DE102020109579A1 - Carrier for a motor vehicle and method of manufacturing a carrier - Google Patents

Abstract

The present invention relates to a support for a motor vehicle, in particular a motor vehicle pillar 1, manufactured as a shell component, at least one first shell 2 being made from a light metal alloy and a second shell being designed as an attachment 3 and the shells 2, 3 being coupled to one another, the first shell 2 formed at least lengthwise as an extruded hollow profile 5 with a closed cross-section, the first shell 2 being made in one piece and made of the same material.

Description

The present invention relates to a carrier for a motor vehicle according to the features in the preamble of claim 1. The present invention also relates to a method for producing a carrier according to the features in claim 12.

Motor vehicle bodies are known from the prior art, which are produced in particular as self-supporting bodies. Metallic materials are used as preferred materials for this purpose, steel material being very particularly preferred. In some cases, however, light metal materials, in particular aluminum, are also used.

A respective motor vehicle body is produced in particular as a self-supporting body, so that individual structural components are coupled to one another.

As an alternative or in addition, components such as cross members or longitudinal members are then additionally coupled to the body. Side impact beams are also built into a respective door.

In such a motor vehicle body, the aim is fundamentally to achieve the highest possible rigidity in order to keep the torsional rigidity of the motor vehicle body high. At the same time, however, the lowest possible dead weight should be achieved and the lowest possible use of material and low manufacturing costs should be achieved.

Another requirement for the motor vehicle body is crash safety. In addition to high torsional rigidity, the highest possible resistance to a respective vehicle crash should also be produced. A frontal crash and, in particular, a side impact are named as possible crash scenarios as examples.

For example, from the DE 10 2018 106 526 A1 the manufacture of an impact beam is known. For this purpose, a hollow profile is first extruded. This hollow profile is optionally coupled with a strike plate or another shell.

Based on the prior art, the object of the present invention is to provide a support, in particular a motor vehicle pillar, for a body of a motor vehicle, which has a particularly simple and inexpensive manufacturing option, and which can be adapted to partial crash safety requirements of the motor vehicle body and has a low dead weight owns.

The aforementioned object is achieved according to the invention with a carrier for a motor vehicle having the features in claim 1.

A procedural part of the task is achieved with the features in claim 12.

Advantageous design variants of the present invention are the subject of the dependent claims.

The carrier for a motor vehicle, the carrier being in particular a motor vehicle pillar, particularly preferably a B-pillar, is produced as a shell component.

At least one first shell is made from a light metal alloy and a second shell is designed as an attachment or also a striking plate or coupling plate. The shells are coupled to one another. The coupling is designed in particular as a materially bonded joining, very particularly preferably as welding and here in particular as spot welding. However, the shells can also be glued to one another, for example, and optionally additionally riveted to one another. If, in particular, different materials are used, so that, for example, the attachment is made from a steel alloy, then a weld riveting process can also be used. However, the first shell is made in particular from a light metal alloy and here from an aluminum alloy. In particular, ultra-high-strength aluminum alloys are used, which are very particularly preferably 6000 or 7000 aluminum alloys. The second shell is preferably also made from a light metal alloy, in particular aluminum alloy, and is then coupled to the first shell.

According to the invention, the first shell is now designed at least transversely and lengthwise as an extruded hollow profile with a closed cross-section, the first shell being produced in one piece and made of the same material. The shell has a hollow chamber in cross section at least in sections. The extrusion direction is preferably formed in the longitudinal direction of the first shell.

This means that the first shell has a hollow chamber in its own cross section. Within the scope of the invention, however, two- or three-chamber hollow profiles can also be formed in the cross section of the first shell. The extrusion thus initially produces a profile which is designed as a closed hollow profile in cross section. Subsequently, this hollow profile is particularly preferably machined, at least in sections, with a cutting operation. Here the chambers of the hollow profile are then cut out lengthwise in particular.

