DE102021118538A1 - Frame component for a motor vehicle - Google Patents

Abstract

The invention relates i.a. a frame component (10) for a motor vehicle, having a tubular plug-in area (12) for plugging into a further frame component (34). The tubular plug-in area (12) is arranged at one end of the frame component (10). The tubular plug-in area (12) extends along a central axis (M). The male tubular portion (12) has a plurality of opposed side walls (16, 18, 20, 22) that are substantially planar and a plurality of transition walls (24, 26, 28, 30), each two adjacent, at an angle < 180° mutually oriented side walls of the plurality of side walls (16, 18, 20, 22) interconnect and are recessed towards the central axis (M).

Description

The invention relates to a frame component for a motor vehicle with a tubular plug-in area for plugging into another frame component. The invention also relates to a frame assembly for a motor vehicle. The invention also relates to a motor vehicle.

In commercial vehicle construction, especially in buses, hollow profiles or tubular supports are predominantly used to construct a vehicle lattice frame. The hollow profiles are assembled into a frame structure. The hollow profiles can, for example, be designed as square profiles.

The connection of the hollow profiles is usually done with thermal joining methods, mainly gas metal arc welding. The connections are usually designed as a butt joint. External load introductions can lead to high loads on the weld seams. For the joining process, the components must first be aligned and clamped in order to ensure a defined alignment with one another. Any deviations can have a negative impact on the load-bearing capacity of the joining zone. In addition, the use of gas metal arc welding processes has the disadvantage that the use of high-strength materials is restricted, since the thermal influence during the joining process has a negative effect on them.

From the DE 10 2008 003 719 A1 a skeleton construction of a bus is known. Cast or forged multi-armed nodes are used in the skeleton construction, on the outer ends of which metal profile elements can be fastened. One end of the metal profile element to be welded to the arm end is slipped over the arm end.

the US 6,276,111 B1 discloses a structural connection assembly comprising a pair of four-sided elongated hollow members. One end of one of the elements is buckled. The upset end of one element and the non-upset end of the other element are telescopically disposed relative to each other and the two elements are connected together.

the US 9,988,093 B2 discloses a vehicle body exoskeleton comprising a plurality of nodes each defining a socket. A plurality of tubes have first and second end portions that are smaller than and taper inwardly from a main portion. Each end section is recorded in one of the recordings. An adhesive is applied to the end sections and fills a gap defined between the sockets and the end sections to bond the tubes and sockets.

The invention is based on the object of creating an improved frame component with which a joining process with a further frame component can preferably be improved, with the technology also being usable particularly preferably with a frame component made of a high-strength material.

The object is achieved by the features of independent claim 1. Advantageous developments are specified in the dependent claims and the description.

One aspect of the present disclosure relates to a frame component for a motor vehicle (e.g. for a space frame of a motor vehicle). The frame component has a tubular plug-in area for plugging into another frame component. The tubular plug-in area is arranged at one (e.g. free) end of the frame component. The tubular mating portion extends along a central axis. The tubular plug portion has a plurality of side walls that are opposed to each other and are generally planar. The tubular plug-in area has a plurality of transition walls, which each connect two adjacent side walls of the plurality of side walls which are oriented at an angle of <180°, preferably at an angle of essentially 90°, and are recessed towards the central axis.

The frame component can advantageously be connected to the further frame component in a simple manner by means of the plug-in area. The design of the plug-in area can enable the two frame components to be held securely together and at the same time be easy to produce, e.g. B. by forming an end portion of the frame member. Additionally, the recessed transition wall can reinforce or stiffen a structure of the male component. Preferably, the recessed transition wall can also be used to ensure that the frame component and the further frame component can be joined together particularly effectively and securely, e.g. B. by introducing adhesive into the recesses of the transition walls. A further advantage can result from the fact that clamping systems that may be required for aligning the frame component and the further frame component can be dispensed with, since they can be fixed or positioned relative to one another by the plug-in connection. The push-on connection advantageously enables the use of different joining technologies, such as thermal but also adhesive and mechanical joining methods. Also are Hybrid joining process possible. In particular, the use of adhesive, also in combination with thermal and mechanical joining processes, offers the advantage that high-strength materials can also be used, since the joining can take place without or at least only with little heat input.

The plug-in area and/or the frame component can preferably be three-sided, four-sided or five-sided, etc. For example, the mating area can be n-sided and have n side walls, with n ≥ 3.

In one embodiment, the plurality of transition walls are grooved or channeled (e.g., toward the central axis). Alternatively or additionally, the plurality of transition walls have a V-shaped or U-shaped cross-section (e.g., in a plane perpendicular to the central axis). On the one hand, these shapes advantageously allow particularly effective stiffening or reinforcement in the plug-in area. These forms can preferably support the subsequent joining (eg applying adhesive to the side walls and/or introducing adhesive into the recess or soldering or welding in the recesses). Preferably, these shapes can also be particularly suitable for reducing the cross section of the frame component uniformly and over the entire circumference in an end area to create the plug-in area.

In another embodiment, the plurality of transition walls extend substantially parallel to the central axis, and/or the plurality of transition walls face each other. A plug-in area that is particularly easy to implement can thus advantageously be provided.

In another embodiment, a number of the plurality of sidewalls and a number of the plurality of transition walls are the same, and preferably is four.

The plug-in area can preferably be mirror-symmetrical with respect to a central plane through the central axis and/or n-fold rotationally symmetrical about the central axis (e.g. 3-fold, 4-fold or 5-fold rotationally symmetrical).

In another embodiment, the plurality of sidewalls and the plurality of transition walls are each alternately arranged (e.g., in a circumferential direction about central axis M).

In a further exemplary embodiment, the tubular plug-in area is essentially designed as a polygonal tube, preferably a square tube, with the multiple transition walls in (e.g. longitudinal) edge sections (or corner sections) of the polygonal tube. This can advantageously enable the plug-in area to be manufactured simply, since it can simply be derived, for example, from a polygonal hollow profile, e.g. B. by forming.

