Composite body part comprising metal filaments for a road vehicle, relative road vehicle and relative production method
A body part for a road vehicle comprising an outer portion configured to be arranged on the outer side of a road vehicle and defining a first side of the roof panel; an inner portion configured to be arranged, with respect to the outer portion, towards a passenger compartment of the road vehicle and defining a second side of the roof panel; wherein the outer portion comprises one or more first composite material layers, each comprising a reinforcement texture; wherein the outermost layer of said one or more first composite material layers, i.e. the one visible, in use, from the outside of the road vehicle, comprises a plurality of metal filaments woven into the reinforcement texture.
1 . A body part for a road vehicle ( 1 ) comprising:
an outer portion ( 10 ) configured to be disposed outwardly of a road vehicle ( 1 ) and defining a first side ( 11 ) of the body part;
an inner portion ( 12 ) configured to be arranged, with respect to the outer portion ( 10 ), towards a passenger compartment ( 3 ) of the road vehicle ( 1 ), and defining a second side ( 13 ) of the body part; and
an intermediate portion ( 16 ) disposed between the inner portion ( 12 ) and the outer portion ( 10 ); wherein the intermediate portion ( 16 ) comprises a layer ( 17 ) of sound-absorbing material (M) formed of a continuous closed cell foam;
wherein the outer portion ( 10 ) comprises a plurality of first composite material layers ( 14 ), each comprising a reinforcement texture (W) formed of a carbon fiber fabric (F), wherein an outermost layer ( 19 ) of the outer portion ( 10 ), which is visible from outside of the road vehicle when in use, further comprises a plurality of metal filaments woven into the reinforcement texture (W), wherein the plurality of metal filaments ( 20 ) have a thickness equal to or greater than the carbon fiber fabric (F),
wherein the first composite material layers ( 14 ) underlying the outermost layer ( 19 ) comprise an odd number of alternating first composite material layers of a first grammage and a second grammage, wherein the grammage indicates a weight of the respective carbon fiber fabric (F) of each first composite material layer, and
wherein the inner portion ( 12 ), the intermediate portion ( 16 ) and the outer portion ( 10 ) are solidly coupled together forming a single multilayer body ( 18 ), and
wherein the outermost layer ( 19 ) is resin impregnated and integrally formed as part of the multilayer body ( 18 ).
2 . The body part according to claim 1 , wherein the metal filaments ( 20 ) are made of copper.
3 . The body part according to claim 1 , wherein the metal filaments ( 20 ) are woven between fibers (F) of the carbon fiber fabric.
4 . The body part according to claim 1 , wherein the inner portion ( 12 ) comprises at least one or more second composite material layers ( 15 ).
5 . The body part according to claim 4 , wherein the layer of sound-absorbing material (M) has a thickness of 8 mm or less.
6 . The body part according to claim 4 , wherein the intermediate portion ( 16 ) and the inner portion ( 12 ) are coupled to each other by means of a first adhesive film ( 21 ) disposed therebetween; and wherein the intermediate portion ( 16 ) and the outer portion ( 10 ) are coupled to each other by means of a second adhesive film ( 22 ) disposed therebetween.
7 . The body part according to claim 1 , wherein the outer portion ( 10 ) comprises, in addition to the outermost layer ( 19 ) at least two first composite material layers ( 14 ) having at least a first grammage and at least one first composite material layers ( 14 ) having a second grammage, which are arranged alternately; wherein the first grammage is from 200 g/m 2 to 300 g/m 2 , and the second grammage is from 300 g/m 2 to 500 g/m 2 ; and, wherein the inner portion ( 12 ) comprises at least two second composite material layers ( 15 ) made with a grammage from 200 g/m 2 to 300 g/m 2 .
8 . A method for producing the body part according to claim 1 comprising:
a lamination step, during which the one or more first composite material layers ( 14 ), included the outermost layer ( 19 ) comprising metal filaments ( 20 ), of the outer portion ( 10 ) are shaped by lamination on a special mould;
a first forming step ( 24 ), subsequent to the lamination step ( 23 ), during which the outer portion ( 10 ) is formed by at least one autoclave cycle of the one or more first composite material layers ( 14 );
a coupling step ( 25 ), subsequent to the first forming step ( 24 ), during which the layer of sound-absorbing material (M) and the one or more second layers ( 15 ) of composite material of the inner portion are coupled to the outer portion ( 10 ), and shaped on the previously formed inner portion ( 12 );
a second forming step ( 26 ), following the coupling step ( 25 ), during which the single multilayer body ( 18 ) is formed by arranging the previously coupled outer portion ( 10 ), the intermediate portion ( 16 ) and the inner portion ( 12 ) in an autoclave.
9 . The method according to claim 8 , wherein, during the coupling step ( 25 ), the intermediate portion ( 16 ) is coupled to the inner portion ( 12 ) and to the outer portion ( 10 ) by means of a first adhesive film ( 21 ) and a second adhesive film ( 22 ), respectively.
10 . A road vehicle ( 1 ) comprising:
two pairs of wheels ( 2 ), of which at least one pair of the two pairs of wheels ( 2 ) is driven;
a shell comprising a body ( 7 );
the road vehicle ( 1 ) being characterised in that the body ( 7 ) comprises at least one body part according to claim 1 .
11 . The road vehicle ( 1 ) according to claim 10 , wherein the body part is a vehicular roof ( 9 ).
12 . The road vehicle ( 1 ) according to claim 11 , wherein the vehicular roof ( 9 ) is mounted to the rest of the vehicle ( 1 ) by perimeter bonding.