CN105313811A - 用于汽车的保险杠结构 - Google Patents

用于汽车的保险杠结构 Download PDF

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CN105313811A
CN105313811A CN201510382735.XA CN201510382735A CN105313811A CN 105313811 A CN105313811 A CN 105313811A CN 201510382735 A CN201510382735 A CN 201510382735A CN 105313811 A CN105313811 A CN 105313811A
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CN105313811B (zh
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M.尼克尔
T.霍克
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GM Global Technology Operations LLC
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Abstract

本发明涉及一种用于汽车的保险杠横梁(1)及其制造方法，所述保险杠横梁包括由纤维强化的复合材料制成的嵌件(3)和在嵌件(3)上注塑成型的加固强化结构(2、8)。

Description

用于汽车的保险杠结构
技术领域
本发明涉及一种用于汽车的保险杠结构，特别用于车尾部分。
背景技术
传统的保险杠多有钢制或铝制的横梁。钢制横梁多由多个部件接合而成，尽管这使横梁结构有可能灵活调整以适应由其支撑的保险杠外皮，但同时也使横梁的加工耗费变大并且与之相应的成本升高。铝制横梁多以挤压型材制成。尽管挤压型材加工简单且价格便宜，不过也存在缺点，就是其造型灵活性低，因此在支撑与横梁结构并不精确相配合的保险杠外皮时，需要有额外的部件或加工步骤，这使挤压型材的成本优势受到抑制。
发明内容
本发明的目的是创造一种用于汽车的保险杠结构，其加工成本低，重量轻并且在其外表造型方面有灵活性。
该目的首先通过一种用于汽车的保险杠结构来实现，在这种结构中保险杠横梁包括由纤维强化的复合材料(该材料也被称为有机板)制成的嵌件，还包括在嵌件上注塑成型的加固强化结构。
嵌件应在保险杠横梁的整个高度和宽度上延伸。
在嵌件上可制作至少第一沟槽，加固强化结构包括了在第一沟槽中制作的肋片。
特别是当肋片倾斜于沟槽的纵向并从沟槽的一侧壁向另一侧壁延伸时，就可以给予沟槽或者说是保险杠横梁较高的弯曲刚度。
为进一步提高保险杠横梁的载荷承受能力，特别是扭转载荷，此外嵌件可制作第二沟槽。
所述第一和第二沟槽在嵌件的两个相对置面上是开口的。
两个沟槽的相对定位使两个沟槽共有侧壁成为可能。如此可以实现保险杠横梁在嵌件截面尺寸很小的情况下而具有高刚度。
当第二沟槽的肋片分别在第一沟槽的肋片的延长线延伸时，通过这两个沟槽总体上的竖直的尺寸有效传递拉力和压力，这又使横梁刚度增强。
因为载荷承受能力的原因，保险杠横梁从上面看起来在通常情况下不应该向不同的方向上弯曲，对受其支撑的保险杠外皮来说则不必然总是这种情况。特别是保险杠外皮上经常有由凸出弯曲部分包围之中的中央凹处用于安装车牌。为了能在保险杠整个宽度上对外皮有相同的支撑，对保险杠外皮开口的第一道沟槽的肋片可以至少在局部从沟槽内向外突出到外皮。
肋片将第一道沟槽分隔为很多向保险杠外皮开口的空腔。这些空腔可用来安装传感器，比如说泊车辅助系统的距离传感器，以保护其在碰撞事故中不被损毁。传感器在一个这样的空腔内是可以永久性安装的；可以想到的是，特别是在肋片没有直接延伸到保险杠外皮的时候，传感器构成固定于保险杠外皮上的，由保险杠外皮向内突出的部分，该突起在碰撞事故中保险杠外皮向肋片移动时，向空腔内推进。这样的突起，可以包括除了传感器外的其它部件，比如用来固定装饰条的固定拱顶等类似部件。
在嵌件上注塑成型的加固强化结构此外可包括碰撞盒。
为了能与保险杠横梁一体成型，碰撞盒应该在背离保险杠横梁的一端是开口的并且有向这个开口端减小的壁厚度。
