WO2009103327A1 - Framework component and method for the production thereof - Google Patents

Framework component and method for the production thereof Download PDF

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Publication number
WO2009103327A1
WO2009103327A1 PCT/EP2008/010671 EP2008010671W WO2009103327A1 WO 2009103327 A1 WO2009103327 A1 WO 2009103327A1 EP 2008010671 W EP2008010671 W EP 2008010671W WO 2009103327 A1 WO2009103327 A1 WO 2009103327A1
Authority
WO
WIPO (PCT)
Prior art keywords
sheet metal
metal profile
profile
structure part
stiffening structure
Prior art date
Application number
PCT/EP2008/010671
Other languages
German (de)
French (fr)
Inventor
Konrad Goetz
Eckhard Reese
Original Assignee
Daimler Ag
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Daimler Ag filed Critical Daimler Ag
Publication of WO2009103327A1 publication Critical patent/WO2009103327A1/en

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B62LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62DMOTOR VEHICLES; TRAILERS
    • B62D25/00Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/06Fixed roofs
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1271Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed parts being partially covered
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B62LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62DMOTOR VEHICLES; TRAILERS
    • B62D29/00Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B62LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62DMOTOR VEHICLES; TRAILERS
    • B62D29/00Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B62D29/004Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material the metal being over-moulded by the synthetic material, e.g. in a mould
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14311Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
    • B29C2045/14327Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles anchoring by forcing the material to pass through a hole in the article
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1214Anchoring by foaming into a preformed part, e.g. by penetrating through holes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14311Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/74Joining plastics material to non-plastics material
    • B29C66/742Joining plastics material to non-plastics material to metals or their alloys
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2305/00Use of metals, their alloys or their compounds, as reinforcement
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2705/00Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
    • B29K2705/02Aluminium
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/30Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3002Superstructures characterized by combining metal and plastics, i.e. hybrid parts

Definitions

  • the invention relates to a frame component according to the preamble of claim 1 and a method for its production according to the preamble of claim 5.
  • a generic frame component or method is known from DE 10 2006 015 405 A1.
  • the related there as a roof frame frame member consists of three sheets, two of which are bent and joined together by a screw that they form a hollow profile.
  • a third sheet is formed as a hat-shaped profile, is joined to the hollow profile and forms with a portion which is outside the joints, the visible side of the frame member.
  • Such a frame member is relatively complex to produce due to its multiple joining operations and requires to fulfill a sufficient crash safety a slightly larger volume.
  • the invention has the object of developing a generic frame member to the effect that its size can be reduced without sacrificing crash safety in a simple manner. Furthermore, a method for its production should be specified.
  • the frame member is reduced to only two components, wherein the one component, the stiffening structure part, is received in the other component, ie in the sheet metal profile, so that the size of the frame member is additionally reduced.
  • This provides the occupants of the vehicle with an improved overview of the traffic or the external environment. In addition, it provides the vehicle occupants a greater headroom, which has a mitigating effect in a crash.
  • Farther The elimination of a component and joining elements simplifies manufacture and reduces costs.
  • the reduction in the number of components without increasing the massiveness of the remaining components is particularly beneficial to the lightweight construction, which reduces vehicle consumption and exhaust emissions.
  • the rigidity of the frame member is unchanged, if not improved, since the stiffening structure part more than compensates for the weakening of the frame component caused by the omission of the cup-shaped hollow profile structure.
  • the stiffening structure part can be adapted against the usual construction methods in a simple manner with respect to its stiffening properties especially to the local mechanical loads, so that on the one hand a particularly high crash safety is given as well as the use of excess material is prevented, which also accommodates the lightweight and material resources.
  • the stiffening structure part consists of a lightweight material, which is also advantageous for the lightweight construction of the entire vehicle.
  • the stiffening structure part can be arranged in a simple manner inside the hat profile-shaped sheet-metal profile and fixed there to this depending on the related material, for example by gluing, welding, soldering.
  • an unstructured sheet is deep-drawn into a hat profile-shaped sheet-metal profile and then inserted into an injection mold, in which the stiffening structure part of the lightweight material is injected onto the sheet metal profile in its interior. While in Verbauungslage of the frame member, the interior of the sheet metal profile is directed toward the vehicle interior, forms its outer side with a portion of the visible side of the component.
  • the sheet metal profile at points that lie in the installed state of the frame member outside the field of view, passages or passages through which the injection molding can pass and closes during solidification, wherein the material passed through a blind rivet or tie rod forms, with which the stiffening structure part clings to the sheet metal profile. It is also conceivable that the injection molding material surrounds the sheet-metal profile on the edge, wherein this takes place in sections of the sheet-metal profile, which lie outside the field of view.
  • the sheet metal profile on form-fitting elements by means of which the stiffening structure part with the Sheet metal profile is positively connected.
  • the stiffening structure part on the sheet metal profile is given a particularly good non-slip and rotationally stable hold.
  • the positive-locking elements are formed in a preferred embodiment according to claim 6 in the deep-drawing process in the form of trough-like depressions and / or elevations, after which the interlocking elements are encapsulated.
  • the stiffening structure part can be produced at the same time and fixed immovably without joining process on the sheet metal profile.
