DE102016222435B4 - Sandwich element, load-bearing structure and vehicle - Google Patents

Abstract

Sandwich element (100), comprising:
a core (120) comprising a plurality of core modules (122);
two cover layers (118) covering the core (120),
wherein at least one of the cover layers (118) extends along a plurality of core modules (122) of the core (120),
wherein the core modules (122) at least approximately completely fill an intermediate space (126) of the sandwich element (100) formed between the two cover layers (118),
wherein the core modules (122) are connected in a puzzle-like manner and
wherein one of the cover layers (118) has an opening through which a core module (122) extends out of the gap (126).

Description

The present invention relates to a sandwich element which can be used, for example, as part of a supporting structure in a vehicle.

Sandwich elements are known, for example, from the following publications: DE 10 2007 026 296 A1 ; EP 1 072 396 A2 ; DE 10 2014 018 081 A1 ,

The present invention has for its object to provide a sandwich element, which is simple in construction and stable.

This object is achieved by a sandwich element with the features of claim 1.

Because at least one of the cover layers extends along a plurality of core modules of the core, the sandwich element may preferably be manufactured in a modular manner using a plurality of core modules. The at least one cover layer, which extends along a plurality of core modules of the core, preferably allows an increased stability of the sandwich element and / or a high variability with respect to the basic properties of the sandwich element.

The at least one cover layer, which extends along a plurality of core modules of the core, is in particular substantially continuous and / or in one piece.

It may be advantageous if the core modules have integrated connection sections, by means of which the core modules are connected or connectable to one another.

In particular, it can be provided that the core modules have complementary border areas.

The core modules are puzzle-like in one another or ineinanderzufügbar. The core modules preferably overlap one or more times. In particular, it can be provided that the core modules a) partially or completely and / or b) overlap one or more times and / or c) horizontally and / or vertically.

It may be favorable if plug-in connections for connecting the core modules are formed by means of the integrated connection sections of the core modules.

In one embodiment of the invention can be provided that the core modules are positively, non-positively and / or materially connected to each other.

For example, a connection of the core modules can be provided by means of one or more screw connections.

One or more screw elements of the screw connection preferably extend in each case through two or more adjoining edge regions of two or more mutually adjacent core modules.

The core modules fill at least approximately completely an intermediate region of the sandwich element formed between the two cover layers.

The core modules extend in particular in a thickness direction from one of the cover layers to a further or next cover layer.

The core preferably comprises a plurality of identically designed core modules.

Alternatively or additionally, it may be provided that the core comprises a plurality of core modules, which differ from each other in terms of their nature, their size, their shape, their mechanical properties, their rigidity, their stability and / or their material.

The core is preferably formed homogeneous or inhomogeneous.

Alternatively or additionally, directed core modules can be provided.

One or more core modules of the sandwich element are preferably designed as cast products, in particular die-cast products or injection-molded products.

Furthermore, it can be provided that one or more core modules of the sandwich element are designed as 3D printed products.

One or more core modules of the sandwich element are preferably formed from a metallic material and / or from a plastic material and / or from a natural material, in particular wood, or comprise a metallic material and / or a plastic material and / or a natural material, in particular wood.

It may be favorable if the sandwich element is plate-shaped, planar and / or planar, for example extending along a plane.

Furthermore, it can be provided that the sandwich element is formed in three dimensions.

In particular, the sandwich element can be curved in three dimensions.

Preferably, the sandwich element has at least approximately a constant thickness.

The thickness is in particular the locally shortest distance between the two opposite outer sides of the two cover layers.

It can be advantageous if the sandwich element does not comprise planar, curved or otherwise shaped surfaces, cover layers and / or core modules.

The cover layers are preferably curved or planar plate-shaped elements.

Preferably, one or both cover layers may be formed as a cast product, in particular die-cast product or injection-molded product, or as a 3D printed product.

For example, a production in a pressing process, in particular a transfer molding process (Resin Transfer Molding process) may be provided.

Furthermore, it can be provided that one or both cover layers are formed as a sheet or a film, for example of a metallic material and / or a plastic material.

One or more core modules preferably each comprise one or more channels for receiving and / or guiding lines, cables and / or one or more fluids.

It may be favorable if the one or more channels are formed by one or more recesses or recesses on a side of the respective core module facing a cover layer. In particular, one or more connections may be provided for the one or more channels on and / or in the cover layer.