碰撞盒的内部空间应向开口端变宽，以方便脱模。
在碰撞盒的背离保险杠横梁的一端可以成型用于在车身纵梁上组装保险杠结构的固定法兰。
可通过在其内部成形的蜂窝结构提高碰撞盒的能量吸收能力。
此外本发明的内容还包括所述保险杠结构的加工方法，步骤如下：
a)制备由纤维强化复合材料制成的坯料；
b)进行坯料深冲，以得到嵌件，以及
c)在嵌件上注塑成型加固强化结构
注塑成型可在一个也用于坯料深冲的成型工具内有效并节省成本的完成。
附图说明
本发明的其它特点和优点在参考附图对实施例的如下描述中加以说明。其中：
图1表示按照本发明第一实施例所述保险杠横梁的透视图；
图2表示按照第二实施例所述横梁类似于图1的视图；
图3表示带有按图1或图2所示横梁的保险杠结构的沿中间面的截面图；
图4表示带有按图2所示横梁的保险杠结构的沿非中间面的截面图；
图5表示按照保险杠结构的一种变型的类似于图4的截面图；
图6表示按照保险杠结构的另一种变型的类似于图4的截面图；
图7表示从车辆内面向外的保险杠横梁部分视图；
图8表示图7中沿VIII-VIII的截面图；以及
图9表示所述保险杠横梁加工方法的步骤。
具体实施方式
图1显示按照本发明第一实施例的保险杠横梁1和在保险杠横梁1内侧面突伸出的碰撞盒2。保险杠横梁包括一个由有机板制成的嵌件3，其通过深冲制成，以形成向车辆外部的方向开口的沟槽4以及沟槽4上面和下面的端壁5，6。嵌件3的、由上部端壁5的上缘沿指向车辆内部的方向延伸形成的水平壁7构成了在指向车辆内部的方向上开口的、并因此在图1中不可见的第二沟槽的上侧壁。
很多的肋片8在沟槽4内的下侧壁9和在图1中不可见的上侧壁之间延伸，所述图1中不可见的上侧壁同时又构成了在端壁5之后向内开口的沟槽13的下侧壁。注塑成型的肋片8由热塑性塑料制成，所指热塑性塑料与嵌件3的热塑性材料基体是化学兼容或化学相同的，以便其注塑在嵌件3上时可与之深入形成紧密的材料键合性的连接。
肋片8总是与水平面成45°倾斜角地延伸，在沟槽4的中间相交并且在下侧壁9和上侧壁上成对彼此相交。如图1中用虚线示例表明的，上面沟槽13的肋片10总是在肋片8的延长线上延伸。
碰撞盒2由和肋片8相同的热塑性塑料制成并且也和其一样在嵌件3上一体成型。碰撞盒2具有在指向车辆内部的方向上略微变细的六面体形状，所述碰撞盒2背离保险杠横梁1的端壁是开口的，其用于固定在被人们熟知的、在图中未显示的汽车车身的纵梁上的螺纹法兰12置于其两侧。在碰撞盒2的侧壁上成形的纵向延伸的肋片11支撑着螺纹法兰12。
图3显示保险杠横梁1和受其支撑的、由塑料-扁材深冲制成的保险杠外皮14的截面，所述截面是沿着保险杠1的中间镜面对称平面的。肋片8的前缘是与对沟槽4进行上下限制的端壁5、6齐平的并且以很小的到用于安装车牌17的保险杠外皮14的中央凹处15的距离延伸。在保险杠外皮14和保险杠横梁1之间的固定连接可逐点设置，因为在图3中其位于截面以外，所以是不可见的。
在指向车辆内部的方向开口的此处用13表示的沟槽，由在其整个长度上分布的肋片10以和沟槽4相同的方式被加强。肋片8、10在所述两个沟槽4、13共同的侧壁29上相交。
下部端壁6从沟槽4的下侧壁向下自由延伸，这是为给予保险杠横梁1垂直的尺寸，这对于确保保险杠横梁1对和不同类型车辆并以不同高度布置的保险杠碰撞都能阻挡到，是不可缺少的。在图3中，由侧壁9和端壁6限制而成的凹角16内并未显示加固强化结构，很清楚的是，如果必需的话，这里也可以在侧壁9和端壁6之间布置延伸的肋片等类似结构，以给予端壁6必要的刚度。
图2以和图1类似的视图显示了保险杠横梁1的实施例变型。嵌件3的形状与图1所示情况中的一样，一体化成型碰撞盒2也与图1中的相同。沿沟槽4可分成三段，一个中间段18，在其中的肋片8的前缘是与端壁5、6齐平的，以及在中间段18的左右两侧的两个侧段19，在其中的肋片8相对于端壁5、6是向外突出的。中间段18的布置，是为了容纳保险杠外皮14的凹处15，因此按照这种实施例的保险杠结构的截面与图3中显示的是一样的。
在显示了保险杠横梁1的侧段19和保险杠外皮14的截面图的图4中，清楚表示出了，突出的肋片8的功能，在于对凹处15之外的保险杠外皮14进行紧密距离上的支撑，因此在碰撞情况中在保险杠外皮14碰到端壁5、6之前，就已经通过肋片8的镦缩得到了缓冲。
