limited Reinforced structural member
US5715637A (en) * 1995-04-27 1998-02-10 Pan-Brick, Inc. Prefabricated composite building panel with improved fire retardancy
US6085479A (en) * 1997-11-25 2000-07-11 Carver; Tommy Lee Premanufactured structural building panels
US6363674B1 (en) * 1997-11-25 2002-04-02 Tommy Lee Carver Premanufactured structural building panels

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7146732B2 (en) * 2001-08-23 2006-12-12 Arvinmeritor Gmbh Roof module and method of producing a roof module
EP1342650A1 (en) * 2002-03-01 2003-09-10 Webasto Vehicle Systems International GmbH Vehicle body part and method of producing such a part
US20150001754A1 (en) * 2012-02-13 2015-01-01 Bridgestone Corporation Mold, method for manufacturing molded foam body, and molded foam body
US10099409B2 (en) * 2012-02-13 2018-10-16 Bridgestone Corporation Mold, method for manufacturing molded foam body, and molded foam body

Also Published As

Publication number Publication date
DE50201387D1 (en) 2004-12-02
EP1285845A1 (en) 2003-02-26
EP1285845B1 (en) 2004-10-27
DE10141242A1 (en) 2003-03-20
US20040169302A1 (en) 2004-09-02
US7146732B2 (en) 2006-12-12

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