Furthermore, it can be provided that one or more channels of the one or more core modules is arranged completely within the one or more core modules. This one or more channels are then in particular completely surrounded by the material of the one or more core modules.

The sandwich element preferably further comprises one or more energy absorbers and / or predetermined breaking points, which are in particular part of one or more core modules and / or one or both cover layers or arranged and / or formed thereon.

The sandwich element according to the invention is particularly suitable for use as part of a supporting structure.

The present invention therefore also relates to a load-bearing structure which comprises one or more structural components which are designed as sandwich elements according to the invention.

In particular, the load-bearing structure according to the invention has one or more of the features and / or advantages described in connection with the sandwich element according to the invention.

It may be favorable if the load-bearing structure comprises an edge element or end element for the lateral delimitation of one or more structural components. The edge element or closing element preferably has a connecting portion, which is designed to be complementary to a connecting portion of one or more core modules.

One or more edge elements or one or more end elements are thus preferably connectable to one another by means of the same connection mechanism as the one or more core modules.

On the other hand, the one or more edge elements or the one or more end elements on the one hand and the one or more core modules on the other hand can be plugged into one another and / or otherwise connected to one another, for example screwed together.

An edge element or end element is in particular a side skirts or cross members or longitudinal members of a vehicle.

An edge element or final element can be, for example, a cast product, in particular a die-cast product or injection-molded product, or a 3D printed product.

The supporting structure may in particular be part of a vehicle.

The present invention therefore also relates to a vehicle comprising a supporting structure according to the invention.

The vehicle is in particular a land vehicle, a watercraft or an aircraft.

Preferably, the vehicle is a road-bound land vehicle, in particular a motor vehicle, for example a passenger car or truck.

The vehicle according to the invention preferably comprises one or more of the features and / or advantages described in connection with the sandwich element according to the invention and / or the supporting structure according to the invention.

It can be favorable if one or more structural components of the supporting structure constructed as sandwich elements form a vehicle floor, a vehicle roof, a side panel, a vehicle front and / or a vehicle rear of the vehicle.

The core modules of the core of one or more sandwich elements are in particular modular manner connected to each other.

Preferably, both cover layers are formed such that they extend along a plurality of core modules, in particular along all core modules, of the core.

The core modules are preferably load-bearing and / or force-transmitting connectable or connected to one or more edge elements or end elements of a supporting structure.

The core modules preferably have mutually different individual and / or locally varying properties.

Preferably, the core modules are modular combined with each other arbitrarily.

• - eine integrierte Fluidführung;
• - eine integrierte Kabelführung;
• - Gewährleistung der Steifigkeit, beispielsweise bei Beanspruchung auf Biegung und Torsion;
• - Ermöglichung der Energieumwandlung, insbesondere im Crashfall;
• - Bereitstellung einer Dämpfungswirkung, beispielsweise mit akustischer und/oder thermischer Wirkung oder zur Reduktion von Geräuschen, Vibrationen und Rauheit (NVH, Noice Vibration Harshness);
• - eingegossene und/oder integrierte Steckverbindung, insbesondere für signaltechnische Anschlüsse;
• - Basis oder Bestandteil eines Sitzquerträgers;
• - Kraftübertragung durch Bereitstellung von geeigneten Lastpfaden;
• - Anbindung an umliegende Struktur;
• - Anbindung und/oder Verbindung der modularen Bestandteile oder Bauteile untereinander;
• - Bereitstellung einer Absorberstruktur;
• - kostengünstige Herstellung von Gleichteilen;
• - variable Einsatz- und Verwendungsmöglichkeiten;
• - Eignung für zahlreiche Derivate und ein oder mehrere Baukastensysteme;
• - lastpfadgerechte Ausgestaltung trotz bestehender Modularität.

The sandwich element, in particular the core, for example the core modules, preferably offer one or more or all or the following functions and / or advantages:

• - An integrated fluid guide;
• - an integrated cable guide;
• - ensuring rigidity, for example when bending and twisting;
• - Enabling energy conversion, especially in the event of a crash;
• - Providing a damping effect, for example, with acoustic and / or thermal effect or to reduce noise, vibration and harshness (NVH, Noice Vibration Harshness);
• - Molded and / or integrated connector, especially for signaling connections;
• - base or component of a seat cross member;
• - Power transmission by providing suitable load paths;
• - connection to surrounding structure;
• - Connection and / or connection of the modular components or components with each other;
• - provision of an absorber structure;
• - cost-effective production of identical parts;
• - variable uses and uses;
• - suitability for numerous derivatives and one or more modular systems;
• - Lastpfadgerechte design despite existing modularity.

