DE102014002612B3 - Method for producing a lightweight component and component set for use in a corresponding method - Google Patents

Abstract

A method for producing a lightweight component (1) comprising a shell-shaped, open, thin-walled insert (3) made of a first material and at least one rib or honeycomb reinforcing structure (4) locally connected to the insert (3) comprising the steps of: providing the insert (3) and the reinforcing structure (4); three-dimensionally positioning the insert (3) and the reinforcing structure (4) to form a desired distance from one another and at least one cavity (10) having a vent (5) between the insert (3) and the reinforcing structure (4); then fixing the insert (3) and the reinforcing structure (4); Adhering the reinforcing structure (4) to the insert (3) on the inside thereof by means of an adhesive (17) injected into the at least one cavity (10) through an access (6), joining the insert (3) and the reinforcing structure (4) only on discrete adhesive surfaces. A component set suitable for use in such a method is also disclosed.

Description

The invention relates to a method for producing a shell-shaped, open, thin-walled insert made of a first material and at least one on its inside locally connected to the insert rib or honeycomb reinforcing structure comprising a second material comprising lightweight component. Furthermore, the invention relates to a set of components for use in such a method, wherein the set of components comprises a shell-shaped, open, thin-walled insert of a first material and at least one rib or honeycomb-shaped reinforcement structure of a second material to be connected locally to the insert on the inside thereof. If the term "lightweight component components" is used in the following, this includes the insert and the reinforcing structure.

In the lightweight component with the aforementioned features (cf., for example DE 10153712 C1 ) is typically a hybrid component, that is, the insert and the reinforcing structure are made of different materials, but it is also possible to produce a lightweight member having a liner and a reinforcing structure of the same material, that is, the first material is the same second material. The lightweight component with the features specified in particular as a body component, z. As in the automotive industry, mainly used for material savings and weight reduction while high load capacity. Such a body component is mainly used as an elongated carrier with lengths in the range of about 20 cm to 1.5 m, z. B. as a side member, cross member or as an instrument panel support. Furthermore, however, lightweight components in question are also produced, for example, as flat components with integrated carriers, for. B. as seating structures.

The insert can be made in particular thin-walled, d. H. it has a material thickness of about 3 mm and less and is typically made of sheet metal, for. As steel sheet (for example, standard steel, Tailor Rolled steel or Tailor-welded steel) or light metal sheet (for example, based on an aluminum, magnesium or other light metal material). The cross-sectional profile of the insert is typically substantially U-shaped or cup-shaped, but also closed cross-sectional profiles come into question.

The reinforcing structure is typically made of a light metal material, preferably based on aluminum or magnesium, and serves to reinforce the insert or the lightweight component. The connection between insert and reinforcing structure takes place only in discrete areas, that is locally and not nationwide, whereby a considerable material savings and weight reduction can be achieved. Typically, less than 40% of the surface of the insert is bonded to and covered by the reinforcing structure, and more than 60% of the surface of the insert is typically flank, that is, not joined to, or covered by, the reinforcing structure. The reinforcement of the insert by the reinforcing structure is preferably provided where high loads usually occur in the installed state by local bulging. The reinforcing structure has no solid profile and may be formed, for example, rib-shaped or honeycomb-shaped, wherein the ribs or honeycombs are preferably made thin-walled, in particular with a material thickness between about 1 mm and 8 mm.

A lightweight component with the features mentioned is, for example, from the DE 101 53 712 C1 known. The inserts shown therein made of a steel sheet and the reinforcing structure of a light metal material are positively, positively and / or materially connected to each other. The lightweight component is characterized in particular by a high structural performance and bond strength between insert and reinforcing structure.

However, steel of the insert and light metal of the reinforcing structure touch each other over a large area, at least wherever they are connected to each other, which increases the risk of contact corrosion. Furthermore, it is provided that the reinforcing structure is cast on the insert. The resulting heat input into the insert can lead to negative changes in the material properties of the insert. Due to the different coefficients of thermal expansion of the materials of depositors and reinforcing structure also occurs the so-called delta alpha problem, which can cause distortion in the finished lightweight component with the result that dimensional tolerances of the lightweight component can not be met. The DE 101 53 712 C1 does not yet provide an approach to how these risks and problems can be counteracted.

In the journal article "Flexible into the future - A modular bodywork kit for small series" (Dr. Frank O. Hrachowy in Krafthand 12/2012, pp 36-38) a profile construction for bodies of small series vehicles is described. Structural profiles (eg of high-strength steel, stainless steel, aluminum, fiberglass or CFRP) and body knots (for example made of aluminum) are joined to form a body. The individual components are firmly inserted into each other and then glued together. The DE 10329017 B4 also relates to a support structure, in particular for bodywork of vehicles, from interconnected profile parts. The profile parts in the form of substantially rectangular hollow profiles are positively connected to each other at nodes and glued together flat. With a similar technology for the connection of profile parts, the DE 19607820 A1 ).

From the DE 602 14 699 T2 a hybrid component is known in which a reinforcing structure is glued by means of an expandable adhesive material in a hollow insert with closed cross-section. For this purpose, the reinforcing structure comprises at least two pairs of extensions, in particular parallel ribs, which approach the inner surface of the insert and within which the expandable adhesive material is arranged. The adhesive material may be adhered to the reinforcement structure prior to insertion into the insert, e.g. B. by extrusion coating, over-molding or injection molding. The adhesive-provided reinforcing structure is inserted into the inserter and the subsequent heating-induced expansion of the adhesive material is passed through the pairs of extensions.