  • the interlocking elements are located at locations of the sheet metal profile, which are in the installed state of the sheet metal profile outside the field of view, whereby the formation of the frame member can also meet high optical standards, as arranged on edge strips of the profile pot otherwise visible Positive locking elements are covered by the subsequent sheets or panels.
  • Other interlocking elements, which are arranged in the interior of the profile pot, are formed exclusively on the side walls of the pot, which are also not visible in Verbauungslage of the frame member.
  • the stiffening structure part along the sheet metal profile and mutually parallel slats, which are interconnected by means of transverse blades and diagonal louvers.
  • This structure is very weight and space saving and yet it meets the high stiffness requirements.
  • the distribution of the forces acting in a collision is better distributed, which has a favorable impact on the occupant protection.
  • the transverse lamellae and diagonal louvers not only provide an increase in rigidity for the frame member but also stabilize the stiffening lamellae running parallel to one another and preventively prevent them from being unthreaded from the interlocking elements.
  • An increase in the stiffening effect of the stiffening structure part can preferably be achieved by carrying out the injection molding parallel to the sheet metal profile.
  • the injection molding material with fiber material, such as glass fibers or carbon fibers interspersed, so that the fibers are given a preferential direction with the one-dimensional injection molding, which favors the resistance of the stiffening structure component and thus of the frame part against bending.
  • a casting material with the name BKV 60 EF polyamide with a high glass fiber content of about 60%
  • BKV 60 EF polyamide with a high glass fiber content of about 60%
  • the lightweight material is injection molded by foam injection, resulting in great advantages in terms of lightweight construction, in addition, the stiffness of the injection molding element by the microcellular nature of the solidified foam is particularly large and thereby the crash safety is further improved.
  • the sheet metal profile is coated prior to injection molding with a lightweight material similar or equivalent material.
  • the coating is partially melted, resulting in a cohesive connection due to the material similarity or uniformity of the coating material and the molded lightweight material, which further improves the support of the stiffening structure component on the sheet metal profile.
  • the lightweight material is glued to the sheet metal profile.
  • the bonding can be done alternatively or additionally to the positive connection.
  • the sheet-metal profile is provided with an adhesive layer which either already has adhesive properties under normal conditions, ie room temperature and atmospheric pressure, or can only be thermally activated at a later time. This can be advantageously caused, for example, by the waste heat of the injected hot lightweight construction material.
  • the bonding results in a very good hold of the stiffening structural component on the sheet-metal profile, or the hold is improved even if forms a positive connection between the two components.
  • Fig. 1 is a bottom view of a portion of an inventive
  • a frame member 1 of a vehicle body which forms a front roof frame.
  • the frame member 1 includes a hat profile-shaped sheet metal profile 2, the outer side 3 forms in the installed state of the sheet metal profile 1 with a portion 4, the visible side of the component 1.
  • the frame member 1 further comprises a stiffening structure part 5 of a lightweight material, which may be a plastic, preferably interspersed with fibers, in particular glass fibers. However, it is also conceivable instead to use light metals such as magnesium or aluminum or aluminum alloys.
  • the stiffening structure component 5 is arranged in the interior 6 of the hat profile-shaped sheet-metal profile 2 and is fastened there to it (see in particular FIG. 2).
  • the sheet metal profile 2 has form-locking elements 7 in the form of beads, by means of which the stiffening structure part 5 is positively connected to the sheet metal profile 2.
  • the beads may be elongate or even selectively formed in the manner of knob-like elevations.
  • the interlocking elements 7 may be formed as trough-shaped depressions such as calottes, optionally embossed.
  • the interlocking elements 7 are located at locations of the sheet metal profile 2, which lie in the installed state of the sheet metal profile 2 outside the field of view, such as here on the side walls 8 and the edge strip 9 of the hat profile.
  • the stiffening structure part 5 is formed by longitudinally of the sheet metal profile 2 and mutually parallel slats 10, which are connected to each other by means of transverse blades 11 and diagonal louvers 12.
  • an unstructured sheet is first deep-drawn to the hat profile-shaped sheet metal profile 2, wherein at the same time the interlocking elements 7 are formed in the form of trough-like depressions and / or elevations.
  • the sheet metal profile 2 is then inserted into an injection mold, where the stiffening structure part 5 is molded from the mentioned lightweight material to the sheet metal profile 2 in its interior 6.
  • the interlocking elements 7 are encapsulated, wherein on the lamellae 10 fastening tabs 13 are formed, which surround the interlocking elements 7 and completely enclose.
  • the injection molding is carried out parallel to the sheet metal profile 2 and preferably by means of Schaumspritzg portrait technology.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Body Structure For Vehicles (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

The invention relates to a framework component (1) of a vehicle body, comprising a shell-type sheet metal profiled element (2), a partial region of the outer side (3) of the profiled element forming the visible side of the component (1) in the constructed state of the sheet metal profiled element (2). In order to be able to easily reduce the the size of the component without impairing the crash safety, the framework component (1) comprises a reinforcing structural part (5) consisting of a lightweight construction material, arranged inside (6) the shell-type sheet metal profiled element (2) and fixed thereto. The invention also relates to a method for producing such a component.

