FR2958567A1 - METHOD FOR MANUFACTURING A COMPOSITE COMPONENT COMPRISING A FIXED INSERTION ELEMENT IN A CAVITY OF A PART OF A PROFILE COMPONENT - Google Patents

Abstract

The present invention relates to a method of manufacturing a composite component, wherein an insertion member is disposed and fixed in a cavity of a portion of a shaped component having a hollow section, knowing that the insertion element (16) preferably in the form of a sleeve is connected by means of at least one form-compliant coupling (60) to the profiled component (10) produced as deformed component under high internal pressure.

Description

The invention relates to a method of manufacturing a composite component in which an insertion element is arranged and fastened to a composite component comprising an insertion element fixed in a cavity of a portion of a profiled component. in a cavity of a portion of a shaped component having a hollow section. The invention further relates to a shaped component having a hollow section at least in a component part, in the cavity of which an insertion element is arranged and fixed on the profiled component.

Document DE 10 2005 013 719 A1 discloses a method, wherein a composite component is obtained in that an insertion element is at least partially provided with a plastic envelope by coating and thus disposed and fixed in a cavity. a portion of the shaped component having a hollow section.

The present invention aims to provide a method of manufacturing a composite component and a composite component as such, where is obtained a particularly stable connection of the insertion element inside the hollow section of the component profile.

This problem is solved according to the invention by a method, which is characterized in that the preferably socket-shaped insertion element is connected by means of at least one complementary fit coupling to the profiled component produced as a component deformed under high internal pressure, and by a composite component, which is characterized in that the profiled component is formed as deformed component under high internal pressure, which is connected by means of at least one form-complementary coupling to the insertion element.

In order to obtain a method, by means of which an insertion element is particularly advantageously fastened within the hollow section of a portion of the shaped component, it is provided according to the invention that the insertion element, preferably in the form of a sleeve, is connected by means of at least one form-fitting coupling to the profiled component produced as deformed component under high internal pressure. In other words, it is provided firstly according to the invention to implement a shaped component made as deformed component under high internal pressure.

This component deformed under high internal pressure has at least a portion with a hollow section where the insertion element is arranged, said insertion element being connected by means of at least one form-complementary coupling preferably generated during the deformation under high pressure of the profiled component, which makes it possible to obtain the composite component. The advantage is therefore presented that the preferably socket-shaped insertion element is fastened in a particularly robust and advantageous manner inside the hollow section of the profiled component, so as to obtain a reinforcement and / or a point of contact. assembly of the shaped component to other particularly advantageous components. The insertion element can in particular allow the integration of complementary functions of the profiled component, such as the housing of a towing ring for a bent biased front bumper, the local structural reinforcement of the deformed component under high internal pressure. in locations subject to high mechanical stress, the integration of coupling functions of the shaped component to another component or the integration of auxiliary fastening means in the profiled component. For all the aforementioned functions, obtaining a particularly rigid and stable reinforcement and / or fixing the profiled component in the region of the insertion element is of great importance. In particular, it will be possible to dispense with welded connections between the insertion element and the profiled component, which could cause a material weakening of the shaped component due to the application of heat.

In another embodiment of the invention, it has been found to be advantageous for the insertion element to be pre-attached to the profiled component before deformation under high internal pressure. This can be achieved in particular by means of a seal, in particular by gluing. It will therefore be possible to possibly give up a separate attachment of the insertion element during the deformation under high internal pressure proper.35 Alternatively, it will be possible in another embodiment of the invention that the element d insertion is pre-fixed on the profiled component only during deformation under high internal pressure.

This can be achieved in particular by means of a compacting punch of a deformation plant under high internal pressure. This embodiment of the process thus makes superfluous the use of a seal, in particular a glued joint.

According to another embodiment of the invention, the shaped component is at least partially provided with a plastic material to form a hybrid composite component.

The overall result is a hybrid composite component, where the shaped component is reinforced by application of the plastic material at specific locations, for example, and / or simply comprises functional areas such as connection points, consoles or the like. formed by the plastics material.

According to another embodiment of the invention, the form-complementary coupling or couplings are obtained by a pressure applied from the outside to the profiled component. This can be done in a simple way, in particular by means of a punch or another tool, and even in particular directly in the tool of the deformation plant under high internal pressure. It is also conceivable that the externally applied pressure on the shaped component is generated by the plastic casting of the hydride component. The use of a separate punch or other deformation tool will be superfluous.

