Patent Publication Number: US-2023158784-A1

Title: Vehicle component unit and method for producing a vehicle component unit

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority of U.S. Provisional Patent Application Ser. No. 63/005,698 filed Apr. 6, 2020, which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention in general relates to composites and in particular to a composite sandwich structure assembly with an intervening open area core support matrix and surface sheets adhered to the open area core to provide at least one surface that meets vehicle exterior surface gloss standards. 
     BACKGROUND OF THE INVENTION 
     Weight savings in the automotive, transportation, and logistics based industries has been a major focus in order to make more fuel efficient vehicles both for ground and air transport. In order to achieve these weight savings, light weight composite materials have been introduced to take the place of metal structural and surface body components and panels. Composite materials are materials made from two or more constituent materials with significantly different physical or chemical properties, that when combined, produce a material with characteristics different from the individual components. The individual components remain separate and distinct within the finished structure. A composite material may be preferred for many reasons: common examples include materials which are stronger, lighter, or less expensive when compared to traditional materials. A sandwich-structured composite is a special class of composite material that is fabricated by attaching two thin but stiff skins to a lightweight but thick core. The core material is normally a low strength material, but its higher thickness provides the sandwich composite with high bending stiffness with overall low density. 
     While sandwich structures have previously been developed to provide strength and reduced weight, the ability to obtain a vehicle exterior quality high gloss surface has remained a challenge, regardless of whether the surface outermost layer is thermoset resin or thermoplastic. It is conventional to either not use such structures in settings where vehicle high surface gloss is required, or resort to an additional outer layer to provide a high gloss outermost layer. Such outermost layers can be applied after structure production or through in mold coatings, both of which add to the cost and complexity of production. 
     Still another problem conventional to the art is that sandwich structure edges often require an additional processing step of cutting excess material from the vehicle component, resulting in edges that are ineffective and allow for infiltration of humidity or moisture that becomes entrained within the core and often inconsistent with finished vehicle surface requirements. With temperature extremes this entrained moisture can reduce the operational lifetime of the structure, while increasing the weight thereof. These problems of moisture infiltration are particularly pronounced in instances when the core is formed of cellulosic materials such as paper. 
     Thus, there exists a need for a sandwich composite structure vehicle component that affords a high gloss surface, moisture resistance, and well-trimmed edges without resort to additional processing after production or the addition of further outermost surface layers. 
     SUMMARY OF THE INVENTION 
     The present invention provides a vehicle component unit that includes a reinforcing open area core layer, a high gloss surface layer, and an encapsulating plastic layer. The reinforcing open area core layer has a first side and an oppositely opposed second side and a first end and an oppositely opposed second end each extending between the first side and the second side. The high gloss surface layer is positioned on the first side of the reinforcing open area core layer. The encapsulating plastic layer has a first end and a second end and is positioned on the second side of the reinforcing open are core layer. The first end and the second end of the encapsulating plastic layer are embedded into the high gloss surface layer with an embedded length L, such that the encapsulating plastic layer covers the first end and the second end of the reinforcing open area core layer. 
