DE102006048291A1 - Support tank particularly for receiving and supporting battery for vehicle, particularly for commercial vehicle, is made of pre-impregnated fiber-matrix semi-finished product, particularly thermoplastic semi-finished product - Google Patents

Abstract

The tank is made of a pre-impregnated fiber-matrix semi-finished product, particularly a thermoplastic semi-finished product, which is reinforced locally with an inlaid part. The pre-impregnated fiber-matrix semi-finished product is a fiber mat, particularly glass-fiber mat, comprises long or endless fibers. A fiber semi-finished product, particularly, a netting layer or fleece layer or similar item is arranged as inlaid parts.

Description

The The invention relates to a carrying trough, in particular for receiving and Mounting a battery for a motor vehicle, in particular a truck in the preamble of the patent claim 1 specified type.

to Recording and mounting, for example, a vehicle battery in the series production of motor vehicles, especially trucks used a variety of trays. In particular, carrying tubs for trucks subject to a special stress, as they usually unprotected are arranged on the support frame and near vehicle wheels of the motor vehicle. So are such trays mostly spray water on the one hand, dirt as well as rockfall and on the other hand mechanical loads, for example exposed to vibrations or twisting of the support frame. It is also important to take into account that such trays a certain protective function, for example for the Vehicle batteries in the event of an accident or an accidental force must have. For this reason, previous trays are mostly as sheet steel structures been designed, which by appropriate forming process as well by joining together the individual sheet metal parts are produced. As a disadvantage in Such hoppers is therefore the circumstance to be considered that these are relatively expensive to manufacture and also a very high weight exhibit.

For this reason, carrier tubs have already been developed, which are to be made of plastic in a relatively simple manufacturing process. Such a trough is for example already out of the DE 199 61 853 C1 to be known, in which a space for receiving the vehicle battery is separated by means of an intermediate wall within the carrying tub. The entire tray is pressed from a thermoplastic in one piece, the thermoplastic material is mixed with glass fibers in order to improve the mechanical properties of the carrier tub. However, such admixture of glass fibers to the plastic allows only a gain or improvement of the mechanical properties of the supporting trough to a limited extent.

task The present invention is therefore a support trough the above to create the type mentioned, improves their mechanical properties are.

These The object is achieved by a Carrying tub solved with the features of claim 1. advantageous Embodiments with appropriate and Non-trivial developments of the invention are specified in the dependent claims.

Around To improve the mechanical properties of the suspension trough is it is provided according to the invention that these consist of a preimpregnated fiber matrix semifinished product, in particular a thermoplastic semi-finished product (GMT) is, which is at least locally reinforced with at least one insert. Accordingly, it is therefore provided according to the invention, as a starting material for the carrying tub to use a semi-finished, the reinforcing fibers with a plastic matrix soaked or waterproof are. Such fiber-matrix semi-finished products have the great advantage an unproblematic or process-reliable processing, whereby extremely stable and low weight Tragwannen can be produced. Especially fiber matrix semi-finished products with thermoplastic matrix, and especially glass mats reinforced thermoplastics (GMT) are suitable in particular for the production of such a carrying trough, since They are produced in short cycle times and can be easily recycled can. About that In addition, such fiber-matrix semi-finished products are thermoplastic Matrix also weldable.

One Another advantage of such preimpregnated fiber-matrix semi-finished products is it that these are extremely simple Way to connect with the at least locally provided insert are. This can preferably be done in a well-controlled pressing process take place, in which both the fiber-matrix semi-finished in his final Form formed as well as the at least locally provided insert can be connected to this. In other words is a special one Advantage of the carrier tray according to the invention to see that in one and the same pressing process both the pre-impregnated Fiber-matrix semi-finished molded as well as this with the insert can be connected. It is clear that doing the insert itself - together with the fiber-matrix semifinished product itself - reshaped can be. In this case, the insert of the flowable fiber-matrix semifinished product partially or completely enclosed.

One Another advantage of using a fiber-matrix semifinished product for the production The carrying trough is that these as one-piece and tool falling Component can be created, which in terms of their design no further processing steps required.

In a further embodiment of the invention, it has also proven to be advantageous if the preimpregnated fiber matrix semifinished product (GMT) comprises a fiber mat, in particular a glass fiber mat of long or continuous fibers. Such a fiber mat of long fibers has in particular the The advantage that a good surface quality and very good mechanical properties can be realized with it. Furthermore, such a preimpregnated fiber-matrix semifinished product is particularly well suited to connect to the at least one local insert after heating or pressing.