In one embodiment, the multiple transition walls merge into the two adjacent side walls in a rounded manner, preferably with an arc angle (e.g., inside) of <90°. Alternatively or additionally, the multiple transition walls each have a rounded bottom section, which preferably has a (eg internal) arc angle <90°, particularly preferably <45°. Stress peaks in the material can thus advantageously be prevented and improved load paths through the plug-in area can be made possible. Improved centering of the additional frame component on the plug-in area can also be advantageously achieved in this way.

In another embodiment, the plurality of sidewalls includes a first sidewall, a second sidewall, a third sidewall, and a fourth sidewall. The first sidewall and the third sidewall are substantially parallel. The second sidewall and the fourth sidewall are substantially parallel.

In another embodiment, the plurality of transition walls includes a first transition wall, a second transition wall, a third transition wall, and a fourth transition wall. The first transition wall connects the first and second sidewalls together (e.g., with respect to a circumferential direction about the central axis). The second transition wall connects the second and third sidewalls together (e.g., with respect to a circumferential direction about the central axis). The third transition wall connects the third and fourth sidewalls together (e.g., with respect to a circumferential direction about the central axis). The fourth transition wall connects the first and fourth sidewalls together (e.g., with respect to a circumferential direction about the central axis).

In one embodiment variant, the frame component tapers at a transition to the tubular plug-in area, preferably over the entire circumference. A smooth transition without stress peaks to the plug-in area can preferably be provided in this way, which can be produced simply by means of forming, for example.

In a further embodiment variant, the frame component also has a, preferably tubular, main body area which merges into the tubular plug-in area, preferably with a tapered area arranged between the main body area and the plug-in area of the frame component. A smooth transition towards the plug-in area can preferably be provided in this way, which can be produced simply by means of forming, for example.

In another embodiment, a cross section of the tubular plug portion, which is preferably substantially constant along the central axis, is smaller than a cross section of the main body portion, which is preferably substantially constant along the central axis.

In one embodiment, the frame component has a tensile strength of ≧750 MPa or ≧800 MPa. As mentioned, the plug-in area can be used particularly advantageously in the case of high-strength frame components, since the plug-in area allows for a large number of joining hazards that do not impair the tensile strength.

In a further exemplary embodiment, the frame component is designed as an elongate (e.g. straight or curved) beam or as a frame node for connecting a plurality of beams. The present technology can thus be used advantageously for a large number of possible frame components.

Another aspect of the present disclosure relates to a frame assembly for a motor vehicle. The frame assembly includes a frame member as disclosed herein. The frame assembly has a further frame component, preferably formed as an elongate beam or as a frame node. The frame component is inserted into the further frame component by means of the tubular plug-in area. The frame assembly can advantageously realize the advantages already described for the frame component.

In one embodiment, the frame component and the further frame component are joined together at the tubular plug-in area, preferably materially, particularly preferably by means of gluing, by means of spot welding and/or by means of soldering, and/or non-positively, particularly preferably by means of screwing. As mentioned, the plug-in area advantageously opens up a large number of possibilities for joining the frame components, which can also be used particularly advantageously with high-strength materials.

In a further embodiment, the frame component and the further frame component are joined together at the tubular plug-in area by means of gluing. An adhesive can preferably be applied to flat sections of the plug-in area (eg on the outside of the side walls of the plug-in area). Alternatively or additionally, an adhesive can preferably be introduced into the recessed transition walls and expanded and/or cured therein. On the one hand, a joining method that can be used with high-strength materials can thus be used particularly preferably. On the other hand, the special shape of the deepened transition walls can also be used advantageously for gluing.

In one embodiment variant, the main body area of the frame component and the further frame component are flush with one another, preferably over the entire circumference. Alternatively or additionally, an outer contour of the frame component and an outer contour of the further frame component are aligned with one another in a viewing direction running along the central axis. It can thus advantageously be made possible that the same semi-finished products can be used for the frame component and the further frame component. The frame component and the further frame component can have the same cross sections. The construction and design of the frame assembly can preferably also be simplified in this way.

A further aspect of the present disclosure relates to a motor vehicle, preferably a commercial vehicle (eg truck or bus). The motor vehicle includes a frame component as disclosed herein or a frame assembly as disclosed herein, preferably as part of a space frame of the motor vehicle.

Another aspect of the present disclosure relates to a method for manufacturing a frame component for a motor vehicle. The method includes providing a precursor for the frame member. The preliminary stage has a tubular end region with a polygonal shape, preferably a square shape. The method includes reducing (e.g. compressing or compressing) a cross section of the tubular end region by reshaping edge sections of the polygonal shape that extend parallel to a central axis of the tubular end region into transition walls that are recessed toward the central axis to create a plug-in region for plugging into another frame component. Advantageously, the method enables the same advantages to be achieved as already described herein for the frame member aspect. The method particularly preferably enables the plug-in area to be shaped in a simple manner by reshaping a polygonal shape. The frame component can advantageously be produced from the preliminary stage by reducing the cross section.

In one embodiment, the cross section is reduced over its entirety. This can advantageously be achieved in that the plug-in area can be plugged into another frame component Has a cross-section that matches the precursor or a main body region of the precursor adjacent to the plug-in region. The preliminary stage and the further frame component can thus advantageously be of the same type of semi-finished product or possibly even identical parts.

In a further exemplary embodiment, the forming takes place in one or more stages. Alternatively or additionally, the reshaping takes place by means of a die or a plurality of dies, which are preferably positioned one after the other in the tubular end region. The method can thus advantageously be adapted to the respective requirements and enable a process-reliable forming of the end area into the plug-in area. The matrices can prevent undesired material flow and undesired deformations during forming and at the same time specify a target geometry for a respective forming step.