Alternatively or in addition, the cross section of the hollow profile can be changed. This change can take place by tapering and / or coining and / or widening. The aforementioned operations are performed lengthwise. This makes it possible to adjust the required bending stiffnesses and / or moments of inertia, in particular in the transverse direction of the vehicle and / or the longitudinal direction of the vehicle, in a targeted manner through material and / or cross-sectional geometry, changes with regard to deformation and energy absorption properties at a respective height in the vehicle vertical direction, for example in the case of a motor vehicle pillar . If, for example, a hollow profile is present, the flexural rigidity in the transverse direction of the motor vehicle (lateral direction) is higher than in the length sections in which the hollow profile is removed by cutting. However, a further lateral deformation can also be influenced. The deformation in the motor vehicle is a transverse deformation to the longitudinal direction of the motor vehicle. Here, too, a lateral deformation behavior of the carrier, in particular the motor vehicle pillar, is influenced.

This measure makes it possible to produce a shell, in particular a motor vehicle pillar, very particularly preferably a motor vehicle B-pillar, as an extrusion profile and, through subsequent processing, by means of forming and / or cutting technology, the extrusion profile is specifically designed to resist loads in the transverse direction of the vehicle and / or in the longitudinal direction of the vehicle adjust the associated crash properties. This is produced by means of plastic deformation of the extrusion profile. The reshaping and / or the trimming are preferably carried out mechanically, in particular tool-based, in the same process steps or in upstream or downstream process steps.

The first shell is then particularly preferably coupled to the attachment. Here again the attachment part can come into contact over the entire surface with the first shell or the hollow profile of the first shell by length. In cross section, the attachment with the first shell can also form a double layer, at least in sections.

The material of the first shell is particularly preferably an aluminum alloy with a yield point greater than 200 MPa. The yield strength is preferably up to 550 MPa.

So that the first shell and the attachment are coupled to one another, the first shell preferably has laterally protruding flanges.

Furthermore, particularly preferably, the wall thickness in cross section can be varied in a targeted manner by the extrusion process. For example, in the case of the flanges, a wall thickness that is smaller in cross section is possible, with a wall thickness that is relatively greater than that being provided in the area of a central section or of the hollow profile of the first shell. In the respective longitudinal direction, however, the wall thicknesses, which differ in cross-section, are homogeneous.

• - Extrudieren einer ersten Schale aus einer Leichtmetalllegierung, mit im Querschnitt zumindest einer Hohlkammer,
• - mechanisches umformtechnisches und/oder schneidetechnisches Bearbeiten der ersten Schale mit längenabschnittsweise voneinander abweichender Querschnittskonfiguration,
• - optional längenabschnittsweises Entfernen der mindestens einen Hohlkammer,
• - Bereitstellen einer zweiten Schale in Form eines Anbauteils, vorzugsweise als Umformbauteil,
• - Koppeln der ersten und zweiten Schale miteinander.

The present invention further relates to a method for producing the carrier according to the invention. The procedure is characterized by the following procedural steps:

• - Extrusion of a first shell made of a light metal alloy, with at least one hollow chamber in cross section,
• - Mechanical forming and / or cutting-related processing of the first shell with a cross-sectional configuration that differs from one another in length sections,
• - optionally removing the at least one hollow chamber lengthwise,
• - Provision of a second shell in the form of an attachment, preferably as a formed component,
• - Coupling the first and second shell to one another.

In the context of the invention, an extrusion component with at least one hollow chamber in cross section can thus initially be produced. Several hollow chambers can also be present in cross section. The wall thicknesses in the cross section itself can differ from one another. In the longitudinal direction of the extrusion profile, however, the respective wall thickness is designed to be homogeneous.

Particularly preferably, flanges protrude from the side of the first shell. The flanges can in particular serve as at least one respective coupling area with the second shell in the form of an attachment. Furthermore, however, the second shell can also be coupled to the first shell in the region of a hollow chamber.

The coupling takes place in particular in a materially bonded manner by means of a welding process, in particular a spot welding process. The coupling can, however, also be formed by an adhesive process, again preferably in combination with a weld riveting and / or riveting process.

By cutting and / or shaping the hollow profile, it is possible to create a specific moment of resistance against deformation in a targeted manner by length to adjust. The load occurs in particular in the installed state of a motor vehicle in the respective lateral direction to the carrier. In the case of a motor vehicle B-pillar, these lateral directions are both the transverse direction of the motor vehicle and the longitudinal direction of the motor vehicle and / or mixed forms of the directions described above.

