DE10064522A1 - Component for a motor vehicle - Google Patents

Abstract

The invention relates to a structural part (10), particularly a cross member for placing between A-pillars of a motor vehicle, comprising an essentially tubular base body (14) in which at least one channel (24) is provided. The aim of the invention is to provide an improved lightweight structural part, which can be produced more easily, with fewer working steps and, therefore, more economically, and in which a channel (24) can be advantageously integrated. To this end, the interior of the base body (14) is lined with plastic (22) in order to form plastic channel walls (25). The inventive structural part is used as an instrument panel support in a motor vehicle.

Description

The invention relates to a component for a motor vehicle, in particular a Cross member for the cockpit area, according to the preamble of claim 1 as well as a manufacturing process and uses of this component.

Cross members made of pipes are from automotive engineering known, which consist of metal and correspondingly large wall thicknesses have sufficient bending, buckling and torsional rigidity and thus there is sufficient pressure resistance. from that result in a high weight and cost disadvantages. The pipes can be principally for air routing, for example from one in the middle of the vehicle arranged air conditioning system for side vents (see e.g. DE 197 53 877), although this has not been used to date since the Metal pipes can easily separate unwanted condensation.

Cross members are also known which have a double-shell construction have welded bars for stabilization. Such one Cross member is known for example from DE 197 20 902. such Cross members are very complex to manufacture and have a high height Weight. Air routing is not possible.

EP 0 370 342 describes a carrier that can be used in a motor vehicle Lightweight component in hybrid construction known, which is preferably made of metal  existing, bowl-shaped base body, in the interior Reinforcing ribs are arranged. The reinforcing ribs consist of injected plastic and are discreet with the metal body Connections connected by the plastic in the metal part arranged openings penetrated and over the surfaces of the openings extends. The metal base body is U-shaped, and the Reinforcing ribs to achieve high rigidity and Strength the interior of the body. This well-known hybrid component has an advantageous low weight with sufficient Strength, rigidity and resilience. An air duct is with this as Lightweight component that can be used as a carrier is not possible.

From DE-U 200 08 201 is a cross member in hybrid construction with a shell-like base body by an injected Plastic ribbing is stiffened, known. The plastic ribs are shaped such that a plastic tube serving as an air duct can be inserted positively. Such a channel insertion is complex because the channel is manufactured separately and in one step must be inserted. The ribs adapted in this way lose stability.

Another cross member is known from DE-U 299 16 470, in which a Plastic air duct encased by two metal shells forming the cross member is. Such a construction is the problem of the tight connection of the based on both metal shells, because the coated plastic prohibits them for example, due to its weak temperature resistance Welding the metal shells. Another disadvantage is that the Plastic pipe and the metal shells manufactured in individual steps and then have to be assembled in a further step.

Based on this prior art, it is an object of the invention to to provide improved lightweight component that is easier with less Steps and therefore cheaper to manufacture and in the advantageously a channel can be integrated, as well as a manufacturing process and uses of the component.  

This object is achieved by an object with the features of Claim 1 and uses with the features of claims 15 and 16 and a manufacturing method with the features of claim 17.

According to the invention, the base body is lined with plastic on the inside, so that the channel walls are made of plastic. additional Air routing components such as blow parts, air hoses or the like are not more necessary. The wall thickness of the usually made of metal Base body can be reduced, which saves weight can. Can on the channel walls, which are made of plastic on the inside no or at least less condensation of the conditioned air contained moisture occur. The same applies to condensation the outside of the channels. Other media such as Washer fluid for the headlights or the windshield, cooling water, Oil, compressed air or the like are carried or stored. Likewise can the duct for the protected laying of cables, fuel line, oil line, Compressed air lines or the like or for storing Serve objects.

In the production of the component according to the invention is more economical and in a simple manner essentially only the base body in one Tool inserted and the base body by molding the plastic lined so that a suitable channel, for example air channel is formed is.

The component according to the invention has the further advantage that compared to the known components, in which a combination of metal and Plastic is used, now cheaper according to the invention Plastic can be used, because in the component according to the invention the plastic does not have to perform an essential strength function. The Plastic is mostly used for insulation, e.g. B. thermal or Soundproofing. The strength results from the combination of Base body and plastic, thus achieving a synergistic effect  becomes. For example, compared to previously known components thinner sheet and cheaper plastic can be used.