Description

Rahmenbauteil und ein Verfahren zu dessen Herstellung Frame component and a method for its production
Die Erfindung betrifft ein Rahmenbauteil gemäß dem Oberbegriff des Patentanspruches 1 und ein Verfahren zu dessen Herstellung gemäß dem Oberbegriff des Patentanspruches 5.The invention relates to a frame component according to the preamble of claim 1 and a method for its production according to the preamble of claim 5.
Ein gattungsgemäßes Rahmenbauteil bzw. Verfahren ist aus der DE 10 2006 015 405 A1 bekannt. Das dort als Dachrahmen verwandte Rahmenbauteil besteht aus drei Blechen, von denen zwei so gebogen und miteinander durch eine Schraubverbindung gefügt sind, dass sie ein Hohlprofil bilden. Ein drittes Blech ist als hutförmiges Profil ausgeformt, ist an das Hohlprofil gefügt und bildet mit einem Abschnitt, der außerhalb der Fügestellen liegt, die Sichtseite des Rahmenbauteils. Ein derartiges Rahmenbauteil ist aufgrund seiner mehrfachen Fügeoperationen relativ aufwändig herzustellen und erfordert zur Erfüllung einer ausreichenden Crashsicherheit ein etwas größeres Bauvolumen.A generic frame component or method is known from DE 10 2006 015 405 A1. The related there as a roof frame frame member consists of three sheets, two of which are bent and joined together by a screw that they form a hollow profile. A third sheet is formed as a hat-shaped profile, is joined to the hollow profile and forms with a portion which is outside the joints, the visible side of the frame member. Such a frame member is relatively complex to produce due to its multiple joining operations and requires to fulfill a sufficient crash safety a slightly larger volume.
Der Erfindung liegt die Aufgabe zugrunde, ein gattungsgemäßes Rahmenbauteil dahingehend weiterzubilden, dass dessen Baugröße ohne Einbussen in der Crashsicherheit in einfacher Weise verringert werden kann. Des Weiteren soll ein Verfahren zu dessen Herstellung angegeben werden.The invention has the object of developing a generic frame member to the effect that its size can be reduced without sacrificing crash safety in a simple manner. Furthermore, a method for its production should be specified.
Die Aufgabe ist erfindungsgemäß durch die Merkmale des Patentanspruches 1 hinsichtlich des Rahmenbauteils und durch die Merkmale des Patentanspruches 5 hinsichtlich des Verfahrens gelöst.The object is achieved by the features of claim 1 with respect to the frame member and by the features of claim 5 with respect to the method.
Aufgrund der Erfindung wird das Rahmenbauteil auf nur zwei Bauteile reduziert, wobei das eine Bauteil, das Versteifungsstrukturteil, im anderen Bauteil, also im Blechprofil aufgenommen ist, so dass die Baugröße des Rahmenbauteils zusätzlich verringert wird. Dies erbringt für die Insassen des Fahrzeugs eine verbesserte Übersicht des Verkehrs bzw. der äußeren Umgebung. Darüber hinaus gewährt es dem Fahrzeuginsassen eine größere Kopffreiheit, was sich bei einem Crash verletzungsmindernd auswirkt. Weiterhin werden durch den Entfall eines Bauteils und von Fügeelementen die Herstellung vereinfacht und der Kosten reduziert. Die Verringerung der Bauteilezahl ohne Erhöhung der Massivität der noch vorhandenen Bauteile ist in besonders hohem Masse dem Leichtbau zuträglich, was den Fahrzeugverbrauch und die Abgasemission absenkt. Trotz der Erreichung einer geringeren Baugröße ist die Steifigkeit des Rahmenbauteils unverändert, wenn nicht gar verbessert, da das Versteifungsstrukturteil die durch den Wegfall der schalenförmigen Hohlprofilstruktur entstandene Schwächung des Rahmenbauteils mehr als kompensiert. Hierbei kann das Versteifungsstrukturteil auch entgegen der bisher üblichen Bauweisen in einfacher Weise hinsichtlich seiner Versteifungseigenschaften speziell an die lokal anfallenden mechanischen Belastungen angepasst werden, so dass einerseits eine besonders hohe Crashsicherheit gegeben ist als auch der Einsatz von überschüssigem Material verhindert wird, was ebenfalls dem Leichtbau entgegenkommt und Materialressourcen schont. Zudem besteht des Versteifungsstrukturteil aus einem Leichtbauwerkstoff, was zusätzlich vorteilhaft für den Leichtbau des Gesamtfahrzeugs ist.Due to the invention, the frame member is reduced to only two components, wherein the one component, the stiffening structure part, is received in the other component, ie in the sheet metal profile, so that the size of the frame member is additionally reduced. This provides the occupants of the vehicle with an improved overview of the traffic or the external environment. In addition, it provides the vehicle occupants a greater headroom, which has a mitigating effect in a crash. Farther The elimination of a component and joining elements simplifies manufacture and reduces costs. The reduction in the number of components without increasing the massiveness of the remaining components is particularly beneficial to the lightweight construction, which reduces vehicle consumption and exhaust emissions. Despite the achievement of a smaller size, the rigidity of the frame member is unchanged, if not improved, since the stiffening structure part more than compensates for the weakening of the frame component caused by the omission of the cup-shaped hollow profile structure. Here, the stiffening structure part can be adapted against the usual construction methods in a simple manner with respect to its stiffening properties especially to the local mechanical loads, so that on the one hand a particularly high crash safety is given as well as the use of excess material is prevented, which also accommodates the lightweight and material resources. In addition, the stiffening structure part consists of a lightweight material, which is also advantageous for the lightweight construction of the entire vehicle.
