WO2007038912A1

WO2007038912A1 - Supporting frame, in particular for a roof system for a motor vehicle field

Info

Publication number: WO2007038912A1
Application number: PCT/DE2006/001730
Authority: WO
Inventors: Matthias Dichtl
Original assignee: Webasto Ag
Priority date: 2005-10-04
Filing date: 2006-10-02
Publication date: 2007-04-12
Also published as: DE102005047390B4; DE102005047390A1

Abstract

The invention relates to a supporting frame (1), in particular to a roof system for a motor vehicle field, comprising at least two longitudinal elements (2, 2', 3, 3') and at least two transversal elements (4, 5), wherein said longitudinal and transversal elements (2, 2', 3, 3', 4, 5) are made of a first high-strength material (10) for a first segment (6), of a second lower-strength material (11) for a second segment (7) and of the first and second materials (10, 11) for a third segment (8). A corresponding production method is also disclosed.

Description

description

Support frame, in particular for roof systems in the automotive sector

The present invention relates to a support frame, in particular for roof systems in the automotive sector, and to a corresponding method for producing such a support frame.

Such support frame for roof system in motor vehicles usually consist of metallic components, such as aluminum or steel profiles, injection molded parts or SMC components (Sheet Molding Compound). These components are used when mounting a roof system

Motor vehicle assembled and mounted on the vehicle body in different ways.

The functional elements necessary for the roof system, for example for adjusting a sunroof, can be attached to the

Pre-assembled frame or be attached during assembly with. Further assembly of, for example, wind deflectors and moldings requires appropriate mounting options on the support frame.

These mounting options, recordings, bearings, etc. require cost-intensive integration in the tool for producing the metallic components of the support frame.

Furthermore, in a frame manufacturing often welding processes for the preparation of compounds are involved, which are costly and also require subsequent straightening.

For this reason, functional elements for the roof systems in components of the support frame, for example in a front cross member, were integrated from an injection molding material. DE 101 44 738 A1 describes a frame for a vehicle Sliding roof, which has a front part made of plastic injection molding for receiving a drive motor with associated drive cable channels and attachable side parts made of metallic profile. The front part has transition sections, which are provided with receptacles for the attachment of the side parts, wherein seals of the parts are present. The side parts as metallic profiles are cost-intensive to produce, the front part made of plastic must be provided due to its lower strength with numerous stiffeners that limit its freedom of design.

DE 101 44 742 A1 describes a frame for a vehicle sliding roof, in which the front part of the frame is made of plastic and partially encloses guide tubes for the cable drive of the sunroof in deflection areas. When assembling the front part with metallic side profiles, it is important that the ducts are aligned for the cable drives, which requires special precision. The attachment of the side panels to the front part via

Resting the side panel ends on projections of the corner areas of the front part and by means of screwing. A stiffening of the front part made of plastic with ribbing is necessary.

In DE 100 15 504 Al a roof module with an exposed roof skin made of plastic is described which can be used in a vehicle roof. The functional elements are integrated into the roof skin by being cast in with it. Also, the roof skin can be made of injection molding. The functional elements also have reinforcing elements in the form of ribs, which are connected to the roof skin and other functional elements. For production, the functional elements are placed in an injection mold for the roof skin and at least partially enclosed with injection-molded material.

These systems have proven themselves, but on the one hand have the disadvantage of high tool and assembly costs and on the other hand the disadvantage of injection molded parts with low overall stiffness.

It is therefore the object of the present invention to improve a support frame for roof systems in such a way that the abovementioned disadvantages are eliminated and a better economy compared with the prior art is achieved.

This object is achieved by the support frame with the features of claim 1 and a method for producing the support frame with the features of claim 15.

The idea on which the present invention is based is that the support frame has both metallic components whose high rigidity / strength is utilized, with injection-molded components being connected to the metallic components in a hybrid construction whose representation possibilities of integrations of functional elements in the

Injection molding can be exploited.

An inventive support frame, in particular for roof systems in the motor vehicle sector, has at least two Längsele- elements; and having at least two transverse elements, wherein the longitudinal and transverse elements are formed in first portions of a first material having a high strength, in second portions of a second material having a lower strength and in third portions of the first and the second material. The combination of these different materials in different sections allows a weld-free construction, in which it is preferred that the longitudinal and transverse elements are connected to one another via connection points in third sections.

