DE102019101413A1 - Body frame element with a fiber composite hollow component - Google Patents

Abstract

The invention relates to a body frame element (1) for a motor vehicle, comprising a hollow fiber composite component (2) with a cavity (4) which runs along its longitudinal extent and is closed in the circumferential direction (U) and at least one flange (10, 10 *, 20, 20 *) for connecting vehicle components, and a method for producing such a body frame element (1, 1 *) by means of an injection molding system (60).

Description

The invention relates to a body frame element for a motor vehicle and to a method for producing such a body frame element by means of an injection molding system (resin transfer molding (RTM)).

The invention is described below in the context of roof frames of passenger vehicles, but can also be used independently of this context, in particular for other load-bearing body elements of motor vehicles to which vehicle components are to be connected.

In classic body structures of passenger vehicles, there is usually a multi-part sheet metal shell structure with high wall thicknesses and, if necessary, high-strength material grades in the area of the roof frame (in particular between the A pillar and C or D pillar). The sheet metal shells form flanges to which further vehicle components such as components of the outer or inner lining are attached.

In newer vehicles, for example, extruded aluminum profiles with flanges are inserted in a bent state. Additional shell components (such as inside / outside side frames in particular) complement the flanges of the extruded profile.

A CFRP braided component is incorporated in the RTM process in the applicant's current luxury class vehicles. The required connecting flanges are formed on additional shell components such as, for example, the outer or the inner side frame, the shell components being spaced apart and fixed to the CFRP braided component by partially introduced rigid foam.

In the DE 10 2011 003 626 B4 A method for the production of such fiber composite components, which have at least one prefabricated fiber composite shell element and at least one fiber composite hollow component, is shown, wherein the at least one fiber composite shell element is pre-assembled with the at least one fiber composite hollow component to form a structural unit which is subsequently injection molded is solidified to the fiber composite component.

Based on this, it is an object of the invention to improve a body frame element with a hollow fiber composite component and an RTM manufacturing method.

This object is achieved by a body frame element having the features of claim 1 and by a method for producing such a body frame element, in particular by means of an injection molding system, having the features of claim 11. The dependent claims relate to advantageous developments of the invention.

According to one aspect of the invention, a body frame element for a motor vehicle is provided. The body frame element has at least one hollow fiber composite component with a cavity which runs along at least part of the longitudinal extension of the high fiber composite component and is closed in the circumferential direction at least along part of the longitudinal extension. In particular, the hollow fiber composite component has a fiber composite tube.

In addition, the body frame element has at least one flange for connecting vehicle components, which is molded onto the hollow fiber composite component, in particular with a resin. In particular, the body frame element can have a plurality of flanges arranged in this way, which are in particular spaced apart from one another in the circumferential direction and / or in the longitudinal direction of the hollow fiber composite component, for example a first flange and a second flange. In the present case, a fixed molding is to be understood in particular to mean a connection which cannot be released without being destroyed.

• - Anordnen von Fasermaterial um einen Hohlbauteilkern; insbesondere wird ein Flechtling um einen Flechtkern geflochten, wobei insbesondere der Flechtkern in einer geeigneten Art und Weise ausgebildet ist, um anschließend an das Aufbringen des Flechtlings in einem Spritzpress-Verfahren verwendet zu werden. Alternativ können auch Textilbänder oder Textilmatten um den Hohlbauteilkern gewickelt werden.
• - Einlegen des Hohlbauteilkerns mit dem darum angeordneten Fasermaterial in die Kavität der Spritzpress-Anlage; insbesondere ist in der Kavität ein Einlegeplatz für den Hohlbauteilkern mit dem darum angeordneten Fasermaterial vorgesehen.
• - Anlegen von Flanschmaterial an das um den Hohlbauteilkern angeordnete Fasermaterial; insbesondere ist in der Kavität ein Einlegeplatz für Flanschmaterial an der dafür vorgesehenen Umfangs- und Längserstreckungsposition vorgesehen.
• - Durchführen des Spritzpress-Vorgangs mittels der Spritzpress-Anlage; insbesondere wird die Kavität verschlossen, Matrixmaterial mit einer geeigneten Druck- und Temperaturführung eingepresst und der Inhalt der Kavität ausgehärtet.