在图1和图2中可以看到，肋片8将沟槽4分隔成了很多的在向车辆外部的方向开口的空腔20，其截面为三角形或菱形。个别空腔20可以被使用，如在图4中显示的那样，在其中安装传感器21，比如说泊车辅助系统中的超声波传感器。在这里传感器21深埋至端壁5、6所处平面之后，以在仅仅使肋片8相对于端壁5、6突出的部分变形的轻微碰撞中保护传感器。因为传感器21并未占满空腔20的整个深度，而是在传感器21和沟槽4的底部22之间还有一部分自由空间，在力的作用情况下传感器21可以缩回这部分空间内，即便在使嵌件3变形的碰撞情况下传感器21也可能会不受损坏的经受住，因此，只要不超过保险杠横梁1的弹性极限，就没有维修的必要。
图5显示了图4所显示的截面的一种变型，该变型中在端壁5、6的高度上也将保险杠横梁1和保险杠外皮的距离减小，即在端壁5、6上沿肋片8的延长线制作低矮的肋片23。
在另外的显示在图6的变型中在保险杠外皮14上锚固有装饰条或缓冲条33，即，用在装饰条或缓冲条33上向内突出的销钉35插进在保险杠外皮14内侧上通过成型，胶粘或其他合适的方法固定的固定拱顶34。通过将固定拱顶34和超出固定拱顶34向内突出的销钉35的倒钩36在空腔20内嵌接，可使它们在轻微碰撞时向车辆内避让移动，而不会产生损坏。
图7显示了保险杠横梁1的一部分和在其上成型的碰撞盒2，视角为从车辆纵向由车辆内部向外的方向。基本为盒状的、在指向车辆内部的方向上开口的碰撞盒2内部由六边形蜂窝24结构填充。特别是根据图8显示的纵向截面可以看到，蜂窝24的空腔总是向保险杠横梁1的方向变细，和/或蜂窝的壁25以及碰撞盒的外壁26、27、28的厚度总是在向保险杠横梁1的方向上增加，以使在碰撞盒2注塑成型后将用于成型蜂窝24的模具在箭头P1的方向上顺利地从碰撞盒2上取下。在图8的显示中，壁25延伸至在竖直的外壁26、27上成型的螺纹法兰12所在的平面。为减小壁25的厚度和通过这样减轻重量，可有目的的将壁25在螺纹法兰12所在的平面之前就结束。
另外，在成型碰撞盒外壁26、27时靠着的模具于注塑成型后以正交于箭头P1的方向P2、P3取下。取下外壁27的模具后可将另外的模具从保险杠横梁1内侧以P4方向取下，在该处的模具用以成型向内开口的沟槽13的肋片10。用于成型肋片8的模具以朝向车辆外部的方向P5取下。因为肋片10、11和壁25全都沿车辆纵向定向，使用少量可移动模具就足够将保险杠横梁1和碰撞盒2在一个工作步骤中注塑成型。
图9说明了制造保险杠横梁1的方法的步骤。所显示的是用于成型保险杠横梁1内侧和外侧的两个模具30、31。图中左侧显示的第一阶段中，有机板坯料32位于模具30、31之间。模具30、31相向移动，以将坯料32通过深冲成型为嵌件3。如在图中部显示的那样，嵌件3填满了模具30、31之间的与5、6、7、9、22、29各壁相应的那些空腔，但并未填充与肋片8、10相应的空腔。
用于成型碰撞盒2所需的模具也定位之后(图9所示截面范围之外)，热塑性材料被注入，用以成型肋片8、10和碰撞盒并在此状况下表面融合嵌件3。所注入材料有足够的凝固时，模具28、29被从箭头P4、P5的方向取下，并且所完成的保险杠横梁1可被取出。
不言而喻的是，尽管以上详细的说明和图示展示了本发明特定的示范性的实施例，但是它们仅被考虑用于阐述并且不应作为本发明的范围被有限制的实施。如果不脱离随后的权利要求的框架和其等效范围，所述实施例的各种不同的变型是可能的。特别的，由说明和图示也产生了在权利要求中未提及的实施例特征。这些特征可以在不同于此处特别公开的组合中出现。多个这样的特征是以相同的句子或一种其它上下文联系形式相互涉及的事实因此不说明这样的结论，即其仅出现在特别公开的组合中；取而代之的是基本上可以认为，个别特征可以从多个这样的特征组合中删除或进行变化，只要其不危害到本发明的功能可用性。
标注列表
1保险杠横梁
2碰撞盒
3嵌件
4沟槽
5端壁
6端壁
7壁
8肋片
9下侧壁
10肋片
11肋片
12螺纹法兰
13沟槽
14保险杠外皮
15凹处
16凹角
17车牌
18中间段
19侧段
20空腔
21传感器
22底部
23肋片
24蜂窝
25壁
26外壁
27外壁
28外壁
29侧壁
30模具
31模具
32坯料
33条
34固定拱顶
35销钉
36倒钩