Advantageous embodiments and improvements are the subject of the dependent claims. The second material is preferably an injection-molded material, which is advantageously formable in corresponding injection molding tools. Here, the longitudinal and transverse elements of the first material overlap at their connection points in a certain area and corresponding connection openings have corresponding connection openings. The injection molding material penetrates these openings and envelops the connection points to a certain extent, whereby an advantageous corrosion protection of these compounds is ensured. Due to the design of the injection molding tool influencing the wrapping area is feasible in a simple manner.

It is advantageous that the connection openings are provided with edges, since this results in improved strength.

In a further embodiment, the longitudinal elements of the second material and at least one transverse element of the second material are integrally formed. Thus, large parts of the frame of the injection molding material can be produced, which can be used for receiving and / or training of puncture elements with great design freedom.

But also certain areas of the longitudinal and transverse elements of the first material can be provided for positive connection with enclosing components of the second material at any point with openings. The enveloping components made of the injection-molding material can be advantageously designed, so that a variety of design options for fasteners, receptacles and the like. results.

It is provided in a further embodiment that the longitudinal and transverse elements of the second material stiffening inserts of the first material or another material having a higher strength than the second material. By simply introducing suitable inserts into the injection molding tool so the components can be low Stiffness values are stiffened at the relevant sites.

It is particularly advantageous that the longitudinal and transverse elements made of the first material are provided with stiffeners of the second material. As a result, simple metal profiles can be used as components whose rigidity is easily achieved by suitable design, for example in the shape of a cross rib, by injection-molding or spraying on of second material.

A method according to the invention for producing a carrier frame has the following method steps: (i) providing the longitudinal and transverse elements of the first material with suitable dimensions, openings and connecting openings;

(ii) inserting the longitudinal and transverse elements of the first material into an injection mold; and; (iii) forming the support frame by introducing a second material as an injection molding material into the injection molding tool to form junctions of the longitudinal and transverse members of the first material.

Thus, a production of the support frame in a simple manner without elaborate welding operations with high component rigidity is achieved in a single operation.

It is advantageous that in process step (iii) forming the support frame functional elements for roof systems and / or recordings for such by the second material are advantageously formed simultaneously.

Stiffeners of the longitudinal and transverse elements of the first material by the second material are also created in a simple manner as well as longitudinal and transverse elements of the second material with.

The invention is explained in more detail below on the basis of exemplary embodiments with reference to the accompanying figures of the drawing. Hereby shows: Figure 1 shows a first embodiment of a support frame according to the invention;

Figure 2 shows a connecting portion of the support frame of Figure 1 in a schematic sectional view ..;

Figure 3 is a schematic sectional view of receptacles and fasteners;

Figure 4 is a sectional view according to A-A of Figure 1 and a schematic plan view thereof.

Figure 5 shows a second embodiment of a support frame according to the invention; and

6 shows a sectional view of a further connection point of the support frame according to FIG. 5.

In the figures of the drawing, the same reference numerals designate the same or functionally identical components, unless indicated otherwise.

In Fig. 1, a first embodiment of a support frame 1 according to the invention is shown in a schematic plan view.

The support frame 1 consists of a first and a second side element 2, 3 and a first and second transverse element 4, 5. The side elements 2, 3 are each connected at their ends to a transverse element 4, 5 in connection points such that a Frame for a roof system (not shown) for use in a motor vehicle results.

In this embodiment, the side and cross members 2, 3, 4, 5 are made of a first material 10, which may be, for example, steel or aluminum. In each of the connection points, a side element 2, 3 and a transverse element 4, 5 are arranged with their ends overlapping. These ends have connecting openings 18, which are expediently one above the other, as can be seen from an enlarged sectional illustration of a connection point in FIG. 2.

On the support frame 1, a portion representative of other portions with a circle by the reference numeral 6 is marked for a first section. In this area, only one component of the first material 10 is present.

A second section, which designates only one component with a second material 11, is not present in this first exemplary embodiment. Such will be described below in connection with a second embodiment in Fig. 5.

The connection points are marked with a circle which bears the reference numeral 8. This is a third section referred to, in which both the first material 10 and a second material 11 is present. In this case, the second material 11 is an injection-molded material, for example a suitable plastic, which has a lower rigidity than the first material 10.

This third section will now be explained in connection with FIG.

In Fig. 2, the junction of the end of the first

Cross member 4 with the end of the second side member 3 as a third section 8 shown. These ends are arranged overlapping, wherein the end of the transverse element 4 in this example is arranged above the end of the side element 3. Both ends each have a connection opening 18 which lie one above the other. The connection openings 18 are provided with an edge 17 which has been introduced, for example, during production by punching. The lateral and transverse elements 2, 3, 4, 5 are inserted in the arrangement shown in Fig. 1 after prior processing in dimensions and perforations in an injection mold (not shown). The mold is closed and the second material 11 is injected, the mold guiding it into the third sections 8 in this example. At these junctures of the lateral and transverse elements 2, 3, 4, 5, the injection-molding material forms a connection after cooling and curing, as shown in FIG. 2.

