FR3041303A1 - STRUCTURAL AND / OR ENERGY ABSORPTION ELEMENT FOR A MOTOR VEHICLE AND METHOD FOR MANUFACTURING THE SAME - Google Patents

Abstract

The present invention relates to a structural element and / or energy absorption for a motor vehicle, comprising a carrier element (1) oblong and three-dimensional shape of a metal material, and at least one hollow body (2) oblong and to closed section of a composite of a thermoplastic matrix material and braided or woven reinforcing fibers, wherein the hollow body (2) and the carrier element (1) are interconnected by material connection via at least one link layer, and / or through positive engagement. According to the invention, the carrier element (1) has an open section with at least one access region (5) and the carrier element (1) surrounds the hollow body (2), so that the part (6) ) of the hollow body (2) which remains accessible in the access region (5) can be used for connection with at least one additional reinforcing element (7). The invention also relates to a method of manufacturing a structural element and / or energy absorption.

Description

DESCRIPTION The invention relates to a structural and / or energy absorbing element for a motor vehicle, comprising an oblong carrier element of three-dimensional shape made of a metallic material, and at least one oblong hollow body with a closed section, in one composite material of a thermoplastic matrix material and braided or woven reinforcing fibers, wherein the hollow body and the carrier member are interconnected by bonding material via at least one bonding layer and / or via a positive engagement. The invention also relates to a method of manufacturing such a structural element and / or energy absorption for a motor vehicle.

Structural and / or energy absorbing elements for a motor vehicle can be derived from DE 10 2014 102 199 A1 or DE 10 2005 020 907 A1. However, the structural and / or absorption elements of Prior art known in the art has the disadvantage that they can only be adapted in a limited way to different load cases and requirements. The object of the invention is therefore to indicate a structural and / or energy absorbing element, as well as a method for its manufacture, which with respect to the elements of the state of the art can be adapted from a significantly more flexible and economical way to different load cases and requirements. The invention achieves this goal by a structural element and / or energy absorption for a motor vehicle comprising an oblong carrier member and three-dimensional shape of a metal material and at least one hollow body oblong and closed section, in one composite of a thermoplastic matrix material and braided or woven reinforcing fibers, the hollow body and the carrier being interconnected by bonding material via at least one bonding layer and / or via a positive engagement (by form complementarity), knowing that the carrier element has an open section with at least one access region and the carrier member surrounds the hollow body, so that the portion of the hollow body that remains accessible in the access region may be used for connection with at least one additional reinforcing element. The configuration according to the invention of the structural element and / or energy absorption allows, by the connection of the hollow body with at least one additional reinforcing element, an unlimited number of configurations of the structural element and / or energy absorption from a basic configuration consisting of the carrier member and the hollow body. Preferably, at least a partial region of the accessible portion of the hollow body then forms a bonding zone with one or the reinforcing element.

The braided or woven reinforcing fibers may in particular be braided or woven reinforcing continuous fibers.

The braided or woven reinforcing fibers may be disposed in the thermoplastic matrix material in a biaxial manner, preferably with a fiber orientation of ± 30 to ± 60 °, in particular ± 45 °, with respect to the direction of longitudinal development of the material. hollow body. The braided or woven reinforcing fibers may also be triaxially disposed in the thermoplastic matrix material. Preferably, the braided or woven reinforcing fibers may be arranged in the thermoplastic matrix material with a fiber orientation of ± 30 to ± 60 °, especially ± 45 °, and with a fiber orientation of 0 ° to 5 °, relative to the longitudinal development direction of the hollow body. The reinforcing member may comprise at least one fiber-reinforced cover layer. The reinforcing element, in particular the at least one fiber-reinforced overlayer, may furthermore be connected to an outer face of the carrier element by bonding material via at least one other bonding layer, and / or by through a positive engagement. The outer face is defined as being a face that is not facing the hollow body. The hollow body and the reinforcing element, in particular the at least one fiber-reinforced overlayer, thus at least partially enclose the carrier element. The carrier element may have at least one recess passing through the carrier element. The recess can in particular be used for the realization of the positive engagement with the hollow body and / or the reinforcing element. In general, the recess can be used so that the hollow body is, via the recess, also accessible from the outside. It may be particularly advantageous for the reinforcement element, in particular the at least one fiber-reinforced overlayer, to extend to the recess, so that the hollow body is connected to the reinforcing element, particularly by bonding material, via a partial region of the accessible portion of the hollow body which forms a connection zone, and in addition in the region of the recess.

The at least one cover layer may be formed by at least one fabric layer consisting of continuous reinforcing fibers in a thermoplastic matrix material, and / or at least one nonwoven layer consisting of continuous reinforcing fibers in a material thermoplastic matrix, and / or at least one layer of multiaxial nonwoven consisting of continuous reinforcing fibers in a thermoplastic matrix material, and / or at least one embroidery layer made of continuous reinforcing fibers in or on a material of thermoplastic matrix, and / or at least one braiding layer consisting of continuous reinforcing fibers in a thermoplastic matrix material, and / or at least one mat consisting of short or long reinforcing fibers in a thermoplastic matrix material, and / or at least one fiber reinforced organic sheet with a thermoplastic matrix material.