In Another embodiment of the invention is as an insert at least a semifinished fiber, in particular a woven or nonwoven layer or the like provided. Such a semifinished fiber product can be particularly good and easy way after heating or when pressing the Carrying tub with the pre-impregnated Fiber matrix semi-finished are connected. Thus, in particular a composite is created in which the fiber-matrix semifinished in Area of locally provided semi-finished fiber particularly well stiffened or reinforced.

A Particularly good stiffening of the carrying tub can be beyond reach if at least two semi-finished fiber products, in particular two woven or nonwoven layers or the like used which are in their orientation transversely or crosswise extend to each other. In the field of intersecting semi-finished fiber products thus uniform mechanical Characteristics of the suspension trough both in their transverse direction as well in their longitudinal direction reached.

In Another embodiment of the invention is the insert as a semi-finished fiber formed with unidirectional fibers. Such a semi-finished fiber product has in particular a high rigidity and strength in the fiber direction and can therefore be exposed to high mechanical loads become. Are the unidirectional fibers or formed from this Insert formed such that they the attachment points to fix the carrier tub on the motor vehicle, so can guarantee a mechanically particularly stable carrying trough become. This is especially true because the endless fibers or the from this formed inserts at no cutting or joint of the profile part are interrupted. Another advantage of such Semi-finished fiber from unidirectional fibers is that this also in a simple and reliable way after heating in the pressing process with the preimpregnated Fiber matrix semifinished product can be connected.

is the insert, however, designed as a metal insert, so this is in a particularly good way to determine the carrying tray on the car suitable. Furthermore is such a metal insert preferably in those Arranged areas, which the batteries and at least one compressed air tank the hull to be set.

One further advantage of the carrying tub according to the invention is created, if its bottom to the contour of the at least one container - in particular of the compressed air tank - adapted is. This can on the one hand a stiffer and vibration Fixing the container created on the support trough and on the other hand arises an aerodynamically more favorable Arrangement of the at least one container on the supporting trough. This is of particular interest when the carrying tub, such as given in the arrangement on a truck, unclad on the outside of the Vehicle frame is arranged.

Finally has it has been found to be advantageous if the preimpregnated Fiber Matrix semi-finished the outside the carrying trough forms, wherein the at least one insert part inside of the fiber-matrix semifinished product is arranged. Through the preimpregnated Fiber matrix semifinished product can thus a carrying tray with a high value appearance created on its outside be while the at least one insert on the inside of the fiber-matrix semifinished product for one corresponding local Stiffening of the carrying tub ensures.

Further Advantages, features and details of the invention will become apparent the following description of a preferred embodiment as well as from the drawings; these show in:

1 a schematic perspective view of a carrying trough of a truck, within which two batteries are received and supported, wherein the carrying trough is to be closed by a lid, and wherein the underside of the carrier trough three in cross-section circular compressed air tank are held;

2 a schematic side view of the carrier according to 1 in particular, it can be seen that the bottom of the carrying trough is adapted to the contour of the compressed air tank;

3 a schematic perspective view of the upside-down support trough according to an alternative embodiment, in particular it can be seen that this is made of a pre-impregnated fiber-matrix semi-finished, which by two cross-laid fiber semi-finished products in the form of glass fiber fabric layers and inserts of unidirectional fibers , which surrounds the attachment points for fixing the carrying trough to the motor vehicle, is reinforced;

4 a schematic perspective view of the arranged during the pressing process between the die and the male or introduced semi-finished products, namely - seen from above - the vorimprä trimmed fiber-matrix semifinished product, the two crosswise arranged glass fiber fabric lay and the mounting points enclosing inserts of unidirectional fibers;

5 a schematic and perspective plan view of the support trough according to the 1 and 2 , wherein in particular the contouring of the bottom of the supporting trough adapted to the compressed air tank can be recognized;

6a . 6b a schematic perspective view of a metal insert or a schematic sectional view of the detail VI in 5 from which the arrangement of the insert is recognizable within the carrier trough;

7 a schematic side view of another insert in the form of a metal insert of detail VII in 5 ;

8a . 8b a schematic and partial perspective view and a partial sectional view of a locking means on the bottom of the supporting trough according to the detail VIII in 5 on which fastening straps for fixing the compressed air tank can be snapped on the underside of the carrying tray;