The core modules are preferably inserts, which in particular are freely combinable with each other.

As a plastic material, if one or more cover layers and / or one or more core modules are formed from a plastic material, for example, fiber-reinforced plastic, in particular glass fiber reinforced plastic and / or carbon fiber reinforced plastic, may be provided.

As metal casting material for producing one or more cover layers and / or one or more core modules, for example magnesium and / or aluminum or an alloy thereof can be provided.

The core of the sandwich element preferably has a topology optimization.

By configuring the core of a plurality of core modules, zones of the core can preferably be formed by different core modules.

Preferably, a lightweight construction of the sandwich element is possible in which predetermined load path profiles are mapped near an optimum by means of suitable core module selection.

Various sandwich elements are preferably also produced with a high common part number.

A force is preferably applied equally and / or simultaneously in one or both cover layers and / or one or more core modules of the core.

It may be favorable if the core of the sandwich element and / or one or more Cover layers glued to a closing element or edge element or otherwise connected cohesively.

Furthermore, it can be provided that the cover layers and the core, in particular the plurality of core modules, are glued together or otherwise materially connected to one another.

It can also be provided that the core modules are interconnected by means of an adhesive bond or otherwise cohesively.

It may be favorable if one or more cover layers and / or one or more core modules, in particular the core as a whole, are designed to be variable in thickness.

In particular, varying material thicknesses and / or thicknesses can be provided along a longitudinal extent and / or along a transverse extent of one or more cover layers and / or one or more core modules, in particular of the core as a whole.

In particular, despite a material thickness variation and / or thickness variation, flat sandwich elements and / or sandwich elements with a total of constant material thickness / thickness can be formed.

By using varying thicknesses and / or material thicknesses, for example, for vehicles with identical or similar dimensions, different mechanical properties, for example load limit values and / or ground stiffness values, etc., can be obtained.

Preferably, by varying thicknesses and / or material thicknesses, mechanical effects can be achieved for the sandwich elements and / or set in a targeted manner.

Further preferred features and / or advantages of the invention are the subject matter of the following description and the drawings of exemplary embodiments not according to the invention.

• 1 einen schematischen Schnitt durch eine erste Ausführungsform eines Sandwichelements, welches zwei miteinander verbundene Kernmodule umfasst, die von durchgängigen Decklagen abgedeckt sind;
• 2 eine der 1 entsprechende schematische Darstellung eines Randbereichs eines Sandwichelements, in welchem dieses mit einem Abschlusselement oder Randelement einer tragenden Struktur verbunden ist;
• 3 eine schematische Draufsicht auf ein Sandwichelement, welches ein herausragendes Kernmodul zur Komponentenanbindung umfasst;
• 4 einen schematischen Schnitt durch das Sandwichelement aus Fig. 3 längs der Linie 4-4 in 3;
• 5 bis 8 verschiedene Varianten von Sandwichelementen, welche unter Verwendung möglichst vieler baugleicher Kernmodule herstellbar sind.

In the drawings show:

• 1 a schematic section through a first embodiment of a sandwich element, which comprises two interconnected core modules, which are covered by continuous cover layers;
• 2 one of the 1 corresponding schematic representation of an edge region of a sandwich element, in which this is connected to a closing element or edge element of a supporting structure;
• 3 a schematic plan view of a sandwich element, which comprises an outstanding core module for component connection;
• 4 a schematic section through the sandwich element of FIG. 3 along the line 4-4 in 3 ;
• 5 to 8th Various variants of sandwich panels, which can be produced using as many identical core modules.

Identical or functionally equivalent elements are provided with the same reference numerals in all figures.

An in 1 illustrated first embodiment of a designated as a whole with 100 sandwich element is for example a structural component 102 a supporting structure 104 ,

The sandwich element 100 can be used in particular as part of a vehicle 106.

The sandwich element 100 can, for example, a vehicle floor 108, a vehicle roof 110 , a side panel 112 , a vehicle front 114 and / or a vehicle rear 116 form or be part of it.

The sandwich element 100 preferably comprises two cover layers 118 between which a core 120 is arranged.

The core 120 of the sandwich element 100 includes several core modules 122 , which by means of connecting sections 124 the core modules 122 interconnected or connectable.