That by the DE 602 14 699 T2 The lightweight component shown and its method of manufacture already make it possible to reduce the risk of contact corrosion by connecting insert and reinforcing structure without having to touch each other at the connection points. Also, the heat input into the insert can be reduced by the adhesive technique shown by means of expandable adhesive material in comparison to a casting of the reinforcing structure to the insert.

The DE 602 14 699 T2 however, does not yet provide any approach as to how advantageous (cup-shaped) inserts with an open cross-sectional profile can be glued to the reinforcing structure. Furthermore, according to the DE 602 14 699 T2 Thus, the adhesive material must have a relatively high viscosity in order to adhere to the reinforcing structure during insertion into the insert while not substantially changing its distribution between the pairs of extensions , Also with respect to the geometries of the adhesive bonds to be generated by the DE 602 14 699 T2 proposed solution relatively limited. In addition, when gluing with the expanding adhesive material is problematic that this must be expanded by heating to the extent that bridges the gap between insert and reinforcing structure and in addition all real occurring tolerances of the insert and the reinforcing structure are balanced. Due to the expansion of the adhesive material, however, its strength is greatly reduced, which in particular adversely affects the strength between insert and reinforcing structure. Furthermore, process reliability can not be ensured and gaps caused by manufacturing tolerances can not be completely filled out.

From the prior art, the adhesion of adhesive beads to the insert and / or the reinforcing structure is known as an alternative to the use of expanding adhesive materials. However, there is the particular problem that the adhesive beads when merging insert and reinforcing structure at least partially strip and thus can not always ensure a durable connection satisfactorily.

It is therefore the object of the invention to provide an improved method for producing a lightweight component with the features mentioned and an improved set of components of the type mentioned, which improved handling of the components during the manufacture of the lightweight component, complex, three-dimensional geometries, an improved balance of Allow deviations in the insert and in the reinforcing structure and increased strength of the adhesive.

The object is achieved by a method according to claim 1 and a component set according to claim 7.

The method according to the invention for producing a lightweight component having the features mentioned in the introduction, in which the insert and the reinforcement structure are adhesively bonded by means of an adhesive which is injected into at least one cavity between the insert and the reinforcement structure, is characterized by the following steps:
Providing the insert and the reinforcing structure;
three-dimensionally positioning the insert and the reinforcing structure with respect to one another to form a desired distance from each other and at least one vented cavity between the insert and the reinforcing structure;
then fixing the insert and the reinforcing structure;
Adhering the reinforcing structure to the insert on the inside thereof by means of an adhesive injected through an access into the at least one cavity, with connection of the insert and the reinforcing structure only on discrete adhesive surfaces.

Accordingly, it is provided according to the invention that the inserts and the reinforcing structure are provided prior to bonding and - also before bonding - the insert and the reinforcing structure are positioned three-dimensionally to each other and then fixed. According to this approach, the insert and reinforcing structure can be particularly easily manufactured separately in a conventional manner and provided for subsequent positioning and fixing.

The positioning of insert and reinforcing structure to each other preferably takes place in all three spatial directions and is divided into the distance positioning and the displacement positioning. In the distance positioning, the lightweight component components are aligned with each other so that corresponding splices on insert and reinforcing structure have a desired distance from each other. In the displacement positioning, the lightweight component components are aligned with each other so that they are already aligned prior to bonding to each other, as provided according to the desired final geometry of the lightweight component.

In particular, by injecting the adhesive and, when using variable volume adhesives, by shrinking the adhesive during its cure, forces can act on the components causing the lightweight component components to shift, thereby failing to maintain the previously made positioning , The fixation counteracts the forces that occur and ensures that the lightweight component components remain in their previously brought about by positioning position to each other.

The cavity into which the adhesive is injected is preferably substantially closed, that is, provided with only one or more accesses to inject the adhesive, and one or more vents to allow escape of the air in the cavity ,

The bonding takes place by injecting at discrete adhesive surfaces of the insert and the reinforcing structure, wherein the adhesive surfaces in each case form boundaries of the cavity. In order that the adhesive also reaches the intended adhesive surfaces with certainty, it is preferably provided that the cavity is completely filled with adhesive. The injection can be done with differential pressure in the created cavity in the adhesive. The differential pressure in the adhesive may be generated by, for example, pumping, gravity or capillary action. In order to ensure a filling of the cavity with adhesive particularly secure, it is advantageously provided that the injection is carried out with a vacuum support or that the adhesive is completely sucked in via a vacuum. Also provided is a volume-controlled injection in which the completeness of the filling of the cavity can be ensured by appropriate metering of the adhesive to be injected.

Preferred adhesives are structural adhesives, for example single-component or two-component adhesives or thermoplastic adhesives. Preferably, the adhesive has a minimum strength, for. B. between about 5-30 MPas. In principle, adhesives can be used whose volume does not change (volume-constant adhesive), shrinks (contracting adhesive) or expands (expanding adhesive).

Particularly preferred are volume constant (theory) or approximately (practice) volume constant adhesive, z. As structural adhesive, for use, which in particular allow optimal filling of the cavities, because the volume of the adhesive, which is injected into the cavity, can be particularly precisely matched to its volume. It is also possible to compensate for deviations in the insert and in the reinforcing structure particularly well with injected volume-constant adhesives because the volumes caused by dimensional deviations in the cavities can be filled by the adhesive. When using volume-constant adhesives, more preferably structural adhesives, the durability of the connection between insert and reinforcing structure in comparison to the use of expanding adhesive is particularly high, because almost no loss of strength of the volume-constant adhesive occurs during its curing. The use of expanding adhesives, on the other hand, offers the advantage that, for example, even larger cavities can be filled more easily, as a result of which, in particular, a particularly clean seal between insert and reinforcing structure can be realized even with larger tolerances.