9 a schematic perspective view of the support trough according to the 1 and 2 wherein two insertion parts of unidirectional fibers indicated by dashed lines are embedded in the fiber-matrix semifinished product, which in each case connect corresponding attachment points for fixing the carrying trough to the motor vehicle;

10 an enlarged and fragmentary perspective view of the detail X in 9 from which a reinforcing bushing of the corresponding insert part in the region of the corresponding attachment point for fixing the carrying trough to the motor vehicle can be seen;

11 an enlarged and fragmentary perspective view of the detail XI in 9 from which the arrangement of the corresponding insert part in the corresponding corner region of the support trough is recognizable;

12 an enlarged and fragmentary perspective view of the support trough in the region of passage openings for fastening straps held under the support trough compressed air tank, the laying of one of the two inserts according to 9 can be seen from unidirectional fibers within the fiber-matrix semifinished product along the passage openings, and in

13 a schematic and partial sectional view through the supporting trough of the supporting trough along the line XIII-XIII in 12 from which the embedding of the insert in the region of the passage openings is recognizable.

In 1 is a schematic perspective view of a support trough for receiving and holding two vehicle batteries 10 for a truck, which by means of a cover 12 is to close. The two batteries 10 are about two battery holders 14 additionally interconnected. Overall, the support trough four not shown conventional vibration damper to be attached to a vehicle frame, also not shown, of the truck. On the underside of the carrying trough are in the present embodiment, three as a compressed air tank 16 trained, essentially circular in cross-section container held.

In synopsis with 2 which the in 1 shown carrying tub in a schematic side view, it will be appreciated that a floor 18 the carrying trough to the contour of the compressed air tank 16 is adjusted. As a result, the floor includes 18 present three in cross-section circular segment-shaped wells 20 to which the compressed air tank 16 lie flat. Between the three hollows 20 are therefore two areas 22 trained, with which the ground 18 in the overlap area of the three compressed air tanks 16 protrudes.

In synopsis of 3 and 4 which shows in a schematic perspective view of the upside down support trough according to an alternative embodiment and in a schematic perspective view between a male part 24 and a die 26 represent the semi-finished products to be introduced, which will be explained in more detail below, the construction and production process of the support trough is to be explained:
First of all, in particular 4 recognizable that the carrier trough as a starting material of a pre-impregnated fiber-matrix semifinished product 28 is formed, which in the present case is a thermoplastic semi-finished product in the form of a glass mat reinforced thermoplastic (GMT). As included in the scope of the invention, however, it should be considered that instead of a glass mat reinforced thermoplastic (GMT), for example, a long-fiber reinforced thermoplastic (LFT) or a thermoplastic prepreg or the like could be used. Also included in the scope of the invention is to consider that also a fiber-matrix semifinished product 28 could be used with a thermoset matrix.

In the present exemplary embodiment, the thermoplastic fiber-matrix semifinished product comprises 28 a fiberglass mat with reinforcing fibers in Form of continuous fibers or long fibers, which are characterized by fiber lengths up to 50 mm. As included in the scope of the invention, it should be considered that other conventional reinforcing fibers could be used instead of the glass fibers.

The thermoplastic fiber matrix semifinished product 28 is present locally by two inserts 30 . 32 reinforced, which are each made here as a woven or nonwoven layer of long or continuous glass fibers. The two fabric layers 30 . 32 are present in their orientation transversely to each other or arranged crosswise. As a result, the floor is 18 at least largely by both inserts 30 . 32 reinforced in the form of the two fabric layers. This is especially out 3 clearly.

Furthermore, the fiber-matrix semi-finished product 28 through an insert 34 in the form of a near an opening edge 36 designed the supporting trough encircling profile part. This insert 34 is designed as a semi-finished fiber product with unidirectional fibers or glass fiber strands, in particular made of glass fiber. Because the insert part 34 formed circumferentially and without interface, this gives the later Tragwanne in the region of its opening edge 36 a particularly high stability.