The base body advantageously has openings which correspond to the Plastic are interspersed and with brackets on the base body, Connection points or housing parts of a heating or air conditioning system or the like. Elements made of plastic are molded in one piece. Due to the The main body is firmly connected to the plastic through openings. Similar to a component in hybrid construction, so that the Component according to the invention also advantageously less weight having. So that channel walls of the formed by the base body However, if the channel remains closed, these breakthroughs are blocked closed the plastic. At the same time when introducing the Plastic brackets, connection points or, for example, also Housing parts of an air conditioning system are molded with, so that in one single process step an instrument panel carrier with cross member can be obtained that is easy, a variety of connection points and brackets and possibly also already has housing parts and into which an air duct, for example for guiding conditioned air, is included.

In one embodiment, the plastic is in an injection molding process recoverable. A plastic introduced in this way can be made relatively firm be and also perform holding functions.

If the plastic is allowed to have a lower strength, it can be made of a foam material, for example a polyurethane foam or a particle foam.

A plastic that is very light and yet has high strength, consists of foam particles bonded together using a binder. Such a composite plastic is, for example, commercially available under the Brand name "Xeratec" available.  

The component preferably forms one between the A-pillars of the Crossbar to be arranged on the vehicle, to which the instrument panel and other components, such as steering column, airbag or the like, are connected can.

Overall, the variety of parts in the manufacture of the motor vehicle reduced because the component according to the invention, for example as Instrument panel support, all brackets and air ducts as well as one May contain part of the air conditioner housing. This can reduce assembly time and labor saved, and an advantageous one Pre-testability of the component is made possible.

In order to increase the rigidity of the component, integrally molded parts can be used Plastic ribs may be provided.

Connection points, such as the connections to A-pillars Vehicles must be very stable and should therefore be made of metal. Such connection elements are in one embodiment of the invention therefore through to the base body before introducing the plastic Welding, clinching or other joining processes can be connected. You could for example, can be further stabilized via plastic ribs.

In one embodiment of the invention, the tubular base body is made of two half-shells formed over the inserted plastic are interconnected. Tubular cross beams with their many Connection points for steering column, airbag etc. are cheaper two half shells can be produced. According to the invention, the Half shells, however, cannot be pre-connected to each other, but can be used as Half shells are inserted into the tool. Can in the tool they are then optionally mechanically connected to one another, for example by caulking. Advantageously, the Half shells additionally or even exclusively over the inserted ones Plastic are connected together, for example in the manner of Rivets so that the plastic forms rivets, among other things. To do this  of course, corresponding openings in the half-shells be provided, which are filled with the plastic.

To ensure an advantageous flow of the plastic in the manufacturing process enable are in further development of the invention between the vents on adjacent edges of the two half-shells are provided, at least partially in the manufacturing process with plastic are fillable.

In order to allow the plastic to flow as evenly as possible, are the ventilation openings in the longitudinal direction at a distance from each other arranged, and advantageously in at least one of the Half-shells seen in the longitudinal direction between two Vent openings provided a filling option.

Depending on the design of the edges of the half-shells, the Adjacent points for additional components form.

The component according to the invention is preferably used as a cross member in one Motor vehicle, the channel being an air duct and / or a Cable duct is used. Alternatively, the component could be considered to be under one Windshield arranged cross member in a motor vehicle, wherein the duct is an air duct for guiding the windshield Deicing or heating a wiper blade holder and / or the Defrost air to be supplied to the side windows can be used. A Another possibility of using the component according to the invention is as Cross member in a front end area of the motor vehicle, the channel is a cable duct or a container for a medium, such as washer fluid for the headlights or the windshield, cooling water, oil, compressed air or the like, or a channel for a protected laying of Gasoline lines, oil lines, compressed air lines or the like forms. The component according to the invention could also be used as a rear end or Find the rear end module.  

The process according to the invention for producing the component is characterized by the following process steps:

• - Forming the base body with the corresponding openings and / or Perforations,
• - Attach the brackets made of the material of the base body the basic body,
• - inserting the base body (s) into a tool,
• - Forming, for example injection molding, all plastic parts and Plastic linings to the main body in one Process step.

The process according to the invention is due to the few process steps particularly inexpensive.

The channel of the component can in one embodiment of the invention in the Process step of inserting plastic through a tool core be formed, which is particularly advantageous if the plastic is injected under pressure. When the plastic is introduced without pressure, for example casting, a blow core, a filled molded tube, Gases, granules, a lost core or a lost core are used become.