According to a further aspect of the invention, a method for producing a body frame element according to an embodiment of the invention, in particular by means of an injection molding plant, is provided. The method has at least the following method steps:

• - Arranging fiber material around a hollow component core; in particular, a braid is braided around a braid core, the braid core in particular being designed in a suitable manner in order to be used after the application of the braid in an injection molding process. Alternatively, textile tapes or textile mats can be wrapped around the hollow component core.
• - Inserting the hollow component core with the fiber material arranged around it into the cavity of the injection molding plant; in particular, an insertion place for the hollow component core with the fiber material arranged around it is provided in the cavity.
• - Applying flange material to the fiber material arranged around the hollow component core; in particular, an insertion place for flange material is provided in the provided circumferential and longitudinal extension position in the cavity.
• - Performing the transfer molding process by means of the transfer molding system; in particular, the cavity is closed, matrix material is pressed in with a suitable pressure and temperature control, and the contents of the cavity are hardened.

A hollow fiber composite component with molded flanges is formed. This means that separate sheet metal shells and joining processes in sub-assemblies of the body shop can be dispensed with at least in sections.

The molded flanges form connecting surfaces, in particular for roofs, panes and / or door seals. Such a body frame element can also be used in other body areas to provide connecting flanges.

According to different designs, either a fiber material can be inserted into the cavity so that the flange produced has a textile fiber element, or a suitably shaped metal sheet can be inserted so that the flange is thereby formed.

If the flange has a metal sheet, for example a steel sheet, this additionally offers the possibility of using standard joining processes in body construction (such as welding, riveting, screwing, etc.) for the integration of the hollow fiber composite component into the body structure.

The invention is based, inter alia, on the idea of not attaching the flange or flanges required for connecting further vehicle components indirectly to the hollow fiber composite component via a rigid foam spacer and a further shell component, but rather directly.

The invention is now based, among other things, on the idea of attaching flange-forming textile strips or sheet metal strips to the braiding (as a semi-finished product for the hollow fiber composite component) during transfer molding (in particular resin transfer molding (RTM)) and then resinifying and curing the braiding and the enclosed elements.

This creates a connection between the hollow fiber composite component and the enclosed elements, which is carried purely by the hardened resin. A fiber reinforcement is not formed. Any resulting weaknesses in the bending, torsional and / or shear strength (especially in relation to the corresponding strengths of the hollow fiber composite component) at the molding point can be tolerated, since those components that are to be attached to the flange generally do not have any structural forces must start from driving the motor vehicle. Rather, the components to be arranged are cladding elements such as door seals.

This applies in particular if, according to one embodiment, the body frame element is a roof frame, a side pillar or part of such a vehicle component.

Depending on the requirements for connecting additional vehicle components, according to one embodiment the flange is arranged along at least a partial area or along the entire longitudinal extent of the hollow fiber composite component. Of course, several flanges can also be arranged along different partial areas and / or partially along the entire longitudinal extent of the hollow fiber composite component.

It can also depend on the requirements for the connection of further vehicle components whether, according to one embodiment, the flange, when viewed over its longitudinal extent, is arranged at a constant or a variable circumferential position of the hollow fiber composite component.

In particular, in order to separate an exterior space and an interior space of the motor vehicle starting from the body frame element, a second flange is provided in addition to a first flange according to one embodiment, the first flange and the second flange being arranged at different circumferential positions of the hollow fiber composite component. In particular, the first flange and the second flange divide the circumference of the body frame element, possibly also the circumference of the hollow fiber composite component, into an outer circumferential region and an inner circumferential region.

So that the outer side frame does not have to be designed as an additional component, according to one embodiment, the outer circumferential region is designed as a vehicle outer skin. The outer skin of the vehicle is in particular set up to withstand external vehicle influences such as high or low temperatures, moisture, icing, dirt, etc. essentially without any visible optical change over time.

Alternatively, the body frame element can also be designed such that it supports a simple connection of an additional outer side frame. Then, according to one embodiment, an outer skin component, which is designed as a vehicle outer skin, is between the first and the second flange on the outer peripheral region arranged and optionally attached to these flanges.