In a further embodiment, the forming includes pressing the edge sections by means of at least one pressing tool against a die that is positioned in the tubular end area, with the die preferably having an outer contour that is a precursor to a desired inner contour of the plug-in area. A process-reliable forming of the edge sections towards the deepened transition areas can thus advantageously be achieved.

In a further exemplary embodiment, the reshaping also includes replacing the die in the tubular end region with a further die and pressing essentially flat side walls of the tubular end region against the further die, with the further die preferably having an outer contour that corresponds to the desired inner contour corresponds to the mating area. The plug-in area can thus advantageously be produced in a particularly process-reliable and precise manner.

In one embodiment, the forming takes place by means of hydroforming, preferably external high-pressure forming. Alternatively, the reshaping can take place, for example, by means of deep-drawing or a roller or roller tool that is rolled onto the tubular end area. Advantageously, the geometry of the plug-in area also enables other forming methods to create the plug-in area, which can be used depending on the requirement.

In a further embodiment, the forming is carried out in such a way that the recessed transition walls are recessed in the form of grooves or troughs (e.g. towards the central axis) and/or have a V-shaped or U-shaped cross section (e.g. in a plane perpendicular to the central axis). These forms can preferably support the subsequent joining (eg applying adhesive to the side walls and/or introducing adhesive into the recess or soldering or welding in the recesses). Preferably, these shapes can also be particularly suitable for reducing the cross section of the frame component uniformly and over the entire circumference in an end area to create the plug-in area.

In a further embodiment, the precursor provided is designed as an elongate, tubular beam or as a frame node for connecting a plurality of beams. The present technology can thus be used advantageously for a large number of possible frame components.

In a further embodiment, the tubular end area is reshaped in such a way that the recessed transition walls merge into two adjacent side walls of the tubular end area in a rounded manner, preferably with an (e.g. internal) arc angle <90°. Alternatively or additionally, the tubular end area is shaped in such a way that the recessed transition walls each have a rounded bottom section, which preferably has a (eg internal) arc angle <90°, particularly preferably <45°. Stress peaks in the material can thus advantageously be prevented and improved load paths through the plug-in area can be made possible. Improved centering of the additional frame component on the plug-in area can also be advantageously achieved in this way.

In one embodiment variant, the tubular end area is reshaped in such a way that the frame component tapers toward the tubular end area, preferably over the entire circumference. A smooth transition without stress peaks towards the plug-in area can preferably be provided in this way, which can be produced simply by means of forming, for example.

In a further embodiment variant, the preliminary stage and/or the frame component provided has a tensile strength of ≧750 MPa or ≧800 MPa. As mentioned, the plug-in area can be used particularly advantageously in the case of high-strength frame components, since the plug-in area allows for a large number of joining hazards that do not impair the tensile strength.

Another aspect of the present disclosure relates to a frame component made by a method as disclosed herein.

A further aspect relates to a method for producing a frame assembly for a motor vehicle. The method includes making a frame component as disclosed herein. The method also includes inserting the plug-in area of the frame component into a further frame component, preferably an elongate beam or a frame node for connecting a plurality of beams.

In one exemplary embodiment, the method also includes joining the frame component and the further frame component to the plug-in area, preferably in a materially bonded manner, particularly preferably by means of gluing, spot welding and/or soldering, and/or with a non-positive fit, particularly preferably by means of screwing. As mentioned, the plug-in area advantageously opens up a large number of possibilities for joining the frame components, which can also be used particularly advantageously with high-strength materials.

In a further exemplary embodiment, the method also includes joining the frame component and the further frame component to the plug-in area by means of gluing. An adhesive can preferably be applied to flat sections of the plug-in area (e.g. on the outside of the side walls of the plug-in area). Alternatively or additionally, an adhesive can preferably be introduced into the recessed transition walls and expand and/or harden therein. On the one hand, a joining method that can be used with high-strength materials can thus be used particularly preferably. On the other hand, the special shape of the deepened transition walls can also be used advantageously for gluing.

In one embodiment, after insertion, a main body area of the frame component adjoining the plug-in area and the further frame component are flush with one another, preferably around the entire circumference. Alternatively or additionally, after insertion, an outer contour of the frame component and an outer contour of the further frame component are aligned with one another in a viewing direction running along the central axis. It can thus advantageously be made possible that the same semi-finished products can be used for the frame component and the further frame component. The frame component and the further frame component can have the same cross sections. The construction and design of the frame assembly can preferably also be simplified in this way.

• 1 eine perspektivische Ansicht eines Rahmenbauteils gemäß einem Ausführungsbeispiel der vorliegenden Offenbarung;
• 2 eine Seitenansicht des beispielhaften Rahmenbauteils;
• 3 eine Stirnansicht des beispielhaften Rahmenbauteils;
• 4 eine perspektivische Ansicht einer Rahmenbaugruppe gemäß einem Ausführungsbeispiel der vorliegenden Offenbarung;
• 5 eine Seitenansicht der beispielhaften Rahmenbaugruppe;
• 6 eine Längsschnittansicht durch die beispielhafte Rahmenbaugruppe;
• 7 eine perspektivische Ansicht einer Vorstufe eines Rahmenbauteils gemäß einem Ausführungsbeispiel der vorliegenden Offenbarung;
• 8 eine Stirnansicht auf einen freien Endbereich der Vorstufe des Rahmenbauteils gemäß 7;
• 9 eine schematische Darstellung eines beispielhaften Verfahrensschritts zum Herstellen eines Rahmenbauteils gemäß einem Ausführungsbeispiel der vorliegenden Offenbarung, in einer Stirnansicht auf den Endbereich; und
• 10 eine schematische Darstellung eines weiteren beispielhaften Verfahrensschritts zum Herstellen eines Rahmenbauteils gemäß einem Ausführungsbeispiel der vorliegenden Offenbarung, in einer Stirnansicht auf den Endbereich bzw. den Steckbereich.