The injection of the adhesive allows three-dimensional adhesive structures of almost any shape can be produced, which are optimally adapted to the geometry of the lightweight component components and their position to each other in the aligned state and to the Discrete joints between the lightweight component components. Furthermore, the viscosity of the liquid adhesive must have no minimum value and can advantageously be chosen very low. Furthermore, the adhesive no longer needs to be applied as before prior to contacting the insert and reinforcing structure, which facilitates handling during manufacture of the lightweight component.

Particularly preferably, the splices or joints are subjected prior to the injection of the adhesive pretreatments, which are for a particularly high bonding strength between the lightweight component components. In this context, in particular cleaning preparations, Passivierungsvorbereitungen or pickling are provided.

The method according to the invention also makes it possible for virtually any materials and combinations of materials of the insert and the reinforcing structure to be connected to one another, namely in particular those material pairings which can be adhesively bonded together sufficiently firmly by the adhesive. Thus, in addition to the typical materials mentioned above for the insert and the reinforcing structure, in particular composite materials such as fiber-reinforced plastics (eg GFRP or CFRP) or hybrids can also be used.

The lightweight component produced by the method according to the invention and its advantageous embodiments described below is preferably provided for a subsequent connection to another component of the vehicle body as part of a shell process of a vehicle body. In this case, the curing of the adhesive may have already taken place or take place only after the connection during a preferably subsequent cathode dipping (KTL). Furthermore, it is also advantageously provided to initially connect one of the lightweight component components to such a further component and then to use the method according to the invention.

If a lightweight component with a deposit made of a first material and a locally connected to the insert reinforcing structure made of a light metal, for. B. based on an aluminum material, is advantageously provided to pressure-cast the reinforcing structure in the mold cavity of a casting tool and immediately after die casting or even while the reinforcing structure is in the casting tool to inject adhesive in cavities provided for this purpose. The previously cast reinforcing structure thus simultaneously forms an injection mold for the adhesive. In this way, the structure created by the injected adhesive is already present on the reinforcing structure, which is subsequently brought together with the inserter. Another injection step can be omitted.

• – Einlegen des Einlegers in einen Formholraum eines Gusswerkzeugs,
• – Beschichten des Einlegers mit einer Beschichtung, welche einem Stoffschluss der Materialien des Einlegers und der Verstärkungsstruktur entgegenwirkt, wenigstens in Bereichen, welche einen Teil des verbleibenden Formhohlraums des Gusswerkzeugs begrenzen und
• – Gießen der Verstärkungsstruktur in dem verbleibenden Formhohlraum des Gusswerkzeugs.

An advantageous development of the method according to the invention relates to the provision of insert and reinforcing structure and comprises the following method steps:

• Inserting the insert into a mold cavity of a casting tool,
• Coating the insert with a coating which counteracts a material bond of the materials of the insert and the reinforcing structure, at least in areas which define a part of the remaining mold cavity of the casting tool, and
• Casting the reinforcing structure in the remaining mold cavity of the casting tool.

Preferably, the insert consists of a steel sheet, and the reinforcing structure is die-cast from a light metal material. The inserter for example is already finished by a deep-drawing process and adapted to the geometry of the mold cavity. Furthermore, the insert is completely or at least coated everywhere where it comes into contact with casting material of the reinforcing structure in the subsequent casting process. The coating has the effect of preventing a material bond between the insert and the reinforcing structure during and after casting. After the insole and reinforcing structure have been produced in the manner described above, they can be glued together according to the invention. In this way, the development makes a particular contribution that tolerances of the contact surfaces of insert and reinforcing structure can be particularly well met. Both organic and inorganic materials are suitable for the coating. In this context, nano-X, boron nitride, polysiloxanes, talc, nickel or typical cast release agents have proven particularly suitable as coating materials.

Fixing by means of separate clamps, at least one further component, a clip connector of the inserter, riveting, clinching or spot welding is also particularly advantageous.

According to this embodiment, the insert and the reinforcing structure are connected together in one or a few places at least non-positively. Separate clamps can be applied, tensioned, loosened and removed in a particularly flexible manner at suitable areas of the insert and reinforcing structure without the need for constructive adaptations of the lightweight component geometry to the clamps. In particular, the clamps may be provided for fixing so as to bear pressure during injection and curing of the adhesive on the insert and reinforcing structure, thereby holding the components in the previously set position. Then they can be removed from the lightweight component again very easy.

The same or a similar effect as in the provision of clamps can be achieved by the use of at least one further component for fixing. This variant is particularly advantageous if the further component is one that is to be attached to the lightweight component anyway. Such a further component may be, for example, a striking plate for the lightweight component. The lightweight component is preferably added to the insert or the reinforcing structure such. B. by means of a rivet or welded joint that the insert and the reinforcing structure are fixed in their intended according to the final geometry of the lightweight component position to each other. It is in this variant thus a preferred permanent fixation. The fixing by means of the further component always takes place in such a way that accesses for the injection of the adhesive are not obstructed. Furthermore, the other components can make a contribution to the sealing of the cavity by the bracing of the insert relative to the reinforcing structure.