Alternatively, the complementarity-shaped coupling (s) may also be obtained by a pressure applied from the inside to the profiled component and / or the insertion element. This will in particular make it possible also to use the medium otherwise required for the deformation under high internal pressure of the profiled component in order to obtain the complementary fit coupling between the insertion element and the profiled component.

The advantages of the method according to the invention mentioned above are also noted for the composite component with a profiled component having a hollow section at least in a component part, in the cavity of which an insertion element is arranged and fixed on the profiled component, the profiled component being formed as a deformed component under high internal pressure, which is connected by means of at least one form-compliant coupling to the insertion element (16).

Other advantages, characteristics and particularities of the invention will emerge from the description of preferred embodiments hereinafter with reference to the drawings, in which FIG. 1 is a diagrammatic section of a half-product of a profiled component in the form of a component deformed under high internal pressure, an insertion element being disposed in a cavity of a portion of a profiled component having a hollow section, and pre-fixed on the profiled component before the deformation under high internal pressure; fig. 2 shows a schematic section of an alternative shaped component, similar to FIG. 1, the insertion element being pre-fixed on the profiled component or the semi-finished product during the deformation under high internal pressure by maintaining the clamping of said insertion element by means of a compacting punch corresponding to a deformation installation under high internal pressure; fig. 3 shows two schematic sections of the shaped component, similar to FIG. 2, the top drawing illustrating the clamping attachment of the insert member against the corresponding compacting punch, before it is introduced into the cavity of the corresponding hollow section of the corresponding part of the shaped component, and the bottom drawing illustrating the insertion position in the cavity of the insertion member or compacting punch; fig. 4 represents schematic sections of the profiled component, similar to FIG. 3, the top drawing again illustrating the clamping attachment of the insert member against the corresponding compacting punch, prior to its insertion into the cavity of the hollow section of the shaped component, and the bottom drawing illustrating the position of the inserting the insertion member or compacting punch into the cavity of the shaped component; fig. 5 shows new sections of the profiled component, the top drawing illustrating the clamping attachment of the insert member against the compacting punch outside the cavity of the shaped component, and the bottom drawing illustrating the position of the insertion of the compacting punch as well as the insertion element into the cavity of the shaped component FIG. 6 shows another schematic section of the profiled component, similar to FIGS. 3 to 5 5, the insertion element fixed against the compacting punch being already introduced into the cavity of the profiled component and pre-fixed by means of an additional slide which forms the outer wall of the profiled component in a corresponding groove of The insertion element; fig. 7 shows another schematic section of the profiled component, the insertion element being in this case maintained in the cavity of the profiled component, in a central part of said profiled component, by two opposite compaction punches introduced into the cavity of the profiled component. shaped component and provided with spacers; fig. 8 shows two schematic sections of the profiled component with the pre-fixed insertion element, a plurality of form-complementary couplings being generated between the profiled component and the insertion element by means of an applied pressure of the outside by several punches fig. 9 shows again two schematic sections of the shaped component, similar to FIG. 8, a plurality of form-compliant couplings being generated here for attaching the insertion element to the profiled component by means of an applied pressure from the inside, operated by the medium for deformation under high internal pressure of the shaped component; fig. 10 shows two schematic sections of the profiled component, similar to FIGS. 8 and 9, a plurality of form-complementary couplings being generated here between the profiled component and the pressure insertion element applied from the outside to the profiled component by means of the plastic cast iron;

fig. 11 is a schematic cross-section of the shaped component similar to FIGS. 8 to 10, form-complementary couplings being generated here between the profiled component and the pressure insert element applied from the outside by means of a cutting tool equipped with two punches; FIG. 12 shows a perspective view as well as a fragmentary perspective view of a bent biased front bumper of a passenger car, an insert member being provided within a shaped component made as a crash. -box, said insertion member comprising a tow ring housing;

fig. 13 shows a perspective view 25 as well as a cross-sectional and longitudinal sectional view of a profiled component made as a tube, a structural reinforcement in the form of a foam being provided as an insert element;