     The present invention additionally provides a method for producing the above-described vehicle component unit. The method includes stacking the high gloss surface layer, the open area core layer, and the encapsulating plastic layer in a mold having an upper portion and a lower portion that together define a mold cavity, inserting the ends of the encapsulating plastic layer into the high gloss surface layer using sharp edges on the mold and simultaneously trim the encapsulating plastic layer and the open area core layer using the sharp edges on the mold, and pressing the upper portion of the mold and the lower portion of the mold together to impart a shape to the vehicle component. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The subject matter that is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which: 
         FIG.  1    shows a cross sectional view a vehicle component according to embodiments of the present invention; 
         FIG.  2    shows a cross sectional detailed view illustrating the end portion of the internal plastic layer inserted in the SMC layer of the vehicle component of  FIG.  1   ; 
         FIG.  3    shows a cross sectional view a vehicle component according to embodiments of the present invention; 
         FIG.  4    shows a cross sectional detailed view illustrating the end portion of the internal plastic layer inserted in the SMC layer of the vehicle component of  FIG.  3    illustrating the length L and the thickness T 1  of the SMC layer; 
         FIG.  5    shows a cross sectional view a vehicle component according to embodiments of the present invention; 
         FIG.  6    shows a cross sectional view a vehicle component according to embodiments of the present invention; 
         FIG.  7    shows a cross sectional detailed view illustrating the end portion of the internal plastic layer inserted in the SMC layer of the vehicle component according to embodiments of the present invention illustrating the length L and the thickness T 1  of the SMC layer; 
         FIG.  8    shows a cross sectional detailed view illustrating the end portion of the internal plastic layer inserted in the SMC layer of the vehicle component according to embodiments of the present invention illustrating the region X, the thickness T 1 , T 2  and the length L; 
         FIG.  9    shows a cross sectional view a vehicle component according to embodiments of the present invention having a thickness Tm of the vehicle component and the thickness Tc of the core layer; 
         FIG.  10    shows a cross sectional detailed view illustrating the end portion of the internal plastic layer inserted in the SMC layer of the vehicle component according to embodiments of the present invention illustrating the thickness Tm of the vehicle construction unit and the thickness Tc of the core layer; 
         FIG.  11    shows a cross sectional view a vehicle component according to embodiments of the present invention illustrating the thickness Tm of the vehicle component and the thickness Tc of the core layer; 
         FIG.  12    shows a cross sectional view a vehicle component according to embodiments of the present invention illustrating the thickness Tm of the vehicle component and the thickness Tc of the core layer; 
         FIG.  13 A  shows a cross sectional view illustrating a method for producing a vehicle component according to embodiments of the present invention with an upper mold and a lower mold before the molds closed; 
         FIG.  13 B  shows a cross sectional view illustrating a method for producing a vehicle component according to embodiments of the present invention with the molds after the mold closed; 
         FIG.  13 C  shows a cross sectional view illustrating a method for producing a vehicle component according to embodiments of the present invention with the molds after the mold closed; 
         FIG.  14 A  shows a cross sectional view illustrating a sharp edge inserting the end portion of the internal plastic layer into the SMC layer before the mold closed; 
         FIG.  14 B  shows a cross sectional view illustrating a sharp edge inserting the end portion of the internal plastic layer into the SMC layer after the mold closed; 
         FIGS.  15 A and  15 B  show cross sectional views illustrating a secondary trimming process of a vehicle component according to a conventional method; and 
         FIGS.  16 A- 16 C  show cross sectional views illustrating a method of forming a vehicle component according to embodiments of the present invention using a masking method. 
     
    
    
     DESCRIPTION OF THE INVENTION 
     The present invention has utility as a composite sandwich vehicle component with an open area core sandwiched between and encapsulated within a sheet molding compound (SMC) layer and an encapsulating plastic layer and a method of producing the same. The SMC layer has a high gloss surface finish such that secondary finishing of the vehicle component to obtain a high gloss surface finish is avoided. The present invention is suitable for all vehicle components made of composite material, but in particular for vehicle body shell components, such as vehicle roof modules, a cover of a roof opening system such as a sliding roof or spoiler roof, a surface component of a roof module, roof posts, A, B, C or D pillars of vehicles, vehicle doors, wings, engine compartment covers, luggage compartment covers, rear-end modules, roof shells of cabriolet hoods, a trim component of a vehicle, or front or rear spoilers. Embodiments of the present invention further provide sound dampening and temperature variation resistance qualities. Additionally, the inventive method and vehicle component of the present invention provide a vehicle component that is finished at the ends thereof to additionally avoid secondary trimming or cutting of the vehicle component after molding of the vehicle component. The result is a low cost, light weight, high strength vehicle component that is finished with a high quality of aesthetics upon completion of the molding process. 
     It is to be understood that in instances where a range of values are provided that the range is intended to encompass not only the end point values of the range but also intermediate values of the range as explicitly being included within the range and varying by the last significant figure of the range. By way of example, a recited range of from 1 to 4 is intended to include 1-2, 1-3, 2-4, 3-4, and 1-4. 
