DE102013101801A1 - Structural element e.g. frame element for motor car, has electrical conduit that is arranged between fiber layers of composite and is firmly connected to electrical contact - Google Patents

Abstract

The structural element (60) has fiber layers composite (62) having fiber layers (66,68). An electrical conduit (12) has terminal sections (14,16) at opposite ends, and is surrounded by an electrical contact (50). The electrical conduit is arranged between fiber layers of the composite and is firmly connected to electrical contact. An independent claim is included for method for manufacturing structural element.

Description

The present invention relates to a structural element for a motor vehicle, in particular a frame element for a chassis or a passenger compartment of the motor vehicle, comprising a plurality of laminated fiber layers which form a rigid fiber composite, and wherein the fiber composite comprises at least a first and a second fiber layer, with a electrical lead assembly having terminal portions at opposite ends for electrically contacting the electrical lead assembly.

The invention further relates to a method for producing a structural element for a motor vehicle, in particular a frame element for a chassis or a passenger compartment, wherein a first fiber layer, an electrical line arrangement and a second fiber layer are arranged in a mold and the fiber layers are laminated to a rigid Fiber composite form.

Finally, the invention relates to a motor vehicle frame with a structural element according to the invention.

Such structural elements serve to form a part of a supporting frame or an attachment element of a motor vehicle and to reduce the weight of the motor vehicle through the fiber composite.

In automotive engineering, it is well known to assemble parts of the chassis and parts of the passenger compartment from sheet metal and to form attachments of the chassis and / or the passenger compartment of carbon fiber reinforced plastics or laminated carbon fiber mats. For the electrical power supply of the motor vehicle and in particular for the power supply of electrically driven vehicles, it is necessary to attach electrical lines to the chassis and / or the passenger compartment having an electrical connection between z. B. to provide the front-side engine compartment and the rear cargo space. This electrical connection is usually formed by a flexible round cable or by a rigid flat cable, which is fastened to the surface of the chassis and / or the passenger compartment or guided in a separate cable channel and having a separate electrical insulation.

The disadvantage here is that the installation of such an electrical line is expensive and the line must be separately and consuming isolated because it must be externally attached to the chassis or the passenger compartment or inserted into the cable channel.

A carbon fiber reinforced plastic component for a door module of a motor vehicle is for example from the EP 0 955 191 A2 known, in which an electrical line for supplying electrical components of the door module is externally attached to the surface of the carbon fiber reinforced plastic component. The disadvantage here is that the electrical wiring must be installed consuming and also need a separate insulation.

Other similar plastic components with metallic inserts or electrical lines for motor vehicles are for example from the EP 1 197 316 A1 or the DE 10 2006 056 330 A1 known.

Overall, it is disadvantageous in the electrical wiring for motor vehicles that they must be assembled consuming and usually need to be isolated separately to avoid short circuits and reduce the risk of electrical shock. In electrically driven vehicles, the electric drives are supplied with high voltages and correspondingly large currents, the electrical insulation of the supply lines of the electric drive by the high voltages and high currents is very expensive and requires a large amount of space.

It is therefore an object of the present invention to provide structural elements with electrical lines for motor vehicles, which require a smaller space than the prior art.

This object is achieved in the structure element mentioned above in that the electrical line arrangement between the first and the second fiber layer is arranged and fixedly connected to the fiber composite.

This object is achieved in the manufacturing method mentioned above in that the electrical line arrangement between the first fiber layer and the second fiber layer is arranged and the fiber layers and the electrical line arrangement are arranged to each other such that opposite terminal portions of the electrical line arrangement exposed.

This object is further achieved by a motor vehicle frame with a structural element according to the present invention.

Since the structural element according to the invention has a line arrangement which is integrated between the fiber layers in the structural element, the electrical line can already be integrated in the production of the structural element, so that no separate brackets or cable ducts for the electrical line will be necessary. Because the electrical line arrangement is integrated in the structural element, the electrical line arrangement is protected against external influences, so that the electrical insulation of the line arrangement and thereby the required installation space can be reduced. As a result of the structural element according to the invention, overall the technical complexity of the electrical line arrangement in the motor vehicle is reduced, as a result of which the motor vehicle can generally be manufactured more cost-effectively and the weight of the motor vehicle can be reduced.