In particular, a fabric is obtained by weaving together continuous reinforcing fibers. In a nonwoven, the reinforcing fibers may be ideally stretched and parallel to one another. In a multiaxial nonwoven, the continuous reinforcing fibers may not be oriented exclusively in the plane. In addition, the continuous reinforcing fibers may be oriented at least partly perpendicular to the main plane of the nonwoven. In the case of embroidery, the reinforcing fibers are embroidered and fixed on any strips on a carrier material (eg a web). Braid layers are made especially by weaving together continuous reinforcing fibers. Mats are most often constituted of short fibers and / or long irregular orientation, which are interconnected by means of a thermoplastic matrix material. The carrier element may have, at the level of the access region, at least one flange protruding from the carrier element. The reinforcing member may further be connected to the flange by bonding material via the bonding layer and / or another bonding layer, and / or via positive engagement. In a preferred manner, the carrier member and / or the reinforcing member and / or the hollow body may be connected to a material-absorbing energy absorber and / or through positive engagement. The material of the energy absorber may in particular be of identical type or compatible with the matrix material of the reinforcing element or the matrix material of the hollow body. Preferably, the carrier member and / or the reinforcing member is or is connected to an energy absorber by bonding material via the bonding layer or other bonding layer. The structural and / or energy absorbing element may be a bending-biased support, a flexural bending support, an A-pillar, an B-pillar, a C-pillar, a D-pillar, a B-pillar door, roof frame, roof arch, tailgate, door, door reinforcement, door shock mount, bumper, front structure, bumper trim or component aforementioned elements. The carrier member may be an aluminum-based material or a magnesium-based material or a titanium-based material or an iron-based material. The carrier member of three-dimensional shape can be manufactured by a deep drawing process or by a rolling method or by a forging process.

The tie layer and / or the other tie layer may be a layer of a material that includes an adhesion promoting substance. The adhesion promoting substance may comprise in particular a polyurethane, a polyester, a thermoplastic fusible glue and / or an epoxy resin. The tie layer may be formed solely or additionally by an insert of continuous reinforcing fibers in a thermoplastic matrix material.

The semi-product starting from the hollow body may in particular be an oblong hollow body and closed section, consisting of a braided or woven composite, unconsolidated, thermoplastic fibers and reinforcing fibers. This woven composite or non-consolidated woven may in particular be a composite flexible hose consisting of a braided composite or woven thermoplastic fibers and continuous reinforcing fibers. Such a composite may be called a "hybrid wire composite". The braided or woven reinforcing fibers may be arranged biaxially, preferably with a fiber orientation of ± 30 to ± 60 °, especially ± 45 °, with respect to the longitudinal development direction of the composite hose. The braided or woven reinforcing fibers may also be arranged triaxially. Preferably, the braided or woven reinforcing fibers may be arranged with a fiber orientation of ± 30 to ± 60 °, in particular ± 45 °, and with a fiber orientation of 0 ° to 5 °, with respect to the direction. longitudinal development of the composite hose.

Preferably, the composite hose is a composite hose braided in round or woven in a round.

The thermoplastic fibers may be configured as thermoplastic webs or thermoplastic webs.

Preferably, a thermoplastic tubular film is disposed within the composite hose. The tubular film is here of a comparable function or identical to the expansion profiles used (blow tubes for example), as known in the state of the art. The melting temperature of the tubular film material here is preferably greater than the melting temperature of the thermoplastic fibers. Preferably, the melting temperature of the thermoplastic material of the tubular film is at least 30 degrees Kelvin higher than the melting temperature of the thermoplastic fibers. By "melting temperature" is generally meant for thermoplastic materials having a melting range the beginning of the melting range. The thermoplastic tubular film is preferably disposed in the composite flexible pipe as soon as it is manufactured, for example by the fact that the tubular film is surrounded by weaving or braiding by the thermoplastic fibers and / or the continuous reinforcing fibers. The tubular film may comprise at least two layers, knowing that the melting temperature of the material of at least one of the layers is greater than the melting temperature of the thermoplastic fibers. Even more preferably, the material of the layer facing the inner surface of the composite hose is compatible with the material of the thermoplastic fibers. Even more preferably, the material of this layer has a melting point of the level of the thermoplastic fibers. This means in particular that the outer layer, therefore the layer of the tubular film which is turned towards the inner surface of the composite hose when the tubular film is disposed within the composite hose, has compatibility with the material of the thermoplastic fibers. and / or the same melting temperature or a comparable melting temperature, so that a material connection can be achieved by welding or brazing between this layer and the thermoplastic fibers or the thermoplastic matrix material of the hollow body. Preferably, the material of the outer layer, or the material of the layer of the multilayer tubular film which faces the inner surface of the composite flexible pipe, is identical or identical in type to the material of the thermoplastic fibers or to the matrix material. thermoplastic hollow body. The at least one layer among the other layers of the tubular film is then preferably formed by a material whose melting temperature is higher than the melting temperature of the thermoplastic fibers or the thermoplastic matrix material of the hollow body. The outer layer, or the layer that faces the inner surface of the composite hose, can thus serve as a transition layer to the inner surface of the composite hose or the hollow body. Preferably, the multilayer tubular film is made by means of a coextrusion process, and the layers of the tubular film are interconnected by bonding material.

