Roof module for a motor vehicle and process for producing same

Abstract

A roof module for a motor vehicle with an outside roof skin and layers of composite materials located on the vehicle interior side of at least planar portions of the roof skin and a process for producing such a module. The layers on the vehicle-interior side are arranged in the order, beginning from the outside roof skin, of a first fiber-containing layer produced using the long-fiber injection process, and a carrier layer of stiffening material.

1 . Process for producing a multilayer vehicle body component with an outside vehicle body skin and layers of composite materials located on the vehicle interior-side, comprising the following steps: 
 inserting an outside vehicle body skin into a negative mold,    forming a first fiber-containing layer by blowing polyurethane-wetted fibers by means of compressed air onto a vehicle interior-side surface of the outside vehicle body skin,    forming a carrier layer of stiffening honeycomb material by inserting stiffening honeycomb material, which has been covered by a blocking material, into the negative mold so as to cover the first fiber-containing layer, and    pressing together the layers and the outside vehicle body skin for a predetermined time interval at a predetermined temperature, the blocking material prevent fibers of the fiber-containing layer from penetrating into the honeycomb material.    
   
   
       2 . Process as claimed in  claim 1 , comprising the further step of forming a second fiber-containing layer on the vehicle interior-side surface of the carrier layer.  
   
   
       3 . Process as claimed in  claim 2 , wherein the blocking material comprises a first nonwoven layer provided between the first fiber-containing layer and the carrier layer in a manner so as to cover the carrier layer.  
   
   
       4 . Process as claimed in  claim 3 , wherein the blocking material further comprises a second nonwoven layer provided between the second fiber-containing layer and the carrier layer so as to cover the carrier layer.  
   
   
       5 . Process as claimed in  claim 4 , wherein at least one of the first and second nonwoven layers is connected to a surface of the stiffening material of the carrier layer before inserting of the stiffening material into the negative mold.  
   
   
       6 . Process as claimed in  claim 1 , wherein, after the pressing step, the vehicle body component is placed in a cooling mold for cooling of the vehicle body component.  
   
   
       7 . Process as claimed in  claim 6 , wherein said cooling is performed under pressure.  
   
   
       8 . Process as claimed in  claim 6 , wherein said outside vehicle body skin is an outside roof skin and the vehicle body component is a roof module.  
   
   
       9 . Process as claimed in  claim 1 , wherein said outside vehicle body skin ian outside roof skin and the vehicle body component is a roof module.