Das Versteifungsstrukturteil kann in einfacher Weise im Inneren des hutprofilförmigen Blechprofils angeordnet und dort an diesem in Abhängigkeit vom verwandten Material beispielsweise durch Kleben, Schweißen, Löten befestigt werden.The stiffening structure part can be arranged in a simple manner inside the hat profile-shaped sheet-metal profile and fixed there to this depending on the related material, for example by gluing, welding, soldering.
Zur bevorzugten Herstellung des Rahmenbauteils wird ein unstrukturiertes Blech zu einem hutprofilförmigen Blechprofil tiefgezogen und anschließend in ein Spritzgießwerkzeug eingelegt, in dem an das Blechprofil in dessen Inneren das Versteifungsstrukturteil aus dem Leichtbauwerkstoff angespritzt wird. Während in Verbauungslage des Rahmenbauteils das Innere des Blechprofils zum Fahrzeuginnenraum hin gerichtet ist, bildet seine Außenseite mit einem Teilbereich die Sichtseite des Bauteils. Zur verbesserten Haftung des Spritzgießmaterials am Blechprofil ist es denkbar, dass das Blechprofil an Stellen, die im verbauten Zustand des Rahmenbauteils außerhalb des Sichtbereichs liegen, Durchtrittsöffnungen oder Durchzüge aufweist, durch die das Spritzgießmaterial hindurchtreten kann und beim Erstarren verschließt, wobei das hindurchgetretene Material einen Blindniet oder Zuganker bildet, mit dem das Versteifungsstrukturteil sich am Blechprofil festkrallt. Ebenfalls ist es denkbar, dass das Spritzgießmaterial das Blechprofil randseitig umgreift, wobei dies in Abschnitten des Blechprofils erfolgt, die außerhalb des Sichtbereichs liegen.For the preferred production of the frame component, an unstructured sheet is deep-drawn into a hat profile-shaped sheet-metal profile and then inserted into an injection mold, in which the stiffening structure part of the lightweight material is injected onto the sheet metal profile in its interior. While in Verbauungslage of the frame member, the interior of the sheet metal profile is directed toward the vehicle interior, forms its outer side with a portion of the visible side of the component. For improved adhesion of the injection molding on the sheet metal profile, it is conceivable that the sheet metal profile at points that lie in the installed state of the frame member outside the field of view, passages or passages through which the injection molding can pass and closes during solidification, wherein the material passed through a blind rivet or tie rod forms, with which the stiffening structure part clings to the sheet metal profile. It is also conceivable that the injection molding material surrounds the sheet-metal profile on the edge, wherein this takes place in sections of the sheet-metal profile, which lie outside the field of view.
In einer besonders bevorzugten Weiterbildung der Erfindung nach Anspruch 2 weist das Blechprofil Formschlusselemente auf, mittels derer das Versteifungsstrukturteil mit dem Blechprofil formschlüssig verbunden ist. Hierdurch wird dem Versteifungsstrukturteil am Blechprofil ein besonders guter rutsch- und drehfester Halt gegeben. Hierzu werden die Formschlusselemente in bevorzugter Ausgestaltung nach Anspruch 6 im Tiefziehverfahren in Form von muldenartigen Vertiefungen und/oder Erhebungen ausgeformt, wonach die Formschlusselemente umspritzt werden. In besonders verfahrensökonomischer Weise kann dabei gleichzeitig das Versteifungsstrukturteil hergestellt werden und ohne Fügevorgang am Blechprofil unverrückbar festgesetzt werden.In a particularly preferred embodiment of the invention according to claim 2, the sheet metal profile on form-fitting elements, by means of which the stiffening structure part with the Sheet metal profile is positively connected. As a result, the stiffening structure part on the sheet metal profile is given a particularly good non-slip and rotationally stable hold. For this purpose, the positive-locking elements are formed in a preferred embodiment according to claim 6 in the deep-drawing process in the form of trough-like depressions and / or elevations, after which the interlocking elements are encapsulated. In a particularly process-economical way, the stiffening structure part can be produced at the same time and fixed immovably without joining process on the sheet metal profile.