FIG. 14 shows two sections of two profiled components, in the cavity of which is respectively provided an insertion member, the two profile components which extend parallel to each other being connected by hydraulic crimping during a combined process of deformation under high internal pressure and injection molding;

fig. 15 shows an elevational view as well as a section at a connection of two shaped components extending parallel to each other in the form of tubes obtained by deformation under high internal pressure, an insertion element being disposed in the connection area of the two profiled components, in the corresponding cavity of each profiled component, and the two profiled components being connected by hydraulic crimping, and by one or more additional sheet metal plates during a combined process of deformation under high pressure internal and injection molding;

fig. 16 is a perspective view as well as two enlarged and sectional fragmentary perspective views of the connection arrangement of two perpendicular shaped components or extending parallel to each other with corresponding insertion elements, having been hydraulically crimped, and one or more additional sheet metal plates during an internal high pressure deformation and injection molding process;

fig. 17 shows a perspective view as well as a fragmentary side view and a fragmentary perspective view of a sill of the side door of a particular car with a plurality of shaped components, at least one insertion member for the housing of sockets, hinges or the like being provided in at least one shaped component; and FIG. 18 is a perspective view as well as two enlarged fragmentary perspective views in cross-section of the connection of two shaped components with corresponding insertion elements, said profiled components extending perpendicularly or angularly with respect to one another. Other, having been hydraulically crimped, and one or more additional sheet metal plates during a combined process of deformation under high internal pressure and injection molding.

Fig. 1 shows, in schematic section, a half-product of a profiled component 10 in the form of a component deformed under high internal pressure, which is here made as a tube. In this case, the shaped component 10 is made in particular of a metal alloy, such as an alloy of aluminum or steel. Other materials such as FVK are possible alternatively. The profiled component 10 or its semi-product comprises at least a portion of component 12 with a hollow section, in the cavity 14 of which is disposed an insertion element 16. The insertion element 16 can in this case be in particular consisting of a metal alloy such as an aluminum alloy or steel, but also a non-reinforced or reinforced plastic material, in particular a fiber reinforced plastic or cellular material. Where appropriate, the insertion element 16 may comprise integrated auxiliary fixing means.

The shaped component 10 of FIG. 1 must also be deformed under high internal pressure, the insertion element 16 must have a passage opening 18 allowing free movement of the pressurized medium inside the cavity 14 of the profiled component 10, thus avoiding disturbing the increase in pressure in the whole of the profiled component 10.

So that the insertion element 16 is disposed at a location defined with respect to the profiled component 10, a pre-fixation of the insertion element 16 is here carried out according to the embodiment of FIG. 1 in that it is fixed on the profiled component 10 prior to deformation under high internal pressure. This is in particular obtained by means of a seal 20 between the insertion element 16 and the profiled component 10. This seal 20 may in particular be a glued joint or an electromagnetic seal. Alternatively, a form-fit coupling or a pre-fixation of the insertion element 16 on the profiled component 10 may be performed instead of a material connection, in particular a joint 20. The fixing of the insertion element 16 may in particular take place before introducing the profiled component 10 in the deformation plant under high internal pressure or the deformation tool under high internal pressure.

The type of material connection may vary depending on the material combination between the profiled component 10 and the insertion element 16. Thus, when using an aluminum profile component and an insertion element 16 in plastic material, polyamide for example, it will be possible to use the connection already used by primary coating of the profiled component 10 aluminum.

If the seal 20 is made by electromagnetic assembly (electromagnetic pulse technology, EMPT), the effect of a magnetic field pulses will obtain a direct deformation of bodies, cylindrical or otherwise shaped, of electrically conductive material. The profiled component 10 and the inserted or inserted insertion element 16 can thus be linked at the atomic level.

This pre-fixation ensures that the insertion element 16 remains at the desired position during the deformation process under high internal pressure, possibly combined with injection molding, until the final fixing described below.

Whereas fig. 1 represents the pre-fixation of the insertion element 16 on the profiled component 10 before the deformation under high internal pressure, the exemplary embodiments illustrated in FIGS. 2 to 7 show processes where the insertion element 16 is pre-fixed on the profiled component 10 during deformation under high internal pressure.