     As used herein, the term “high gloss surface” refers to a surface having minimal perceptible surface defects when visually inspected for about three seconds from about 24-28 inches from the viewer and normal to the part surface +/−90 degrees in a well-lit area. That is, the term “high gloss surface” refers to a surface capable of being painted and accepted as a “Class A” autobody part. This is commonly measured by ASTM D523. In the automotive industry, a Class A surface is a surface a consumer can see without functioning the vehicle (e.g., opening the hood or decklid), while a Class A surface finish generally refers to painted outer panels and specifically to the distinctness of image (DOI) and gloss level on the part. It is appreciated that a surface layer may be subjected to sanding, trimming, and priming prior to receiving a paint coating that imparts high gloss yet must retain dimensionality and adhesion uniformity to primer and paint so as to achieve a high gloss finish. 
     Referring now to the figures, a vehicle component  100  according to embodiments of the present invention comprises a high gloss surface layer  10 , a reinforcing open area core layer  20 , and an encapsulating plastic layer  30 . The reinforcing open area core  20  has a first side  22  and an oppositely opposed second side  24  and a first end  26  and an oppositely opposed second end  28  each extending between the first side  22  and the second side  24 . The high gloss surface layer  10  is positioned on the first side  22  of the reinforcing open area core layer  20  with the high gloss surface  12  positioned such that it is outwardly facing, that is, facing away from the open area core layer  20 . The encapsulating plastic layer  30  is positioned on the second side  24  of the reinforcing open area core layer  20 . The encapsulating plastic layer  30  has a first end  32  and a second end  34  that are embedded into the high gloss surface layer  10  with an embedded length L, such that the encapsulating plastic layer  30  covers the first end  26  and the second end  28  of the reinforcing open area core layer  20 . While the structure  100  depicted in  FIG.  1    is planar, it is appreciated that both the high gloss surface layer  10  and the encapsulating plastic layer  30  can each independently be formed with non-planar contours. 
     The high gloss surface layer  10  according to the present invention is formed from sheet molding compound (SMC), thermoplastic, dicyclopentadiene (DCPD), overmolded polyurethane (PU), or a combination thereof. According to embodiments, the high gloss surface layer  10  includes a filler material  14  to reinforce and/or serve to decrease the weight of the high gloss surface layer  10 . The filler material  14  is any of glass fibers, carbon fibers, basalt fibers, natural fibers, hollow or solid glass microspheres, a fiber mat, or a combination thereof. The fibers may be oriented or non-oriented. It is appreciated that the high gloss layer  10  routinely includes additives to retain dimensionality. Such additives routinely including glass fiber; carbon fiber; inorganic particulate fillers such as calcium carbonate, talc, and carbon black; glass microspheres; carbon nanotubes; graphene; low profile additives; moisture scavengers; and combinations thereof. Typical thicknesses of the high gloss surface layer in the present invention range from 0.5 to 5 millimeters (mm) without regard to edges. According to embodiments, the high gloss surface layer  10  is formed on a thermosetting SMC containing short dispersed fibers. A high-gloss surface is obtained either by a corresponding high-gloss surface in a mold or by subsequent polishing of the component. High-gloss, matt or structured component surfaces are obtained in accordance with the mold surface. According to embodiments, the high gloss surface layer  10  includes contrasting colors or be made in the color of the paint color of the final vehicle. According to embodiments, the high gloss surface layer  10  exhibits a reduced density of smaller than 1.4 kg/dm 3  and in particular between 1.3 kg/d m 3  and 1.0 kg/d m 3 . 
     The thickness of the high gloss surface layer  10  is chosen to cover the underlying structure to a high quality, so that no bumps or the like occur or are recognizable at the surface of the high gloss surface layer  10 . When the thickness of the high gloss surface layer  10  is reduced, the weight of the vehicle component  100  is reduced. However, when the thickness T 1  of the high gloss surface layer  10  at a periphery region X where the ends  32 ,  34  of the encapsulating plastic layer  30  are inserted is too thin, the high gloss surface layer  10  in the periphery region X where the ends  32 ,  34  are inserted is broken due to cracking. Therefore, according to embodiments the high gloss surface layer  10  has a non-uniform thickness across its length, in which the thickness increases in the periphery region X as shown in  FIGS.  4  and  8   . 