According to different embodiments of the method, a fiber material and / or a metal sheet is applied as the flange material.

In order to support simple production, according to one embodiment, recesses are provided on the cavity of the injection molding plant for the application and for the resin of the flange material.

• 1 zeigt ein bekanntes Karosserierahmenelement nach der betrieblichen Praxis der Anmelderin in einer schematischen Schnittansicht.
• 2 zeigt ein Karosserierahmenelement nach einer ersten beispielhaften Ausführung der Erfindung in einer schematischen Schnittansicht.
• 3 zeigt ein Karosserierahmenelement nach einer zweiten beispielhaften Ausführung der Erfindung in einer schematischen Schnittansicht.
• 4 zeigt in einer schematischen Schnittansicht eine Spritzpress-Anlage, die zur Herstellung eines Karosserierahmenelements nach 2 entsprechend einem Verfahren nach einer beispielhaften Ausführung der Erfindung verwendet wird.

Further advantages and possible uses of the invention result from the following description in connection with the figures.

• 1 shows a known body frame element according to the operational practice of the applicant in a schematic sectional view.
• 2nd shows a body frame element according to a first exemplary embodiment of the invention in a schematic sectional view.
• 3rd shows a body frame element according to a second exemplary embodiment of the invention in a schematic sectional view.
• 4th shows in a schematic sectional view an injection molding plant, which is used to manufacture a body frame element 2nd according to a method according to an exemplary embodiment of the invention.

1 shows a schematic sectional view of a known body frame element 100 , which is installed, for example, as a roof frame element in the applicant's current luxury class vehicles.

In the sectional view shown, the plane of the drawing corresponds to a vehicle transverse plane, so that the known body frame element extends longitudinally 100 runs approximately perpendicular to the plane of the drawing and the circumferential direction can be represented in the plane of the drawing. The cutting planes of the 2-4 are applied analogously.

The well-known body frame element 100 has a hollow fiber composite component 102 on that along the length of the body frame member 100 extends, with a cavity 104 in the circumferential direction - at least in the sectional plane, but in the present known embodiment but essentially along the entire longitudinal extent - completely through the tubular fiber composite hollow component 102 is delimited.

The hollow fiber composite component 102 is manufactured by means of an injection molding process, in the present case an RTM process, starting from a wicker that has been braided around a suitable core.

In the circumferential direction around the hollow fiber composite component 102 is on an outer peripheral portion U1 an outer side frame 141 arranged. On an inner peripheral portion U2 is an inner side frame 142 arranged.

The two side frames 141 and 142 are in relation to the hollow fiber composite component 102 using a rigid foam 106 a cured foam connection positioned and thereby also to the fiber composite hollow component 102 fixed. If necessary, a further determination is made by connecting the two side frames 141 and 142 at their flanges to one another, for example by means of a riveted joint.

2nd shows a schematic sectional view of a body frame element 1 According to an exemplary embodiment of the invention, which in the present case is designed as a roof frame element, but can also be used in other applications with an analog design.

In the sectional view shown, the plane of the drawing corresponds to a vehicle transverse plane, so that the body frame element extends longitudinally 1 runs approximately perpendicular to the plane of the drawing and the circumferential direction can be represented in the plane of the drawing. The cutting planes of the 3rd and 4th are applied analogously.

The body frame element 1 has a hollow fiber composite component 2nd on that along the length of the body frame member 1 extends, in which a fiber braid is arranged in a hardened plastic matrix. Through the hollow fiber composite component 2nd is a cavity 4th in the circumferential direction U - At least in the sectional plane, but in the present exemplary embodiment along essentially the entire longitudinal extent - completely through the tubular fiber composite hollow component 2nd delimited.

Radially on the outside of the hollow fiber composite component 2nd is at a circumferential position U10 a first flange 10th arranged. In the embodiment of the 2nd is the flange 10th a fiber composite component in which fiber tapes and / or fiber mats are arranged in a hardened plastic matrix. In any case, the fiber material of the flange grips 10th and the fibers of the braid of the fiber composite hollow component 2nd at the circumferential position U10 not in one another or even spaced apart.