Fig. 2 thus represents a schematic cross-section of the profiled component 10, which is deposited as a semi-finished product in a tool 22 of an internal high-pressure deformation installation 24. Two compaction punches 28 displaceable by means of rolls 26 are provided therein , the corresponding ends of the shaped component 10 can be closed by said punches and an internal high-pressure deformation medium of the shaped component 10 to be injected. It is also apparent from FIG. 2 that one of the two compaction punches 28 comprises a clamping device 30 on which the insertion element 16 can be clamped or pre-fixed. After introduction of the insertion element 16 into the corresponding cavity 16 of the profiled component 10, a precise pre-fixation of said insertion element 16 with respect to the profiled component 10 will be obtained thanks to the compacting punch 28. No part of The spacing of the type described in more detail below is not used in the present case. It is also apparent from FIG. 2 that the insertion element 16 is in this case arranged against the edge of the profiled component 10, so as to require only one compacting punch 28. According to the corresponding method, the insertion element 16 is preferably tightened outside the tool 22 by means of compacting punch 28. To execute the damping mechanism, it must be ensured that the passage of the pressurized medium is not impeded.

Fig. 3 again shows two sections of the profiled component 10, the drawing of the top clearly showing that the insertion element 16 is fixed on the compacting punch 28 corresponding by means of a clamping device 30. The clamping device 30 comprises for this purpose a clamping clamp 32 mounted on axial pressure springs 34 integrated in the compaction punch 28. Clamping jaws 36 pressing against the wall of the through opening 18 make it possible to obtain the clamping or fixing of the insertion element 16 on the compacting punch 28. It is recognized that the attachment of the insertion element 16 to the compacting punch 28 is made outside the profiled component 10.

Once the insertion member 16 is attached to the compacting punch 28, the compacting punch 28 is inserted into the cavity 14 with the insertion member 16 as shown in the bottom drawing of FIG. 3, and the compacting punch 28 is then clamped against the profiled component 10, the deformation under high internal pressure can take place. In this case, it is obvious that other clamping means are possible instead of the axial clamping device or the clamping device by means of spring elements 30.

Fig. 4 thus represents, in a similar manner to the drawings of FIG. 3, an AC clamping device. The clamping device 30 is here at the origin of a radial clamping, for example by means of two pressure springs 38 arranged radially, which are in their clamping position compressed again by respective clamping jaws 36 against the wall corresponding to the insertion element 16, which delimits the outer contour of the passage opening 18. These pressure springs 38 or clamping jaws 36 are thus integrated with the compacting punch 28.

As can be seen from the drawing at the top of FIG. 4, in this case, clamping of the insertion member 16 to the compacting punch 28 also takes place before the compacting punch 28 or the insertion member 16 is inserted into the cavity 14 of the semi-finished profile component.

Fig. 5 shows, similarly to FIGS. 3 and 4, another embodiment where the pre-fixation of the insertion member 16 with respect to the shaped component 10 is performed during the deformation process under internal high pressure in that the insertion element 16 formed of a magnetizable material is held against the compacting punch 28 by means of a magnet incorporated therein. The attachment of the insertion element 16 to the profiled component 10 is again performed outside the semi-finished profiled component 10, an introduction of the compacting punch 28 or the insertion element 16 into the cavity 14 of the profiled component 10 being performed as shown in the bottom drawing of FIG. 5. FIG. 6 shows another embodiment, similarly to FIGS. 3 to 5, the fastening of the insertion element 16 against the compacting punch 28 being made by means of spring elements 42 of the clamping device 30.

These spring elements 42 bear against the outer peripheral wall of the passage opening 18 of the insertion element 16. The attachment of the insertion element 16 on the profiled component 10 with respect to the compacting punch 28 may for example still be performed outside the profiled component 10, the compacting punch 28 is then introduced with the insertion element 16 in the cavity 14 of the semi-finished profile component 10. It emerges in this case from fig. 6 that a slide 44 may further be provided in the form of a movable clamping punch and forming. This slide 44 passes through the profiled component 10 in transverse or perpendicular direction and is engaged in a peripheral groove 44 of the insertion element 16 - in the case of correct orientation of the insertion element 16 with respect to the shaped component 10. This results in a complementary pre-fixation, which is required in particular when using tubes receiving complex geometric shapes by deformation process under high internal pressure. It is to be considered as part of the invention that several slides 44 of this type can also be used where appropriate. The slide (s) 44 will in this case preferentially be integrated with the halves of the tool 22 and mounted in a mobile manner.