In the following, the invention is described using exemplary embodiments Reference to the drawing explained in detail. In the drawing demonstrate:

Fig. 1 is a perspective view of a component according to the invention as an instrument panel support;

FIG. 2 shows a view like FIG. 1 from a different perspective;

Fig. 3 is a view of the component of Figure 1 from the side.

Figure 4 is a view of an embodiment of the device according to the invention with two half-shells.

Fig. 5, the two half-shells of the device of Figure 4 in an exploded view.

FIG. 6 shows the two half-shells of the component from FIG. 4 assembled;

FIG. 7 shows a detailed view of the component from FIG. 4;

8 is a view of the edges of the two half-shells from the view VIII of FIG. 6.;

FIGS. 9 and 10 are cross sections along the lines IX-IX and XX of FIG. 7;

FIG. 11a-c and Figures 12a to b show cross sections of various embodiments of the compounds of the half shells.

Figs. 13 to 18 views of different embodiments of the component with various edges and possibly additional channels;

FIG. 19 is a component having a non-circular cross-section;

Fig. 20 representation of the plastic flow in the injection molding process.

A component 10 according to the invention shown in the drawing is designed in the exemplary embodiment shown as an instrument panel carrier and is referred to below as a cross member. The cross member 10 is arranged in a vehicle, not shown, between the A-pillars of the vehicle and can be fixed to it in a suitable manner. The direction of travel is indicated by arrow 12 .

The cross member 10 has a base body 14 , which is preferably made of metal and is essentially tubular. Mounts, for example a steering column mount 16 and 17 and connecting elements 18 , 20 , 21 for a passenger airbag, are connected to the base body 14 . These brackets and connecting elements essentially also preferably consist of metal and are connected to the base body 14 in a suitable manner, for example welded on. For reinforcement and better stiffening, reinforcement ribs made of plastic, as indicated, for example, by reference number 19 , can be provided. The brackets and connecting elements can also be surrounded by the plastic, which increases the rigidity, prevents rattling and provides edge protection.

The base body 14 is lined on the inside with plastic 22 and forms a channel 24 with inner walls 25 for guiding media, for example air. The plastic can be introduced into the base body 14 in an injection molding process. Alternatively, and depending on the type of plastic, it can also be foamed, cast in or introduced in a similar manner, as already explained in detail at the beginning. In the following description, only injection in the injection molding process is mentioned by way of example, without being limited thereto.

Furthermore, the base body 14 has a multiplicity of openings which are penetrated by the plastic, as is shown, for example, by the reference numerals 26 and 28 . At 26 and 28 , the plastic virtually forms a rivet, so that the plastic is firmly connected to the base body 14 .

The base body 14 has a further large number of openings, which are likewise penetrated by the plastic, but which form a holder on the outside of the cross member 14 , as is indicated, for example, by 30 or 32 . Here the brackets 30 and 32 are shown schematically as simple eyelets and hooks. A wide variety of shapes for the brackets are conceivable.

Furthermore, the cross member has a larger opening 34 approximately in the middle, to which a plastic shell 36 connects. This plastic shell 36 can form part of an air conditioning system housing, not shown, from which conditioned air can be introduced into the channel 24 . The air is guided through the channel 24 to outlet openings 40 , 42 , 44 , 46 provided in the cross member. Air outlet connections 50 , 52 , 54 , 56 , which preferably also consist of the plastic, adjoin the outlet openings.

All plastic parts, such as channel inner walls 25 , rivets 26 , 28 , brackets 30 , 32 , housing part 36 , air outlet connection 50 , 52 , 54 , 56 , reinforcing ribs 19 are injection molded in a single injection molding process. For the manufacture, the base body is first shaped and provided with the corresponding openings. Then the metal brackets are welded, riveted, toxed, screwed or the like attached. The base body is then placed in a corresponding injection mold and all plastic parts are injection molded onto the base body in one injection process.

In a further preferred embodiment of the invention, the base body 114 of the component 110 according to the invention forming the channel is formed in two parts ( FIG. 4) and consists of first and second half-shells 116 and 118 , which are shown individually in FIG. 5. The half-shells 116 and 118 each have angled longitudinal edges 120 and 122 or 124 and 126 , which lie against one another when the tubular base body 14 is formed , as shown in FIG. 6. The longitudinal edges 120 , 122 , 124 and 126 are shaped in such a way that ventilation openings 128 remain free when they lie next to one another ( FIG. 6), as is shown in detail in FIG. 8. The function of these ventilation openings 128 is explained in more detail below in the description of the manufacturing method. Air outlet ports 151 and 153 can be provided in one or both half-shells 116 , 118 .