For the production of the support trough is first the thermoplastic and pre-impregnated fiber-matrix semifinished product 28 as well as the three inserts 30 . 32 . 34 initially tailored accordingly separately or produced and then heated in a heating process. The heated blanks are then placed in the 4 sequence shown on the die 26 placed on or between the die 26 and the patrix 24 inserted. Then the heated blanks - the fiber-matrix semi-finished 28 and the inserts 30 . 32 . 34 - Squeezed in a pressing process and connected to each other. Following this, the semifinished products assembled to form the supporting trough become 28 . 30 . 32 . 34 inside or outside the press, of which in the present case only the male 24 and the matrix 26 are shown, cooled. Due to the outside arrangement of the fiber-matrix semifinished product 28 is achieved that this ultimately forms the outside of the carrier, whereby a uniform surface can be realized. Consequently, the inserts are 30 . 32 . 34 on the inside of the fiber-matrix semifinished product 28 and are with this fiber matrix semifinished product 28 connected.

In 5 is a schematic perspective view of the carrying tray according to the 1 and 2 shown in particular that the inside of the floor 18 becomes recognizable. It can be seen that for holding the two batteries 10 or the two battery holders 14 two threaded rods 38 in the ground 18 are screwed in. The thread for receiving the respective threaded rod 38 is doing by an in 6a in perspective view threaded disc 40 formed, which in the present case is made of a metal alloy. The integration of the threaded disc 40 in the ground 18 as well as the attachment of the respective threaded rod 38 it is in 6b in a schematic sectional view of the detail VI in 5 recognizable. It is particularly apparent that the threaded disk 40 within the plastic or thermoplastic of the fiber-matrix semifinished product 28 is integrated. The threaded disc 40 is this during the in 4 Pressing shown from the flowable fiber-matrix semifinished product 28 been pressed. In addition, in the area of each of the two threaded disks 40 at the top of the floor 18 a collar 42 molded, on which a spacer 44 the respective threaded rod 38 can support. As a result, the screwing depth of the threaded rod 38 in the ground 18 limited.

7 shows in a schematic and enlarged side view the detail VII in 5 , It can be seen that in this area an insert in the form of a disc-shaped metal insert 46 is provided, which analogous to the two threaded disks 40 according to the 6a and 6b can be integrated during the pressing process in the supporting trough or in particular in the fiber matrix semifinished product. The metal insert 46 serves to fasten the vibration damper, not shown, which are arranged between the vehicle frame and the supporting trough. Next to the metal insert 46 is in 7 a centering for an assembly aid on the vibration damper, not shown, formed in the supporting trough.

In the 8a and 8b is a schematic and partial perspective view and a schematic sectional view of the detail VIII in 5 one of a variety of retaining tabs 48 shown with which to the compressed air tank 16 On the outer circumference guided around straps 50 are held stationary. The fastening straps 50 be doing through openings 52 within the soil 18 out of the carrying tub and around the compressed air tank 16 led around.

In addition to those in the 6a to 8b details shown is off 5 In addition, it can be seen that within one of the vertical walls of the supporting trough a passage 54 intended for battery cable. Furthermore, they are on the ground 18 support surfaces 56 for the two batteries 10 recognizable. In addition, at the upper edge of the opening 36 the carrying tub closure means 58 recognizable to which the cover 12 can be determined.

In 9 is shown in a schematic perspective view of the carrying tub in an alternative embodiment, in which instead of the insert 34 two indicated by dashed lines inserts 60 . 62 are provided, which at least partially in the fiber-matrix semifinished product 28 embedded and consequently in 9 are indicated only schematically. It can be seen that the two inserts 60 . 62 extend between the respective corresponding attachment points for fixing the support wall to the motor vehicle. Each of the two inserts includes 60 . 62 a semi-finished fiber with unidirectional fibers, which in the present case as each circumferential strands 64 . 66 are formed. As a result, the two strands run 64 . 66 twice or at a small distance from each other between the respective corresponding attachment points for fixing the support wall to the motor vehicle.

In synopsis with 10 in which is an enlarged and fragmentary perspective view of one of the two inserts 60 according to the detail X in 9 represents in the region of one of the attachment points of the carrier trough, it can be seen that by the circumferential associated strand 64 a reinforcement bush 68 is entwined. The reinforcement bush 68 can by a suitable Fügverbindung already in advance with the associated strand 64 of the insert 60 be connected. In the present embodiment, the reinforcing bushing 68 from an aluminum alloy. Of course, other metal or plastic alloys would be conceivable. In this case includes the reinforcing bushing 68 a disk area 70 which runs substantially parallel to the associated wall of the support trough. From the disc area 70 there is a collar 72 from the inside, the one-piece with the disc area 70 is trained. To this collar 72 around is the associated strand 64 of the insert 60 looped.