When fixing by means of at least one clip connector of the insert the latter and the reinforcing structure are also permanently fixed. The clip connectors are firmly connected to the insert and particularly preferably integrally connected to the insert in the way that they are resiliently resilient, z. B. clamp-like areas are formed, which can clasp a corresponding region of the reinforcing structure. In particular, the insert and the reinforcing structure can be locked together. This creates a permanent connection between the components. However, this is in a particularly simple way nondestructive separable. Furthermore, the respectively provided detent position provides a particularly suitable orientation aid during the positioning of the components relative to each other. In the course of producing the lightweight component, this contributes in particular to simplifying handling, reducing the risk of incorrect positioning and shortening the duration of the process.

By joining the components by riveting, clinching or spot welding a particularly firm and permanent fixation of the components can be achieved while the adhesive is not cured by the latter at least non-positively and in addition cohesively (in the case of clinching and spot welding) or positively (in the case of Vernietens) braced and connected together.

When injecting the adhesive into the cavity between the components, it must be ensured that the adhesive remains in the cavity to achieve a uniform and firm bond. Furthermore, it is to be avoided that adhesive emerging from the cavity has a negative effect on subsequent production steps, in particular on a subsequent immersion of the lightweight component in a bath for cathodic dip painting. The insert and reinforcing structure define the mold cavity. One possible opening from which adhesive can escape is given by the venting of the cavity. Furthermore, gaps may exist between the lightweight component components delimiting the cavity, in particular due to existing manufacturing tolerances, through which adhesive may escape from the cavity. According to a further embodiment of the method according to the invention for producing a lightweight component, it is therefore advantageously provided that the cavity is sealed by means of juxtaposing insert and reinforcing structure, an additional sealing tool or by injecting an amount of structural adhesive adapted to the cavity.

The pressing together of the lightweight component components to each other represents a particularly simple way of sealing, including in particular the previously described method for fixing, which clamp the lightweight component components to each other, can be used. The pressing together takes place at least during the injection and the (at least partial) curing of the adhesive after injection. The juxtaposition of the lightweight component components together - both for the purpose of fixing and sealing - for example, by means of a hold-down and lever, a hold-down and a spring and by means of vacuum or autoclave methods.

When using at least one additional sealing tool, the lightweight component components do not have to be clamped to each other. The additional sealing tool is brought into abutment with the insert and the reinforcing structure, so that at least one cavity located between the lightweight component components is sealed from the outside.

Another variant in which it is possible to dispense with an additional sealing tool and the juxtaposition of the lightweight component components together is to inject a matched to the volume of the cavity to be filled amount of adhesive of tuned viscosity. Thereby, a contribution is made such that the risk of adhesive leakage, in particular in the area of vents of the cavity and any leaking gaps between the lightweight components, is reduced solely due to the amount of adhesive injected.

Alternatively, it is also advantageously provided, a metered amount of adhesive in a gap between insert and reinforcing structure, which does not necessarily have to form a substantially closed cavity, so that the gap is completely filled, but the adhesive does not spread on the lightweight component outside the gap such that the appearance of the lightweight component and its connecting flanges are impaired. Such a gap may also be provided as an offset between the lightweight component components, in the sense that the insert and reinforcing structure at least for the most part do not touch each other and form large spaced opposite outer contours of small distance, which are glued together by injecting adhesive.

A further advantageous embodiment of the method according to the invention is directed to the geometry of the adhesive surfaces on the insert and reinforcing structure within the cavity. The design of the geometry of the adhesive surfaces should support the discrete support effect of the reinforcing structure. In this context, it is therefore particularly advantageous to provide said adhesive surfaces over a large area or particularly preferably channel-shaped, punctiform or channel-shaped and punctiform. Large adhesive surfaces ensure a particularly high durability between the lightweight component components. Channel-shaped and selective adhesive surfaces or a combination of both allow a particularly effective and efficient use of adhesives by arranging the adhesive surfaces in places that are technically meaningful in terms of stress.

The component set according to the invention for use in the method according to the invention described above has the features mentioned above and is characterized in that the insert and / or the reinforcing structure have at least one indentation for forming a cavity between insert and reinforcing structure, wherein the cavity has at least one access for injecting an adhesive and at least one vent.

According to the method of the invention, adhesive is injected into at least one cavity between the insert and the reinforcement structure, so that corresponding adhesive surfaces on the insert and reinforcing structure are glued together. In a shell-shaped open insert with open cross-sectional profile, which particularly preferably has a substantially U-shaped cross-section and a base and two arranged on opposite sides of the base and angled relative thereto edge portions, is advantageously provided at least one cavity in the base and / or provide the flanks. To form the cavity, either the insert, the reinforcing structure or both have at least one indentation, the opening of which is covered or closed by the respectively other lightweight component component. An indentation in the respective lightweight component component can, for example, be configured in such a way that the course of the outer contour inclined towards the respective other lightweight component component is reset in the region of the indentation with respect to the regions of the outer contour adjoining the indentation, z. B. substantially U-shaped. Further, it is also provided to make the indentation arcuate, that is, each of the cavity forming component is concave in the region of the cavity from the direction of the other lightweight component considered. When providing a plurality of cavities is particularly advantageous, these at least partially with each other, z. B. channels, to connect, which in particular access for injecting and / or vents can be saved.

The access serves to supply adhesive into the cavity and may be formed, for example, as an opening, an open connection flange or channel in the insert or in the reinforcement structure. At the entrance can be an injection tool. z. As a nozzle, are set to inject, for example, pressurized adhesive through the access into the cavity. The access preferably forms a surface for the sealing of the injection point in interaction with the nozzle geometry. The vent may also be in the form of an opening, an open connection flange or a channel and serves to maintain the pressure in the cavity to ambient pressure. Furthermore, it is also provided that adhesive is sucked into the cavity by generating a differential pressure. In this case, it is possible to suck in either via the access or the vent and thereby create a negative pressure in the cavity. The supply of adhesive then takes place via the other opening (access or ventilation).