In einer bevorzugten Weiterbildung der Erfindung nach Anspruch 3 befinden die Formschlusselemente sich an Stellen des Blechprofils, die im verbauten Zustand des Blechprofils außerhalb des Sichtbereichs liegen, wodurch die Ausbildung des Rahmenelements auch hohen optischen Ansprüchen genügen kann, da die auf Randstreifen des Profiltopfes angeordneten ansonsten sichtbaren Formschlusselemente von den sich anschließenden Blechen oder Blenden verdeckt werden. Weitere Formschlusselemente, die im Inneren des Profiltopfes angeordnet sind, sind ausschließlich an den Seitenwänden des Topfes ausgebildet, welche in Verbauungslage des Rahmenbauteils ebenfalls nicht sichtbar sind.In a preferred embodiment of the invention according to claim 3, the interlocking elements are located at locations of the sheet metal profile, which are in the installed state of the sheet metal profile outside the field of view, whereby the formation of the frame member can also meet high optical standards, as arranged on edge strips of the profile pot otherwise visible Positive locking elements are covered by the subsequent sheets or panels. Other interlocking elements, which are arranged in the interior of the profile pot, are formed exclusively on the side walls of the pot, which are also not visible in Verbauungslage of the frame member.
In einer bevorzugten Weiterbildung der Erfindung nach Anspruch 4 beinhaltet das Versteifungsstrukturteil längs des Blechprofils und parallel zueinander verlaufende Lamellen, die mittels Querlamellen und Diagonallamellen miteinander verbunden sind. Diese Struktur ist sehr gewichts- und platzsparend und trotzdem erfüllt sie die hohen Steifigkeitsanforderungen. Außerdem wird die Verteilung der einwirkenden Kräfte bei einem Aufprall besser verteilt, was sich günstig auf den Insassenschutz auswirkt. Die Querlamellen und Diagonallamellen erbringen nicht nur eine Erhöhung der Steifigkeit für das Rahmenbauteil sondern stabilisieren auch die parallel zueinander laufenden versteifenden Lamellen und verhindern haltgebend, dass diese nicht aus den Formschlusselementen ausknüpfen. Zum sicheren Eingehen einer formschlüssigen Verbindung mit den besagten Formschlusselementen des Blechprofils ist es förderlich, seitlich abragende Haltelappen an die Lamellen anzuspritzen, welche Lappen dann den Formschluss eingehen. Alternativ können auch die Lamellen lokal dick genug gespritzt werden, damit Formschlusselement umfasst wird. Dies erfordert jedoch mehrIn a preferred embodiment of the invention according to claim 4, the stiffening structure part along the sheet metal profile and mutually parallel slats, which are interconnected by means of transverse blades and diagonal louvers. This structure is very weight and space saving and yet it meets the high stiffness requirements. In addition, the distribution of the forces acting in a collision is better distributed, which has a favorable impact on the occupant protection. The transverse lamellae and diagonal louvers not only provide an increase in rigidity for the frame member but also stabilize the stiffening lamellae running parallel to one another and preventively prevent them from being unthreaded from the interlocking elements. For safe entry of a positive connection with said form-fitting elements of the sheet metal profile, it is beneficial to spray laterally projecting retaining tabs on the slats, which then enter the form-fitting lobes. Alternatively, the lamellae can be sprayed locally thick enough so that positive-locking element is included. However, this requires more
Spritzgussmaterial als die erste Variante.Injection molding material as the first variant.
Eine Erhöhung der Versteifungswirkung des Versteifungsstrukturteils kann bevorzugt dadurch erzielt werden, dass das Spritzgießen parallel zum Blechprofil erfolgt. Hierzu wird vorab das Spritzgießmaterial mit Fasermaterial, beispielsweise Glasfasern oder Karbonfasern durchsetzt, so dass mit dem eindimensionalen Spritzgießen den Fasern eine Vorzugsrichtung gegeben wird, die den Widerstand des Versteifungsstrukturbauteils und damit des Rahmenteils gegenüber Biegung begünstigt.An increase in the stiffening effect of the stiffening structure part can preferably be achieved by carrying out the injection molding parallel to the sheet metal profile. For this purpose is advance the injection molding material with fiber material, such as glass fibers or carbon fibers interspersed, so that the fibers are given a preferential direction with the one-dimensional injection molding, which favors the resistance of the stiffening structure component and thus of the frame part against bending.
Bevorzugt wird hierbei ein Gießmaterial mit der Bezeichnung BKV 60 EF (Polyamid mit einem hohen Glasfaseranteil von etwa 60%) verwandt. Mit diesem Material ist es zudem möglich, die Schmelzetemperatur und den Spritzdruck zu verringern, wodurch geringere Anforderungen an das Gießwerkzeug und den Druckerzeuger gestellt werden, was den Einsatz von einfacheren preisgünstigeren Materialien und Vorrichtungskonstruktionen für die Herstellung nach sich zieht.Preference is given here a casting material with the name BKV 60 EF (polyamide with a high glass fiber content of about 60%) is used. With this material, it is also possible to reduce the melt temperature and injection pressure, thereby placing lower demands on the casting tool and the pressure generator, which entails the use of simpler, less expensive materials and device designs for manufacture.
In einer weiteren besonders bevorzugten Weiterbildung nach Anspruch 9 wird der Leichtbauwerkstoff mittels Schaumspritzgießen angespritzt, wodurch sich hinsichtlich der Leichtbautechnik große Vorteile ergeben, wobei zusätzlich die Steifigkeit des Spritzgusselementes durch die mikrozelluläre Ausprägung des erstarrten Schaumes besonders groß ist und dadurch die Crashsicherheit noch weiter verbessert wird.In a further particularly preferred embodiment according to claim 9, the lightweight material is injection molded by foam injection, resulting in great advantages in terms of lightweight construction, in addition, the stiffness of the injection molding element by the microcellular nature of the solidified foam is particularly large and thereby the crash safety is further improved.