The preferred embodiments and features of the invention described above can be combined with one another as desired. Further details and advantages of the invention are described below with reference to the accompanying drawings. Show it:

• 1 a perspective view of a frame member according to an embodiment of the present disclosure;
• 2 a side view of the exemplary frame member;
• 3 an end view of the exemplary frame member;
• 4 a perspective view of a frame assembly according to an embodiment of the present disclosure;
• 5 12 is a side view of the exemplary frame assembly;
• 6 Figure 12 is a longitudinal sectional view through the example frame assembly;
• 7 a perspective view of a preliminary stage of a frame component according to an embodiment of the present disclosure;
• 8th an end view of a free end area of the preliminary stage of the frame component according to FIG 7 ;
• 9 a schematic representation of an exemplary method step for producing a frame component according to an embodiment of the present disclosure, in a front view of the end area; and
• 10 a schematic representation of a further exemplary method step for producing a frame component according to an exemplary embodiment of the present disclosure, in a front view of the end area or the plug-in area.

The embodiments shown in the figures correspond at least in part, so that similar or identical parts are provided with the same reference symbols and, for their explanation, reference is also made to the description of the other embodiments or figures in order to avoid repetition.

the 1 until 3 12 show a frame component 10. The frame component 10 is suitable for use in a motor vehicle (not shown). The frame component 10 can preferably be used as part of a lattice frame (e.g. lattice vehicle frame or lattice driver's cab frame) of the motor vehicle. Particularly preferably, the motor vehicle is a commercial vehicle such. B. a truck or a bus. The frame component 10 is preferably high-strength or made from a high-strength material, preferably a metal alloy, and has, for example, a tensile strength of ≧750 MPa or ≧800 MPa.

The frame component 10 can preferably be designed as an elongate beam. For reasons of clarity, the elongate carrier is made comparatively short in the figures. In practice, the elongate carrier can be made significantly longer. The elongate carrier is preferably tubular or is designed as a hollow profile. The elongate support is preferably designed as a polygonal tube, particularly preferably a square tube, e.g. B. with a substantially square or rectangular cross-section. The elongate support can be straight. It is also possible for the elongate beam to be bent into a desired shape, for example in a bending process, in order to meet geometric requirements of the vehicle structure.

As an alternative to the configuration as an elongate carrier, the frame component 10 can also be designed, for example, as a frame node for connecting a plurality of, preferably elongate, carriers (not shown).

The frame component 10 has a plug-in area 12 . Optionally, the frame member may include a tubular main body portion 14, preferably when the frame member 10 is embodied as an elongate beam.

The plug-in area 12 is tubular. The plug-in area 12 extends along a central axis M. The plug-in area 12 is designed to be plugged into another frame component. The plug-in area 12 can connect the frame component 10 to the other frame component.

The plug-in area 12 is arranged at a free end of the frame component 10 . It goes without saying that the free end is “free” only when the frame component 10 is unassembled or not installed. In the assembled state, the further frame component is arranged at this end of the frame component 10 . It is possible for the frame component 10 to have a further plug-in area or no plug-in area at an opposite end.

The mating portion 12 has a plurality of side walls 16,18,20,22 and a plurality of transition walls 24,26,28,30. The side walls 16, 18, 20, 22 and the transition walls 24, 26, 28, 30 together may form the tubular shape of the plug portion 12.

In the illustrated preferred embodiment, a number of the plurality of side walls 16, 18, 20, 22 is four and a number of the plurality of transition walls 24, 26, 28, 30 is also four. It is possible that a different number of side walls and transition walls is included for other (e.g. prismatic) profile types or polygonal profiles. A number of side walls 16, 18, 20, 22 and a number of transition walls 24, 26, 28, 30 preferably match one another.

The side walls 16, 18, 20, 22 face each other. Specifically, a first sidewall 16 may directly oppose a third sidewall 20 . A second sidewall 18 may directly oppose a fourth sidewall 22 . The side walls 16, 18, 20, 22 can be in different spatial planes. The first side wall 16 can be oriented essentially perpendicularly or at a 90° angle to the second side wall 18 . The second side wall 18 can be oriented essentially perpendicularly or at a 90° angle to the third side wall 20 . The third side wall 20 can be oriented essentially perpendicularly or at a 90° angle to the fourth side wall 22 . The fourth side wall 22 can be oriented essentially perpendicularly or at a 90° angle to the first side wall 16 .

Preferably, the first sidewall 16 and the third sidewall 20 can be parallel, and/or the second sidewall 18 and the fourth sidewall 22 can be parallel. The side walls 16, 18, 20, 22 can be parallel to the central axis M.

The side walls 16, 18, 20, 22 are essentially flat, preferably with respect to the outer surfaces of the side walls 16, 18, 20, 22. The side walls 16, 18, 20, 22 can be designed to lie flat on the inside of the further frame component .

The transition walls 24, 26, 28, 30 each connect two adjacent side walls of the plurality of side walls 16, 18, 20, 22 together. The respective adjacent side walls of the plurality of side walls 16, 18, 20, 22 are each oriented at an angle of <180° to one another. In the case of a shape derived from a triangular tube, the angle can be essentially 60° (=180°/3). In a preferred shape derived from a square tube, as shown, the angle can be essentially 90° (=2*180°/4). In the case of a shape derived from a pentagonal tube, the angle can essentially be 108° (=3*180°/4) etc.

The transition walls 24, 26, 28, 30 can be used instead of conventional edge sections (see main section 14 or 7 ) be arranged in a conventional polygonal profile.

For example, a first transition wall 24 can connect the first and second side walls 16, 18 together. The second transition wall 26 can connect the second and third side walls 18, 20 together. The third transition wall 28 can connect the third and fourth side walls 20, 22 together. The fourth transition wall 30 may connect the first and fourth side walls 16, 22 together.

The transition walls 24, 26, 28, 30 and the side walls 16, 18, 20, 22 are preferably each arranged alternately, preferably in relation to a circumferential direction around the central axis M. Each transition wall 24, 26, 28, 30 may be adjacent to two of the side walls 16, 18, 20, 22 and vice versa.