     According to embodiments, the thickness T 1  of the high gloss surface layer  10  is measured in a region X, which is a region within 5.0 mm from the insertion point of the ends  32 ,  34  of the encapsulating plastic layer  30 , as shown in  FIGS.  2 ,  4 , and  8   . According to embodiments, the thickness T 1  of the high gloss surface layer  10  is between 1.0 mm and 4.0 mm. According to embodiments, a minimum thickness of 3 mm at region X is required to use a sharp edge  1303 , but this may vary when different SMC grade is used to form the high gloss surface layer  10 . 
     According to embodiments, the relationship between the thickness T 1  of the periphery region X and a minimum thickness T 2  of the high gloss surface layer  10  is 1.1&lt;T 1 /T 2 . When it is 1.1&lt;T 1 /T 2 , T 2  is sufficiently smaller than T 1 . Therefore, the overall weight of the vehicle component  100  is reduced by reducing the thickness of the high gloss surface layer  10 . According to embodiments, the relationship is 1.1&lt;T 1 /T 2 &lt;4.0, more preferably 1.3&lt;T 1 /T 2 &lt;3.5 even more preferably 1.5&lt;T 1 /T 2 &lt;3.0. According to embodiments, the minimum thickness T 2  of the high gloss surface layer  10  is 0.5 mm to 3.0 mm, and more preferably, the thickness T 2  is 1.0 mm to 2.0 mm. 
     According to embodiments, the open area core layer  20  is formed of a lightweight material that defines a plurality of pores  23  so as to reduce the overall density of the open area core layer  20 . An open area core layer  20  according to the present invention is formed from a variety of materials that include cellulosics such as corrugated fiberboard, paper board, paper stock; phenolic resin, thermoplastics such as poly(methyl methacrylate) (PMMA), acrylonitrile butadiene styrene (ABS), polyamides, polylactides, polybenzimidazoles, polycarbonates, polyether sulfones, polyethylene, polypropylene, polystyrene, polyvinyl chloride, and block copolymers of any one of the aforementioned where at least one of the aforementioned makes up the majority by weight of the copolymer and regardless of the tacticity of the polymer or copolymer; thermosets such as polyesters, polyureas, polyurethanes, polyurea/polyurethanes, epoxies, vinyl esters; metal such as aluminum, magnesium, and alloys of any one of the aforementioned where at least one of the aforementioned metals constitutes the majority by weight of the alloy; a foam formed from polyurethane, polyethylene, ethylene vinyl acetate, polypropylene, polystyrene, polyvinyl chloride, oraerogels, regardless of whether the foam is open-celled or closed-celled. 
     The open area core  20  includes internal wall material  21  that defines a plurality of pores  24 . The pores  24  may be disordered, such as when the open area core  20  is formed of a foam material, or may be in an ordered array, in which the pores are in a shape of honeycombs, diamonds, squares, triangles, parallelograms, circles, or a combination thereof. It is appreciated that while pores are depicted as isolated from one another that wall structures  21  are readily formed from extended folded strips that define a portion of several pores and when made contiguous with other such folded strips define an array of pores that are intercommunicative along the lines of contact between contiguous strips. According to embodiments, at least some pores  23  of the open area core  20  are in fluid communication with at least one other pore  23 . According to embodiments, the fluid communication is established by forming a transverse hole through a side wall  21  of at least some of the pores  23 . Such holes can be formed in the material of the open area core  20  before the material is formed into the pores of the open are core. 
     Alternatively, the holes allowing for fluid communication between the pores can be formed in the walls  21  of the core  20  after the pores  23  are formed. Fluid communication between at least some of the pores  23  ensures that air that is caught within a pore is able to move to another pore in the event that a given pore is crushed or otherwise deformed. As will be described in greater detail below, in some embodiments the edge region of the core material is crushed when the ends  32 ,  34  of the encapsulating plastic layer  30  are inserted into the high gloss surface layer  10  to form a sealed edge. In such situations, it is beneficial to provide transverse holes in the walls  21  of at least some of the pores  23 , for example those near the edge to be sealed, such that when the seal is formed and the pores  23  near the edge are crushed, the air of those crushed pores is able to move into adjacent pores via the transverse holes. 