• 1 einen erfindungsgemäßen Träger in Form einer Kraftfahrzeugsäule in perspektivischer Ansicht,
• 2 die erste Schale in perspektivischer Ansicht,
• 3a bis 3c verschiedene Querschnittsansichten der ersten Schale und
• 4a und 4b einen Herstellungsvorgang für eine erste Schale.

Further advantages, features, properties and aspects of the present invention are the subject of the following description. Preferred design variants are shown in schematic figures. These serve to make the invention easier to understand. Show it:

• 1 a carrier according to the invention in the form of a motor vehicle pillar in a perspective view,
• 2 the first shell in perspective view,
• 3a until 3c various cross-sectional views of the first shell and
• 4a and 4b a manufacturing process for a first shell.

1 shows a support according to the invention in the form of a motor vehicle pillar 1 in perspective view. The motor vehicle pillar 1 is made of two shells in cross section. A first bowl 2 and a second shell in the form of an attachment 3 are coupled to one another, which is shown in the cross-sectional views according to the section lines DD and EE.

The first bowl 2 itself is in again 2 shown, on the one hand on the left in a perspective view, on the right in a respective cross-sectional view according to the section lines AA, BB and CC. The first shell faces left and right 2 each flange 4th on. In a central area is a hollow profile 5 formed, which is closed in cross section. Length-wise, in the longitudinal direction 6th the first shell 2 , different cross-sections are formed from one another. In a lower area, according to section line CC, is the hollow profile 5 flattened, wherein in particular a widening is formed in the transverse direction. According to the section line BB, for example, the hollow profile 5 the original cross-sectional configuration after extrusion. According to the section line AA is the hollow profile 5 , especially the hollow chamber 8th of the hollow profile 5 , machined by cutting, so that it is no longer formed. The cross-sectional variants of the first shell produced with it 2 are again in 3a until 3c shown. The attachment 3 itself is hat-shaped in cross section and also has two outer flanges 7th on. The first bowl 2 is designed as a hollow profile in cross section and has a hollow chamber 8th on. According to the 3a is the hollow chamber 8th has been cut out by parting.

This separation process is in the 4a and 4b shown. First up is the first shell 2 produced in cross-section as an extrusion component. The hollow chamber is then created in the longitudinal direction 8th cut off lengthwise. According to 3c is the hollow chamber 8th has been flattened in cross section. It also has the first shell 2 wall thicknesses different from one another W1 , W2 on. One wall thickness W1 is greater than a wall thickness W2 . This can be made through the extrusion process. The component can also have a larger width B. are extruded, with the side flanges subsequently being machined, in particular severed. This is shown at 3c compared to 3b and 3a. The striking plate 3 itself is manufactured as a formed component and can therefore have any shape. The lateral height is preferred through a reshaping operation H across the longitudinal direction 6th progressively changed.

It can also be seen in 3c is that a double hollow chamber is formed. On the one hand is a hollow chamber 8th in the hollow profile 5 the first shell 2 educated. Second is a second hollow chamber 9 between the first shell 2 and the attachment 3 educated.

According to 3b is the motor vehicle pillar 1 then in a middle section 13th with three hollow chambers 8th , 9 , 11 educated. In particular, the first shell comes 2 in the area of the flanges 4th , on the other hand the hollow profile 5 and a web of the attachment 3 , in a contact area 10 to the system. Through the three hollow chambers formed in cross-section 8th , 9 , 11 as well as the additional contact area 10 is, in particular, a high level of rigidity in the transverse direction of the vehicle Y educated.

The cross-sectional design according to 3a represents the upper section in the installed state 12th the motor vehicle pillar 1 and extends over a maximum of 1/3 of the length, which is shown in 2 is shown.

Through the cross-sectional design according to 3b arises in the motor vehicle pillar 1 a high degree of deformation resistance with good energy absorption at the same time. In particular, the deformation resistance relates to a resistance to deformation in relation to the vehicle transverse direction Y as well as the longitudinal direction of the vehicle X . This cross-sectional shape represents the middle section 13th the motor vehicle pillar 1 over at least 1/3 of their length, or when the vehicle pillar is installed 1 about 1/3 of their height.