Bei einer weiteren bevorzugten Ausgestaltung der Erfindung nach Anspruch 10 wird das Blechprofil vor dem Anspritzen mit einem dem Leichtbauwerkstoff ähnlichen oder entsprechenden Werkstoff beschichtet. Beim Anspritzen wird die Beschichtung teilweise aufgeschmolzen, wodurch sich durch die Materialähnlichkeit bzw. -gleichheit des Beschichtungswerkstoffs und des angespritzten Leichtbauwerkstoffs eine stoffschlüssige Verbindung ergibt, die den Halt des Versteifungsstrukturbauteils am Blechprofil noch weiter verbessert.In a further preferred embodiment of the invention according to claim 10, the sheet metal profile is coated prior to injection molding with a lightweight material similar or equivalent material. When molding, the coating is partially melted, resulting in a cohesive connection due to the material similarity or uniformity of the coating material and the molded lightweight material, which further improves the support of the stiffening structure component on the sheet metal profile.
Bei einer weiteren bevorzugten Ausgestaltung der Erfindung nach Anspruch 11 wird der Leichtbauwerkstoff mit dem Blechprofil verklebt. Die Verklebung kann alternativ oder zusätzlich zur formschlüssigen Verbindung erfolgen. Hierbei wird das Blechprofil mit einer Kleberschicht versehen, die entweder bei Normalbedingungen, also Raumtemperatur und Atmosphärendruck bereits klebende Eigenschaften aufweist oder erst zu einem späteren Zeitpunkt thermisch aktivierbar ist. Dies kann beispielsweise vorteilhaft durch die Abwärme des angespritzten heißen Leichbauwerkstoffes verursacht werden. Durch die Verklebung ergibt sich ein sehr guter Halt des Versteifungsstrukturbauteils am Blechprofil, bzw. der Halt wird noch verbessert, wenn sich zwischen den beiden Bauteilen auch eine formschlüssige Verbindung ausbildet.In a further preferred embodiment of the invention according to claim 11, the lightweight material is glued to the sheet metal profile. The bonding can be done alternatively or additionally to the positive connection. In this case, the sheet-metal profile is provided with an adhesive layer which either already has adhesive properties under normal conditions, ie room temperature and atmospheric pressure, or can only be thermally activated at a later time. This can be advantageously caused, for example, by the waste heat of the injected hot lightweight construction material. The bonding results in a very good hold of the stiffening structural component on the sheet-metal profile, or the hold is improved even if forms a positive connection between the two components.
Nachfolgend ist die Erfindung anhand eines in der Zeichnung dargestellten Ausführungsbeispieles näher erläutert.The invention is explained in more detail with reference to an embodiment shown in the drawing.
Dabei zeigen:Showing:
Fig. 1 In einer Unteransicht einen Abschnitt eines erfindungsgemäßenFig. 1 is a bottom view of a portion of an inventive
Rahmenbauteils, Fig. 2 Das erfindungsgemäße Rahmenbauteil in einem Querschnitt entlang derFrame component, Fig. 2 The frame member according to the invention in a cross section along the
Schnittlinie l-l aus Fig. 1.Section line l-l of Fig. 1.
In Fig. 1 ist ein Rahmenbauteil 1 einer Fahrzeugkarosserie dargestellt, das einen vorderen Dachrahmen bildet. Das Rahmenbauteil 1 beinhaltet ein hutprofilförmiges Blechprofil 2, dessen Außenseite 3 im verbauten Zustand des Blechprofils 1 mit einem Teilbereich 4 die Sichtseite des Bauteils 1 bildet. Das Rahmenbauteil 1 weist des Weiteren ein Versteifungsstrukturteil 5 aus einem Leichtbauwerkstoff auf, welcher ein Kunststoff, vorzugsweise mit Fasern, insbesondere Glasfasern durchsetzt, sein kann. Es ist jedoch auch anstatt dessen die Verwendung von Leichtmetallen wie Magnesium oder Aluminium bzw. Aluminiumlegierungen denkbar. Das Versteifungsstrukturbauteil 5 ist im Inneren 6 des hutprofilförmigen Blechprofils 2 angeordnet und dort an diesem befestigt ist (siehe insbesondere Fig. 2).In Fig. 1, a frame member 1 of a vehicle body is shown, which forms a front roof frame. The frame member 1 includes a hat profile-shaped sheet metal profile 2, the outer side 3 forms in the installed state of the sheet metal profile 1 with a portion 4, the visible side of the component 1. The frame member 1 further comprises a stiffening structure part 5 of a lightweight material, which may be a plastic, preferably interspersed with fibers, in particular glass fibers. However, it is also conceivable instead to use light metals such as magnesium or aluminum or aluminum alloys. The stiffening structure component 5 is arranged in the interior 6 of the hat profile-shaped sheet-metal profile 2 and is fastened there to it (see in particular FIG. 2).