The transition walls 24, 26, 28, 30 may face each other, e.g. B. depending on a profile shape of the mating portion 12. Specifically, the first transition wall 24 of the third transition wall 28 may be directly opposite. The second transition wall 26 may directly oppose the fourth transition wall 30 . The transition walls 24, 26, 28, 30 can be parallel to the central axis M.

The transition walls 24, 26, 28, 30 are preferably distributed around the circumference of the plug-in area 12 around the central axis M. All of the transition walls 24, 26, 28, 30 are preferably arranged equidistantly from the central axis M. The plug-in area 12 can essentially be designed as a polygonal tube, preferably a square tube. The transition walls 24, 26, 28, 30 can form the edge sections/corner sections of the polygonal tube or be arranged in the edge sections/corner sections.

The transition walls 24, 26, 28, 30 are recessed towards the central axis M. The plurality of transition walls 24, 26, 28, 30 are preferably indented in the form of grooves or channels. The transition walls 24, 26, 28, 30 may have a V-shaped or U-shaped cross-section. Preferably, the cross section of the depression or of the transition walls 24, 26, 28, 30 can be essentially constant over a length of the transition walls 24, 26, 28, 30 parallel to the central axis M.

The transition walls 24, 26, 28, 30 can each transition into the side walls 16, 18, 20, 22 in a rounded manner, e.g. B. with an arc angle < 90 °. The first transition wall 24 can merge into the first and second side walls 16, 18 in a rounded manner. The second transition wall 26 can merge into the second and third side walls 18, 20 in a rounded manner. The third transition wall 28 can merge into the third and fourth side walls 20, 22 in a rounded manner. The fourth transition wall 30 can merge into the first and fourth side walls 16, 22 in a rounded manner.

A respective bottom section of the recessed transition walls 24, 26, 28, 30 can be rounded and include, for example, an arc angle of <90°, particularly preferably <45°. Starting from the rounded bottom section, the respective transition wall can extend in a V or U shape towards the two adjacent side walls 16, 18, 20, 22. The bottom portion of the respective transition wall 24, 26, 28, 30 may be that portion of the transition wall 24, 26, 28, 30 which is located closest to the central axis M.

A length of the plug-in area 12 with respect to the central axis M can be selected, for example, according to the requirements (including mechanical properties) of the frame structure to be manufactured. With respect to the central axis M, the plug-in area 12, the side walls 16, 18, 20 and/or 22 and/or the transition walls 24, 26, 28 and/or 30 can preferably have a length in a range between 10 mm and 200 mm.

The frame component 10 can taper towards the plug-in area 12, preferably over the entire circumference. For example, the frame component 10 can have a tapering area 32 . The taper portion 32 may be tubular. Tapered portion 32 may be located between main body portion 14 and male portion 12, preferably directly adjacent main body portion 14 and male portion 12, respectively. Tapered portion 32 may taper from main body portion 14 along central axis M toward male portion 12. A cross section or an outer contour of the tapered area 32 can decrease along the central axis M towards the plug-in area 12 .

The main body portion 14 may be tubular. The main body portion 14 can essentially be designed as a polygonal tube, preferably a square tube. The main body portion 14, together with the plug portion 12, may form the exemplary frame member 10 embodied as an elongated beam. However, it is also possible for the main body portion to be designed differently, e.g. B. knot-shaped, and together with the plug-in area 12, for example, forms a frame component designed as a frame node.

Preferably, a cross section of the mating portion 12 is smaller than a cross section of the main body portion 14. The cross section refers to a plane perpendicular to the central axis. The cross section of the mating portion 12 may be substantially constant along the central axis M. FIG. The cross section of the main body portion 14 may be substantially constant along the central axis M. FIG. For example, the main body portion 14 may have an overall width in cross section that is greater than an overall width of the mating section 12 in the cross section of the mating section 12 . Alternatively or additionally, the main body portion 14 may have an overall height in cross section that is greater than an overall height of the male portion 12 in the cross section of the male portion 12 .

the 4 until 6 show a frame assembly 34 with the frame component 10 and a further frame component 36.

The frame assembly 34 is adapted for use in a motor vehicle (not shown). Preferably, the frame assembly 34 may be used as part of a lattice frame (e.g., lattice vehicle frame or lattice cab frame) of the motor vehicle.

The further frame component 36 is preferably high-strength or made from a high-strength material, preferably a metal alloy, and has, for example, a tensile strength of ≧750 MPa or ≧800 MPa.

The further frame component 36 can be designed as an elongate beam. For clarity, the elongated carrier in the 4 until 6 comparatively brief. In practice, the elongate carrier can be made significantly longer. The elongate carrier is preferably tubular or is designed as a hollow profile. The elongate support is preferably designed as a polygonal tube, preferably a square tube, e.g. B. with a substantially square or rectangular cross-section. As an alternative to the design as an elongate carrier, the further frame component 36 can also be designed, for example, as a frame node (not shown) for connecting a plurality of, preferably elongate, carriers. It is also possible that the further frame component 36 is curved.

The frame component 10 is inserted into the further frame component 36 by means of the plug-in area 12 . The planar outer surfaces of the side walls 16, 18, 20, 22 can lie flat on the inside of the further frame component 36. The transition walls 24 , 26 , 28 , 30 , which are recessed toward the central axis M, can be spaced at least in sections from an inner peripheral surface of the further frame component 36 .

After the frame component 10 has been inserted into the further frame component 36, these can still be firmly connected or joined to one another. The joining preferably takes place in the overlapping area between the frame component 10 and the further frame component 36, i.e. in and/or on the plug-in area 12.

The frame component 10 and the further frame component 36 are preferably joined without high heat input in order not to impair the strength or the high tensile strength of ≧750 MPa or ≧800 MPa.

The frame component 10 and the further frame component 36 can, for example, be joined to one another in a materially bonded manner (e.g. adhesively), preferably by means of gluing and/or by means of soldering, at the plug-in area 12 .