According to a first embodiment of the component set according to the invention, it is advantageously provided that the insert or the reinforcement structure or both together form the access.

If the access is formed by the reinforcing structure, this can advantageously be done, for example, via connecting points, domes, ribs, honeycombs or other reinforcing geometries formed by it. In particular, in ribs of the reinforcing structure, the accesses may include an opening and a channel, wherein the opening z. B. at the top, facing away from the insert end of the rib is arranged and in a Channel opens, which connects the opening with the adhesive to be filled cavity. If the access is formed by the depositor, this can, for. B. are particularly easy to be provided by a perforation of the insert in the region of the cavity. The joint formation of the access by the insert and the reinforcing structure can be implemented particularly advantageously such that the cavity between the lightweight component components expires freely and thus forms a starting point for a nozzle of an injection tool. By a suitable design of the injection nozzle, the sealing and injection at the entrance can be made possible.

A further embodiment of the component set according to the invention is set up to produce a desired and particularly preferred constant layer thickness of the injected and cured adhesive in a cavity between the lightweight component components, because the layer thickness of the adhesive is of great importance for the formation of a high-performance bond between the lightweight component components. In this connection, it is therefore advantageously provided that the insert and / or the reinforcement structure form spacers for producing a desired spacing between the insert and the reinforcement structure. The spacers have a geometry that allows the spacers to be flowed around in the cavity during injection of the adhesive. The spacers can for this purpose in particular have a pin-shaped geometry. The pins can protrude from the outer contour of one of the lightweight component components or both, extend within the cavity up to the other lightweight component and touch with its free expiring pin end, the outer contour of each other lightweight component and the latter thereby keep at a distance.

Alternatively, it is also advantageous to provide separate spacers between the insert and the reinforcing structure that do not belong to the lightweight component components in order to produce a desired spacing between the insert and the reinforcing structure. This has the advantage that the geometry of the lightweight component components can be made particularly simple. The insuring and ensuring the layer thickness of the adhesive takes place through the separate spacers whose material thickness preferably corresponds to the desired layer thickness. The separate spacers touch the depositor on one of their sides and the reinforcing structure within the cavity with one of their other sides. The geometry of the separate spacers is designed so that they can be flowed around during injection of the adhesive. It is particularly advantageous in this context that the separate spacers are arranged in the adhesive to be injected, whereby the introduction of the separate spacers is particularly simplified in the cavity. Glass beads, so-called gap fillers, can serve as separate spacers in the adhesive.

In particular, in order to simplify the positioning of the lightweight component components relative to one another, it is furthermore advantageously provided that the insert and the reinforcing structure form corresponding pins and holes for positioning. In the holes are preferably elongated holes, in each of which a corresponding pin can intervene displaceable. In addition, the lightweight component components preferably have corresponding pairs of contact surfaces, which can further simplify the positioning.

In order in particular to facilitate the fixing of the lightweight component components in the mutually provided position, it is furthermore advantageously provided that the insert forms at least one clip connector for fixing to the reinforcing structure. The clip connector preferably has a geometry which makes it possible to firmly clamp the reinforcing structure and thereby fix it. Particularly preferably, the clip connector forms a free expiring, bent end, in which a corresponding part of the reinforcing structure can be clamped. With a single clip connector and also formed by the insert abutment for the reinforcing structure, this can be particularly secure and easy braced and fixed in at least one dimensions. The same applies to two clip connectors acting in opposite directions. With regard to further advantages of the clip connectors reference is made to avoid repetition of the statements in connection with the inventive method.

Particularly advantageous is further provided that the component set comprises a further component which fixes the insert and the reinforcing structure in their intended according to the final geometry of the lightweight component position. In this context, it is particularly preferably provided that between the further component and the reinforcing structure, a further cavity with adhesive is at least partially filled, whereby the further component and the reinforcing structure are glued together. In an analogous manner as in the bonding of metal insert and reinforcing structure according to the invention can be injected into the cavity between the reinforcing structure and the other component adhesive. Regarding further advantages and developments also referred to the above description of the method according to the invention.

According to a further embodiment, it is advantageously provided that the insert or the reinforcing structure or both together form the vent, the vent being formed, for example, by an opening in the insert or in the reinforcing structure.

Finally, according to a further advantageous embodiment of the component set according to the invention, a sealing tool is provided with a shape suitable to abut the insert and the reinforcing structure and thereby seal at least one cavity formed by the insert and the reinforcing structure from the outside. In particular, the sealing tool can be shaped such that, like a tentacle, it can be placed on the lightweight component components from outside as far as possible from all the cavities to be sealed.

In the following, embodiments of the invention will be explained in more detail with reference to the drawing. Hereby shows:

1A a perspective view of an embodiment of the component set according to the invention for use in an embodiment of the method according to the invention for producing a lightweight component with vents in the sheet metal insert and with the lightweight component components jointly formed vents,

1B FIG. 2 a partial cross section through a further exemplary embodiment of the component set according to the invention for use in an exemplary embodiment of the method according to the invention with a ventilation opening in the sheet metal insert, FIG.

