DE102009009112A1 - Structural component for motor vehicle, particularly B-column, side sill, or bumper cross beam, comprises base body made of sheet metal, and is partially provided with reinforcement element - Google Patents

Abstract

The structural component comprises a base body (2) made of sheet metal. The base body partially provided with a reinforcement element (3), which is stuck together with the base body. The base body and the reinforcement element are fixed by a placement fastener (5) without prepunching. The base body is configured in a dish-shape, and the reinforcement element rests against the base body. Independent claims are also included for the following: (1) a method for manufacturing a structural component; and (2) a device for manufacturing a structural component.

Description

The The invention relates to a structural component for a motor vehicle, For example, a B-pillar, a sill or a Bumper cross member, as well as a method and an apparatus for producing a structural component for a motor vehicle.

One generic structural component for a motor vehicle comprises a main body of sheet metal, which partially is provided with at least one reinforcing element, wherein glued the reinforcing element to the base body is.

Partially reinforced structural components include, for example, the DE 43 07 563 C2 or the DE 100 49 660 A1 to the state of the art. One speaks in this connection also of Patchworktechnik. Against the background of climate change and the resulting CO ₂ discussion, this is becoming increasingly important in the quest for the most lightweight motor vehicles possible. Due to the patchwork technique, the weight of motor vehicle structural components, in particular body parts, can be reduced by using thinner sheets, which are reinforced locally by so-called patches.

Often consist of the main body and the reinforcing element made of sheet steel. Such compatible material pairings are usually welding technology joined together. Also a bonding technology connection is common.

Increasingly Reinforcement elements made of plastic are also used. The joining of basic bodies made of sheet steel and Plastic reinforcing elements may be due to the material and thermal incompatibilities not by welding, for example resistance spot welding, respectively. The mainly used joining process for such patch solutions is the bonding with thermosetting toughened adhesives. to Fixation of the parts to the complete Adhesive curing is often one- or two-part Rivet bolt used. For fixation by rivet bolts or blind rivets is a pre-punching of the components necessary. The Vorloch and setting process is correspondingly expensive. alternative comes a clamping of the components to be joined by means of clamping elements from the outside to the application. Also this Klebspanntechnik is relatively expensive.

Of the Invention is based on the prior art based on the object a manufacturing technology improved structural component for To provide motor vehicles and a method and a device to show their production.

The Solution of the representational, on the structural component directed part of the task shows claim 1.

After that are the main body and the reinforcing element fixed by means of setting bolts without pre-punching. The invention is made the insight to own, that the bolt setting an optimized joining technique for connecting the reinforcing elements, in particular flat Reinforcing elements, and the body represents without pre-hole operations are necessary. The connection of Components are possible, even if they are only one-sided are accessible. There is a combined addition. The Reinforcement elements are on the basic body glued. Depending on the manufacturing concept, one-component, thermosetting adhesive systems or even two-component, cold-curing adhesive systems are used. For fixation of the components become setting bolts, which are similar to a nail, driven into the components at high speed. in this connection be the walls of reinforcing element and basic body penetrated. The setting bolt rests with a broadened bolt head one side of the structural component in particular flat. On the opposite side of the setting bolt or the bolt shank of the setting bolt out of the structural component and protrudes with respect to the structural component. The setting bolt displaces the material of the components to be joined. During penetration, the material undergoes of the main body and the reinforcing elements in the connection area a high plastic deformation. Due to the high speed when driving the setting bolts, it comes to a locally high heating of the components. To the setting, ie the completion of the driving operation, act restoring forces the plastic deformation on the setting bolts. The binding mechanism the setting bolt connection consists of frictional engagement, material connection and form fit together.