Most preferably, an adhesive may be incorporated into the recessed transition walls 24,26,28,30. The cavities or depressions provided by the transition walls 24, 26, 28, 30 can thus advantageously be used for the adhesive. The adhesive can, for example, expand and/or harden in order to join the plug-in area 12 or the frame component 10 to the frame component 10 and/or to reinforce or strengthen the plug-in area 12 . It is possible that the adhesive hardens and/or expands in a KTL process (cathodic dip painting) and/or KTL oven and, for example, brings additional strength properties with it.

It is also possible that adhesive for joining is applied to the side walls 16, 18, 20, 22 of the plug-in area 12 or the flat section of the plug-in area 12 in order to join the plug-in area 12 to the further frame part 36.

For example, a soldering foil can be positioned between the plug-in area 12 and an inner circumference of the further frame part 36 for soldering.

Alternatively or in addition to gluing and/or soldering, etc., the frame component 10 and the further frame component 36 can, for example, be non-positively connected, e.g. B. by screwing, be joined together at the plug-in area 12.

Before or after gluing, soldering and/or screwing, etc., a connection between the frame component 10 and the further frame part 36 can be fixed by means of spot welds, for example. Preferably, the frame member 10 and the further frame member 36 may be spot welded together. The spot welds can be positioned in the area of the tapering area 32, for example. It is also possible to dispense with spot welding.

A full-circumferential cross-sectional reduction of the frame component 10 in the plug-in area 12 can make it possible for the main area 14 and the further frame component 36 to be aligned flush with one another, preferably over the entire circumference. An outer contour of the frame component 10 or of the main area 14 and an outer contour of the further frame component 36 can be aligned with one another in a viewing direction in the direction of the central axis M.

It is possible for the further frame component 36 to have a plug-in area at an end opposite the frame component 10 for plugging into another frame component (not shown), e.g. B. elongated beam or frame node having. This plug-in area can preferably be designed like the plug-in area 12 .

Referring to the 7 until 10 a method for producing the frame component 10 is described below.

the 7 and 8th 12 show a preform or precursor 38 for the frame member 10. The precursor 38 is preferably formed as an elongate, tubular support. The elongate support preferably has a constant cross-section along its length or along the central axis M. The preliminary stage 38 can preferably be a polygonal tube, particularly preferably a square tube, as shown. In principle, however, it is also possible for the preliminary stage 38 to be designed differently, e.g. B. as a node element for connecting several elongate beams.

The preliminary stage 38 has an end region 40 . The precursor 38 may already include the main body portion 14, preferably unchanged compared to the main body portion 14 of the frame member 10.

The end region 40 can be arranged at a free end of the preliminary stage 38 . The end area 40 is tubular, with a polygonal shape, preferably a square shape. The polygonal shape or the end area 40 can have a plurality of side walls 42, 44, 46, 48 and a plurality of edge sections 50, 52, 54, 56. The side walls 42, 44, 46, 48 and the edge sections 50, 52, 54, 56 together can form the polygonal shape of the plug-in area 12.

The plurality of sidewalls 42, 44, 46, 48 and/or edge portions 50, 52, 54, 56 may extend beyond the end portion 40 along the main body portion 14, preferably parallel to the central axis M.

In the illustrated preferred embodiment, a number of the plurality of side walls 42, 44, 46, 48 is four, and a number of the plurality of edge portions 50, 52, 54, 56 is also four. It is possible that a different number of side walls and edge sections is included for other (e.g. prismatic) profile types or polygonal profiles. A number of the side walls 42, 44, 46, 48 and a number of the edge sections 50, 52, 54, 56 preferably correspond to one another.

The side walls 42, 44, 46, 48 face each other. Specifically, a first sidewall 42 may directly oppose a third sidewall 46 . A second sidewall 44 may directly oppose a fourth sidewall 48 . The side walls 42, 44, 46, 48 can lie in different spatial planes. The first side wall 42 can be oriented essentially perpendicularly or at a 90° angle to the second side wall 44 . The second side wall 44 can be oriented essentially perpendicularly or at a 90° angle to the third side wall 46 . The third side wall 46 can be oriented essentially perpendicularly or at a 90° angle to the fourth side wall 48 . The fourth side wall 48 can be oriented essentially perpendicularly or at a 90° angle to the first side wall 42 .

Preferably, the first sidewall 42 and the third sidewall 46 can be parallel, and/or the second sidewall 44 and the fourth sidewall 48 can be parallel. The side walls 42, 44, 46, 48 can be parallel to the central axis M.

The sidewalls 42, 44, 46, 48 are substantially planar, preferably with respect to the outer surfaces of the sidewalls 42, 44, 46, 48. The edge portions 50, 52, 54, 56 are preferably rounded.

The edge portions 50, 52, 54, 56 each connect two adjacent side walls of the plurality of side walls 42, 44, 46, 48 together. The respective adjacent side walls of the plurality of side walls 42, 44, 46, 48 are each oriented at an angle of <180° to one another.

In the case of a shape derived from a triangular tube, the angle can be essentially 60° (=180°/3). In a preferred shape derived from a square tube, as shown, the angle can be essentially 90° (=2*180°/4). In the case of a shape derived from a pentagonal tube, the angle can essentially be 108° (=3*180°/4) etc.

For example, a first edge portion 50 may connect the first and second sidewalls 42, 44 together. The second edge portion 52 may connect the second and third sidewalls 44, 46 together. The third edge portion 54 may connect the third and fourth side walls 46, 48 together. The fourth edge portion 56 may connect the first and fourth sidewalls 42, 48 together.

The edge sections 50, 52, 54, 56 and the side walls 42, 44, 46, 48 are preferably each arranged alternately, preferably in relation to a circumferential direction around the central axis M. Each edge portion 50, 52, 54, 56 may abut two of the side walls 42, 44, 46, 48 and vice versa.