In a preferred embodiment, the fiber layers are formed by electrically insulating layers.

As a result, electrical insulation of the electrical line arrangement can be completely dispensed with, as a result of which the weight and the required installation space can be further reduced.

It is further preferred if the fiber layers comprise carbon fiber fabric.

As a result, the structural element can be made particularly stable and with a particularly low weight.

It is further preferred if the fiber layers are formed as carbon fiber mats and shed together.

Thereby, the structural element can be manufactured with little technical effort, since the carbon fiber mats must be fastened together only by means of a potting compound.

It is further preferred if the fiber layers are bonded to a composite.

As a result, the fiber layers can form a solid fiber composite, which can be installed as a load-bearing element in the motor vehicle.

It is further preferred if the composite is formed of epoxy resin.

The particular advantage of the epoxy resin is that it has a low electrical conductivity and connects the fiber layers to a very durable structural element, whereby the structural element is generally particularly light and particularly resilient.

It is furthermore preferred if the connection sections of the electrical line arrangement are exposed.

As a result, the electrical line arrangement can be electrically connected to a particularly low technical effort, for example, to connect electrical loads with an electrical energy source.

It is further preferred if the electrical line arrangement is a metallic conductor.

As a result, the electrical line arrangement can be provided with little technical effort and high conductivity.

It is further preferred if the metallic conductor is designed as a flat conductor.

As a result, an electrical line having a high line cross section and low electrical resistance can be integrated in the structural element, wherein the required installation space for the metallic conductor is limited.

It is further preferred if the electrical line arrangement is designed as a flexible ribbon cable with a plurality of separate electrical lines.

As a result, different voltages can be provided and, in particular, data cables with a plurality of lines can be integrated in the structural element, as a result of which in general the wiring complexity in the motor vehicle can be reduced.

In a particular embodiment, the ribbon cable to a flexible carrier on which the electrical lines are applied.

As a result, any flexible ribbon cable with little technical effort can be integrated into the structural element, whereby the manufacturing cost of the structural element is reduced with integrated data lines.

It is furthermore preferred if the electrical line arrangement has carbon nanotubes as the line section.

As a result, the electrical line arrangement can be provided with a high electrical conductance and with a very low weight, whereby the structural element as a whole becomes lighter.

It is furthermore preferred if the connection sections are connected to flexible connection lines.

As a result, the electrical line arrangement can also be connected to vibrating and movable components of the motor vehicle, without the structural element being mechanically damaged.

It is particularly preferred if the flexible connection lines metal strands, in particular copper strands, have.

As a result, the flexible connection lines can be manufactured inexpensively with little technical effort.

It is further preferred if the conduit arrangement comprises a plurality of metallic lines, which are electrically connected to each other between the outer and the inner fiber layer and form a metallic braid.

As a result, the structural element as a whole can be formed with a conductive structure, as a result of which, for example, the motor vehicle always has a defined electrical potential, for example at different installation positions. B. a ground potential can be provided.

The structural element according to the invention is preferably used for electrically driven motor vehicles or for hybrid vehicles, since in such electrically powered vehicles high currents and high voltage are used to drive the electric drive and the electrical energy is usually transported from the rear of the motor vehicle to the built-in front electric drive must become. The electrical line arrangement, which in this application has particularly high electrical voltages and transports large electrical currents, can be isolated by the special arrangement between the fiber layers with little effort, whereby the protection against electrical flashovers is increased.

It is understood that the features mentioned above and those yet to be explained below can be used not only in the particular combination given, but also in other combinations or in isolation, without departing from the scope of the present invention.