The tubular film preferably has a wall thickness in the range of 0.01 to 0.2 mm, even more preferably in the range of 0.05 to 0.1 mm, even more preferably in the range of 0.065 to 0.085 mm.

The thermoplastic matrix material or the material of the thermoplastic fibers of any of the preceding or following definitions may comprise polysulfone (PSU), polyethersulfone (PES), polyetherimides (PEI), polyphenylene sulfide (PPS), polyphenylene sulfone (PPSU) ), polyetheretherketone (PEEK), polyetherketones (PEK), polyamide-imide (PAI), poly (m-phenylene isophthalamide) (PMI), polyphthalamides (PPA), polybenzimidazoles (PBI), polytetrafluoroethylene (PTFE) ), perfluoroalkoxy alkane (PFA), polyoxymethylene (POM), polyamide (PA), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polymethyl methacrylate (PMMA), polystyrene (PS) , syndiotactic polystyrene (sPS), polycarbonate (PC), styrene-acrylonitrile copolymer (SAN), polyphenylene ether (PPE), polyvinylchloride (PVC), polyethylene (PE), polypropylene (PP) ), acrylonitrile-butadi ene-styrene (ABS) or mixtures of the aforesaid materials.

The short, long, continuous reinforcing fibers and / or reinforcing fibers of all the preceding or following definitions may comprise glass fibers, carbon fibers, aramid fibers, flax fibers, jute fibers, boron fibers, sisal fibers, ceramic fibers, metal fibers, basalt fibers or mixtures of the aforementioned fibers.

The open section of the carrier element may in particular be A-shaped, C-shaped, E-shaped, H-shaped, K-shaped, L-shaped, M-shaped, M-shaped, N-shaped, S-shaped, U-shaped, V-shaped, W-shaped, X-shaped, Y-shaped, Z-shaped, Ω or co-shaped.

The term "section" means a cutting surface perpendicular to the longitudinal development respectively of the carrier element, the composite flexible pipe, the hollow body or the structural element and / or energy absorption.

A method according to the invention for manufacturing a structural element and / or energy absorption, in particular of the type described above, comprises the following steps: - provision of an oblong carrier element and of three-dimensional shape in a metallic material, wherein the carrier element has an open section with at least one access region, and - providing an elongate, closed-section composite consisting of continuous reinforcing fibers and braided thermoplastic fibers or woven, unconsolidated, in the form of a composite flexible hose, - positioning of the composite flexible pipe inside the carrier element, so that the carrier element surrounds the composite hose, - connection of the composite hose and the carrier member between them via at least one material bonding layer and / or a positive engagement, - forming a hollow body by solidifying the hose the composite, - connecting the portion of the composite flexible pipe or the hollow body remaining accessible in the access region with at least one additional reinforcing element, via a connection zone.

The bonding layer and / or the other bonding layer can be applied to the carrier element at the step of providing the carrier element, for example by spray or brush application, or already applied. on the carrier element during this step, in particular by a continuous coating ("coil coating") of the starting material (for example a sheet) of the carrier element. Spraying or brushing can preferably be carried out following the three-dimensional shaping of the carrier element. By against the "coil coating" can be carried out preferably before the three-dimensional formatting.

The connection of the composite flexible pipe and the carrier element to one another during the consolidation of the thermoplastic fibers and the reinforcing fibers of the composite flexible pipe can be effected by heating the thermoplastic fibers to or above their temperature. melting with simultaneous increase of the inner pressure of the composite hose.

The consolidation can in particular be carried out by the following steps: provision of an expansion profile inside the composite flexible pipe; heating the composite hose to above the melting temperature of the thermoplastic fibers; receiving the carrier member, with the composite hose positioned within said member, within a cavity of a forming mold - which is surrounded by at least one wall of the forming mold defining the contour of the structural element and / or energy absorption -; and increasing the internal pressure by applying pressure to a fluid under pressure located and / or introduced into the expansion profile. The solidification can be effected by cooling the composite flexible pipe below the melting temperature of the thermoplastic fibers or the thermoplastic matrix material formed therefrom. The expansion profile may in particular be a tubular film described above. The tubular film can remain inside the hollow body that has formed. As pressurized fluid, air, rare gases, oils or water are usually used. For heating purposes, it is possible to use, for example, infrared radiators or convection ovens or comparable heat sources. If the continuous reinforcing fibers have electrical conductivity, it is also possible to heat the composite flexible pipe by induction. The heating can also be performed via induction heating of the carrier element. The step of heating the composite hose up to above the melting temperature of the thermoplastic fibers can be done before, during or after the positioning of the composite hose inside the carrier element, or before during or after receiving the carrier member within the cavity of the forming mold.