The Setting bolt technology makes a rational production of structural components or the fixation of the adhesive bond between reinforcing elements and basic bodies with short cycle times possible. In Advantageously, also structural components in mixed construction and multilayer compounds are produced. Across from the use of conventional rivet bolts or blind rivets is a pre-punching not required.

advantageous Embodiments of the structural component according to the invention are the subject of dependent claims 2 to 10th

To generate the positive / positive fixation of reinforcing element and base body, a pulse-shaped bolt setting method is used in which the nail-shaped setting bolts at high speed and on one side by ver to binding components are driven. Due to the high pin speed even at room temperature difficult to convert materials such. As high-strength thermoformed steels or components made of magnesium, are connected. Particularly advantageous is a structural component of a base made of steel with component-minimized sheet thickness. The main body is reinforced by one or more reinforcing elements in strength or stiffness relevant areas of the structural component. In this case, reinforcing elements made of fiber-reinforced materials, such as fiber-reinforced plastics, can be used in particular. These can be combined particularly advantageously by means of combined adhesive and setting pin joints with the base body.

at A preferred embodiment of the structural component is the main body configured cup-shaped and the reinforcing element fully connected to this.

As already mentioned, it comes by the high joining part speed to plasticize the materials to be joined. Consequently can also be difficult to form materials at room temperature, such as z. B. high and high strength steels and fiber reinforced Plastics are connected. Optionally, the reinforcing element also made of a metallic lightweight material, such. As magnesium or Aluminum, consist. An innovative, weight-reduced structural component can also by the use of a basic body of light metal, in particular a high strength aluminum material.

Around to secure the position of the setting bolts on the structural components and to ensure their captivity, especially at dynamic or oscillatory loads of the structural components in operation, can the set bolts through an abutment body be secured. As an abutment body can For example, nuts or spring clips are used. Also the use of clip nuts made wholly or partly of plastic exist is possible. Through the abutment body In addition, a better corrosion protection for lower layer and a higher connection strength axially to Setting bolt realized. The mounting strength of the setting bolts can In addition, be increased when the stud shafts of the setting bolts are profiled, for example by means of thread, ring profiles or Gearing or the like.

To the Mount the abutment bodies on the bolt shank of the Setting bolt may be provided an assembly unit. This is expediently in the apparatus for producing the inventive Integrated structural components. Beneficial for the practice it is when the abutment body before inserting the Reinforcement elements in the receiving tool in this be positioned, in the recesses, in which the Dip the bolt shafts of the setting bolts when setting. Conveniently, are the abutment bodies with a the dipping process supporting conical or funnel-shaped Infeed contour provided. As a result, the assembly process is supported.

A special design of the setting bolt provides that the bolt shank is provided at a defined location with a predetermined breaking point. In particular, the predetermined breaking point is replaced by a cross-sectional reduction, For example, a circumferential notch realized. The projecting on a structural component Area of the bolt shaft of a setting bolt can after the setting process be separated completely or partially. This allows the weight reduced and possible restrictions of the installation space be counteracted. To facilitate the separation process is used the predetermined breaking point on the bolt shank.

The Surface of the main body can be before joining be provided with a surface coating. Especially with material-like pairings of base body and reinforcing element, ie For example, steel - steel, can be a surface coating on a structural component even after the joining of basic body and reinforcing element are applied. in principle can organic or inorganic coatings, eg. As a galvanizing, electrolytic galvanizing, zinc flake coatings or thermal diffusion layers. In this way the corrosion protection of the structural component is improved.

advantageously, can also other attachments by means of setting without Vorlochen be joined with the body. Such Attachments can be made of steel, light metal, such as aluminum or magnesium, or of plastics, in particular also of fiber-reinforced Plastics, exist.

The Invention provides a partially reinforced structural component in hybrid construction and thus a significant lightweight construction potential reduced production costs, as complex and expensive Rivet solutions omitted.

Of the procedural part of the task is through a A method according to claim 11 solved.

To produce a motor vehicle structural component, corresponding prefabricated reinforcing elements are fed to an adhesive application station. There, an adhesive is applied to the joining surface of the reinforcing element. The reinforcing element is then inserted into a fixing press with egg transferred to a recording tool and positioned there in a recording. Also, the main body is fed to the fixing press and positioned there in a receptacle. For this purpose, stops can be provided for positionally accurate positioning of the base body. Subsequently, the base body and the reinforcing element are brought into contact and pressed against each other. In principle, two or more reinforcing elements can be connected to the base body at the same time. The fixing of the base body and reinforcing element or reinforcing elements is then carried out by setting bolts, wherein the setting bolts are driven without pre-punching through the reinforcing element and the base body. The bolt setting takes place at defined positions in the fixing press. Subsequently, the reinforced structural components are automatically removed and stacked.