Fig. 7 finally represents an alternative section of the profiled component 10 according to another embodiment, the insertion element 16 not being pre-attached at one end of the profiled component 10, unlike the shapes of the shaped component 10. execution of FIGS. 3 to 6, but deep within said profiled component 10. To make possible such positioning and pre-fixing, two compaction punches 28 are in this case implemented at both ends of the profiled component 10, spacers 48, 50 being furthermore used, which can be adjusted according to the desired position for the insertion element 16. The spacers 48, 50 between the respective compaction punch 28 and the element insertion 16 are made of plastic, so-called longitudinal peeling said ribs possibly possible, used in particular for clamping each spacer 48, 50 relative to the profiled component 10 or the fixing of each spacer 48, 50 and consequently of the insertion element 16 with respect to the profiled component 10. The housing of each spacer 48, 50 on the corresponding compacting punch 28 is by means of a respective reception 52 of said corresponding compacting punch 28, which here has a shoulder and optionally the peeling ribs in the case of spacers 48, 50 of plastic. Spacers 48, 50 are preferably furthermore fixed to each compacting punch 28 - for example by means of a snap-in assembly, a screw connection or magnetically - which makes it possible to easily remove them from the cavity 14 of the Furthermore, it is conceivable that the spacers 48, 50 remain in the profiled component 10, in particular if they are made of a very light material, so that this maintenance will be negligible if one consider the total weight of the composite component. Maintaining the spacers simplifies the constructive design of the compacting punch 28, no particular measure being required to secure the spacers to allow their removal.

The insertion element 16 must preferably be compressed in the hollow profiled component 10 to guarantee the seal between said profiled component 10 and said insertion element 16.

Otherwise, it may happen that the pressurized fluid enters the gap between the hollow profile 10 and the insertion element 16, and that said hollow section 10 widens so as not to allow stable maintenance in the part previous section 10 expanded.

For sealing, one or more sealing lips, ribs or crushing edges peripheral contour may in particular be provided on the insertion element 16, which will support the insertion element 16 with a sealing under high pressure against the profiled component 10 following compression. The compression of the crushing edge or the sealing lip will compensate for manufacturing tolerances, ie inequalities that would otherwise weaken the sealing efficiency.

Another guarantee may also be provided by the subsequent stamping of a relief of the profiled component against the insertion element 16, so as to obtain a clamping of said insertion element 16 inside the profiled component 10. The engraving of the tool at the location of the insertion element 16 should also be performed very closely to the profiled component 10 even before the deformation thereof, so that said profiled component 10 can not be used. to expand excessively. The profiled component 10 may therefore be preferentially widened only within the limits of the press fit. This will most often be ensured in that the ends of the hollow profiled component 10 are generally clamped in the tool 22.

If the insertion element 16 is pre-fixed by one of the aforementioned methods, the definitive and durable attachment described below may be performed. Several variants will be possible for this purpose: One of these variants is illustrated in FIG. 8. For this purpose, fig. 8 is composed of schematic sections of the profiled component 10 or the pre-attached insertion element 16 disposed inside the tool 22 of the internal high-pressure deformation installation 24. A plurality of punches 54 is provided in this case, which are integrated in the tool 22 - more precisely: in the upper part of tool 56 and in the lower part of tool 58. During the deformation under high internal pressure, these punches 54 are pressed from the outside against the profiled component 10 in accordance with the right-hand drawing of FIG. 8. This results in a plurality of form-compliant couplings 60 between the profiled component 10 and the insertion element 16, generated by a pressure applied from the outside to the profiled component 10. The two complementarity couplings of FIG. 60 outer shape are in fact made on one or the other end of the insertion element 16 in the profiled component 10, so that it can no longer move axially inside the component profile 10. The central shape complementary coupling 60 is obtained by a relief of the profiled component 10 which engages in a corresponding groove 62 of the insertion element 16. The present stampings and compressions thus make it possible to generate the couplings by form complementarity 60 by means of which the insertion element 16 is permanently fixed on the profiled component 10 made as deformed component under high internal pressure. The punches 54 may be set in motion, in particular by hydraulic cylinders or valve molds present on the tool 22. The insertion element 16 may further comprise other admissions by which the gross wall of the profiled component 10 will be compressed by the force of the punch 34 applied from the outside. The desired durable fixation for the insertion element 16 will thus be obtained. This fixation is simultaneous with the deformation under high internal pressure.