The consolidation can preferably be carried out inside a variothermal forming mold.

A structurally and / or energy absorbing member produced in a corresponding manner may, in the further processing, be introduced into a plastic injection mold, and additional thermoplastic material may be overmolded to form or to form other functional elements such as ribs, other attachment points, decorative areas or sealing portions. Advantageously, it is then possible again to pressurize a tubular film still disposed inside the hollow body, so that a sufficient back pressure can be maintained with respect to the injection pressure of the mold. injection of plastic, so that the hollow body does not flattens. It is furthermore possible for the plastic injection mold itself to form the forming mold, and for the additional plastic injection molding, to shape or form other functional elements such as, for example, ribs. other fixing points, decorative zones or sealing parts, is carried out parallel to the consolidation and / or thermoforming step of the composite flexible pipe or the hollow body, or following this step . The three-dimensional shaped carrier member may be manufactured by a deep drawing process or rolling or forging process. The manufacture of the carrier member may be part of the process described.

The connection of the part of the composite flexible pipe or the hollow body, remaining accessible in the access region, with at least one additional reinforcing element may in particular be carried out simultaneously with the connection of the composite flexible pipe or the hollow body with the carrier element. Even more preferably, the connection of the portion of the composite flexible pipe or the hollow body, remaining accessible in the access region, with at least one additional reinforcing element takes place in the same forming mold in which the connection of the composite flexible pipe or the hollow body with the carrier element is also carried out.

As an alternative to this, it is possible to effect the connection of the part of the hollow body remaining accessible in the access region with at least one additional reinforcing element during a subsequent step, preferably by a new fusion of said part of the hollow body. The following description describes the invention with the aid of the drawings, which represent only exemplary embodiments and among which, schematically: FIGS. 1a, 1b are top views of a first exemplary embodiment of FIG. a structural and / or energy absorbing element, FIG. 2 is a cross-sectional representation of a structural element and / or energy absorption along the section line AA of FIG. FIG. 3 is a cross-sectional representation of the carrier element with bonding layers applied to the carrier element, FIGS. 4a, 4b are top views of another embodiment of a structural element and / or 5 is a cross-sectional representation of a structural element and / or energy absorption along the section line AA of FIG. 4b, FIG. trans cut of the carrier member with bonding layers applied to the carrier member, FIG. 7 shows schematic representations of possible section geometries of the carrier member, as well as the corresponding position of the access regions, FIG. is a cross-sectional representation of a structural element and / or energy absorption along the section line BB of FIG. 9, FIG. 9 is a bottom view of the side of a structural element and / or energy absorption facing the access region, Figure 10 is a cross-sectional representation of a structural element and / or energy absorption along the section line BB of the Fig. 11 is a bottom view of the side of a structural and / or energy absorbing member facing the access region, Fig. 12 is a cross-sectional representation of an element structu rel and / or energy absorption along the section line CC of Figure 13, Figure 13 is a bottom view of the side of a structural element and / or energy absorption that faces 14 is a cross-sectional representation of a structural element and / or energy absorption along the sectional line AA of FIG. 15, FIG. 15 is a view of FIG. above another embodiment of a structural element and / or energy absorption with, as a bonding layer, an insert consisting of continuous reinforcing fibers in a thermoplastic matrix material, FIG. in cross-section of a composite hose and a hollow body, Fig. 17 is another cross-sectional representation of a composite hose and a hollow body, Fig. 18 is a representation of a hose composite and a hollow body.

In the figures, the identical elements or the same function are provided with the same reference numerals. The components of the reinforcing element 7, the hollow body and the bonding layer 3 which are not fully represented in the figures are present integrally in the actual structural parts, and they are interrupted only for purposes of illustration. .

Figures 1 to 15 show variants of a structural element and / or energy absorption for a motor vehicle, comprising a carrier element 1 oblong and three-dimensional shape of a metal material, and at least one hollow body 2 oblong and closed section, a composite of a thermoplastic matrix material 2a and reinforcing fibers 2b braided or woven, knowing that the hollow body 2 and the carrier element 1 are interconnected by material connection via at least one connecting layer 3, 3 ", and / or via a positive engagement 4, knowing that the carrier element 1 has an open section with at least one access region 5 and that the carrier element 1 surrounds the hollow body 2, so that the portion 6 of the hollow body 2 which remains accessible in the access region 5 can be used for connection with at least one additional reinforcing element 7. At least one region that of the accessible portion 6 of the hollow body 2 forms a connecting zone 6 'with a reinforcing element 7. The reinforcing element comprises at least one fiber-reinforced covering layer.

