Compound motor vehicle component and process and device for producing a compound motor vehicle component

Abstract

A motor vehicle roof part with a plastic outside skin which has been preformed by deep drawing and at least one other layer which is connected to the outside skin by an adhesive, a process and a molding tool for production thereof. A spacer part with a large volume and low weight is placed between the inside of the outside skin and a glass fiber mat which is used as another layer and is spaced apart from it. A liquid or foam adhesive which has been applied to the inside of the outside skin or the inside of the glass fiber mat diffuses into the spacer part. A very light and still very stable motor vehicle roof part with high production precision and surface quality results that has a plastic outside skin which, preferably, has already been colored according to the motor vehicle color.

What is claimed is:  
     
         1 . Compound motor vehicle component, comprising: 
 an outside skin,    an inside layer, and    a spacer part which contains hollow chambers and which is located between the outside skin and the inside layer and is connected to them,    wherein the outside skin is a finished surface component which is connected to the spacer part.    
     
     
         2 . Compound motor vehicle component as claimed in  claim 1 , wherein the outside skin is formed of a pre-formed deep-drawn component.  
     
     
         3 . Compound motor vehicle component as claimed in  claim 1 , wherein the outside skin is made of plastic or of metal.  
     
     
         4 . Compound motor vehicle component as claimed in  claim 1 , wherein the spacer part is connected to at least one of the outside skin and the inside layer by an adhesive  
     
     
         5 . Compound motor vehicle component as claimed in  claim 4 , wherein the adhesive is polyurethane.  
     
     
         6 . Compound motor vehicle component as claimed in  claim 4 , wherein the spacer part has an open honeycomb structure with a permeability to the adhesive and with webs which separate the hollow chambers and which extend essentially perpendicular to the outside skin.  
     
     
         7 . Compound motor vehicle component as claimed in  claim 1 , wherein the outside skin is formed of a thermoplastic film which is deformable by deep drawing, and wherein the inside layer is formed of a glass fiber mat.  
     
     
         8 . Compound motor vehicle component as claimed in  claim 7 , wherein the thermoplastic film is comprised of a carrier layer, and an appearance layer on an outer side of the carrier layer.  
     
     
         9 . Compound motor vehicle component as claimed in  claim 8 , wherein the carrier layer is made of a material selected from the group consisting of ASA, ASA-PC and ASA-HDT, and wherein the appearance layer is made of colored PMMA.  
     
     
         10 . Compound motor vehicle component as claimed in  claim 8 , further comprising a protective layer made of transparent material which is disposed on the outside of the appearance layer.  
     
     
         11 . Compound motor vehicle component as claimed in  claim 8 , wherein the transparent material is selected from the group consisting of PMMA and a UV-settable enamel.  
     
     
         12 . Compound motor vehicle component as claimed in  claim 7 , wherein an additional glass fiber mat or reinforcing fibers with random oreintation is disposed between the outside skin and the spacer part.  
     
     
         13 . Compound motor vehicle component as claimed in  claim 12 , wherein the glass fiber mats have a weight per unit of area of 300 to 400 grams per square meter and a thickness of roughly 0.3 millimeters.  
     
     
         14 . Compound motor vehicle component as claimed in  claim 1 , wherein the spacer part has a honeycomb or corrugated shaped structure made of a material selected from the group consisting of cardboard, aluminum and plastic.  
     
     
         15 . Compound motor vehicle component as claimed in  claim 1 , wherein the motor vehicle component is a motor vehicle roof part.  
     
     
         16 . Process for producing a compound motor vehicle component with an outside skin formed of a finished surface component, an inside layer and a spacer part which contains hollow chambers and which is located between the outside skin and the inside layer and is connected to them, comprising the steps of: 
 inserting the finished surface component into a first half of a molding tool,    inserting a glass fiber mat into second half of the molding tool,    applying a liquid adhesive layer to the glass fiber mat in second mold half and to the surface-finished component in a first mold half,    inserting the spacer part between the adhesive layers while the adhesive layers are still liquid, and    closing the a first and second mold halves so as to press the compound motor vehicle component into its final shape and so as to diffuse the adhesive into the spacer part, and    setting the adhesive.    
     
     
         17 . Process as claimed in  claim 16 , wherein the a preshaped, deep drawn component is provided as the finished surface component.  
     
     
         18 . Process as claimed in  claim 16 , wherein a second glass fiber mat is provided on the spacer part before inserting the spacer part into the molding tool, and wherein the spacer part is inserted in the mold half with the second glass fiber mat facing an inner side of the finished surface component.  
     
     
         19 . Process as claimed in  claim 16 , wherein the adhesive is applied at least to the upper glass fiber mat outside of the tool, and the upper glass fiber mat to which the adhesive has been applied is placed horizontally in the tool on the top of the spacer part.  
     
     
         20 . Process as claimed in  claim 16 , wherein after setting of the adhesive, a peripheral area of the glass fiber mat of the compound motor vehicle component is cut away by punching via a movable slider which is located in an edge area of the tool and which is used to hold the outside skin.  
     
     
         21 . Molding tool for producing a compound motor vehicle component with an outside skin, an inside layer and a spacer part which contains hollow chambers and which is located between the outside skin and the inside layer and is connected to them, comprising: 
 a first half for holding the outside skin of the compound motor vehicle component,    a slider which is movable perpendicular to a direction of extension of the compound motor vehicle component,    centering pins for holding the outside skin, and    an edging cutter, and    a second half which is provided with holding devices for holding a glass fiber mat.    
     
     
         22 . Molding tool as claimed in  claim 21 , wherein the edging cutter is provided in the first half of the molding tool; wherein the slider is provided in the second half of the molding tool and is provided with a groove for holding centering pins and which has a surface which is opposite the edging cutter of the lower tool half; and the slider is upwardly displacable on engagement the edging cutter on said surface.  
     
     
         23 . Molding tool as claimed in  claim 21 , further comprising a spray tool for applying adhesive which is insertable between the halves of the molding tool.  
     
     
         24 . Molding tool as claimed in  claim 23 , wherein the spray tool has a spray head with two sets of nozzles on the spray head, each of said sets facing toward a respective one of the halves of the molding tool.