The Recording, in which the reinforcing element and the base body can be positioned and held in the joining operation Be part of the fixing press. The driving in of the setting bolts will then done in the fixing press. It is conceivable that the bolt setting system integrated into the upper tool of the fixing press is. In this way, in a process step all Set bolts at the same time, reducing the cycle time in Dependence of the number of joint points on can be reduced.

Possible It is also natural that the driving of the Setting bolts carried out in a separate setting station becomes.

At the Driving the setting bolts penetrate these at the joining points the main body and the reinforcing element and come out on the opposite side. Dive here the bolt shanks of the setting bolts in correspondingly configured recesses in the recording.

The Setting bolts lie with their bolt head on one side on the structural component at. On the other hand, the bolt shank emerges from the structural component. Here, the bolt can be secured by an abutment body be on the protruding end of the bolt shaft is mounted. It is also possible, the supernumerary Remove the area of the bolt shank and shorten the bolt shank.

The inventive method requires only one one-sided accessibility of the components to be connected. The combination with the gluing technique has the advantage that as well different materials with a high corrosion potential can be interconnected material and form-fitting. The pulse-shaped bolting has the further advantage that materials such as ultra high strength steel materials, no negative heat influence during the Joining process experienced.

A Apparatus for carrying out the vorerläuterten Method is configured according to claim 17. The tool includes a receptacle for the reinforcing element and / or the base body and a bolt setting device for connecting the reinforcing element to the base body Fasteners. In the receptacle recesses are provided, in which immerse the stud shafts of the setting bolts when setting.

In the device are the main body and the reinforcing element supported during setting of the bolt, so that an adverse Material deformation can be prevented. When using multilayer Reinforcing elements, in particular fiber-reinforced Reinforcement elements made of plastic, is further to ensure that delamination is prevented. For this is in the receiving tool a counter-holding system with the recesses provided, in which the Bolzenschäfte the setting bolts can dip when setting. Especially advantageous the recesses mouth side an extension, for example in the form of a phase, rounding or bevel, whereby the Setting operation is facilitated.

In the device may be a mounting unit for mounting or to Fixing abutment bodies on the stud shafts be provided the setting bolt.

Farther is it possible for a separation unit to be in the device integrated, for shortening the stud shafts after setting the setting bolts.

The Invention is described below with reference to drawings. It demonstrate:

1 an inventive structural component in the form of a B-pillar in a side view;

2 a section through the representation of 1 along the line AA;

3 a section of the connecting region between the base body and the reinforcing element of the structural component;

4 to 6 the joining of a reinforcing element with a main body in three process steps;

7 a detail of a receiving tool with the representation of a recess for the bolt shank of a setting bolt;

8th the representation of an alternative embodiment of a recess;

9 the process for producing a partially reinforced structural component based on a plant concept representation;

10 and 11 in each case a section of the connection region between the base body and the reinforcing element of a structural component with securing by an abutment body;

12 and 13 the representation of a separation process on the bolt shank of a setting bolt and

14 the process for producing a partially reinforced structural component based on a second system concept representation.

Based on 1 to 3 is a motor vehicle structural component 1 described in the form of a B-pillar.

The structural component 1 has a bowl-shaped body 2 of sheet metal, in particular a high-strength thermoformed steel sheet. Partial is the basic body 2 by at least one reinforcing element 3 strengthened. The reinforcing element 3 consists of a fiber-reinforced plastic and is configurational to the inner contour of the body 2 adjusted in the area to be reinforced ( 2 ). The reinforcing element 3 is with the main body 2 bonded. The adhesive layer is in the 3 with the reference number 4 characterized. For bonding, a one-component or multi-component adhesive can be used.

In addition to the adhesive connection are the main body 2 and the reinforcing element 3 by means of setting bolts 5 fixed. The fixing bolts 5 are unilaterally from the outside at high speed without pre-piercing through the material of the body 2 and the reinforcing member 3 driven. The nail-like setting pin 5 displaced with its bolt shank 6 the material of the main body 2 and the reinforcing member 3 in the connection area, which leads to a high plastic deformation. In this way, a stable, high-strength combined connection between the body 2 and the reinforcing element 3 produced by the adhesive connection and the setting bolt connection.