The at least one cover layer may be formed by at least one fabric layer consisting of continuous reinforcing fibers in a thermoplastic matrix material, and / or at least one nonwoven layer consisting of continuous reinforcing fibers in a material thermoplastic matrix, and / or at least one layer of multiaxial nonwoven consisting of continuous reinforcing fibers in a thermoplastic matrix material, and / or at least one embroidery layer made of continuous reinforcing fibers in or on a material of thermoplastic matrix, and / or at least one braiding layer consisting of continuous reinforcing fibers in a thermoplastic matrix material, and / or at least one mat consisting of short or long reinforcing fibers in a thermoplastic matrix material, and / or at least one fiber reinforced organic sheet with a thermoplastic matrix material. The carrier element 1 has, at the level of the access region 5, at least one flange 8 protruding from the carrier element 1, and the reinforcing element 7 is further connected to the flange 8 by connection of material via the bonding layer 3 and / or another bonding layer 3 ', and / or via a positive engagement. The carrier element 1 and / or the reinforcing element 7 is / are connected to a energy absorber 11 by bonding material via the bonding layer 3 or the other bonding layer 3 ', and / or through a positive engagement. The structural and / or energy absorbing element may be a bending-biased support, a flexural bending support, an A-pillar, an B-pillar, a C-pillar, a D-pillar, a B-pillar door, roof frame, roof arch, tailgate, door, door reinforcement, door grab, front structure, bumper, bumper trim or component aforementioned elements. The carrier element 1 may consist of a material based on aluminum or magnesium or titanium or iron. The carrier element 1 of three-dimensional shape can be manufactured by a deep drawing process or rolling or forging.

The tie layer 3, 3 "and / or the other tie layer 3 'may be a layer made of a material which comprises an adhesion promoting substance.

The bonding layer 3 "may be formed solely or additionally by an insert consisting of continuous reinforcing fibers in a thermoplastic matrix material.

The thermoplastic matrix material may comprise polysulfone (PSU), polyethersulfone (PES), polyetherimides (PEI), polyphenylene sulfide (PPS), polyphenylene sulfone (PPSU), polyetheretherketone (PEEK), polyetherketones (PEK) , polyamide-imide (PAI), poly (m-phenylene isophthalamide) (PMI), polyphthalamides (PPA), polybenzimidazoles (PBI), polytetrafluoroethylene (PTFE), perfluoroalkoxy alkane (PFA), polyoxymethylene (POM) ), polyamide (PA), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polymethyl methacrylate (PMMA), polystyrene (PS), syndiotactic polystyrene (sPS), polycarbonate (PC) , a styrene-acrylonitrile copolymer (SAN), polyphenylene ether (PPE), polyvinylchloride (PVC), polyethylene (PE), polypropylene (PP), acrylonitrile-butadiene-styrene (ABS) or mixtures of the aforesaid materials.

The short, long and / or continuous reinforcing fibers may comprise glass fibers, carbon fibers, aramid fibers, flax fibers, jute fibers, boron fibers, sisal fibers, ceramic fibers, metal fibers, basalt fibers or mixtures of the aforementioned fibers.

A method of manufacturing a structural element and / or energy absorption, in particular as described above, comprises the following steps: providing an oblong and three-dimensional shaped carrier element 1, in one metal material, knowing that the carrier member 1 has an open section with at least one access region 5, and provided with an oblong composite and closed section consisting of continuous reinforcing fibers 2b and thermoplastic fibers 2a braided or woven, unconsolidated, in the form of a composite hose 2 ', positioning the composite hose 2' within the carrier member 1, so that the carrier member 1 surrounds the composite hose 2 connecting the composite flexible pipe 2 'and the carrier element 1 to each other via at least one material connecting layer 3, 3 "and / or a positive engagement 4, forming a hollow body 2 by lidification of the composite flexible pipe 2 ', connection of the part 6 of the composite flexible pipe 2' or of the hollow body 2 remaining accessible in the access region 5 with at least one additional reinforcing element 7, via a connection zone 6 ' .

The connection layer 3, 3 "and / or the other bonding layer 3 'can, during the step of providing the carrier element 1, be applied or have already been applied to the carrier element 1 .

The connection of the composite hose 2 'and the carrier element 1 between them during the consolidation of the thermoplastic fibers 2a and the reinforcing fibers 2b of the composite hose 2' can be effected by heating the thermoplastic fibers 2a to or up to their melting temperature with simultaneous increase in the internal pressure of the composite hose 2 '.

Consolidation can be done inside a variothermic mold.