As in the first exemplary embodiment, the tubular base body 114 is lined on the inside with a plastic 130 , the plastic being injected in an injection molding process. The plastic 130 not only covers the inside of the base body 114 with its half-shells 116 and 118 , but also passes through the ventilation openings 128 and encompasses the outermost edges 132 and 134 of the angled edges 120 , 122 , 124 and 126 , as is the case, for example, in FIG. 7 and can be seen in the cross section in Fig. 9. This shows a first possibility of how the two half-shells 116 and 118 can be connected to one another via the injected plastic 130 .

A second possibility for connecting the two half-shells 116 and 118 is also shown in FIG. 7 and in the cross section in FIG. 10. Here, the angled side edges 120 and 124 or 122 and 126 each have openings 136 and 138 corresponding to one another, as is shown in detail in FIG. 11c, for example. When the plastic 130 is injected, a plastic rivet 140 is simultaneously injected into and around the openings 136 and 138 , so that a further connection possibility is provided via this plastic rivet 140 . The openings 136 and 138 can be designed differently in detail, as is shown in detail in individual examples in FIGS. 11a, b and c. For example, the openings 136 and 138 can have passages 142 and 144 , through which the precise joining together of the half-shells 116 and 118 can be simplified.

As shown in FIG. 12a, these passages can also be bent over a punch 146 , for example after inserting the half-shells in an injection molding tool, in such a way that a mechanical connection between the two half-shells 116 and 118 is provided at the same time. As indicated in FIG. 12 b, the stamp and the associated die can be retracted after the passage 144 has been flanged and the outer shape of the plastic rivet 140 injected thereafter determined.

The shape of the half-shell 116 and 118 can be designed differently in detail, as is shown, for example, by the illustrations in FIGS. 13 to 19.

For example, the channel formed by the base body 114 may not only be round, but also polygonal, as shown for example in FIG. 19. In Fig. 19, the possibility is also shown that the half-shells may be formed integrally 116 and 118 and along a hinge 117 are relative to each other. Before injection of the plastic material 130, the half-shells 116 and 118 are pivoted together to form the base body 114, in the plastic is then injected 130th In this embodiment, there are then only the angled longitudinal edges 120 ′ and 124 ′ on one long side of the base body 114 .

Furthermore, the longitudinal edges 120 , 122 , 124 and 126 of the half-shells 116 and 118 can be designed in a wide variety of ways, as shown in FIGS. 13 to 18. In particular, they can be designed such that the longitudinal edges form connection points for further components, such as, for example, steering column, airbag or the like. If the longitudinal edges are formed spreading, such as in FIG. 15 at the longitudinal edges 120 and 124, these edges may be reinforced by plastic fins 150 120 and 124, wherein the plastic fins 150 preferably are injected into the same injection molding process. The reinforcing ribs 150 can also have openings 152 , as shown in FIG. 16, so that, for example, cables can be guided parallel to the channel formed by the base body.

In Fig. 18 an embodiment is shown in which the longitudinal edges 120 , 122 , 124 and 126 are not angled, but are formed in the direction of the circumference of the base body 114 , so that the half-shells 116 and 118 are quasi pluggable. The connection of the half shells 116 and 118 can in turn be realized via rivet connections, not shown, as shown in FIGS. 11 and 12.

This second embodiment 110 of the component according to the invention is produced essentially in exactly the same way as the previously described embodiment with reference to FIGS. 1 to 3. First, the half-shells 116 and 118 of the base body 114 are shaped, for example in a deep-drawing process, and the corresponding holders are attached, for example welded on , The half-shells 116 and 118 are then inserted into the injection mold and the plastic 130 is injected, as a result of which the base body 140 is then lined with plastic on the inside and at the same time the two half-shells 116 and 118 are connected to one another, as described above.

In a further development of the method, it is advantageous if the half-shells have injection openings 160 which are arranged in the circumferential direction centrally on at least one preferably two half-shells 116 , 118 and are each arranged in the longitudinal direction between two ventilation openings 128 . Then, as indicated in FIG. 20 by flow lines 162 , the injected plastic can advantageously flow relatively without pressure, starting from the injection openings 160 , the air displaced in the injection molding process being able to escape through the ventilation openings 128 . This enables a process-safe injection molding process in which the plastic can flow better in all areas.

In one embodiment of the invention, after inserting the half-shells 116 and 118 into the injection mold and before the injection molding of the plastic, caulking of the passages 144 can be provided , as indicated in FIGS. 12a and 12b and as already described above.