Fig. 9 illustrates in two cross-sectional drawings another permanent final fixing variant of the insertion element 16 inside the profiled component 10. While the embodiment of FIG. 8 provided the possibility of insertion elements 16 with a large wall thickness, the embodiment of FIG. 9 preferentially uses an insertion element 16 having a small wall thickness. It then becomes possible to use the internal pressure prevailing inside the profiled component 10 during the process of deformation under high internal pressure for fixing the insertion element 16. Several orifices 64 in the form of bores , recesses, moldings or the like are then formed in the profiled component 10 surrounding the insertion element 16 before insertion into the tool 22, wall parts 66 of the insertion element 16 being therein. compressed by internal pressure.

Fixing is therefore performed by respective hydraulic crimps. These hydraulic crimps can be performed actively or passively. In case of active hydraulic crimping, it is resorted to a plurality of punches 68, which are integrated in the upper part of tool 56 and the lower part of tool 58 - similarly to the embodiment of FIG. 8. These counter punches 68 are movable and controlled depending on the pressure. Alternatively, the counter punches 68 may also be fixedly adjustable - as in the drawing on the left of FIG. 9 - thus allowing a passive hydraulic crimping. A better seal on the hydraulic crimping points between the tool 22 and the profiled component 10 can be obtained by means of slides 70 integrated in the tool 22, which will be clamped against the rough outer wall of the profiled component 10 during the process of deformation under high internal pressure. To facilitate the flow of material from the insertion member 16 into the orifices 64, it may first be made with a particularly inferior wall thickness at these locations.

It is therefore generally apparent from FIG. 9 that the present insertion element 16 covers the corresponding orifices 64 sealingly, so that the high internal pressure generated or a pressure applied from the inside to the profiled component 10 and / or the insertion element 16 compressing the latter in the orifices 64 to form the plurality of form-matching couplings 60 again. The form-matching couplings 60 may be formed by stamping, or by hydraulic crimping, the wall portions 66 passing through the orifices 64 and an opposite counter-punch action 68 compressing the material of the insertion member 16.

Fig. 10 is composed of two drawings illustrating an alternative embodiment for forming form-fit couplings 60, the shaped component 10 being shown in a non-deformed state on the left, and deformed on the right. In a similar manner to the embodiment of FIG. 8, a pressure is here also applied from the outside to the profiled component 10, which generates the plurality of form-fitting couplings 60. More precisely: the pressure applied from the outside to the profiled component 10 is generated by a The channel 74 is in this case assigned to an injection molding device 76, which can equip the shaped component 10 to form a hybrid component. It is therefore particularly advantageous in this variant to be able to use the existing internal high pressure / injection molding 24 installation. The injection pressure presented can thus be exploited for the application of external reinforcing structures of plastics material or the like, simultaneously with the attachment of the insertion element 16 disposed inside the cavity 14 of the profiled component 10 No additional mechanical punch will be required. Alternatively to the plastic cast iron 72, a conventional aqueous emulsion or other medium may be used as a pressure medium. The result will be in all cases the obtaining of a new plurality of form-matching couplings 60, by means of which the insertion element 16 will be permanently fixed on the profiled component 10.

So that the material of the profiled component 10 is not forced into the channels 74 because of the high internal pressure, and to prevent an expansion of the profiled component 10 does not take place, the section of the channels 74 will have to be relatively reduced on the one hand, and a favorable pressure process and regulation will have to be presented for the high internal pressure and the casting pressure, on the other hand. The selection of a process where the cast iron 72 is first injected with a reduced regulated pressure in the channels 74 has proved particularly advantageous for this purpose. There is also minimal pipe burst pressure in this context. The deformation under internal pressure is further performed then at reduced pressure, the shaped component 10 widening accordingly. The pressure of the plastic cast iron 72 is then raised. Finally, the internal pressure is raised again with alternating or simultaneous pressure regulation, in order to obtain the final shape of the shaped component 10. In other words, the high internal pressure and the casting pressure of the plastic cast iron 72 are selected here so that the formation of the relief or the respective shape-matching couplings 70 are performed only in a subsequent step, where the profiled component 10 is already applied with contour matching against the engraving or cavity of the 22. The internal pressure is then lowered relative to the casting pressure until the depressions can be made.