     According to embodiments, the pores  23  defined by walls  21  of the open area core layer  20  extend between first side  22  and the second side  24  of the open area core layer  20 . In some embodiments, the internal wall material  21  is treated to modify a property thereof such as hydrophobicity or surface energy to promote adhesion thereto. By way of example, cellulosics are prone to moisture uptake and are readily coated with a wax such as a paraffin, or a silicone to render the cellulosic more hydrophobic compared to a native state. Alternatively, the cellulosic is readily alkylated by conventional reactions such as those with chloroacetic acid. Sarymsakov, A. A et al., Chem. Nat. Compd. (1997) 33: 337. Metals are similarly coated with a primer or other corrosion inhibitor. Alternatively, metals or polymers are plasma treated to modify surface energies to facilitate adhesion thereto. 
     In certain inventive embodiments, the ratio of the thickness of a wall  21  to the maximal linear extent between the first side  22  and the second side  24  of the open area core layer  20  is between 0.01-10:1. A wall  21  thickness ranges from 0.1 mm to 100 mm in such inventive embodiments. According to embodiments, the pores  23  of the open area core  20  include a fill, the fill being at least one of a sound dampening foam, a fire retardant, or a phase change material. 
     According to embodiments, the encapsulating plastic layer  30  predominantly contains polyurethane or is made of glass fiber reinforced plastic (GFRP) having a glass fiber mat impregnated with polyurethane. As shown in  FIG.  1   , the encapsulating plastic layer  30  is layered on the second side  24  of the open area core  20 . According to embodiments, the encapsulating plastic layer  30  is fastened to the second side  24  of the open are core  20  using an adhesive. The adhesive is a polyurethane or polyurethane prepolymer adhesive, which may be in the form of glue, a moisture cure adhesive, a reactive hot melt adhesive, or a polyurethane resin. According to embodiments, due to the compressive force applied to the optional adhesive between the encapsulating plastic layer  30  and the open area core layer  20 , the adhesive is engineered to have an initial viscosity on contact with the second side  24  of the open area core  30  and the walls  21  so as partially fill the pores  23  of the open area core layer  20 . It is appreciated that the viscosity upon application is a function of factors that include application temperature, pore dimensions at the face, and intrinsic adhesive viscosity. The viscosity of the first adhesive layer ensures that the adhesive does not excessively run into the pores defined in the open area core layer  20  before the adhesive attains final strength. 
     According to embodiments, the high gloss surface layer  10  of the vehicle component  100  is connected to the open area core layer  20  by an internal plastic layer  40 . According to embodiments, the internal plastic layer  40  formed from sheet molding compound (SMC), thermoplastic, dicyclopentadiene (DCPD), polyurethane (PU), or a combination thereof. According to embodiments, the internal plastic layer  40  includes a filler material to reinforce and/or serve to decrease the weight of the internal plastic layer  40 . The filler material is any of glass fibers, carbon fibers, basalt fibers, natural fibers, hollow or solid glass microspheres, a fiber mat, or a combination thereof. The fibers may be oriented or non-oriented. It is appreciated that the internal plastic layer  40  may also include other additives to tune the properties thereof. Such additives routinely including glass fiber; carbon fiber; inorganic particulate fillers such as calcium carbonate, talc, and carbon black; glass microspheres; carbon nanotubes; graphene; low profile additives; moisture scavengers; and combinations thereof. According to embodiments, the internal plastic layer  40  may be omitted as a fibrous layer, if high gloss surface layer  10  takes over the structural properties of the internal plastic layer  40 . In such situations, the bonding of high gloss surface layer  10  directly to the open area core layer  20  is then carried out only by an adhesive such as polyurethane or polyurethane prepolymer adhesive, which may be in the form of glue, a moisture cure adhesive, a reactive hot melt adhesive, or a polyurethane resin, as described above. 