The reinforcing element 3 may also consist of a metal, for example steel or a light metal, in particular magnesium or aluminum. Also the basic body 2 may consist of a light metal material, in particular a high-strength aluminum material.

The surface of the main body 2 can in particular before, but also after the joining of the reinforcing element 3 be provided with a surface coating, preferably a zinc coating.

The steps for producing a shell-shaped or hat-shaped motor vehicle structural component 1 are based on the 4 to 6 as well as the 9 respectively. 14 explained.

A flat, configurative on the contour of a basic body 2 matched reinforcing element 3 becomes an adhesive application station 7 fed. There is an adhesive K on the joining surface of the reinforcing element 3 applied. The reinforcing element 3 then gets into a fixation press 8th transferred. The fixing press 8th has an upper tool 33 and a recording tool 9 with a recording 10 for the reinforcing element 3 on. In the recording 10 becomes the reinforcing element 3 positioned. In the recording tool 9 are in the field of recording 10 recesses 11 provided in the form of holes. The recesses 11 are in places in the pickup tool 9 at which later in the process the setting bolts 5 be set, and provide clearance for the penetration of the stud shafts 6 the setting bolt 5 represents.

Also the basic body 2 becomes the fixing press 8th fed and there in the recording tool 9 over the reinforcing element 3 set. Like in the 9 To recognize, this is done by a handling robot 12 , The recording tool 9 has attacks 13 for positionally accurate positioning of the body 2 on. Subsequently, the basic body 2 and the reinforcing element 3 brought into contact and pressed together (see 5 and 9 ).

After that, the main body 2 and the reinforcing element 3 by setting bolts 5 fixed. In the 9 is a fully automatic controlled robot 14 with a bolt setting device 15 shown. When bolting are the main body 2 and the reinforcing element 3 in the recording tool 9 held and in a setting station 16 positioned, which is part of the fixing press 8th can be.

The fixing bolts 5 be through the material of the body 2 and the reinforcing member 3 driven, without the components 2 respectively. 3 have been pre-punched for this purpose. This step is in the 6 and the 9 shown. Subsequently, the structural components 1 by means of a handling robot 17 from the recording tool 9 taken.

In order to prevent inadmissible material deformation, in particular delamination, of the reinforcing component 3 To prevent, if this consists of a fiber-reinforced plastic, become the basic body 2 and the reinforcing element 3 in the picture mewerkzeug 9 supported. To collect the set bolts 5 to enable are in the pickup tool 9 - As already stated - recesses 11 in the form of holes 18 (please refer 7 and 8th ) available. These are clearances into which the bolts 5 or the stud shafts 6 the setting bolt 5 can immerse themselves when they are driven in without deforming.

As in the 7 and 8th to recognize the recesses 11 an extension on the mouth side 19 in the form of a phase or rounding ( 7 ) or a slope ( 8th ) on. At the recess 11 according to 7 the hole widens 18 of diameter D (D = 4 - 10 mm) evenly with a radius R (R = 1 - 3 mm) curved to the mouth 20 , In the embodiment of the recess 11 , as in 8th As can be seen, the bore widens 18 Diameter D1 (D1 = 4 - 10 mm) over one step 21 and a circumferential inclined surface 22 to the mouth 20 where the recess 11 has a diameter D2. The angle α of the inclined surface 22 to the vertical can be between 45 ° and 70 °. In the illustrated embodiment, the angle α is 60 °.

On one side is the setting bolt 5 with his bolt head 23 on the motor vehicle structural component 1 at. The bolt shaft 6 occurs on the opposite side of the structural part 1 out and faces this. In practice, the bolt shank becomes 6 have a diameter d of 2 mm to 8 mm, in particular 3 mm to 4 mm.

In the 10 to 13 are three other embodiments of a setting bolt 5a . 5b and 5c to recognize. The fixing bolts 5a - 5c have profiled stud shafts 6a . 6b . 6c on.