2 a partial cross section through a further embodiment of the component set according to the invention with access and ventilation in the reinforcing structure,

3 a partial cross section through a further embodiment of the component set according to the invention, in which the vent is formed by insert and reinforcing structure,

4 a partial cross-section through a casting tool, in which a lightweight component or its components is or are produced with a further embodiment of the method according to the invention,

5 a partial cross section through a further embodiment of the component set according to the invention with a clip connection of the insert,

6A a partial cross section through a further embodiment of the component set according to the invention with a further component for fixing insert and reinforcing structure,

6B an enlarged further partial cross section through a part of the component set after 6A in which a further cavity filled with adhesive is shown between the reinforcing structure and the further component,

7 a partial cross section through a further embodiment of the component set according to the invention with an additional sealing tool,

8th 3 shows a partial cross-section through a further exemplary embodiment of the component set according to the invention with an access formed jointly by both light-bypass components,

9 a partial cross section through a further embodiment of the component set according to the invention with indentations in the insert,

10 a partial cross section through a further embodiment of the component set according to the invention with indentations in the insert and in the reinforcing structure,

11 to 15 Partial cross sections through five further embodiments of the component set according to the invention with different spacers,

16 a partial cross section through a further embodiment of the component set according to the invention with a pin and with this corresponding hole and

17 - 20 various embodiments of adhesive surfaces on sections of a Einleger of another embodiment of the component set according to the invention.

1A and 1B show in a perspective view and in a schematic partial cross-sectional view of two similar embodiments of the component set according to the invention 2 , which each have a depositor 3 from a steel sheet and a reinforcing structure 4 based on an aluminum material. The depositor 3 and the reinforcing structure 4 be through an embodiment of the invention Procedure locally, that is, at discrete locations and not connected to each other area-wide, whereby the whole called by the reference numeral "1" lightweight component is created.

The previously produced in a thermoforming process, in cross-section cup-shaped insert 3 includes a base 3B , two almost perpendicularly projecting from this leg 3S and two laterally outwardly projecting flange portions 3F , where in 1B only one each of the legs 3S and one of the flange areas 3F is shown. The in 1B right thigh shown 3S or the in 1A thighs shown on the left and right 3S of the depositor 3 each form a vent 5 in the form of an opening from which air can escape during the injection of adhesive.

The reinforcing structure previously made in a die-casting process 4 and the depositor 3 were positioned spatially to each other and then by suitable, in 1 not shown fixed means, wherein the in 1A and 1B illustrated alignment of the lightweight component components 3 . 4 to each other that of the desired final geometry of the lightweight component 1 equivalent. The fixation is carried out by pressing the Leichbauteilkomponenten 3 . 4 to each other, in such a way that at the same time a seal of a cavity 10 (see below) between depositors 3 and reinforcing structure 4 is sealed. The reinforcing structure 4 includes several reinforcing ribs 4R (in 1 only one of them is shown on the left), which in each case have an access at two of their upper, free-running ends 6 form in the form of another opening. In the opening or access 6 can a nozzle 7 an injection tool 8th be introduced so that the nozzle 7 in one in the rib 4R running channel 9 (see in particular 1B ) which introduces the opening of the reinforcing rib 4 with a cavity 10 between the depositor 3 and the reinforcing structure 4 combines.

To form the cavity 10 has the reinforcing structure 4 at least one indentation 11 on. The indentation 11 arises from the fact that the course of the depositor 3 opposite outer contour 12 the reinforcing structure 4 in the area of the cavity 10 is reset relative to adjacent areas. Through the access 6 and the channel 9 can be adhesive in the cavity 10 be injected. The indentation 11 extends for example (see 1B ) - interrupted only by the in the cavity 10 opening channel 9 - up to the venting 5 forming opening of the inserter 3 ,

In the flange areas 3F are the depositor 3 and the reinforcing structure 4 partially spaced so that the cavity 10 between the lightweight components 3 . 4 can leak freely. In this way, the depositors form 3 and the reinforcing structure 4 together a vent 5 out.

By means of in the channel 9 inserted nozzle 8th is an unillustrated adhesive, in this case a structural adhesive whose volume remains at least approximately constant during its curing, with a differential pressure through the channel 9 in the cavity 10 injected. The amount and the differential pressure in the created cavity in the injected structural adhesive are dimensioned such that the cavity 10 up to the openings 5 or vents of the insert 3 almost completely filled with structural adhesive, the latter, however, not from the opening 5 exit. It can by the structural adhesive in the channel 9 and in the cavity 10 displaced air over the openings 5 of the depositor 3 or by the lightweight component components 3 . 4 jointly designed vents 5 escape. The each other in the area of the cavity 10 opposite outer contours 12 . 13 the lightweight component components 3 . 4 are thereby wetted by the structural adhesive and thus form splices 12 . 13 from where the depositor 3 with the reinforcing structure 4 is glued.

The 2 and 3 show in a cross-sectional view schematically each a part of another embodiment of the component set according to the invention 2 , where in 2 both the access 6 as well as the vent 5 through two openings in the reinforcing structure 4 are trained and in 3 the vent 5 through a spout between the depositor 3 and the reinforcing structure 4 is trained. At all through 1 to 3 shown embodiments is preferably provided that on the vent 5 a negative pressure in the cavity 10 is generated to promote its filling with adhesive and at the same time air pockets within the cavity 10 especially safe to avoid. Furthermore, the by 1 to 3 shown vents 5 alternatively as access 6 and the latter serve as vents when over the vents 5 an adhesive is injected.