The edge portions 50, 52, 54, 56 may face each other, e.g. B. depending on a profile shape of the end portion 40. In detail For example, the first edge portion 50 may be directly opposite the third edge portion 54 . The second edge portion 52 may directly oppose the fourth edge portion 56 . The edge portions 50, 52, 54, 56 may be parallel to the central axis M.

The edge sections 50 , 52 , 54 , 56 are preferably distributed around the circumference of the end region 40 around the central axis M. All edge sections 50, 52, 54, 56 are preferably arranged equidistantly from the central axis M.

The frame component 10 can now be produced from the preliminary stage 38 in such a way that the end area 40 is formed into the plug-in area 12 . A cross-section of the end area 40 is reduced by reshaping the edge sections 50, 52, 54, 56 to form the transition walls 24, 26, 28, 30, preferably over the entire circumference.

The forming of the end area 40 to form the plug-in area 12 can take place, for example, in a single-stage or multi-stage forming process. The deformation can, for example, take place at ambient temperature or at a temperature above ambient temperature. Elevated temperature forming may optimize the formability of the precursor 38 material. However, this must be coordinated with the material used in order to avoid a negative influence on the material properties.

For example, one or more matrices or dies (e.g. 58, 70), which are introduced (inserted) or positioned in the end region 40, can be used for forming. A targeted material flow control for the forming process can be achieved by means of the die(s). A geometry of the plug-in area 12 can be designed flexibly by means of the die(s).

the 9 and 10 show an exemplary forming process.

According to 9 a matrix 58 can first be introduced or positioned in the end region 40 . An outer contour of the matrix 58 can preferably be a precursor to a desired inner contour of the plug-in area 12 .

The edge portions 50, 52, 54, 56 (see 8th ) can be pressed against the die 58 by pressing tools 60. The edge portions 50, 52, 54, 56 are formed inwards. Preliminary stages 62, 64, 66, 68 for the transition walls 24, 26, 28, 30 can arise. The pressing tools 60 can preferably have a rounded contact surface for contacting the edge sections 50, 52, 54, 56. The pressing tools 60 can, for example, deform the edge sections 50, 52, 54, 56 simultaneously or one after the other. For example, there can be a pressing tool 60 for each edge section 50, 52, 54, 56, or the edge sections 50, 52, 54, 56 can be successively formed by the same pressing tool 60. The pressing tools 60 can be designed as stamps, for example.

For example, the first edge portion 50 can be formed into the first precursor 62 for the first transition wall 24 . The second edge portion 52 can be formed into the second precursor 64 for the second transition wall 26 . The third edge portion 54 can be formed into the third precursor 66 for the third transition wall 28 . The fourth edge portion 56 can be formed into the fourth precursor 68 for the fourth transition wall 30 .

According to 10 the die 58 can be exchanged for another die 70 . The die 58 can be removed from the end region 40 which has already been partially formed. The matrix 70 can be positioned in the end region 40 which has already been partially formed. An outer contour of the further matrix 70 can preferably correspond to a desired inner contour of the plug-in area 12 . The further matrix 70 can depict a target geometry.

The side walls 42, 44, 46, 48 (see 8th and 9 ) can be pressed against the additional die 70 by pressing tools 72 . The transition walls 24, 26, 28, 30 are formed from the preliminary stages 62, 64, 66, 68 and the side walls 16, 18, 20, 22 are formed from the side walls 42, 44, 46, 48 and thus the plug-in area 12 as a whole the pressing tools 72 have a flat contact surface for contacting the side walls 42, 44, 46, 48. The pressing tools 72 can, for example, deform the side walls 42, 44, 46, 48 simultaneously or one after the other. For example, there can be a press tool 72 for each side wall 42, 44, 46, 48, or the side walls 42, 44, 46, 48 can be formed sequentially by the same press tool 72. The pressing tools 72 can preferably be in the form of stamps with planar contact surfaces.

For example, the first side wall 42 of the end area 40 can be formed into the first side wall 16 of the plug-in area 12 . The second side wall 44 of the end area 40 can be deformed into the second side wall 18 of the plug-in area 12 . The third side wall 46 of the end area 40 can be formed into the third side wall 20 of the plug-in area 12 . The fourth side wall 48 of the end portion 40 to the fourth Side wall 22 of the plug-in area 12 are reshaped.

For example, the first edge portion 50 of the end portion 40 can be formed into the first transition wall 24 of the male portion 12, preferably over the first precursor 62. The second edge portion 52 of the end portion 40 can be formed into the second transition wall 26 of the male portion 12, preferably over the second Precursor 64. The third edge portion 54 of the end portion 40 may be reformed into the third transition wall 28 of the male portion 12, preferably over the third precursor 66. The fourth edge portion 56 of the end portion 40 may be reformed into the fourth transition wall 30 of the male portion 12, preferably over the fourth precursor 68.

It is understood that with reference to the 9 and 10 Explained manufacturing process is particularly preferred, but only by way of example. The reduction of the cross section of the end area 40 to the plug-in area 12 can also take place by means of other methods, preferably forming methods. The forming process can, for example, only be a one-stage process and use only one die. The forming process can, for example, also have three stages or even more stages and use three or more dies.

It is also possible, for example, for the end area 40 to be formed into the plug-in area 12 by means of hydroforming, preferably external high-pressure forming. It is also possible, for example, for the end area 40 to be shaped by means of deep-drawing or by means of a roller or roller tool that is rolled onto the end area 40 .

The invention is not limited to the preferred embodiments described above. Rather, a large number of variants and modifications are possible, which also make use of the idea of the invention and therefore fall within the scope of protection. In particular, the invention also claims protection for the subject matter and the features of the subclaims independently of the claims referred to. In particular, the individual features of independent claim 1 are each disclosed independently of one another. In addition, the features of the subclaims are also disclosed independently of all the features of independent claim 1. All ranges herein are to be understood as disclosed such that all values falling within each range are disclosed individually, e.g. B. also as the respective preferred narrower outer limits of the respective area.