The thermoplastic matrix material or the material of the thermoplastic fibers may comprise polysulfone (PSU), polyethersulfone (PES), polyetherimides (PEI), polyphenylene sulfide (PPS), polyphenylene sulfone (PPSU), polyetheretherketone (PEEK) , polyetherketones (PEK), polyamide-imide (PAI), poly (m-phenylene isophthalamide) (PMI), polyphthalamides (PPA), polybenzimidazoles (PBI), polytetrafluoroethylene (PTFE), perfluoroalkoxyalkane (PFA) ), polyoxymethylene (POM), polyamide (PA), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polymethyl methacrylate (PMMA), polystyrene (PS), syndiotactic polystyrene (sPS) , polycarbonate (PC), styrene-acrylonitrile copolymer (SAN), polyphenylene ether (PPE), polyvinylchloride (PVC), polyethylene (PE), polypropylene (PP), acrylonitrile butadiene-styrene (ABS) or mixtures of écités.

FIGS. 1a and 1b show, in a three-dimensional top view on a structural element and / or of energy absorption for a motor vehicle, the bonding layer 3 which has an adhesion promoting substance which allows a bond of material between the hollow body 2 and the carrier element 1. The reinforcing element 7 is formed by a fiber-reinforced covering layer, which is formed by a layer of nonwoven consisting of continuous reinforcing fibers in a matrix material thermoplastic with a fiber orientation of 0 ° with respect to the direction of longitudinal development of the structural element and / or energy absorption, and another layer of nonwoven made of continuous reinforcing fibers in a material of thermoplastic matrix with a 90 ° fiber orientation with respect to the longitudinal development direction of the structural element and / or absorption energy. The two-layer structure of the cover layer is again visible more clearly in Fig. 2, which corresponds to a cross-sectional representation of the section line A-A of Fig. 1b. In FIGS. 2 and 3, a flange 8 protruding from the carrier element 1, which is connected by bonding material to the reinforcing element 7 via the bonding layer 3, can also be distinguished. The element of FIG. reinforcement 7 is thus connected by material connection to both the hollow body 2 and, via the connecting zone 6 ', to the carrier element 1.

FIG. 3 shows that the carrier element 1 has on its outer face another bonding layer 3 ', which can be used for bonding the carrier element with additional thermoplastic material.

Figures 4a and 4b show, in a three-dimensional top view on a structural element and / or energy absorption for a motor vehicle, the bonding layer 3 which has an adhesion promoting substance which allows a connection of material between the hollow body 2 and the carrier element 1. The reinforcing element 7 is formed by a fiber-reinforced covering layer, which is formed by a mat made of short or long reinforcing fibers in a thermoplastic matrix material, and by a nonwoven layer made of continuous reinforcing fibers in a thermoplastic matrix material with a 90 ° fiber orientation with respect to the direction of longitudinal development of the structural element and / or energy absorption .

The two-layer structure of the cover layer is again visible more clearly in Fig. 5, which corresponds to a cross-sectional representation of the section line A-A of Fig. 4b. In FIGS. 5 and 6, it is furthermore possible to distinguish a flange 8 protruding from the carrier element 1, which is connected by bonding material to the reinforcing element 7 via the bonding layer 3. The element of FIG. reinforcement 7 is thus connected by material connection to both the hollow body 2 and, via the connecting zone 6 ', to the carrier element 1.

FIG. 6 shows that the carrier element 1 has on its outer face another bonding layer 3 ', which can be used for bonding the carrier element with additional thermoplastic material.

FIG. 7 shows possible geometries of the open section of the carrier element, which may be A-shaped, C-shaped, E-shaped, H-shaped, L-shaped, K-shaped, M-shaped, m-shaped, N-shaped, S-shaped, U-shaped, V-shaped, W-shaped, X-shaped, Y-shaped, Z-shaped, Ω-shaped or en-shaped.

Figure 8 shows, in a cross-sectional view along section line B-B of Figure 9, a structural element and / or energy absorption for a motor vehicle. The carrier element 1 has at least one recess passing through the carrier element 1. The recesses serve to make positive engagement with the hollow body 2. The hollow body 2 is further connected by material connection to the carrier element 1 via the bonding layer 3. The reinforcing element 7 corresponds to that of FIG. 5.

Figure 10 shows, in a cross-sectional view along section line B-B of Figure 11, a structural and / or energy absorbing member for a motor vehicle. The carrier element 1 has at least one recess passing through the carrier element 1. The recesses serve to make positive engagement with the hollow body 2. The hollow body 2 is further connected by material connection to the carrier element 1 via the bonding layer 3. The reinforcing element 7 corresponds to that of FIG. 3. The reinforcing element is further connected by bonding material to an outer face of the carrier element 1 via at least one other layer. link 3 '. The outer face is defined as being a face that is not opposite the hollow body 2. The hollow body 2 and the reinforcing element 7 thus at least partially enclose the carrier element 1 between them. The reinforcing element 7 extends to the recess or the recesses, so that the hollow body 2 is connected to the reinforcing element 7, in particular by material connection, via the partial region of the accessible part. 6 of the hollow body 2 which forms a connecting zone 6 ', and in addition in the region of the recess.