4 schematically shows a simplified casting tool 14 with an upper mold half 15 and a lower mold half 16 , what a 4 are shown in their closed position, in which they one through an insert 3 made of sheet steel and an already cast reinforcing structure 4 limit mold cavity filled with magnesium. Before the reinforcing structure 4 as in 4 has been cast, became the depositor 3 in the open state of the casting tool 14 in the upper half of the mold 15 used and everywhere coated with a coating, not shown, where the insert 3 not on the upper half of the mold 15 is applied. The coating, which consists of a boron nitride material, prevented during the subsequent casting of the reinforcing structure 4 and their cooling a connection of the steel sheet of the insert 3 and the magnesium of the reinforcing structure 4 , After depositor 3 and reinforcing structure 4 In the manner described above, they can be glued together according to the invention. This can be done either in the casting tool 14 done, or only after the lightweight components 3 . 4 from the casting tool 14 were removed.

5 shows in a schematic partial cross-sectional view of another embodiment of the component set according to the invention 2 with a depositor 3 made of sheet steel, a reinforcing structure 4 made of an aluminum material and an adhesive 17 (Structural adhesive), with which the lightweight component components 3 . 4 glued according to the invention. The lightweight component components 3 . 4 were aligned prior to injection bonding and through a clip connector 18 of the depositor 3 fixed in the sense of a catch. The clip connector 18 is integral with the depositor 3 connected and clamp-shaped, so that one of the in 5 illustrated free-running ends of the reinforcing structure 4 in the clip connector 18 is clamped. In this way, the lightweight components are 3 . 4 clamped together and fixed in their previously adjusted alignment to each other.

6A shows in a schematic partial cross-sectional view of another embodiment of the component set according to the invention 2 with a depositor 3 made of sheet steel, a reinforcing structure 4 made of a light metal material and another component 19 made of sheet steel, which by a riveted joint 20 with a flange area 3F of the depositor 3 connected is. The other component 19 lies on the free ends of the reinforcing rib 4R the reinforcing structure 4 and exerts on this a compressive force, so that depositors 3 and reinforcing structure 4 are clamped and thereby fixed in their intended according to the final geometry of the lightweight component position. At the height of the through the rib 4R trained access 6 has the other component 19 an opening 21 to which an injection tool, not shown, can be attached.

How out 6B can be seen, is the other component 19 partially with the free-running end of the reinforcing rib 4R bonded. In the 6B shown enlarged partial cross-sectional view cuts the in 6A shown component set a little deeper into the plane into it. In this area points the reinforcing rib 4R another indentation 11 ' and thereby forms another cavity 11 ' between her 4R and the other component 19 out. The further cavity 11 ' is with the in 6A presented access 6 , Channel 9 and the vent 5 connected, so that according to the invention injecting adhesive 17 in the cavity 11 between the depositor 3 and the reinforcing structure 4 also the further cavity 11 ' filled with adhesive, as in 6B is shown. In this way, corresponding splices of the reinforcing rib 4R and the other component 19 within the further cavity 11 ' with adhesive 17 wetted and the components mentioned 4R . 19 glued together.

7 shows in a schematic partial cross-sectional view of another embodiment of the component set according to the invention 2 with a depositor 3 made of sheet steel, a reinforcing structure 4 made of a light metal material and an additional sealing tool 22 , The latter is shaped to fit the insert 3 and the reinforcing structure 4 rests while the between the depositor 3 and the reinforcing structure 4 located cavities 10 seals from the outside.

8th shows a schematic partial cross-section of another embodiment of the component set according to the invention 2 in which two approaches 6 through both lightweight component components 3 . 4 are formed together. By 7 shown cavities 10 run free. By a correspondingly shaped nozzle of an injection tool, not shown, the injection of adhesive with simultaneous sealing of the free-running cavities 10 possible.

The 9 and 10 show in two further schematic partial cross-sections two further embodiments of the component set according to the invention 2 , with a depositor 3 made of sheet steel and a reinforcing structure 4 based on a light metal material. Here are according to 9 two cavities 10 by indentations 11 in the depositor 3 and according to 10 two cavities 10 by pairs corresponding indentations of both lightweight component components 3 . 4 educated.

The 11 to 15 show in five further schematic partial cross sections five further embodiments of the component set according to the invention 2 with spacers 23 - 26 to create a desired distance between a depositor 3 made of sheet steel and a reinforcing structure 4 from an aluminum material. According to 11 forms the depositor 3 book-like spacers 23 whereas in 12 the reinforcing structure pin-shaped spacers 24 formed. 13 shows a combination of a book-like spacer 23 of the depositor 3 and two pin-like spacers 24 the reinforcing structure 4 , In 14 are separate spacers 25 between the depositor 3 and the reinforcing structure 4 shown. According to 15 are glass balls 26 , so-called gap-filler, as a spacer in the adhesive 17 intended.

16 shows in a further schematic partial cross section a further embodiment of the component set according to the invention 2 in which, for the purpose of easier positioning, the reinforcing structure 4 made of an aluminum material a pin 27 which passes through a corresponding hole 28 in the depositor 3 made of sheet steel is inserted.

Finally, the show 17 to 20 with interrupted lines adhesive surfaces 12 on a section of the insert 3 made of sheet steel, with the adhesive surfaces shown 12 in the same way also on a reinforcing structure 4 can be provided. In 17 the adhesive surface is provided over the entire surface. According to 18 are 4 channel-shaped adhesive surfaces 12 , according to 19 3 circular adhesive surfaces 12 and according to 20 a circular, of two channel-shaped adhesive surfaces 12 overlaid adhesive surface 12 intended.