The connecting sections 124 the core modules 122 are preferably formed complementary to each other, so that the core modules 122 in particular puzzle-like inserted into each other and thereby can be connected to each other. Alternatively or additionally, a connection can be provided by positive locking, frictional connection and / or engagement, for example by means of snap hooks.

The one from the core modules 122 formed core 120 fills one between the cover layers 118 formed gap 126 preferably substantially completely off or on.

It may further be provided that one or more core modules 122 a recess 128 have, whereby in particular a channel 130 in the one or more core modules 122 is formed. Alternatively or additionally, it can be provided that one or more channels 130 in the manufacture of the sandwich element 100 be integrated into it.

The channel 130 For example, it is used to guide lines 132 , in particular signal lines or fluid lines, etc.

As 1 it can be seen, the cover layers extend 118 at the in 1 illustrated embodiment of the sandwich element 100 consistently through the core modules 122 away, so especially in the area of the connecting section 124 continuous cover layers 118 are provided. This can increase the stability of the sandwich element 100 when using multiple core modules 122 for the production of the core 120 be guaranteed.

This in 1 illustrated sandwich element 100 can be prepared, for example, as follows:

For example, the core modules 122 be connected to each other, in particular inserted into each other and / or locked together.

Before, during or subsequently, for example, lines 132 into the recess 128 of the one or more core modules 122 appropriate.

Finally, the two cover layers 118 on opposite sides of the core 120 set, causing the channel 130 closed and ultimately the sandwich element 100 is completed.

An in 2 illustrated second embodiment of a sandwich element 100 is adjacent, for example, to a closure element 134 or edge element 136 a supporting structure 104 at.

The final element 134 or edge element 136 may be formed, for example, in a shell construction.

The final element 134 or edge element 136 is preferably at least partially complementary to a connecting portion 124 a core module 122 of the core 120 of the sandwich element 100 educated.

The core module 122 especially on the closing element 134 or edge element 136 be plugged.

For additional anchoring, for example, a screw 138 may be provided.

A screw element 140 the screw connection 138 preferably extends through the connecting portion 124 of the core module 122 as well as through a section of the closing element 134 or boundary element 136 through, in order to ultimately ensure, for example, a form-fitting and / or frictional determination.

Optionally, in addition, a bonding of the core module 122 and / or the topsheets 118 on the one hand with the final element 134 or edge element 136 on the other hand be provided.

The final element 134 or edge element 136 is for example a side sill 142 , a crossbeam 144 and / or a side member 146 of a vehicle 106 which is the supporting structure 104 includes.

By the possibility of connecting the core module 122 of the core 120 with the conclusion element 134 or edge element 136 in particular, a power transmission directly from the core 120 on the final element 134 or edge element 136 or vice versa. The cover layers 118 , which are then down to the final element 134 or edge element 136 extend or even can end before, are then only optionally provided for stiffening.

Preferably, the termination element 134 or edge element 136 provided with a force-transmitting filling, so that in particular a force distribution, power transmission and / or power transmission from the end element 134 or edge element 136 directly to the core 120 is possible or done.

Incidentally, the in 2 illustrated second embodiment of the sandwich element 100 in terms of structure and function with the in 1 illustrated first embodiment, so that reference is made to the above description in this respect.

One in the 3 and 4 illustrated third embodiment of a sandwich element 100 is different from the one in 1 shown first embodiment essentially in that a core module 122 from the gap 126 between the two cover layers 118 protrudes.

One of the top layers 118 thus includes an opening 148 through which the core module 122 from the gap 126 extends out.

Such an outstanding core module 122 For example, for mounting other components on the sandwich element 100 be provided.

The outstanding core module 122 may for example be part of a one-piece or one-piece core module 122 be.

Alternatively, it may be provided that a protruding element on a completely in the space 126 arranged core module 122 fixed or definable. This can be advantageous, for example, if the sandwich element 100 is used on different vehicle models and a modular design, for example, a uniform vehicle floor and at the same time allow the installation of different vehicle seats. In particular, different insert elements are then provided as outstanding elements for different vehicle seats, each of which is attached to a unitary core module 122 are definable.

Incidentally, the right in the 3 and 4 illustrated embodiment of the sandwich element 100 in terms of structure and function with the in 1 illustrated first embodiment, so that reference is made to the above description in this respect.