In synopsis with 11 which shows in an enlarged and fragmentary perspective view the detail XI in 9 represents, becomes recognizable that the strand 64 of the insert 60 in the corner between the floor 18 and the associated sidewall within a respective rib 74 runs. The negative form of this rib 74 forms inside the matrix 26 a recording, within which the associated strand 64 of the insert 60 can be positioned. This ensures that the respective strand 64 right opposite the fiber matrix semifinished product 28 is positioned. Ribs 74 In addition, they provide additional reinforcement between the floor 18 and the sidewalls of the suspension trough.

In 12 is an enlarged and fragmentary perspective view of the corner area between the floor 18 and the associated side wall in the region of two passage openings 52 recognizable by which the fastening straps 50 for fixing the respective compressed air tank 16 passed through. In particular, it can be seen that the ground 18 a channel-shaped groove 76 which is located in the corner between the floor 18 and the associated side wall extends. In the area of this groove 76 is the dashed line indicated strand 64 of the insert 60 - like out 13 becomes recognizable - led. This shows 13 in a schematic sectional view along the line XIII-XIII in 12 that area of the hull from which the embedding of the strand 64 of the insert 60 in the area of the lead-through openings 52 becomes recognizable. Out 13 is particularly evident that the strand 64 near the top of the ground 18 arranged and at least predominantly in the fiber-matrix semifinished product 28 is embedded.

Claims (14)

Carrying tray, in particular for receiving and holding a battery ( 10 ) for a motor vehicle, in particular a truck, which is designed as a fiber-reinforced plastic part and attachment points for fixing to the motor vehicle, characterized in that the carrying trough of a pre-impregnated fiber-matrix semifinished product ( 28 ), in particular a thermoplastic semi-finished product (GMT) is produced, which at least locally with at least one insert ( 30 . 32 . 34 ; 40 . 46 . 60 . 62 ) is reinforced. Supporting trough according to claim 1, characterized in that the preimpregnated fiber-matrix semifinished product ( 28 ) comprises a fiber mat, in particular a glass fiber mat of long or continuous fibers. Carrying tub according to claim 1, characterized in that as inserts ( 30 . 32 ) is provided at least one semifinished fiber product, in particular a woven or nonwoven layer or the like. Carrying tub according to claim 1, characterized in that as inserts ( 30 . 32 ) are provided at least two semi-finished fiber products, in particular two woven or nonwoven layers or the like., Wherein, the two semi-finished fiber products in their orientation extend transversely to each other. Carrying tub according to claim 3, characterized in that the insert part ( 34 . 60 . 62 ) is formed as a semi-finished fiber with unidirectional fibers. Carrying tub according to claim 3, characterized in that two inserts ( 60 . 62 ) are seen, which comprise fiber semi-finished products with unidirectional fibers and via which at least two of the fastening points for fixing the carrying trough to the motor vehicle are connected to each other. Carrying tub according to claim 6, characterized in that the two inserts ( 60 . 62 ) in the region of the fastening points in each case a reinforcing bushing ( 68 ) assigned. Tray according to claim 7, characterized in that the reinforcing bushes ( 68 ) of the respective insert ( 60 . 62 ) are wrapped by a strand-shaped semi-finished fiber. Carrying tub according to claim 5, characterized in that the unidirectional fibers comprising insert part ( 34 ) is formed as a circumferential profile part, which close to an opening edge ( 36 ) of the trough runs. Carrying tub according to claim 1, characterized in that as an insert ( 40 . 46 ) At least one metal insert is provided. Carrying tub according to claim 10, characterized in that the metal insert ( 46 ) forms one of the attachment points for fixing the carrying trough on the motor vehicle. Carrying tub according to claim 10, characterized in that the metal insert ( 46 ) for fixing the battery ( 10 ) within the carrying tub or a container (compressed air tank 16 ) is provided on the supporting trough. Carrying tub according to claim 12, characterized in that a floor ( 18 ) of the carrying trough to the contour of the at least one container (compressed air tank 16 ) is adjusted. Supporting trough according to claim 1, characterized in that the preimpregnated fiber-matrix semifinished product ( 28 ) forms the outside of the carrying trough, wherein the at least one insert part ( 30 . 32 . 34 ) is at least partially enclosed by the fiber matrix semifinished product (GMT).