The connection point in the third section 8 is enveloped by the second material 11, this injection-molding material completely penetrating the connection opening 18 and surrounding a specific region of the end of the overlapping elements 3, 4. This is a positive connection, which is additionally stabilized by the edges 17 and secured against pulling out of the side and cross member 3, 4. Furthermore, the envelope with the second material 11 forms a corrosion protection of the connecting parts.

In the further context with Fig. 1, the side and cross members 3 and 4 are provided with openings 9, 9 ', which may be introduced at any point. At these points, which in turn form a third section with first and second material 10, 11, the second material 11 may, for example, be designed such that, as shown in FIG. 3, it completely penetrates and determines the openings 9, 9 'or 18 Wrapped areas.

In Fig. 3, several examples are shown, but are not limited to these. In the left-hand area, a core hole 13 is introduced above a connection opening 18, which serves for fastening a functional element, for example a cable guide. In the middle region, the component made of the second material 11 has a projection 15 which forms a receptacle, for example for a decorative strip or the like. In the right area an insert 14 is placed over the opening 9, for example, for attachment to the Vehicle body is provided. The arrangement of these inserts is only an example.

Such a component as shown in Fig. 3 of the injection-molded material may also be stiffened in certain areas with inserts of the first or another material.

It is particularly advantageous that the second material 11 can be used in one embodiment as a stiffener for the side and cross members 2, 3, 4, 5. Such

Example by means of a side member in section A-A of FIG. 1 in the upper part of Fig. 4 in a perspective view. The side member of the first material 10 is here embodied as a simple profile that is stiffened by the second material 11 within its legs. The lower part of Fig. 4 shows a plan view of the stiffening arrangement in one example as intersecting ribs.

This stiffening by the second material 11 can be carried out simultaneously with the third sections 8 of the joints in one operation during injection molding of the second material 1. This allows the use of cheaper profiles made of the first material.

A second embodiment of a support frame 1 shows

5. Here, the second transverse element 5 with two side elements 2 'and 3' is produced in one piece "from a casting", which can also be done in an injection molding tool as described above The transverse element 5 can be reinforced from the first material 10 by insert parts, for example angles (not shown).

The left region of the carrier frame in FIG. 5 is constructed as described in connection with FIG. 1. It is different, however, that the side elements 2, 2 'and 3, 3' consist of two materials 10, 11. These are connected in third sections 8, which is shown in Fig. 6 and will be explained below. In Fig. 5, the side members 2 ', 3' and the cross member 5 form second portions 7, in which only the second material 11 is present. Of course, certain areas, such as the corners, can be provided with reinforcements of the first or another material. This one-piece part of the second material 11 forms a frame portion, in which a high functional integration of functional elements at low cost by the free design of the second material 11 is made possible. These integrated functional elements can be, for example:

Guide rails, wind deflector connections, guide cable (duct) integration, trim fixing, screw (mounting) points, roller bearings, end stops and the like. more.

Fig. 6 shows a connection point between the side member 3 of the first material 10 and a side member 3 'of the second material 11. The side member 3 has at its end at this connection point the connection opening 18, which is completely penetrated by the second material 11 and forms a penetration 12 with a positive connection. In this case, the end of the side member 3 'of the second material 11 envelops the end of the side member 3 of the first material 10 by overlapping the Verbindungsδffnung 18 in a certain area.

A carrier frame 1 according to the invention is produced in the so-called hybrid method, the simple steps of which are described above.

In this way, a support frame with special advantages, namely:

no welding process necessary high component rigidity high integration capability

Corrosion protection easily executable Production "in one go" low closing pressure during injection molding, since the component is not completely back-injected, with the resulting additional advantages: - reduction of the area

Reduction of investment prices Reduction of investment tool costs

Although the present invention has been described above by means of preferred embodiments, it is not limited thereto, but modifiable in many ways.

For example, a sunroof drive motor may be mounted on a second material component as shown in FIG. 3, exploiting the damping characteristics of the second material.

In an embodiment of the guide cable channels in the second material results in a particularly advantageous noise reduction, which can be used specifically for it.

The connection openings 18 may be present in greater numbers than in the examples described. You can also have geometries that differ from a circular shape.