The setting bolt 5a , like in the 10 to recognize, has a bolt shank 6a on that with a profiling 24 provided in the form of a thread. For securing and fixing the setting bolt 5a is on the bolt shank 6a an abutment body 25 assembled. The abutment body 25 is formed by a nut, which is based on the profiling 24 is screwed on. To facilitate the assembly process is the abutment body 25 with a conically shaped insertion opening 26 Mistake.

At the setting bolt 5b according to the 11 is the bolt shaft 6b with a profiling 24 provided in the form of a toothing or a ring profile. The setting bolt 5b is through an abutment body 27 secured. As an abutment body 27 a clip nut is used. This is preferably made of plastic and has inside locking plates 28 that with the profiling 24 resetting to engage. Also the abutment body 27 has a conically shaped insertion opening 26 on.

The setting bolt 5c as in the 12 and 13 shown, also has a tooth-like profiling 24 at the bolt shaft 6c on. Furthermore, on the bolt shank 6c a breaking point 29 provided in the form of a circumferential notch. At the breaking point 29 can the bolt shaft 6c after the setting process of the setting bolt 5c separated and so the bolt shank 6c be shortened. This is done by means of a plunger-like separation unit 30 in the device for producing a motor vehicle structural component according to the invention 1 or integrated into the production chain. By means of the separation unit 30 a force F becomes transverse to the pin axis of the setting bolt 5c introduced and so the opposite the motor vehicle structural component 1 protruding part of the bolt shaft 6c away. This can reduce the weight. In addition, limitations of the installation space are reduced and a risk of protruding peaks is reduced.

The 14 shows again a process for producing a partially reinforced structural component 1 based on a plant concept representation. The sequence corresponds to the system concept representation according to 9 , so that corresponding components or component components are provided with the same reference numerals.

When in the 14 shown plant or device is a bolt setting device 15 in the fixing press 8th integrated. These are several bolt setting units 31 in the upper tool 32 the fixing press 8th arranged.

As previously described, the main body 2 and the reinforcing element 3 in the recording tool 9 positioned. Subsequently, the upper tool 32 shut down and the fixing press 8th closed. All bolts 5 are then time-parallel or, if technically advantageous in terms of process or component, offset in time at the predetermined locations by means of the bolt setting units 31 introduced and the reinforcing element 3 at the base body 2 fixed.

In this way, a particularly rational approach to connect the body 2 with reinforcing elements 3 and the manufacture of the motor vehicle structural components 1 possible.

1

Motor vehicle structural component

2

body

3

reinforcing element

4

adhesive layer

5

fasteners

5a

fasteners

5b

fasteners

5c

fasteners

6

bolt shaft

6a

bolt shaft

6b

bolt shaft

6c

bolt shaft

7

Adhesive application station

8th

fusing

9

recording tool

10

admission

11

recess

12

handling robots

13

attack

14

robot

15

Bolt setting means

16

setting station

17

handling robots

18

drilling

19

extension

20

muzzle

21

step

22

sloping surface

23

bolt head

24

profiling

25

Abutment body

26

insertion

27

Abutment body

28

Rest slats

29

Breaking point

30

separation unit

31

Actuated fastening unit

32

upper tool

33

upper tool

D

diameter

D1

diameter

D2

diameter

F

force

K

adhesive

radius

α

angle

d

Diameter v. 6

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - DE 4307563 C2 [0003]
• - DE 10049660 A1 [0003]

Claims (22)