At one of the circumferential position U10 circumferentially spaced circumferential position U20 is radially outside of the hollow fiber composite component 1 a second flange 20 arranged. In the embodiment of the 2nd is also the flange 20 a fiber composite component in which fiber tapes and / or fiber mats are arranged in a hardened plastic matrix. In any case, the fiber material of the flange grips 20 and the fibers of the braid of the fiber composite hollow component 2nd at the circumferential position U20 not in one another or even spaced apart.

Both flanges 10th and 20 could, however, in the embodiment of the 2nd also be designed as metal sheets.

The first flange 10th and the second flange 20 divide the circumference of the body frame member 1 in an outer peripheral area U1 and an inner peripheral area U2 . On the outer peripheral area U1 is the hollow fiber composite component 2nd on the outside as a vehicle outer skin 7.2 trained, in particular resistant to influences from the surroundings of the vehicle. The outer sides of the two flanges are also in the exemplary embodiment 10th and 20 each as an outer skin 7.10 or. 7.20 educated.

At the attachment points of the two flanges 10th and 20 - to the side of the circumferential positions U10 or. U20 - Pure resin areas result from the production by means of an injection molding process 5.1 , 5.2 , 5.3 and 5.4 , in particular due to overlaps and demoulding directions to be provided on the half molds of the injection press.

3rd shows a schematic sectional view of a body frame element 1* , which is designed as a roof frame element in the present case, but can also be used in other applications with an analog design, according to a further exemplary embodiment of the invention.

The body frame element 1* has a hollow fiber composite component 2nd on that along the longitudinal extent of the body frame member 1 extends, in which a fiber plait is arranged in a cured plastic or resin matrix. Through the hollow fiber composite component 2nd is a cavity 4th in the circumferential direction U - At least in the sectional plane, but in the present exemplary embodiment along essentially the entire longitudinal extent - completely through the tubular fiber composite hollow component 2nd delimited.

Radially on the outside of the hollow fiber composite component 2nd is at a circumferential position U10 a first flange 10 * arranged. In the embodiment of the 3rd is the flange 10 * a suitably curved steel sheet which is fixed to the hollow fiber composite component by means of a hardened resin (or plastic; the two terms are used synonymously in the present case) 2nd connected is. Instead of a steel sheet, it is of course also possible to use an appropriately or analogously shaped sheet made of another iron, an aluminum, a magnesium or another suitable metal alloy.

At one of the circumferential position U10 circumferentially spaced circumferential position U20 is radially outside of the hollow fiber composite component 1 a second flange 20 * arranged. In the embodiment of the 2nd is also the flange 20 * a suitably curved steel sheet, which is fixed to the hollow fiber composite component by means of a hardened plastic or resin 2nd connected is.

Both flanges 10 * and 20 * could, however, in the embodiment of the 3rd can also be designed as metal sheets in which fiber tapes and / or fiber mats are arranged in a hardened plastic matrix.

The first flange 10 * and the second flange 20 * divide the circumference of the body frame member 1 in an outer peripheral area U1 and an inner peripheral area U2 .

In the circumferential direction around the hollow fiber composite component 2nd is on the outer peripheral portion U1 an outer side frame 40 arranged, both in the exemplary embodiment by means of a riveted connection, an adhesive connection or another suitable connection on the first flange 10 * as well as in the second flange 20 * is attached. The outer time frame 40 is designed on the outside as the outer skin of the vehicle.

4th shows in a schematic sectional view (along the sectional plane of FIG 2nd ) an injection molding machine 60 used to manufacture a body frame member 1 to 2nd according to a method according to an exemplary embodiment of the invention.

The injection molding machine 60 is set up to carry out an RTM injection molding and has an upper half shape 61 and a lower half shape 62 on.

In 4th is the injection molding machine 60 in a closed state during the curing of the matrix material with half-molds lying against one another 61 and 62 shown.

The representation of the contour cut of the two half forms 61 and 62 is only to be understood as a schematic example and is intended to clarify that First the flange material (for example fiber material or a metal sheet) and then the core wrapped with the wicker, from which the hollow fiber composite component is made during the injection molding 2nd results in the lower half form 62 can be inserted. Then the upper half shape 61 be created.