Figure 12 shows, in a cross-sectional view along section line C-C of Figure 13, a structural and / or energy absorbing member for a motor vehicle. The carrier element 1 and the at least one hollow body 2 are connected by bonding material to an energy absorber IL. The material of the energy absorber 11 is of identical or compatible type with the thermoplastic matrix material 2a of the hollow body 2. The material connection with the carrier element 1 is performed via the other bonding layer 3 '. The energy absorber can be formed on the structural element and / or energy absorption by means of a plastic injection process.

Fig. 14 shows, in a cross-sectional view along section line A-A of Fig. 15, a structural and / or energy absorbing member for a motor vehicle. The hollow body 2 at least one is connected by bonding material to the carrier element 1 by a connecting layer 3, 3 ". The tie layer 3 comprises an adhesion promoting substance. The other bonding layer 3 "is formed by an insert consisting of unidirectional orientation reinforcing continuous fibers in a thermoplastic matrix material, knowing that this thermoplastic matrix material is of identical type or compatible with the thermoplastic matrix material 2a. hollow body 2.

FIG. 16 schematically represents a cross-section of a composite flexible hose 2 'that can be used in the process according to the invention, consisting of a composite of thermoplastic fibers 2a and of unstructured, woven or woven reinforcing continuous fibers 2b. A tubular film 15 is disposed within the composite hose 2 '; it serves as an expansion profile and, by increasing the internal pressure by applying a pressurized fluid under pressure and / or introduced into the expansion profile, it increases the internal pressure of the composite hose 2 '. FIG. 16 also similarly represents an oblong and closed-section hollow body 2 consisting of a composite of thermoplastic matrix material 2a and braided or woven reinforcing fibers 2b, whereas here, relative to in the composite flexible pipe 2 ', the only difference is that the thermoplastic matrix material 2a has formed by melting the thermoplastic fibers 2a. Due to its low self weight, the tubular film 15 can remain in the hollow body 2.

FIG. 17 differs from FIG. 16 only in that the tubular film is made multilayer and has an additional outer layer 16 which is made of a material which is compatible with the material of the thermoplastic fibers 2a of the composite hose 2 or with the thermoplastic matrix material 2a of the hollow body 2.

FIG. 18 schematically represents a composite flexible hose 2 'used in the process according to the invention, consisting of a composite of thermoplastic fibers 2a and of continuous, non-consolidated, braided or woven reinforcement fibers 2b. FIG. 18 also shows, in a similar manner, an oblong and closed-section hollow body 2 consisting of a composite of a thermoplastic matrix material 2a and of braided or woven reinforcing fibers 2b, whereas here, with respect to in the composite flexible pipe 2 ', the only difference is that the thermoplastic matrix material 2a has formed by melting the thermoplastic fibers 2a.

Of course, the invention is not limited to the embodiments described and shown in the accompanying drawings. Modifications are possible, particularly from the point of view of the constitution of the various elements or by substitution of technical equivalents, without departing from the scope of protection of the invention.

Claims (16)