Embodiments of the invention are illustrated in the drawings and are explained in more detail in the following description. Show it:

1 a schematic representation of a motor vehicle frame with integrated electrical line;

2 a schematic representation of a motor vehicle having a plurality of electrical supply lines and a Datenbusleitung;

3 a sectional perspective view of a structural element with integrated electrical line;

4 a detailed view of the structural element 3 ; and

5 an perspective assembly drawing of the structural element 3 ,

In 1 is a motor vehicle frame shown schematically and generally with 10 designated. The motor vehicle frame 10 forms in this particular embodiment, a passenger compartment of a motor vehicle. The motor vehicle frame 10 is made of a fiber composite material formed from a plurality of fiber layers laminated together. In the motor vehicle frame 10 is an electrical line 12 integrated in the 1 is shown in dashed lines. At opposite ends of the electrical line 12 are connection sections 14 . 16 formed, for electrically connecting the electrical line 12 serve.

The electrical line 12 is in the motor vehicle frame 10 integrated, so that the electric wire 12 over the in 1 shown dashed area completely from the laminated fiber layers of the motor vehicle frame 10 is enclosed. The connection sections 14 . 16 at the opposite ends of the electrical line 12 are formed, protrude at opposite ends of the motor vehicle frame 10 from the motor vehicle frame 10 out and are accordingly open, so that the electrical line 12 by means of the connection sections 14 . 16 can be contacted electrically.

At one of the connection sections 16 is an electrical energy storage 18 in the form of a battery 18 connected. The opposite connection section 14 is with an electrical component 20 connected, in the embodiment shown here as an electrical machine 20 is designed for driving the motor vehicle and for generating electrical energy by means of recuperation.

By doing that, the battery 18 at the connection section 16 connected and the electric machine 20 at the opposite terminal section 14 connected is the electric machine 20 over the electrical line 12 be supplied with electrical energy or can from the electric machine 20 generated energy in the energy storage 18 get saved.

Because of the electrical line 12 in the motor vehicle frame 10 integrated, can be based on a separate assembly of the electrical line 12 be waived by brackets or in cable ducts and in that the motor vehicle frame 10 is formed from fiber composite material, at the same time on an electrical insulation of the electrical line 12 be waived. As a result, the motor vehicle can generally be manufactured with less effort, while at the same time the total weight of the motor vehicle can be reduced.

The electrical line 12 can be formed as a metallic flat cable made of aluminum or copper or at least partially formed in a particular embodiment by carbon nanotubes. The connection sections 14 . 16 may be parts of the metallic flat conductor coming from the motor vehicle frame 10 protrude or be designed as flexible strands, in the motor vehicle frame 10 are laminated and connected there to the metallic flat conductor. Unless the connection sections 14 . 16 Parts of the metallic flat conductor are and protrude from the motor vehicle frame, it is advantageous if the connection sections with metallic strands z. B. made of copper, to the battery 18 or the electric machine 20 with the electric wire 12 to connect, as this may occur vibrations and mechanical stresses not on the electrical line 12 be transferred and thus the risk of mechanical damage is reduced.

Overall, thanks to the integrated electrical line 12 the electrical energy supply in the motor vehicle can be provided with simple means and low assembly costs.

In 1 a preferred embodiment is shown in total, in which the motor vehicle by the electric machine 20 is driven and is designed overall as an electrically driven vehicle or as a hybrid vehicle. Because of the electrical line 12 to supply the electrical machine 20 in the fiber composite material of the motor vehicle frame 10 integrated, can the electric line 12 , which in this application high electrical currents leads to be isolated with simple means to the environment. In general, therefore, the suitable in the motor vehicle frame 10 Integrated electric cable especially for electric mobility in general.

Alternatively or in addition to electrical supply lines can also be electrical lines in the motor vehicle frame 10 are integrated, which serve for data transmission and are designed as bus lines with multiple individual lines. Further, alternatively or additionally, in the motor vehicle frame 10 also a network of electrical wires 12 be integrated, for example, throughout the vehicle frame 10 To be able to produce a defined electrical potential and, for example, to provide a ground potential at each point, which otherwise has to be produced in a fiber composite material by appropriate grounding lines.