Claims (17)

Method for producing a bowl-shaped, open, thin-walled insert ( 3 ) of a first material and at least one on the inside thereof locally with the insert ( 3 ) connected rib or honeycomb reinforcing structure ( 4 ) comprising a second material comprising lightweight component ( 1 ), with the following steps: providing the inserter ( 3 ) and the reinforcing structure ( 4 ); three-dimensional positioning of the inserter ( 3 ) and the reinforcing structure ( 4 ) to each other to form a desired distance generated by at least one spacer to each other and at least one between the insert ( 3 ) and the reinforcing structure ( 4 ), a vent ( 5 ) having cavity ( 10 ); subsequent fixing of the inserter ( 3 ) and the reinforcing structure ( 4 ); Gluing the reinforcing structure ( 4 ) with the depositor ( 3 ) on the inside thereof by means of an access ( 6 ) in the at least one cavity ( 10 ) injected adhesive ( 17 ) under the intermediary of the depositor ( 3 ) and the reinforcing structure ( 4 ) only on discrete adhesive surfaces. Method according to claim 1, characterized by - inserting the inserter ( 3 ) in a mold cavity of a casting tool ( 14 ), - coating of the depositor ( 3 ) having a coating which is a material bond of the materials of the insert ( 3 ) and the reinforcing structure ( 4 ), at least in areas which form part of the remaining mold cavity of the casting tool ( 14 ) and - casting the reinforcing structure ( 4 ) in the remaining mold cavity of the casting tool ( 14 ). Method according to claim 1 or 2, characterized by fixing by means of separate clamps, at least one further component ( 19 ), Clip connector ( 18 ) of the depositor ( 3 ), Riveting, clinching or spot welding. Method according to one of the preceding claims, characterized by sealing the cavity ( 10 ) by means of - presses of inserts ( 3 ) and reinforcing structure ( 4 ), - an additional sealing tool ( 22 ) or by injecting one onto the cavity ( 10 ) adjusted amount of adhesive ( 17 ). Method according to one of the preceding claims, characterized by injecting a structural adhesive ( 17 ) with a constant or expanding volume. Method according to one of the preceding claims, characterized by providing - large area, - channel-shaped, - punctual or - channel-shaped and punctiform splices ( 12 . 13 ) within the cavity ( 10 ) to depositors ( 3 ) and / or reinforcing structure ( 4 ). Component set ( 2 ) for use in a method for producing a lightweight component ( 1 ) according to one of the preceding claims, comprising a cup-shaped, open, thin-walled insert ( 3 ) of a first material and at least one locally with the depositor ( 3 ) on the inside to be joined rib or honeycomb reinforcing structure ( 4 ) of a second material, the insert ( 3 ) and / or the reinforcing structure ( 4 ) at least one indentation ( 11 ) for the formation of an intermediate deposit ( 3 ) and reinforcing structure ( 4 ) arranged cavity ( 10 ), the at least one vent ( 5 ) and at least one access ( 6 ) for injecting an adhesive ( 17 ) for bonding the reinforcing structure ( 4 ) with the depositor ( 3 ) on the inside thereof by means of access ( 6 ) in the at least one cavity ( 10 ) injected adhesive ( 17 ) under the intermediary of the depositor ( 3 ) and the reinforcing structure ( 4 ) only on discrete adhesive surfaces. Component set ( 2 ) according to claim 7, characterized in that the insert ( 3 ) or the reinforcing structure ( 4 ) or both ( 3 . 4 ) share access ( 6 ) train. Component set ( 2 ) according to claim 7 or 8, characterized in that the insert ( 3 ) and / or the reinforcing structure ( 4 ) Spacers ( 23 to 26 ) for creating a desired spacing between inserts ( 3 ) and reinforcing structure ( 4 ) train. Component set ( 2 ) according to one of claims 7 to 9, characterized by separate spacers ( 25 . 26 ) between the depositor ( 3 ) and the reinforcing structure ( 4 ) for creating a desired spacing between inserts ( 3 ) and reinforcing structure ( 4 ). Component set ( 2 ) according to claim 10, characterized in that the separate spacers ( 26 ) in the adhesive to be injected ( 17 ) are arranged. Component set ( 2 ) according to one of claims 7 to 11, characterized in that the insert ( 3 ) and the reinforcing structure ( 4 ) corresponding pins ( 27 ) and holes ( 28 ) for positioning. Component set ( 2 ) according to one of claims 7 to 12, characterized in that the insert ( 3 ) at least one clip connector ( 18 ) for fixing with the reinforcing structure ( 4 ) trains. Component set ( 2 ) according to one of claims 7 to 13, characterized by a further component ( 19 ), which the depositor ( 3 ) and the reinforcing structure ( 4 ) in their according to the final geometry of the lightweight component ( 1 ) fixed position. Component set ( 2 ) according to claim 14, characterized in that between the further component ( 19 ) and the reinforcing structure ( 4 ) another at least partially with adhesive ( 17 ) cavity to be filled ( 11 ' ), whereby the further component ( 19 ) and the reinforcing structure ( 4R ) are glued together. Component set ( 2 ) according to one of claims 7 to 15, characterized in that the insert ( 3 ) or the reinforcing structure ( 4 ) or both ( 3 . 4 ) together the vent ( 5 ) train. Component set ( 2 ) according to one of claims 7 to 16, characterized by a sealing tool ( 22 ) with a shape suitable to the insert ( 3 ) and the reinforcing structure ( 4 ) and at least one by the depositor ( 3 ) and the reinforcing structure ( 4 ) formed cavity ( 10 ) from the outside.

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