Fig. 11 illustrates finally another variant of attachment of the insertion element 16 in the cavity 14 of the profiled component 10. A new schematic section of the profiled component 10 with the insertion element 16 is shown for this purpose. A cutting tool 76 is also recognized with two compaction punches 78 which can penetrate into the wall of the profiled component 10. Tabs 82 are generated by the two punches 78 after the formation of corresponding openings 80, said tabs laterally gripping the element 16 and thus forming form-complementary couplings 60. In other words, the two punches 78 produce the corresponding tabs 82 by cutting and folding. The cutting tool 76 or the punches 78 must in this case be designed to close the openings 80 made by cutting processes while the high internal pressure is applied in the profiled component 10. Moreover, it will be possible to use more than two punches 78.

It is therefore recognized that, in the variants described with reference to FIGS. 8 to 11, the durable attachment of the insertion element 16 to the profiled component 10, which is itself deformed under high internal pressure, is obtained by means of corresponding form matching couplings 60. These may be the result of external pressure as in the embodiments of FIGS. 8, 10 and 11, or a high internal pressure as in the embodiments of FIG. 9.

Fig. 12 also shows a perspective view and a fragmentary perspective view of a possible application of the arrangement described here of the insertion element 16 inside the cavity 12 of the corresponding profiled component 10. In the present exemplary embodiment, the profiled component 10 is made as a crash-box or energy absorbing element of a bent biased front bumper. In other words, the insertion element 16 is integrated with the cavity 12 of the crash-box or the profiled component 10 and it has, for example, a plurality of grooves 84 for effecting the corresponding form-matching coupling with the crash-box. For the integration of other functions, the insertion element 16 comprises a passage opening 86 which is formed as a housing for a towing ring 88. This can therefore - as shown in the drawing at the top of FIG. . 12 - be screwed into the crash-box or its insertion element 16, to allow a secure hold of the towing ring 88 on the front bumper biased bending.

Fig. 13 shows another application of the insertion member 16 within a corresponding component 10. In the present case, the insertion element 16 is a cellular foam or other synthetic material which is first solidified externally before being introduced into the cavity 12 of the shaped component 10. As is also apparent from the view in cross-section or in longitudinal sectional view, several insertion elements 16 may be used, in particular at locations subject to high mechanical stresses. The insertion members 16 are thus responsible for local structural reinforcement of the hollow profile component per se.

Channels will preferably be provided inside the cellular foam or similar material, by means of which the pressurized fluid required for the performance of the deformation under high internal pressure can flow, or the pressure can be raised everywhere in the fluid. The foam may further comprise a part of metallic elements in the form of a metal foam or the like.

Fig. 14 illustrates two other possibilities of application, inserts 16 being provided within corresponding shaped components 10. The possible embodiments are represented according to their arrangement inside a tool 22 of a corresponding internal high pressure deformation installation 24.

It appears first of the drawing on the left of fig. 14 that the ends of the profiled components 10 have been closed by respective compaction punches 28, by means of corresponding cylinders 26. In the present case, a hydraulic crimping process is also performed during the deformation process under internal high pressure, so that wall portions 90 of each shaped component 10 are compressed in corresponding receptions 92 of the insertion element. 16 of the adjacent profile component 10. In other words, each wall portion 90 of each shaped component 10 is compressed in each corresponding recess 92 of the insertion member 16 of the other shaped component 10, to obtain corresponding shape-matching couplings 60. As a result, two shaped components 10 extending parallel to each other are connected by hydraulic crimping. Instead of hydraulic crimping, the aforementioned connection will of course also be achievable by means of a plastic cast iron 72.

The drawing on the right differs from the one on the left in that an additional coupling is provided by plastic sheathing. Plastic 94 is shown schematically.

Fig. 15 also shows in elevational view and in sectional view in a similar manner to FIG. 14 the connection of two profiled components 10 extending parallel to each other, by hydraulic crimping with one or more sheets 96, 98 complementary. The sheets may also be connected to one another or to the corresponding shaped component during the deformation process under high internal pressure. It will be possible to further provide a plastic coating or a hybrid plastic connection 94. It again appears from the sectional view that the two shaped components 10 are clamped in the sheets 96, 98 before coating by the Plastics 94. The sheets 96, 98 serve to enlarge the gripping surface of the composite subjected to very high external mechanical forces, and therefore to a better distribution of forces. The longevity of the coupling of the hollow profiles is increased.