2 shows a schematic plan view of a motor vehicle, which generally with 30 is designated. The car 30 generally indicates the motor vehicle frame 10 on, in this particular embodiment, a support frame of the chassis of the motor vehicle 30 forms.

In the motor vehicle frame 10 is the electrical line 12 integrated or laminated and has the connection sections 14 . 16 on to the electrical line 12 with the battery 18 and with the electric machine 20 connect to. The car 30 indicates in addition to the battery 18 and the electric machine 20 , which is formed in this embodiment as a starter or generator, nor a DC-DC converter 32 and a control unit 34 on, according to the electrical energy supply in the motor vehicle 30 controls. The connection section 16 is by means of a cable 36 with the control unit 34 connected and the control unit 34 is by means of another cable 38 with the battery 18 connected. The DC-DC converter 32 The purpose of this is to connect different on-board voltage systems with voltages of different voltages, such as 12 volts / 48 volts, to convert the electrical voltages accordingly and to exchange electrical energy between the two on-board networks.

The car 30 also has a second electrical line 40 on, which is also in the motor vehicle frame 10 is laminated and a ground line for the motor vehicle 30 forms. The ground line 40 has a plurality of ground connection points 42 on, according to different electrical consumers or electrical equipment with the ground terminal of the battery 18 connect to. The ground connection points 42 form through holes through the motor vehicle frame 10 and the plastic fiber layers to the ground line 40 to different installation positions in the motor vehicle 30 the ground potential of the battery 18 provide. The ground connection points 42 each with a connection section 44 . 46 be connected to the ground connection points 42 corresponding to electrical units of the motor vehicle 30 connect to. The ground line 40 is over the connection section 46 and a cable 48 with the earth pole of the battery 18 connected.

Overall, by means of the electrical line 12 a busbar through the Motor vehicle frame 10 be provided through and by means of the electrical ground line 40 a ground rail through the motor vehicle frame 10 be provided so that the electrical power supply between the battery 18 and the electrical components 20 . 32 compact and small in size can be provided.

In 2 is also an electrical data line 50 shown having a plurality of individual insulated electrical wires and like the electrical lines 12 . 14 in the motor vehicle frame 10 is laminated. The electrical data line 50 forms part of a vehicle electrical system of the motor vehicle 30 and is over a bus line 52 with the control unit 34 connected. The electrical data line 50 can with any electrical appliances 20 . 32 of the motor vehicle 30 connected in accordance with measurement data to the control unit 34 to transmit and control commands from the control unit 34 to transfer to the electrical units. The electrical data line 50 is by means of connection sections 54 . 56 with the bus line 52 and the electrical units of the motor vehicle 30 connected to transmit the electrical signals. The electrical data line 50 can be designed as a ribbon cable or in the form of a flexible carrier with printed electrical lines (Flexprint) be formed and how the electrical lines 12 . 40 in the motor vehicle frame 10 be laminated.

The electrical data line 50 can thus already in the production of the motor vehicle frame 10 in the motor vehicle frame 10 be integrated or laminated, so that the cabling effort for the electrical system by the motor vehicle frame 10 is reduced through. It is understood that the electrical data line 50 not just the two connection sections 54 . 56 for contacting, but that the electrical data line 50 also further connection sections between the two ends of the electrical data line 50 may have in order to connect corresponding electrical units with the electrical system.

As a result, thus both the electrical power supply and the electrical data transmission in the motor vehicle 30 be integrated with simple means and save space and weight.

3 shows a schematic perspective sectional view of a structural element, which generally with 60 is designated. The structural element 60 can be part of the motor vehicle frame 10 form or a rigid attachment of the motor vehicle 30 form such. As a door element, a hood, a tailgate or the like.