Structural component for a motor vehicle, for example a B-pillar, a sill or a bumper cross member, which has a basic body ( 2 ) made of sheet metal, wherein the base body ( 2 ) partially with at least one reinforcing element ( 3 ), which is connected to the main body ( 2 ), characterized in that the basic body ( 2 ) and the reinforcing element ( 3 ) by means of setting bolts ( 5 . 5a - 5c ) are fixed without pocketing. Structural component according to claim 1, characterized in that the basic body ( 2 ) is configured shell-shaped and the reinforcing element ( 3 ) flat on the base body ( 2 ) is present. Structural component according to claim 1 or 2, characterized in that the basic body ( 2 ) consists of metal. Structural component according to one of claims 1 to 3, characterized in that the reinforcing element ( 3 ) made of plastic, in particular a fiber-reinforced plastic. Structural component according to one of claims 1 to 3, characterized in that the reinforcing element ( 3 ) consists of metal. Structural component according to one of claims 1 to 5, characterized in that the setting bolt ( 5a - 5c ) a profiled bolt shank ( 6a - 6c ) owns. Structural component according to one of claims 1 to 6, characterized in that the setting bolts ( 5a . 5b ) by one with the bolt shank ( 6a . 6b ) cooperating abutment body ( 25 . 27 ) are secured. Structural component according to one of claims 1 to 7, characterized in that the setting bolt ( 5c ) a bolt shank ( 6c ) with a predetermined breaking point ( 29 ) having. Structural component according to one of claims 1 to 8, characterized in that the basic body ( 2 ) is provided with a surface coating. Structural component according to one of the claims 1 to 9, characterized in that attachments by means of setting bolts without pre-punching with the main body are joined. Method for producing a structural component ( 1 ) for a motor vehicle, which has a basic body ( 2 ) made of sheet metal and the main body ( 2 ) partially with at least one reinforcing element ( 3 ), which is connected to the main body ( 2 ), characterized by the following steps: - feeding the reinforcing element ( 3 ) to an adhesive application station ( 7 ); Applying adhesive (K) to the reinforcing element ( 3 ); - feeding the reinforcing element ( 3 ) to a recording tool ( 9 ) and positioning the reinforcing element ( 3 ) in the picking tool ( 9 ); - feeding the basic body ( 2 ) to the recording tool ( 9 ) and positioning the main body ( 2 ) in the picking tool ( 9 ); - pressing together of basic body ( 2 ) and reinforcing element ( 3 ); - fixation of basic body ( 2 ) and reinforcing element ( 3 ) by setting bolts ( 5 . 5a - 5c ), wherein the set bolts ( 5 . 5a - 5c ) without pre-punching through the base body ( 2 ) and the reinforcing element ( 3 ) to be driven; - removal of the structural component ( 1 ). Method according to claim 11, characterized in that the receiving tool ( 9 ) Component of a fixing press ( 8th ) and the driving in of the setting bolts ( 5 . 5a - 5c ) in the fixing press ( 8th ) is carried out. Method according to claim 11, characterized in that the driving in of the setting bolts ( 5 . 5a - 5c ) in a setting station ( 16 ) is carried out. Method according to one of claims 11 to 13, characterized in that the Bolzenschäfte ( 6 ) the setting bolt ( 5 . 5a - 5c ) when driving the body ( 2 ) and the reinforcing element ( 3 ) and in each case a recess ( 11 ) in the picking tool ( 9 ) immerse. Method according to one of claims 11 to 14, characterized in that the setting bolts ( 5a . 5b ) after driving through an abutment body ( 25 . 27 ). Method according to one of claims 11 to 14, characterized in that the Bolzenschäfte ( 6c ) the setting bolt ( 5c ) are shortened after driving. Device for carrying out a method according to one of Claims 11 to 16, characterized by a receiving tool ( 9 ) for receiving the reinforcing element ( 3 ) and the basic body ( 2 ) and a bolt setting device ( 15 ) for connecting the reinforcing element ( 3 ) with the basic body ( 2 ) by setting bolts ( 5 . 5a - 5c ), whereas in the recording tool ( 9 ) Recesses ( 11 ) are provided, in which the Bolzenschäfte ( 6 . 6a - 6c ) the setting bolt ( 5 . 5a - 5c ) at the Put a dip. Apparatus according to claim 17, characterized in that the bolt setting device ( 15 ) Bolting units ( 31 ), which in a fixing press ( 8th ) are integrated. Apparatus according to claim 18, characterized in that the bolt setting units ( 31 ) in the upper tool ( 32 ) of the fixing press ( 8th ) are arranged. Apparatus according to claim 17 to 19, characterized in that the recesses ( 11 ) an extension on the mouth side ( 19 ) exhibit. Device according to one of claims 17 to 20, characterized in that a mounting unit for fixing abutment bodies ( 25 . 27 ) on the stud shanks ( 6a . 6b ) the setting bolt ( 5a . 5b ) is provided. Device according to one of claims 17 to 21, characterized in that a separation unit ( 30 ) for shortening the stud shanks ( 6c ) the setting bolt ( 5c ) is provided.