Furthermore, it is conceivable that for the creation of seals also a two-component injection molding process may be possible at a suitable location. Also sealing lips in execution with the second material are conceivable. LIST OF REFERENCE NUMBERS

1 support frame

2, 2 'First longitudinal element

3, 3 'second longitudinal element

4 First cross element

5 second cross element

6 First section

7 Second section

8 Third Section

9, 9 'opening

10 First material

11 Second material

12 penetration

13 core hole

14 use

15 advantage

16 rib

17 edge

18 connection opening

Claims

claims

1. support frame (1), in particular for roof systems in the automotive field, with at least two longitudinal elements (2, 2 ', 3, 3'); and with at least two transverse elements (4, 5),

wherein the longitudinal and transverse elements (2, 2 ', 3, 3', 4, 5) in first sections (6) of a first material (10) having a high strength, in second sections (7) of a second material ( 11) with a lower one

Strength and in third portions (8) of the first and the second material (10, 11) are formed.

Second support frame (1) according to claim 1, characterized in that the longitudinal and transverse elements (2, 3, 4, 5) are interconnected via connection points in third sections (8).

3. support frame (1) according to claim 2, characterized in that the longitudinal and transverse elements (2, 3, 4, 5) of the first material (10) overlap at their connection points in a certain area and corresponding connection openings (18) exhibit.

4. support frame (1) according to claim 2, characterized in that the longitudinal and transverse elements (2, 2 ', 3, 3', 4, 5) from the first material (10) and from the second

Material (11) overlap at their connection points in a certain range, wherein the longitudinal and transverse elements (2, 3, 4, 5) of the first material (10) connecting openings (18).

5. support frame (1) according to claim 3 or 4, characterized in that the connecting openings (18) of the second material (11) are penetrated, wherein the overlapping Rich of the longitudinal and transverse elements (2, 3, 4, 5) in a certain area of the second material (11) is wrapped.

6. support frame (1) according to one of claims 3 to 5, characterized in that the connecting openings (18) are provided with edges (17).

7. support frame (1) according to one of claims 1 to 6, characterized in that the longitudinal elements (2 ', 3') of the second material

(11) and at least one transverse element (5) from the second

Material (11) are integrally formed.

8. support frame (1) according to any one of claims 1 to 7, characterized in that the longitudinal and transverse elements (2, 3, 4, 5) of the first material (10) openings (9, 9 ') for the form-fitting Having compound with enveloping components of the second material (11).

9. Support frame (1) according to claim 8, characterized in that the enveloping components made of the second material (11) have means for attachment.

10. support frame (1) according to one of claims 1 to 9, characterized in that the longitudinal and transverse elements (2 ', 3', 4, 5) of the second material (11) form functional elements for roof systems and / or recordings for form such.

11. carrier frame (1) according to one of claims 1 to 10, characterized in that the longitudinal and transverse elements (2 ', 3', 4, 5) of the second material (11) stiffening inserts of the first material (10) or another material with one have higher strength than the second material (11).

12. support frame (1) according to one of claims 1 to 11, characterized in that the longitudinal and transverse elements (2, 3, 4, 5) of the first material (10) with stiffeners of the second material (11) are provided ,

13. support frame (1) according to claim 12, characterized in that the stiffeners are formed as ribs (16).

14, support frame (1) according to one of claims 1 to 13, characterized in that the first material (10) is a metallic material and the second material (11) is an attachable by injection molding material.

15. A method for producing a support frame (1) according to any one of claims 1 to 13, characterized in that the method comprises the following method steps:

(I) providing the longitudinal and transverse elements (2, 3, 4, 5) of the first material (10) with appropriate dimensions, openings (9, 9 ') and connecting openings (18);

(ii) inserting the longitudinal and transverse elements (2, 3, 4, 5) of the first material (10) into an injection mold; and;

(iii) forming the support frame (1) by inserting a second material (11) as an injection molding material into the injection molding tool to form junctions of the longitudinal and transverse elements (2,3,4,5) of the first material (10).

16. The method according to claim 15, characterized in that in step (iii) forming the support frame (1) functional elements for roof systems and / or receptacles for such by the second material (11) are formed.

17. The method according to claim 15 or 16, characterized in that in step (iii) forming the support frame (1) stiffening of the longitudinal and transverse elements (2, 3, 4, 5) of the first material (10) by the second material (11) are formed.

18. The method according to any one of claims 15 to 17, characterized in that in step (iii) forming the support frame (1) longitudinal and transverse elements (2 ', 3', 4, 5) from the second material (11) are formed ,