Claims (15)

1.一种用于汽车的保险杠结构，其中，保险杠横梁(1)包括了由纤维强化的复合材料制成的嵌件(3)和在嵌件(3)上注塑成型的加固强化结构(2、8、10)。
2.按照权利要求1所述的保险杠结构，其中，在嵌件(3)上成型了至少一个第一沟槽(4)并且所述加固强化结构包括成型在第一沟槽中的肋片(8)。
3.按照权利要求2所述的保险杠结构，其中，肋片(8)倾斜于沟槽(4)的纵向从沟槽(4)的一侧壁(7)向另一侧壁(29)延伸。
4.按照权利要求2或3所述的保险杠结构，其中，嵌件(3)此外成型了第二沟槽(13)并且所述第一和第二沟槽(4、13)在嵌件(3)的相对的面上开口。
5.按照权利要求4所述的保险杠结构，其中，所述第一和第二沟槽(4、13)有共同的侧壁。
6.按照权利要求5所述的保险杠结构，其中，第二沟槽(13)的肋片(10)总是在第一沟槽(4)的肋片(8)的延长线上延伸。
7.按照权利要求2到6之一所述的保险杠结构，此外配有保险杠外皮(14)，其由保险杠横梁(1)支撑，其中，第一沟槽(4)面向保险杠外皮(14)开口并且在第一沟槽(4)内成型的肋片(8)至少在沟槽(4)的一段(19)由沟槽(4)向外突出而抵靠到保险杠外皮(14)。
8.按照权利要求2到7之一所述的保险杠结构，其中，在第一沟槽(4)内成型的肋片(8)围成至少一个空腔(20)，在其中至少在碰撞事故中容纳传感器或保险杠外皮的突起(34、35)。
9.按照以上权利要求之一所述的保险杠结构，其中，所述在嵌件(3)上注塑成型的加固强化结构包括碰撞盒(2)。
10.按照权利要求9所述的保险杠结构，其中，所述碰撞盒(2)的外壁(26、27、28)有向其背离保险杠横梁(1)的开口端逐渐减小的厚度。
11.按照权利要求10所述的保险杠结构，其中，所述碰撞盒(2)的外壁(26、27)至少在背离保险杠横梁(1)的区域用长肋片(11)强化。
12.按照权利要求10或11所述的保险杠结构，其中，固定法兰(12)成型在碰撞盒的背离所述保险杠横梁(1)的一端上。
13.按照权利要求9、10、11或12所述的保险杠结构，其中，蜂窝结构(24)成型于碰撞盒(2)的内部。
14.一种用于制造保险杠结构的方法，包括如下步骤：
a)制备由纤维强化复合材料制成的坯料(32)；
b)深冲坯料(32)，以得到嵌件(3)；以及
c)在嵌件(3)上注塑成型加固强化结构(2、8、10)。
15.按照权利要求14所述的方法，其中，注塑成型在用于坯料(32)深冲的模具(30、31)内进行。
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CN105313811B (zh) 2020-02-28
US20170157863A1 (en) 2017-06-08
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