In the 5 to 8th are different variants of cores 120 of sandwich elements 100 shown.

The cores 120 are in particular from several core modules 122 formed, in particular a plurality formed as equal parts core modules 122 for producing different cores 120 are provided.

By the numbering of the individual core modules 122 the identical parts used are indicated.

According to 5 are for example two rectangular core modules 122 , four triangular core modules 122 as well as two trapezoidal core modules 122 intended.

By suitable arrangement of the core modules 122 This results in particular in a total component, which is formed, for example, substantially rectangular.

According to 6 are core modules 122 each provided with a rectangular shape in two different sizes.

According to 7 can the core 120 in comparison to the core 6 thereby extending in one direction that two more core modules 122 be supplemented.

According to 8th is, for example, an elongated additional core module 122 provided, which two rows of five rectangular core modules 122 connects with each other.

The in the 5 to 8th illustrated variants of cores 120 are examples of flexibility in the manufacture of sandwich panels 100 if their cores 120 from several core modules 122 getting produced.

In particular, through the use of many identical parts numerous different variants of sandwich elements 100 be prepared without having to rely on a single order for every conceivable deviation.

The in the 5 to 8th represented cores 120 are especially on both sides of cover layers 118 surrounded to ultimately the sandwich elements 100 manufacture.

LIST OF REFERENCE NUMBERS

100

sandwich element

102

structural component

104

carrying structure

106

vehicle

108

vehicle floor

110

vehicle roof

112

side panel

114

vehicle front

116

vehicle rear

118

topsheet

120

core

122

core module

124

connecting portion

126

gap

128

recess

130

channel

132

management

134

termination element

136

Boundary element

138

screw

140

screw

142

side skirts

144

crossbeam

146

longitudinal beams

148

opening

Claims (13)

Sandwich element (100), comprising: a core (120) comprising a plurality of core modules (122); two cover layers (118) covering the core (120), wherein at least one of the cover layers (118) extends along a plurality of core modules (122) of the core (120), wherein the core modules (122) at least approximately completely fill an intermediate space (126) of the sandwich element (100) formed between the two cover layers (118), wherein the core modules (122) are connected in a puzzle-like manner and wherein one of the cover layers (118) has an opening through which a core module (122) extends out of the gap (126). Sandwich element (100) after Claim 1 characterized in that the core modules (122) have integrated connection portions (124) by means of which the core modules (122) are interconnected. Sandwich element (100) according to one of Claims 1 or 2 , characterized in that the core modules (122) are positively, non-positively and / or materially connected to each other. Sandwich element (100) according to one of Claims 1 to 3 , characterized in that the core modules (122) at least approximately completely fill the intermediate space (126) formed between the two cover layers (118) of the sandwich element (100). Sandwich element (100) according to one of Claims 1 to 4 , characterized in that the core (120) comprises a plurality of identically formed core modules (122). Sandwich element (100) according to one of Claims 1 to 5 , characterized in that the core (120) comprises a plurality of core modules (122), which differ from each other in terms of their nature, their size, their shape, their mechanical properties, their rigidity, their stability and / or their material. Sandwich element (100) according to one of Claims 1 to 6 , characterized in that one or more core modules (122) of the sandwich element (100) are formed as cast products, in particular die cast products or injection molded products. Sandwich element (100) according to one of Claims 1 to 7 , characterized in that one or more core modules (122) of the sandwich element (100) are formed as 3D printed products. Sandwich element (100) according to one of Claims 1 to 8th characterized in that one or more core modules (122) each comprise one or more channels (130) for receiving and / or guiding conduits (132), cables and / or a fluid. A supporting structure (104) comprising one or more structural components (102), which are used as sandwich elements (100) according to one of the Claims 1 to 9 are formed. Carrying structure (104) after Claim 10 , characterized in that the supporting structure (104) comprises an edge element (136) or end element (134) for laterally delimiting one or more structural components (102), wherein the edge element (136) or end element (134) has a connecting portion (124) which is complementary to a connecting portion (124) of one or more core modules (122). A vehicle (106) comprising a support structure (104) according to any one of Claims 10 or 11 , Vehicle (106) to Claim 12 , characterized in that one or more than the sandwich elements (100) formed structural components (102) of the supporting structure (104) a vehicle floor (108), a vehicle roof (110), a side trim (112), a vehicle front (114) and / or forming a vehicle rear end (116) of the vehicle (106).

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