     As shown in the figures, the first end  32  and the second end  34  of the encapsulating plastic layer  30  are folded down and wrapped over the ends  26 ,  28  of the open area core  20 , such that the encapsulating plastic layer  30  covers the first end  26  and the second end  28  of the reinforcing open area core layer  20 . With this design, the open area core layer  20  is not visible from the outside of the vehicle component  100  and the aesthetic at the ends of the vehicle component  100  is excellent and suitable for application on a vehicle without the need for additional finishing such as trimming or cutting. Furthermore, when the open area core layer  20  is made of a honeycomb, for example a paper honeycomb, not only does the encapsulating plastic layer  30  cover the ends  26 ,  28  of the core  20  to improve the aesthetics, but also the encapsulating plastic layer  30  seals the open area core layer  20  and prevents water and humidity infiltration into the open area core  20 , which is particularly important when the vehicle component  100  is used as a vehicle exterior surface component given that such components are often directly in contact with snow, rain, and dew. 
     As noted above, the first end  32  and the second end  34  of the encapsulating plastic layer  30  are embedded into the high gloss surface layer  10  with an embedded length L. the ends  32 ,  34  of the encapsulating plastic layer  30  are held within the high gloss surface layer  10  by a friction fit or by an adhesive. Furthermore, a plasticizer may be placed on the ends  32 ,  34  of the encapsulating plastic layer  30  within the high gloss surface layer  10  to account for differences in thermal expansion of the respective materials. According to embodiments, the relationship between the length L and the thickness T 1  of the high gloss surface layer  10  is T 1 ×0.7&gt;L. With this design, the first and second ends  32 ,  34  of the encapsulating plastic layer  30  is prevented from delamination, and the ends  26 ,  28  of the open area core layer  20  are covered from view and sealed off from the external environment. When the relationship between the length L and the thickness T 1  of the high gloss surface layer  10  is T 1 ×0.7&gt;L, the high gloss surface layer  10  does not crack due to the insertion of the end  32 ,  34  of the encapsulating plastic layer  30 . According to embodiments, the relationship between the length L and the thickness T 1  is T 1 ×0.5&gt;L, and more preferably, T 1 ×0.2&gt;L. Whereas, when the lower limit of the insertion length L is L&gt;T 1 ×0.01 preferably, the ends  32 ,  34  do not easily peel off or come disconnected from the high gloss surface layer  30 . According to embodiments, the lower limit of the insertion length L is L&gt;T 1 ×0.05, and more preferably L&gt;T 1 ×0.1. 
     Hereinafter, more specifically the insertion length L is explained. According to embodiments, the insertion length L is between 0.1 mm and 1.0 mm. In other words, the ends  32 ,  34  of the encapsulating plastic layer  30  are inserted into the high gloss surface layer  10  by 0.1 mm to 1.0 mm. When the insertion length L is 0.1 mm or more, the ends  32 ,  34  tend to not be easily peeled from the high gloss surface layer  10 . Furthermore, when the insertion length L is 1.0 mm or less, the high gloss surface layer  10  is not destroyed by cracks due to the insertion of the ends  32 ,  34 . The insertion length L is more preferably between 0.2 mm and 0.8 mm, and even more preferably between 0.3 mm and 0.6 mm. 
     According to embodiments, a sealant  50  is applied to the exterior of the encapsulating plastic layer  20  where it intersects with the high gloss surface layer  10 . The sealant  50  act as an adhesive to help hold the encapsulating plastic layer  20  in its position inserted in the high gloss surface layer  10  as well as helping to further seal the encapsulating plastic layer  20  and the high gloss surface layer  10  to prevent moisture infiltration into the open area core layer  20 . 