The cross-sectional design according to 3c represents the lower section when installed 14th the motor vehicle pillar 1 and also extends over a maximum of 1/3 of the length of the motor vehicle pillar 1 . The lower section 14th serves to connect the sill and serves as a target deformation zone for the targeted displacement of the buckling area of the motor vehicle pillar 1 in a side impact, away from the center (in relation to the vertical direction of the vehicle Z ) the motor vehicle pillar 1 further down. At the same time, this cross-section offers, among other things, its hollow chamber 8th still have a high energy absorption capacity. Depending on the requirements and type of vehicle (e.g. electric vehicle), the hollow profile 5 also be less compressed or have only slightly concave or convex side walls (indentation or bulge). The cross-sectional view is shown as an example in a section line.

Longitudinal 6th the motor vehicle pillar 1 the different cross-sections then flow into one another. In a respective section 12th , 13th , 14th the cross-sections can also differ from one another in the longitudinal direction. However, the differences in the cross-sections within a section are small.

Both shells are in the flanges with one another, but also in the contact area 10 joined, in particular welded and / or glued.

List of reference symbols

1

Automotive pillar

2

first shell

3

Attachment

4th

Flange to 2

5

Hollow profile

6th

Longitudinal direction

7th

Flange to 3

8th

Hollow chamber

9

second hollow chamber

10

Contact area

11

third hollow chamber

12th

upper section

13th

middle section

14th

lower section

B.

broad

H

height

X

Longitudinal direction of the vehicle

Y

Vehicle transverse direction

Z

Motor vehicle vertical direction

W1

first wall thickness

W2

second wall thickness

QUOTES INCLUDED IN THE DESCRIPTION

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

Patent literature cited

• DE 102018106526 A1 [0007]

Claims (13)

Carrier for a motor vehicle, in particular a motor vehicle pillar (1), made as a shell component, at least one first shell (2) being made from a light metal alloy and a second shell being designed as an attachment (3) and the shells (2, 3) being coupled to one another , characterized in that the first shell (2) at least lengthwise and optionally within a cross section as an extruded hollow profile (5) closed in cross section with one or more chambers, wherein the first shell (2) is made in one piece and made of the same material. Carrier after Claim 1 , characterized in that the beam is a longitudinal beam, roof frame, cross beam or side impact beam. Carrier after Claim 1 or 2 , characterized in that the hollow profile (5) has a laterally varying width (B) and / or has a laterally varying height (H). Carrier according to one of the preceding claims, characterized in that the hollow profile (5) is shaped lengthwise and this reshaping takes place mechanically. Carrier according to one of the preceding claims, characterized in that the hollow profile (5) is widened lengthwise in sections. Carrier according to one of the preceding claims, characterized in that the hollow profile comes into contact over the entire surface with the attachment part (3), at least in sections. Carrier according to one of the preceding claims, characterized in that the first shell (2) has a yield point greater than 200 MPa. Carrier according to one of the preceding claims, characterized in that the attachment (3) and the hollow profile (5) form a hollow body, in particular a multiple hollow chamber, at least in sections of length. Carrier according to one of the preceding claims, characterized in that the first shell (2) has two laterally protruding flanges (4). Carrier according to one of the preceding claims, characterized in that the first shell (2) has wall thicknesses (W1, W2) which are homogeneous in the longitudinal direction (6). Carrier according to one of the preceding claims, characterized in that the first shell (2) has wall thicknesses (W1, W2) that are different from one another in cross section. Method for producing a carrier according to the features in Claim 1 , characterized by the following process steps: - extrusion of a first shell (2) from a light metal alloy, with at least one hollow chamber (8) in cross-section, - mechanical forming and / or cutting processing of the first shell (2) with a cross-sectional configuration that differs from one another in length sections, - optional Removing the at least one hollow chamber (8, 9) lengthwise, providing a second shell in the form of an attachment (3), preferably as a forming component, coupling the first and second shell to one another. Procedure according to Claim 12 , characterized in that the geometric fit of the contact areas (10), in particular the contact surfaces of the first shell (2), is carried out during the mechanical forming.

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