The structural element 60 is formed by a plurality of fiber layers 62 , which are laminated in layers by means of an adhesive and form a rigid fiber composite. Preferably, the structural element 60 formed by carbon fiber mats, which are interconnected by means of epoxy resin and thus form a carbon fiber composite (CFRP). Between the fiber layers 62 is the electrical line 12 arranged or laminated so that the electrical line 12 in the structural element 60 is integrated and from the fiber layers 62 is enclosed. The electrical line 12 is in this example as a metallic flat conductor 12 formed at opposite ends of the structural element 60 protrudes and accordingly exposed to the terminal sections 14 . 16 at the opposite ends of the electrical line 12 to build.

The fiber composite of the structural element 60 is formed by an electrically insulating material or has a very low conductivity, so that the electrical line 12 through the structural element 60 or through the fiber layers 62 is electrically isolated from the environment. As a result, advantageously, a separate isolation of the electrical line 12 be waived.

The fiber layers 62 are by means of a cover layer 64 sheathed to the fiber layers 62 to protect against external influences.

In an alternative embodiment, the electrical line 12 at least partially formed by carbon nanotubes, the electrical resistance of the electrical line 12 to reduce and continue the weight of the electrical line and thus the entire structural element 60 to reduce. In this embodiment, the terminal portions 14 . 16 be formed as a laminated metal contacts or as laminated metal strands to the carbon nanotubes with the battery 18 and / or the electrical consumers 20 connect to.

In 4 is a detailed view of the sectional view of the structural element 60 out 3 shown. The same elements are designated by the same reference numerals, in which case only the special features are explained.

Between the fiber layers 62 , which together form a fiber composite, is the electrical conductor 12 arranged or laminated. The fiber composite is formed by a plurality of upper fiber layers 66 and a plurality of lower fiber layers 68 , The electrical line 12 is between the upper fiber layers 66 and the lower fiber layers 68 integrated into the fiber composite and thus runs parallel to the fiber layers 62 ,

The fiber layers 62 are preferably formed as carbon fiber mats and are laminated in layers by means of epoxy resin, so that between the upper and the lower fiber layers 66 . 68 the electrical line 12 can be laminated.

During the production of the structural element 60 According to the invention, first of all a casting mold is provided into which the cover layer 64 is inserted. Then the lower fiber layers are layered 68 placed in the mold and glued or laminated by means of epoxy resin. After that, the electrical line 12 on the lower layers 68 applied, in such a way that the connection sections 14 . 16 exposed. The connection sections 14 . 16 As mentioned above, separate elements, e.g. As metal strands, or be a part of the electrical line 12 form. After that, the upper fiber layers 66 applied and bonded by means of epoxy resin or laminated, so that the upper fiber layers 66 and the lower fiber layers 68 form the solid and rigid fiber composite. Thereafter, the upper cover layer is applied to the fiber composite 64 applied.

The transition between the separate connection sections 14 . 16 and the electric wire 12 can generally be done by an ultrasonic welding process.

By the method according to the invention, the electrical line 12 in the structural element 60 are laminated so as to form an electrical connection through the electrically insulating fiber composite.

5 shows a perspective view of a part of the structural element 60 , The same elements are designated by the same reference numerals, in which case only the special features are explained.

In this illustration, one of the connection sections protrudes 14 . 16 from the structural element 60 out, leaving the electrical line 12 There with an electrical component, not shown 20 . 32 or the battery 18 can be connected. The opposite end of the electrical line 12 is in the in 5 illustrated perspective partial view not shown. The structural element 60 also has connection points 70 on, over which the electrical line 12 through the fiber layer 62 can be contacted through. The electrical line 12 thus also points between the connection sections 14 . 16 Connection points, via the electrical consumers with the electrical line 12 can be connected. It is understood that the remarks to the 3 . 4 and 5 as well for the ground line 40 and the corresponding ground connection points 42 as well as for the data line 50 applies or is applicable.

The electrical line 12 . 40 can be made of aluminum in a low pressure die casting process.