     In the present invention, the vehicle component  100  has a region Z in which a relationship between a thickness Tm of the vehicle component  100  and a thickness Tc of the open area core layer  20  is Tm−Tc&gt;Tc×0.2. According to embodiments, the region Z does not need to occupy the entire vehicle component  100 . It is sufficient that at least a part of the vehicle component  100  has the region Z that satisfies Tm−Tc&gt;Tc×0.2. For example, as illustrated in  FIGS.  9 - 12   , the thickness Tm of the vehicle component  100  is the thickness of the vehicle component  100  and Tc is the thickness of the open area core layer  20 . According to embodiments, when a vehicle component  100  has a higher Tm thickness than the thickness of the open area core  20  Tc, it is necessary to fill the space between the high gloss surface layer  10  and the open area core  20  with additional material either on the encapsulating plastic layer  30  or the internal plastic layer  40 . For example, when a shape of the vehicle component  100  has a projection inward as shown in  FIGS.  9 - 11   , a space between the open area core layer  20  and the inner surface  36  of the vehicle component  100  is filled with additional material on the encapsulating plastic layer  30 . Alternatively, when the shape of the vehicle component  100  has a projection outward as shown in  FIG.  12   , a space between the open area core layer  20  and the high gloss surface layer  20  is filled with additional material on the internal plastic layer  40 . 
     According to embodiments, the vehicle component  100  is a vehicle exterior surface component. Such a vehicle exterior surface component is for example a body component, a cover of a roof opening system like a sun roof or a spoiler roof, a surface component of a roof module or a lining construction unit of a vehicle. When the vehicle component  100  is a vehicle exterior surface component, an IMC-TOP coat layer may be provided on the high gloss surface layer  10 . The IMC-TOP coat layer may be attached on the outside of the high gloss surface layer  10 , which forms the outer shell layer together with the high gloss surface layer  10 . 
     The present invention additionally provides a method for producing the light and resilient vehicle component  100  described above. As shown in  FIGS.  13 A- 13 C , the inventive method includes stacking the high gloss surface layer  10 , the open area core layer  20 , and the encapsulating plastic layer  30  in a mold  1301 ,  1302 . According to embodiments, the method also includes layering a second plastic layer  40  between the high gloss surface layer  10  and the open area core  20 . As shown, the open area core layer  20  and the encapsulating plastic layer  30 , and if present the internal second plastic layer  40  are provided with a length that is greater than the desired vehicle component  100  length. 
     The method continues by inserting the ends  32 ,  34  of the encapsulating plastic layer  30  into the high gloss surface layer  10  using a sharp edges  1303  provided on either an upper mold  1301  or the lower mold  1302  as shown in  FIGS.  14 A and  14 B . With the insertion of the ends  32 ,  34  into the high gloss surface layer  10 , the sharp edges  1303  simultaneously cut the encapsulating plastic layer  30 , the open area core layer  20 , and, if present, the second internal plastic layer  40 , leaving a trimmed portion  1304  outside and separate from the vehicle component  100 . This is in contrast to existing processes, such as that shown in  FIGS.  15 A and  15 B , in which after removing a formed sandwich structure vehicle component from a mold, at least one further method step, such as trimming or cutting the edges is necessary to obtain aesthetically appropriate component edges. Thus, the inventive method is an improvement over existing processes in that the inventive method reduces the manufacturing steps, thereby increasing manufacturing throughput and reducing manufacturing costs. 
     The method continues by pressing the upper mold  1301  and the lower mold  1302  together to impart a shape to the vehicle component  100 . According to embodiments, a vacuum is applied to the mold cavity to further assist in shaping the vehicle component  100 . 
     According to embodiments, the sharp edge  1303  penetration is controlled by the tool, and hard stops with adjustable shims may set the penetration distance. Furthermore, according to embodiments, an IMC thin layer can be provided with an outer surface coating or alternatively the high gloss surface layer  10  can be provided with a paintable IMC thin layer and the method may then include painting the vehicle component  100 . Furthermore, an IMC lacquer layer may be applied to the high gloss surface layer  10  on a side that is facing the first mold  1302  to form an outer skin layer in the process. 
     According to embodiments, such as shown in  FIGS.  16 A- 16 C , the method includes masking the ends of the high gloss surface layer  10  with a mask  1601  at the time of molding in order to prevent any adhesion marks or other scaring on the high gloss surface layer  10  during the molding process. 
     The foregoing description is illustrative of particular embodiments of the invention but is not meant to be a limitation upon the practice thereof. The following claims, including all equivalents thereof, are intended to define the scope of the invention.