Reference List

10

frame component

12

mating area

14

main body area

16

First side panel

18

Second side wall

20

Third side panel

22

Fourth side wall

24

First transition wall

26

Second transition wall

28

Third transition wall

30

Fourth Transitional Wall

32

taper area

34

frame assembly

36

Another frame component

38

precursor

40

end area

42

First side wall

44

Second side wall

46

Third side wall

48

Fourth side panel

50

First edge section

52

Second edge section

54

Third edge section

56

Fourth edge section

58

die

60

pressing tool

62

First precursor

64

Second precursor

66

Third precursor

68

Fourth precursor

70

More matrix

72

pressing tool

M

central axis

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited 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 102008003719 A1 [0004]
• US6276111B1 [0005]
• US 9988093 B2 [0006]

Claims (15)

Frame component (10) for a motor vehicle, comprising: a tubular mating portion (12) for mating with another frame member (34), wherein: the tubular plug-in area (12) is arranged at one end of the frame component (10), the tubular plug portion (12) extends along a central axis (M), and the tubular plug-in area (12) has: - a plurality of side walls (16, 18, 20, 22) facing each other and being substantially planar, and - a plurality of transition walls (24, 26, 28, 30), each of which comprises two adjacent side walls of the plurality of side walls (16, 18, 20, 22) oriented at an angle of <180°, preferably at an angle of essentially 90° connect to each other and are recessed towards the central axis (M). Frame component (10) after claim 1 wherein: the plurality of transition walls (24, 26, 28, 30) are grooved or channeled; and/or the plurality of transition walls (24, 26, 28, 30) have a V-shaped or U-shaped cross-section. Frame component (10) after claim 1 or claim 2 wherein: the plurality of transition walls (24, 26, 28, 30) extend substantially parallel to the central axis (M); and/or the plurality of transition walls (24, 26, 28, 30) face each other. Frame component (10) according to any one of the preceding claims, wherein: a number of the plurality of side walls (16, 18, 20, 22) and a number of the plurality of transition walls (24, 26, 28, 30) are the same, and preferably four; and or the plurality of side walls (16, 18, 20, 22) and the plurality of transition walls (24, 26, 28, 30) are each alternately arranged; and or the tubular plug-in area (12) is designed essentially as a polygonal tube, preferably a square tube, with the plurality of transition walls (24, 26, 28, 30) in edge sections of the polygonal tube. Frame component (10) according to any one of the preceding claims, wherein: the multiple transition walls (24, 26, 28, 30) transition into the two adjacent side walls (16, 18, 20, 22) in a rounded manner, preferably with an arc angle of <90°, and/or the plurality of transition walls (24, 26, 28, 30) each have a rounded bottom section, which preferably has an arc angle <90°, particularly preferably <45°. Frame component (10) according to any one of the preceding claims, wherein: the plurality of sidewalls (16, 18, 20, 22) includes a first sidewall (16), a second sidewall (18), a third sidewall (20), and a fourth sidewall (22), wherein: - the first side wall (16) and the third side wall (20) are essentially parallel, - the second side wall (18) and the fourth side wall (22) are substantially parallel, the plurality of transition walls (24, 26, 28, 30) comprises a first transition wall (24), a second transition wall (26), a third transition wall (28), and a fourth transition wall (30), wherein: - the first transition wall (24) connects the first and second side walls (16, 18) to one another, - the second transition wall (26) connects the second and third side walls (18, 20) to one another, - the third transition wall (28) connects the third and fourth side walls (20, 22) to one another, - the fourth transition wall (30) connects the first and fourth side walls (16, 22) to one another. Frame component (10) according to any one of the preceding claims, wherein: the frame component (10) tapers at a transition to the tubular plug-in area (12), preferably over the entire circumference. Frame component (10) according to any one of the preceding claims, further comprising: a, preferably tubular, main body portion (14) which merges into the tubular plug-in portion (12), preferably with a tapering portion (32) of the frame component (10) arranged between the main body portion (14) and the plug-in portion (12). Frame component (10) according to any one of the preceding claims, wherein: a cross section of the tubular plug portion (12), which is preferably substantially constant along the central axis (M), is smaller than a cross section of the main body portion (14), which is preferably substantially constant along the central axis (M). Frame component (10) according to any one of the preceding claims, wherein: the frame component (10) has a tensile strength of ≥ 750 MPa or ≥ 800 MPa. Frame component (10) according to any one of the preceding claims, wherein: the frame component (10) is designed as an elongate beam or as a frame node for connecting a plurality of beams. A frame assembly (34) for a motor vehicle, comprising: a frame member (10) according to any one of the preceding claims; and a further frame component (36), preferably designed as an elongate beam or as a frame node, the frame component (10) being inserted into the further frame component (34) by means of the tubular plug-in region (12). Frame assembly (34). claim 12 , wherein: the frame component (10) and the further frame component (34) are joined to one another on the tubular plug-in area (12), preferably in a materially bonded manner, particularly preferably by means of gluing, by means of spot welding and/or by means of soldering, and/or in a non-positive manner, particularly preferably by means of screwing ; and/or the frame component (10) and the further frame component (34) are joined together at the tubular plug-in area (12) by means of gluing, with an adhesive preferably being applied to flat sections of the plug-in area (12) and/or in the recessed transition walls ( 24, 26, 28, 30) and expanded and/or cured therein. Frame assembly (34). claim 12 or Claim 13 wherein: the main body portion (14) of the frame member (10) and the further frame member (34) are flush with each other, preferably circumferentially; and/or an outer contour of the frame component (10) and an outer contour of the further frame component (34) are aligned with one another in a viewing direction running along the central axis (M). Motor vehicle, preferably utility vehicle, comprising: a frame component (10) according to one of Claims 1 until 11 or a frame assembly (34) according to any one of Claims 12 until 14 , Preferably as part of a lattice frame of the motor vehicle.

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