Claims (23)

1. Component, in particular cross member for arrangement between A-pillars of a motor vehicle, with an essentially tubular base body ( 14 , 114 ) in which at least one channel ( 24 ) is provided, characterized in that the base body ( 14 , 114 ) inside is lined with plastic ( 22 , 130 ) to form plastic channel walls ( 25 ). 2. Component according to one of the preceding claims, characterized in that the base body ( 14 ) has openings which are interspersed with the plastic ( 22 ) and that on the base body mounts ( 30 , 32 ), connection points or housing parts ( 36 ) of a heater - Or air conditioning or the like. Elements made of plastic are molded in one piece. 3. Component according to one of the preceding claims, characterized in that the base body ( 14 ) and / or the brackets and / or connection points ( 21 ) can be stiffened via integrally molded plastic ribs ( 19 ). 4. Component according to one of the preceding claims, characterized characterized in that the plastic in an injection molding process can be introduced. 5. Component according to one of the preceding claims 1 to 3, characterized characterized in that the plastic is made of a foam material,  for example a polyurethane foam or a Particle foam. 6. Component according to one of the preceding claims, characterized characterized in that the plastic consists of a binder interconnected foam particles. 7. Component according to one of the preceding claims, characterized in that further connecting points ( 18 , 20 , 21 ) or brackets ( 16 , 17 ) can be connected to the base body ( 14 ) before the molding of the plastic by welding, clinching or other joining methods and which can be stiffened, for example, via the plastic ribs ( 19 ). 8. Component according to one of the preceding claims, characterized in that the tubular base body ( 114 ) is formed from two half-shells ( 116 , 118 ) which are interconnected via the molded plastic ( 130 ). 9. The component according to claim 8, characterized in that the half-shells ( 116 , 118 ) on the plastic ( 130 ) in the manner of rivets ( 140 ) are held together. 10. Component according to claims 9, characterized in that the half-shells ( 116 , 118 ) are additionally mechanically connected. 11. Component according to one of the preceding claims 8 to 10, characterized in that between adjacent edges ( 120 and 124 , 122 and 126 ) of the two half-shells ( 116 , 118 ) ventilation openings ( 128 ) are provided, which are at least partially in the manufacturing process with plastic ( 130 ) can be filled out. 12. The component according to claim 11, characterized in that the ventilation openings ( 128 ) are arranged in the longitudinal direction at a distance from one another. 13. Component according to claim 12, characterized in that in at least one of the half-shells ( 116 , 118 ) seen in the longitudinal direction between two vent openings ( 128 ), a filling option ( 160 ) is provided. 14. Component according to one of the preceding claims 8 to 13, characterized in that the abutting edges ( 120 and 124 , 122 and 126 ) of the two half-shells ( 116 , 118 ) form connection points for further components. 15. Use of a component according to one of the preceding Claims 1 to 14 as an instrument panel support in one Motor vehicle, the channel being an air duct and / or a Cable duct is. 16. Use of a component according to one of the preceding Claims 1 to 14 as arranged under a windshield Cross member in a motor vehicle, the channel being a Air duct for guiding the windshield and / or the defrost air to be supplied to the side windows and / or Heating a wiper blade holder. 17. A method for producing a component ( 10 , 110 ) according to any one of the preceding claims 1 to 14, in which first the base body ( 14 , 114 ) is shaped and provided with the corresponding openings and / or openings, then the holders made of metal ( 16 , 17 , 21 ) are attached to the base body ( 14 , 114 ) and then the base body ( 14 , 114 ) is inserted into a tool and all plastic parts and plastic linings are molded onto the base body ( 14 , 114 ) in a single process step, for example, are injected. 18. The method according to claim 17, characterized in that the half-shells ( 116 , 118 ) are connected to one another in the tool by, for example, caulking before the method step of introducing plastic. 19. The method according to any one of the preceding claims 17 or 18, characterized in that the channel in the step of Plastic insertion is formed by a tool core. 20. The method according to any one of the preceding claims 17 or 18, characterized in that the channel in the step of Plastic insertion through a blow core, a filled one Shaped hose, is formed by gases or granules. 21. The method according to any one of the preceding claims 17 or 18, characterized in that the channel in the step of Plastic insertion is formed by a melting core. 22. The method according to any one of the preceding claims 17 or 18, characterized in that the channel in the step of Plastic insertion is formed by a lost core. 23. The method according to claim 17, characterized in that the Half-shells forming the basic body before being joined together Plastic lined.