Zur Befestigung weist das Blechprofil 2 Formschlusselemente 7 in Form von Wülsten auf, mittels derer das Versteifungsstrukturteil 5 mit dem Blechprofil 2 formschlüssig verbunden ist. Die Wülste können länglich oder auch nur punktuell nach Art von noppenartigen Erhebungen ausgebildet sein. Anstelle der Wülste oder auch zusätzlich können die Formschlusselemente 7 als muldenförmige Vertiefungen wie Kalotten ausgebildet, gegebenenfalls geprägt sein. Die Formschlusselemente 7 befinden sich an Stellen des Blechprofils 2, die im verbauten Zustand des Blechprofils 2 außerhalb des Sichtbereichs liegen, wie beispielsweise hier an den Seitenwänden 8 und den Randstreifen 9 des Hutprofils. Das Versteifungsstrukturteil 5 ist gebildet durch längs des Blechprofils 2 und parallel zueinander verlaufende Lamellen 10, die mittels Querlamellen 11 und Diagonallamellen 12 miteinander verbunden sind.For attachment, the sheet metal profile 2 has form-locking elements 7 in the form of beads, by means of which the stiffening structure part 5 is positively connected to the sheet metal profile 2. The beads may be elongate or even selectively formed in the manner of knob-like elevations. Instead of the beads or in addition, the interlocking elements 7 may be formed as trough-shaped depressions such as calottes, optionally embossed. The interlocking elements 7 are located at locations of the sheet metal profile 2, which lie in the installed state of the sheet metal profile 2 outside the field of view, such as here on the side walls 8 and the edge strip 9 of the hat profile. The stiffening structure part 5 is formed by longitudinally of the sheet metal profile 2 and mutually parallel slats 10, which are connected to each other by means of transverse blades 11 and diagonal louvers 12.
Zur Herstellung des Rahmenbauteils 1 wird zunächst ein unstrukturiertes Blech zu dem hutprofilförmigen Blechprofil 2 tiefgezogen, wobei gleichzeitig die Formschlusselemente 7 in Form von muldenartigen Vertiefungen und/oder Erhebungen ausgeformt werden. Das Blechprofil 2 wird sodann in ein Spritzgießwerkzeug eingelegt, wobei dort an das Blechprofil 2 in dessen Inneren 6 das Versteifungsstrukturteil 5 aus dem erwähnten Leichtbauwerkstoff angespritzt wird. Hierbei werden die Formschlusselemente 7 umspritzt, wobei an den Lamellen 10 Befestigungslappen 13 angeformt sind, die die Formschlusselemente 7 umgreifen bzw. vollständig einfassen. Das Spritzgießen erfolgt parallel zum Blechprofil 2 und vorzugsweise mittels der Schaumspritzgieß-Technologie.For the production of the frame member 1, an unstructured sheet is first deep-drawn to the hat profile-shaped sheet metal profile 2, wherein at the same time the interlocking elements 7 are formed in the form of trough-like depressions and / or elevations. The sheet metal profile 2 is then inserted into an injection mold, where the stiffening structure part 5 is molded from the mentioned lightweight material to the sheet metal profile 2 in its interior 6. Here, the interlocking elements 7 are encapsulated, wherein on the lamellae 10 fastening tabs 13 are formed, which surround the interlocking elements 7 and completely enclose. The injection molding is carried out parallel to the sheet metal profile 2 and preferably by means of Schaumspritzgieß technology.
Es ist auch denkbar, am Blechprofil 2 im Tiefziehvorgang oder in einem nachgeschalteten Prozess durch Stanzen oder einem sonstigen Schneide- oder Trennverfahren an Stellen Durchzüge zu erzeugen, die im verbauten Zustand des Rahmenbauteils 2 außerhalb des Sichtbereichs liegen. Beim Spritzgießen werden diese Durchzüge vom noch flüssigen Spritzguss durchdrungen werden, welcher in der anschließenden Erstarrungsphase den jeweiligen Durchzug ankerartig hintergreift. It is also conceivable to produce on the sheet metal profile 2 in the deep drawing process or in a downstream process by punching or other cutting or cutting process at points passages that lie in the installed state of the frame member 2 outside the field of view. In injection molding, these passages are penetrated by still liquid injection molding, which engages behind the respective passage anchor-like in the subsequent solidification phase.

Claims

Patentansprüche claims
1. Rahmenbauteil einer Fahrzeugkarosserie mit einem hutprofilförmigen Blechprofil, dessen Außenseite im verbauten Zustand des Blechprofils mit einem Teilbereich die Sichtseite des Bauteils bildet, dadurch gekennzeichnet, dass das Rahmenbauteil (1) ein Versteifungsstrukturteil (5) aus einem Leichtbauwerkstoff aufweist, das im Inneren (6) des hutprofilförmigen Blechprofils (2) angeordnet und dort an diesem befestigt ist.1. Frame component of a vehicle body with a hat profile-shaped sheet-metal profile whose outer side forms in the installed state of the sheet metal profile with a portion of the visible side of the component, characterized in that the frame component (1) has a stiffening structure part (5) made of a lightweight material, which in the interior (6 ) of the hat profile-shaped sheet metal profile (2) is arranged and fixed there to this.