For the production of the body frame element 1 out 2nd the following process steps are carried out: arranging fiber material 63 in the form of a wicker around a hollow component core 64 ; Insert the hollow component core 64 with the fiber material arranged around it 63 into the cavity 65 the injection molding machine 60 ; Creation of flange material 66.1 , 66.2 to the around the hollow component core 64 arranged fiber material; Carrying out the injection molding process using the injection molding machine 60 , especially with feeding 67 of matrix material into the cavity 65 .

The matrix material hardens under suitable temperature and pressure conditions, which creates the body frame element. The flanges are independent of the formation of the flanges with a fiber material or with a metal sheet 10th and 20 each with the hardened resin firmly to the fiber composite hollow component 2nd connected.

Reference list

100

known body frame element

102

Hollow fiber composite component

104

cavity

141

outer side frame

142

inner side frame

1.1 *

Body frame element

2nd

Hollow fiber composite component

4th

cavity

5

Pure resin area

7

Vehicle outer skin

10, 10 *

first flange

20, 20 *

second flange

40

outer side frame

60

Injection molding machine

61

first half form

62

second half form

63

Fiber material

64

Hollow component core

65

cavity

66

Flange material

67

Feeder

U

Circumferential direction

U1

outer peripheral portion

U2

inner peripheral portion

U10

Circumferential position of the first flange

U20

Circumferential position of the second flange

QUOTES INCLUDE IN THE DESCRIPTION

This list of documents listed by the applicant has been generated automatically and is only included 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.

Patent literature cited

• DE 102011003626 B4 [0006]

Claims (14)

Body frame element (1) for a motor vehicle, comprising: - a hollow fiber composite component (2) with a cavity (4) which runs along its longitudinal extent and is closed in the circumferential direction (U), in particular a composite fiber tube, characterized by - at least one flange (10, 10 *, 20, 20 *) for connecting vehicle components, which is firmly molded onto the hollow fiber composite component (2). Body frame element according to Claim 1 , characterized in that the flange is resin-molded to the hollow fiber composite component. Body frame element according to Claim 1 or 2nd , characterized in that the flange (10, 20) has a textile fiber element. Body frame element according to Claim 1 or 2nd , characterized in that the flange (10 *, 20 *) has a metal sheet. Body frame element according to one of the preceding claims, characterized in that the flange (10, 10 *, 20, 20 *) is arranged along at least a partial region or the entire longitudinal extent of the hollow fiber composite component (2). Body frame element according to one of the preceding claims, characterized in that the body frame element (1) is a roof frame, a side pillar or part of such a vehicle component. Body frame element according to one of the preceding claims, characterized by a second flange (20, 20 *), the first flange (10, 10 *) and the second flange (20, 20 *) at different circumferential positions (U10, U20) of the hollow fiber composite component ( 2) are arranged. Body frame element according to Claim 7 , characterized in that the first flange and the second flange divide the circumference of the body frame element into an outer circumferential region (U1) and an inner circumferential region (U2). Body frame element according to Claim 8 , characterized in that the outer peripheral region (U1) is designed as a vehicle outer skin (7). Body frame element according to one of the Claims 7 or 8th , characterized in that an outer skin component (40), which is designed as a vehicle outer skin, is arranged between the first and the second flange and is fastened to these flanges on the outer peripheral region. Method for producing a body frame element (1, 1 *) according to one of the preceding claims by means of an injection molding plant (60), comprising the method steps: - arranging fiber material (63) around a hollow component core (64), Inserting the hollow component core with the fiber material arranged around it into the cavity (65) of the injection molding plant, - applying flange material (66.1, 66.2) to the fiber material arranged around the hollow component core, - Carrying out the transfer molding process using the transfer molding system. Procedure according to Claim 11 , characterized in that a fiber material is created as the flange material. Procedure according to Claim 11 , characterized in that a metal sheet is created as the flange material. Method according to one of the Claims 11 to 13 , characterized in that recesses are provided on the cavity for engaging and for resin-bonding the flange material.

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