A structural and / or energy absorbing element for a motor vehicle, comprising: - an oblong and three-dimensional shaped carrier element (1) made of a metallic material, and - at least one oblong hollow body (2) and closed section, made of a composite of a thermoplastic matrix material (2a) and braided or woven reinforcing fibers (2b), wherein the hollow body (2) and the carrier element (1) are interconnected by material connection via at least one connecting layer (3, 3 ") and / or via a positive engagement (4), characterized in that the carrier element (1) has an open section with at least an access region (5) and the carrier element (1) surrounds the hollow body (2), so that the portion (6) of the hollow body (2) which remains accessible in the access region (5) may be used for bonding with at least one additional reinforcing element (7). 2. Structural element and / or energy absorbing element according to claim 1, characterized in that at least a partial region of the accessible part (6) of the hollow body (2) forms a connection zone (6 ') with a reinforcing element (7). Structural and / or energy absorbing element according to one of the preceding claims, characterized in that the reinforcing element (7) comprises at least one fiber-reinforced cover layer. Structural and / or energy absorbing element according to Claim 3, characterized in that the at least one cover layer is formed by at least one layer of fabric consisting of continuous reinforcing fibers in a thermoplastic matrix material. and / or at least one nonwoven layer consisting of continuous reinforcing fibers in a thermoplastic matrix material, and / or at least one multiaxial nonwoven layer consisting of continuous reinforcing fibers in a thermoplastic matrix material, and / or at least one embroidery layer consisting of continuous reinforcing fibers in or on a thermoplastic matrix material, and / or at least one braiding layer made of continuous reinforcing fibers in a thermoplastic matrix material, and / or less a mat consisting of short or long reinforcing fibers in a thermoplastic matrix material, and / or at least one organic sheet fiber-filled with a thermoplastic matrix material. Structural and / or energy absorbing element according to one of the preceding claims, characterized in that the carrier element (1) has at least one flange at the region of access (5). (8) protruding from the carrier member (1), and the reinforcing member (7) is further connected to the flange (8) by bonding material via the bonding layer (3) and / or a other bonding layer (3 '), and / or via a positive engagement. Structural and / or energy absorbing element according to one of the preceding claims, characterized in that the carrier element (1) and / or the reinforcing element (7) is / are connected to an energy absorber (11) by bonding material, preferably via the bonding layer (3) or the other bonding layer (3 '), and / or via a positive engagement. 7. structural element and / or energy absorption according to one of the preceding claims, characterized in that the structural element and / or energy absorption is a support biased in bending, a support of impact bending, A-pillar, B-pillar, C-pillar, D-pillar, door sill, roof frame, roof arch, tailgate, door, door reinforcement, shock for a door, a bumper, a bumper cover or a component of the aforesaid elements. 8. Structural element and / or energy absorbing element according to one of the preceding claims, characterized in that the carrier element (1) consists of an aluminum-based material or a material based on magnesium or a material based on titanium or an iron-based material. 9. structural element and / or energy absorption according to one of the preceding claims, characterized in that the carrier element (1) of three-dimensional shape is manufactured by a deep drawing process or by a rolling method or by a forging process. Structural and / or energy absorbing element according to one of the preceding claims, characterized in that the bonding layer (3, 3 ") and / or the other bonding layer (3 ') is a layer consisting of a material which comprises a substance promoting adhesion. Structural and / or energy absorbing element according to one of the preceding claims, characterized in that the bonding layer (3 ") is formed solely or additionally by an insert consisting of continuous reinforcing fibers. in a thermoplastic matrix material. 12. Structural and / or energy absorbing element according to one of the preceding claims, characterized in that the thermoplastic matrix material comprises polysulfone (PSU), polyethersulfone (PES), polyetherimides (PEI), polyphenylene sulfide (PPS), polyphenylene sulfone (PPSU), polyetheretherketone (PEEK), polyetherketones (PEK), polyamide-imide (PAI), poly (m-phenylene isophthalamide) (PMI), polyphthalamides (PPA) , polybenzimidazoles (PBI), polytetrafluoroethylene (PTFE), perfluoroalkoxy alkane (PFA), polyoxymethylene (POM), polyamide (PA), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polymethacrylate methyl (PMMA), polystyrene (PS), syndiotactic polystyrene (sPS), polycarbonate (PC), styrene-acrylonitrile copolymer (SAN), polyphenylene ether (PPE), polyvinylchloride (PVC) , polyethylene (PE), polypropylene (PP), acrylonitrile-butadiene-styrene (ABS) or mixtures of the aforementioned materials. Structural and / or energy absorbing element according to one of the preceding claims, characterized in that the short, long and / or continuous reinforcing fibers comprise glass fibers, carbon fibers, aramid, flax fibers, jute fibers, boron fibers, sisal fibers, ceramic fibers, metal fibers, basalt fibers or mixtures of the aforementioned fibers. 14. A method of manufacturing a structural element and / or energy absorption, in particular according to one of claims 1 to 13, comprising the following steps: - provision of a carrier element (1) oblong and of three-dimensional shape, of a metallic material, knowing that the carrier element (1) has an open section with at least one access region (5), and - providing an elongate composite with a closed section consisting of continuous reinforcing fibers (2b) and non-consolidated braided or woven thermoplastic fibers (2a) in the form of a composite flexible pipe (2 '), -positioning the composite flexible pipe (2') inside of the carrier element (1), so that the carrier element (1) surrounds the composite flexible hose (2 '), - connection of the composite hose (2') and the carrier element (1) between them via at least one material bonding layer (3, 3 ") and / or an engagement positive (4), - formation of a hollow body (2) by solidification of the composite flexible pipe (2 '), - connection of the part (6) of the composite flexible pipe (2') or the hollow body (2) remaining accessible in the access region (5) with at least one additional reinforcing element (7) via a connection zone (6 '). Method for manufacturing a structural and / or energy absorbing element according to claim 14, characterized in that the bonding layer (3, 3 ") and / or the other bonding layer (3 ') ), during the step of providing the carrier element (1), is applied or has already been applied to the carrier element (υιό. Method of manufacturing a structural element and / or absorption of energy according to claim 14 or 15, characterized in that the connection of the composite flexible pipe (2 ') and the carrier element (1) between them during the consolidation of the thermoplastic fibers (2a) and reinforcing fibers (2b). ) of the composite flexible pipe (2 ') is effected by heating the thermoplastic fibers (2a) to or above their melting temperature with simultaneous increase of the inner pressure of the composite hose. 17. A method of manufacturing a structural element and / or energy absorption according to claim 16, characterized in that the consolidation is carried out inside a variothermal mold.