2. Rahmenbauteil nach Anspruch 1 , dadurch gekennzeichnet, dass das Blechprofil (2) Formschlusselemente (7) aufweist, mittels derer das Versteifungsstrukturteil (5) mit dem Blechprofil (2) formschlüssig verbunden ist.2. Frame component according to claim 1, characterized in that the sheet metal profile (2) positive locking elements (7), by means of which the stiffening structure part (5) with the sheet metal profile (2) is positively connected.
3. Rahmenbauteil nach Anspruch 2, dadurch gekennzeichnet, dass die Formschlusselemente (7) sich an Stellen des Blechprofils (2) befinden, die im verbauten Zustand des Blechprofils (2) außerhalb des Sichtbereichs liegen.3. Frame component according to claim 2, characterized in that the interlocking elements (7) are located at locations of the sheet metal profile (2), which lie in the installed state of the sheet metal profile (2) outside the field of view.
4. Rahmenbauteil nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass das Versteifungsstrukturteil (5) längs des Blechprofils (2) und parallel zueinander verlaufende Lamellen (10) beinhaltet, die mittels Querlamellen (11) und Diagonallamellen (12) miteinander verbunden sind.4. Frame component according to one of claims 1 to 3, characterized in that the stiffening structure part (5) along the sheet metal profile (2) and mutually parallel lamellae (10), which are interconnected by means of transverse blades (11) and diagonal louvers (12) ,
5. Verfahren zur Herstellung eines Rahmenbauteils einer Fahrzeugkarosserie nach den Ansprüchen 1 bis 4, dadurch gekennzeichnet, dass ein unstrukturiertes Blech zu einem hutprofilförmigen Blechprofil (2) tiefgezogen wird, dass das Blechprofil (2) in ein Spritzgießwerkzeug eingelegt wird und dort an das Blechprofil (2) in dessen Inneren (6) ein Versteifungsstrukturteil (5) aus einem Leichtbauwerkstoff angespritzt wird.5. A method for producing a frame member of a vehicle body according to claims 1 to 4, characterized in that an unstructured sheet to a hat profile-shaped sheet metal profile (2) is deep-drawn, that the sheet metal profile (2) in an injection mold is inserted and there to the sheet metal profile (2) in the interior (6) a stiffening structure part (5) is molded from a lightweight material.
6. Verfahren nach Anspruch 5, dadurch gekennzeichnet, dass im Tiefziehverfahren Formschlusselemente (7) in Form von muldenartigen Vertiefungen und/oder Erhebungen ausgeformt werden und dass die Formschlusselemente (7) umspritzt werden.6. The method according to claim 5, characterized in that in the deep-drawing process positive-locking elements (7) are formed in the form of trough-like depressions and / or elevations and that the positive-locking elements (7) are molded.
7. Verfahren nach einem der Ansprüche 5 oder 6, dadurch gekennzeichnet, dass das Spritzgießen parallel zum Blechprofil (2) erfolgt.7. The method according to any one of claims 5 or 6, characterized in that the injection molding takes place parallel to the sheet metal profile (2).
8. Verfahren nach einem der Ansprüche 5 bis 7, dadurch gekennzeichnet, dass am Blechprofil (2) an Stellen Durchzüge erzeugt werden, die im verbauten Zustand des Rahmenbauteils (1) außerhalb des Sichtbereichs liegen, und dass die Durchzüge vom noch flüssigen Spritzguss durchdrungen werden, welcher in der anschließenden Erstarrungsphase den jeweiligen Durchzug ankerartig hintergreift.8. The method according to any one of claims 5 to 7, characterized in that the sheet metal profile (2) are generated at points passages that lie in the installed state of the frame member (1) outside the field of view, and that the passages are penetrated by still liquid injection molding , which engages behind the respective passage anchor-like in the subsequent solidification phase.
9. Verfahren nach einem der Ansprüche 5 bis 8, dadurch gekennzeichnet, dass der Leichtbauwerkstoff mittels Schaumspritzgießen angespritzt wird.9. The method according to any one of claims 5 to 8, characterized in that the lightweight material is injection molded by foam injection molding.
10. Verfahren nach einem der Ansprüche 1 bis 9, dadurch gekennzeichnet, dass das Blechprofil (2) vor dem Anspritzen mit einem dem Leichtbauwerkstoff ähnlichen oder entsprechenden Werkstoff beschichtet wird.10. The method according to any one of claims 1 to 9, characterized in that the sheet metal profile (2) is coated prior to injection with a lightweight material similar or equivalent material.
11. Verfahren nach einem der Ansprüche 1 bis 10, dadurch gekennzeichnet, dass der Leichtbauwerkstoff mit dem Blechprofil (2) verklebt wird. 11. The method according to any one of claims 1 to 10, characterized in that the lightweight material with the metal profile (2) is glued.
PCT/EP2008/010671 2008-02-23 2008-12-16 Framework component and method for the production thereof WO2009103327A1 (en)

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EP3357798A1 (en) * 2016-06-09 2018-08-08 Dura Operating, LLC Motor vehicle hybrid shelf assembly

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