In a particular embodiment, the connection sections 14 . 16 . 44 . 46 . 54 . 56 as well as the connection points 42 . 70 designed as plug-in or screw system, so that with little effort, the corresponding electrical lines 12 . 40 . 50 can be connected.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 0955191 A2 [0007]
• EP 1197316 A1 [0008]
• DE 102006056330 A1 [0008]

Claims (17)

Structural element ( 60 ) for a motor vehicle ( 30 ), in particular frame element ( 10 ) for a chassis or a passenger compartment of the motor vehicle ( 30 ), with - a plurality of laminated fiber layers ( 62 ), which form a rigid fiber composite, wherein the fiber composite at least a first fiber layer ( 66 ) and a second fibrous layer ( 68 ), - an electrical line arrangement ( 12 ; 40 ; 50 ), which at opposite ends connecting portions ( 14 . 16 ; 44 . 46 ; 54 . 56 ) to the electrical line arrangement ( 12 ; 40 ; 50 ) electrically contact, characterized in that the electrical line arrangement ( 12 ; 40 ; 50 ) between the first fiber layer ( 66 ) and the second fiber layer ( 68 ) is arranged and firmly connected to the fiber composite. Structural element according to claim 1, characterized in that the fiber layers ( 62 ) by electrically insulating layers ( 62 ) are formed. Structural element according to claim 1 or 2, characterized in that the fiber layers ( 62 ) Have carbon fiber fabric. Structural element according to one of claims 1 to 3, characterized in that the fiber layers ( 62 ) are formed as carbon fiber mats and shed together. Structural element according to one of claims 1 to 4, characterized in that the fiber layers ( 62 ) are glued to a composite. Structural element according to claim 5, characterized in that the composite is formed of epoxy resin. Structural element according to one of claims 1 to 6, characterized in that the connecting sections ( 14 . 16 ; 44 . 46 ; 54 . 56 ). Structural element according to one of claims 1 to 7, characterized in that the electrical line arrangement ( 12 ; 40 ) a metallic conductor ( 12 ; 40 ). Structural element according to claim 8, characterized in that the metallic conductor ( 12 ; 40 ) as a flat conductor ( 12 ; 40 ) is trained. Structural element according to one of claims 1 to 7, characterized in that the electrical line arrangement ( 50 ) as a flexible ribbon cable ( 50 ) is formed with a plurality of separate electrical lines. Structural element according to claim 10, characterized in that the ribbon cable ( 50 ) has a flexible support, on which the electrical lines are applied. Structural element according to one of claims 1 to 7, characterized in that the electrical line arrangement ( 12 ; 40 ; 50 ) Has carbon nanotubes as a conduit section. Structural element according to one of claims 1 to 12, characterized in that the connecting sections ( 14 . 16 ; 44 . 46 ; 54 . 56 ) are connected to flexible connecting cables. Structural element according to claim 13, characterized in that the flexible connection lines ( 14 . 16 ; 44 . 46 ; 54 . 56 ) Metal strands, in particular copper strands, have. Structural element according to one of claims 1 to 14, characterized in that the conduit arrangement comprises a plurality of metallic lines, which are electrically connected to each other between the outer and the inner fiber layer and form a metallic braid. Method for producing a structural element ( 60 ) for a motor vehicle ( 30 ), in particular a frame element ( 10 ) for a chassis or a passenger compartment, comprising the steps of: providing a mold, inserting a first fiber layer, 66 ) in the mold, - arranging an electrical line arrangement ( 12 ; 40 ; 50 ) at the first fiber layer ( 66 ), - arranging a second fiber layer ( 68 ) on the electrical wiring arrangement ( 12 ; 40 ; 50 ) and the first fiber layer ( 66 ), - lamination of the fiber layers ( 66 . 68 ) to form a rigid fiber composite in which the electrical line arrangement ( 12 ; 40 ; 50 ) at least partially received and with which the electrical line arrangement ( 12 ; 40 ; 50 ), the fiber layers ( 66 . 68 ) and the electrical line arrangement ( 12 ; 40 ; 50 ) are arranged to each other such that opposite terminal sections ( 14 . 16 ; 44 . 46 ; 54 . 56 ) of the electrical line arrangement ( 12 ; 40 ; 50 ). Motor vehicle frame ( 10 ) with a structural element ( 60 ) according to one of claims 1 to 15.

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