Fig. 16 shows another application, where two shaped components 10 which extend perpendicularly or angularly to each other are connected by hydraulic crimping during a process of deformation under high internal pressure. It emerges in particular from the two sectional views that an insertion element 16 is disposed inside each of the two profiled components 10, each insertion element having a plurality of orifices 100 in which wall portions 102 are compressed. of the corresponding profiled component 10.

The compression of each wall portion 102 of the respective shaped component 10 is again performed by applying a corresponding high internal pressure or a corresponding external pressure. In this specific case, form-fit couplings 60 or hydraulic crimping connections are obtained by corresponding pressure rise within each profiled component 10 or within each insertion element 16 during deformation under high internal pressure. In addition, one or more sheets 104 may again be used, which may also be connected together or to the profiled component 10 and / or to the respective insertion element 16 by a plurality of hydraulic crimps or other connections. . An internal high pressure deformation process combined with injection molding may further be implemented to enhance the bonding of the two shaped components with plastic. In case of particularly limited construction space, the profiled components 10 may also be located on the same plane at the point of intersection, said profiled components 10 being crushed with the insertion element 16 on half of their cross section. This will be done before deformation under high internal pressure, during which creases or dents formed by crushing will be eliminated. The connecting plates 104 shown, crimped to each other, will eventually make superfluous a plastic coating.

Fig. 17 is beside a perspective view a side view and another enlarged fragmentary perspective view of a shaped component 10 which includes a plurality of insertion members 16 formed as sockets, hinge housings, or the like. . The plastic insert can thus have four bushings with a rear structure coated accordingly.

Fig. 18 finally shows, similarly to FIG. 16, another possibility of connecting two cross-section components 10 that intersect, an insertion element 16 being provided again inside each profiled component 10. Openings 100 are again provided inside the insertion member 16, wherein corresponding wall portions 102 of the respective shaped component 10 can be compressed by hydraulic crimping. To obtain less space, the two profiled components 10 and the insertion elements are made with a reduced cross section at the intersection, for example by crushing in the hydroforming tool / injection molding.

It will be emphasized here that the invention is not restricted to the use of a single insertion element 16. Several insertion elements 16 may also be inserted in one and the same profiled component 10. For the enlargement under high internal pressure of a shaped component 10 consisting of FVK, it will further preferably use hot gas, a relatively large number of varieties of FVK being hygroscopic, and the use of water or an aqueous emulsion having disadvantages on the formation and properties of the composite component.

Claims (10)

REVENDICATIONS1. A method of manufacturing a composite component, wherein an insertion member (16) is disposed and fixed in a cavity (12) of a portion (14) of a shaped component (10) having a hollow section, characterized in that the preferably socket-shaped insertion element (16) is connected by means of at least one form-compliant coupling (60) to the profiled component (10) formed as a deformed component under high internal pressure. 2. Method according to claim 1, characterized in that the insertion element (16) is pre-fixed on the profiled component (10) before deformation under high internal pressure. 3. Method according to claim 2, characterized in that the insertion element (16) is pre-fixed on the profiled component (10) by means of a seal (20). 25 A method according to claim 1, characterized in that the insertion element (16) is pre-attached to the profiled component (10) during deformation under high internal pressure. 5. Method according to claim 4, characterized in that the insertion element (16) is pre-fixed on the profiled component (10) during the deformation under high internal pressure, by means of at least one compacting punch. (28) of an internal high pressure deformation installation (24). 6. Method according to one of claims 1 to 5, characterized in that the profiled component (10) is provided on its outer contour of a plastic material (94) to form a hybrid composite component. 7. Method according to one of claims 1 to 6, characterized in that the one or more form-compliant couplings (60) are obtained by a pressure applied from the outside to the profiled component. Process according to claims 6 and 7, characterized in that the pressure applied from the outside to the shaped component (10) is generated by the plastic casting (72). 9. Method according to one of claims 1 to 6, characterized in that the one or more form-compliant couplings (60) are obtained by a pressure applied from the inside on the profiled component (10) and / or the insertion element (16). 30 Composite component with a shaped component (10) having a hollow section at least in a component part (12), in the cavity (14) of which an insertion element (16) is arranged and fixed on the profiled component ( 10), characterized in that the shaped component (10) is formed as a deformed component under high internal pressure, which is connected by means of at least one form-compliant coupling (60) to the insertion element (16). ).