WO2012062391A1 - Structural motor vehicle component comprising semi-finished components connected by means of a node element, and production method - Google Patents

Structural motor vehicle component comprising semi-finished components connected by means of a node element, and production method Download PDF

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Publication number
WO2012062391A1
WO2012062391A1 PCT/EP2011/004886 EP2011004886W WO2012062391A1 WO 2012062391 A1 WO2012062391 A1 WO 2012062391A1 EP 2011004886 W EP2011004886 W EP 2011004886W WO 2012062391 A1 WO2012062391 A1 WO 2012062391A1
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WO
WIPO (PCT)
Prior art keywords
node element
cavity
semi
semifinished
component
Prior art date
Application number
PCT/EP2011/004886
Other languages
German (de)
French (fr)
Inventor
Konrad Eipper
Stephan Goettker
Jan Krüger
Asmir Salkic
Original Assignee
Daimler Ag
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Filing date
Publication date
Application filed by Daimler Ag filed Critical Daimler Ag
Publication of WO2012062391A1 publication Critical patent/WO2012062391A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/84—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks by moulding material on preformed parts to be joined
    • B29C70/845—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks by moulding material on preformed parts to be joined by moulding material on a relative small portion of the preformed parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/462—Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D27/00—Connections between superstructure or understructure sub-units
    • B62D27/02—Connections between superstructure or understructure sub-units rigid
    • B62D27/023—Assembly of structural joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B62D29/004—Superstructures, 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B62D29/005—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material preformed metal and synthetic material elements being joined together, e.g. by adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
    • B62D29/048—Connections therefor, e.g. joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2012/00—Frames
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3055—Cars

Definitions

  • the invention relates to a motor vehicle structural component, which consists of semi-finished components, which are connected by means of a node element. Furthermore, the invention relates to a corresponding manufacturing method.
  • a method for producing a frame for a vehicle in which node element and carrier are connected to each other by magnet forming.
  • the node elements are manufactured in a casting process to form connecting flanges for the carriers.
  • the flanges there are sockets, which generate the positive connection by the magnet forming.
  • the hollow carrier consists of a prefabricated, shaping inner profile part and an outer, integrally molded with the inner profile part, load-bearing light metal cast body.
  • the light metal cast body is provided at least on one side with an inner profile-free, simultaneously cast with the inner profile end portion, which is formed on a reusable, tool-side, the inner profile part during the casting process-fixing mold core.
  • the structural part for a body of a vehicle and method for its production, wherein the structural part should have an improved energy absorption behavior and can be relatively easily formed.
  • the structural part which is integrally formed in a casting process, has an integrated reinforcing element, which is formed at least partially from reinforcing fibers and is positioned precisely in the structural part.
  • Reinforcing fibers are surrounded by the metallic material.
  • Manufacturing process therefore includes the positionally accurate introduction of the
  • Reinforcing element in an open mold, and after closing the mold, pouring a metallic material into the mold, so that the reinforcing fibers are encapsulated by the metallic material.
  • a first embodiment relates to a motor vehicle structural component, which consists of two or more semi-finished components, which are connected by means of a cast node element.
  • the semi-finished components consist of a fiber-plastic composite pultrudate, and have at least one internal hollow volume.
  • the node element is molded onto at least one wall of a connecting end of each of the semi-finished components to be connected in a form-fitting manner, while the semi-finished component outside the node element is free of casting material.
  • the essential part of the motor vehicle structural component is thus formed by the FRP components which are simply joined via a node cast on at their connecting ends.
  • the advantages of the very high fiber content and the load-oriented structures of the FRP components can be utilized by connection via a low-cost casting node while compensating for component tolerances and maintaining the correct introduction of force and power transmission in the manufacture of automotive structural components and allow optimization of costs and lightweight construction.
  • the molded node element can penetrate into a cavity portion which is present at the connecting ends of the semi-finished components, alternatively or additionally, the node element can enclose an outer wall of the connecting ends of the semi-finished components, or come to rest there.
  • the node element and the semi-finished components have passage openings for connecting pins.
  • the node element has the passage openings in the area in which it comes to rest at the connecting ends of the semifinished components; Accordingly, the passage openings of the semifinished components are also present at the connection ends and are congruent with the passage openings of the node element.
  • a further embodiment provides that in a region in which the node element adjoins the wall of a connection end, there is an adhesive bead.
  • a method for connecting two or more semifinished component parts by means of a node element relates to semifinished component parts made of a fiber-plastic composite pultrudate which has at least one internal hollow volume.
  • the node element is formed from a cast material.
  • the semi-finished components to be joined are first of all placed in a precise position in a casting mold.
  • the connection end of the semi-finished component parts to be connected is inserted in relation to a cavity of the casting mold such that the connecting end adjoins at least the cavity.
  • the cavity serves to form the shape of the node element.
  • connection method according to the invention of the direct casting of a node structure onto the FRP structures reduces the number of tools required and the number of Manufacturing steps in the production of complex automotive structural components significantly.
  • a force exerted on the component can be better introduced into the structure and transferred further and thus the material can be better utilized.
  • the connecting ends of the semi-finished component parts to be joined extend into the cavity of the casting mold, so that the node element formed encloses the connecting ends of the semi-finished component parts to be joined.
  • the further component sections are according to the invention free of casting material.
  • the cast material may be a light metal alloy, such as an aluminum or magnesium alloy, but it is also an injection-moldable reinforcing fiber-matrix-plastic mixture conceivable.
  • a casting barrier is introduced into the hollow volume before the step of positionally accurate insertion of the semi-finished component, which is arranged near the connection end and thus prevents further penetration of the casting material into the hollow volume.
  • the cast node element thus remains limited to the area of the connection ends. There, a massive section can be formed.
  • a preform having fibers is arranged in the cavity.
  • the fibers may be metal fibers, carbon fibers, glass fibers and / or textile, in particular aramid fibers.
  • at least one of the walls of the connecting ends of the semi-finished component parts to be joined comes to rest on the preform, which in the subsequent step is penetrated and / or encapsulated by the casting material during introduction of the casting material.
  • This preform can be a shaped core, in particular a fiber preform surrounding a sand core. Due to the preform having reinforcing fibers, the node element is reinforced.
  • a mold core such as a sand core in the cavity is introduced in order to equip the node elements to be formed there with an internal cavity in order to further take into account the concept of lightweight construction.
  • an embodiment provides that at the connecting end of the semi-finished component dams are provided on an Innewandung while the cavity of the mold is designed such that spacers are formed having a shape to be received between two dams, between the dams, in which no spacer is added, adhesive beads are introduced.
  • 1a is a side sectional view of the joining region between two fiber-plastic composite pultrudates and a cast node element
  • Fig. 1 b is a view corresponding to Fig. 1a, but with a fiber having
  • Fig. 2 is a perspective top view of the joining region between a
  • FIG. 3 shows a perspective top view of a further embodiment of two FVK structures connected by means of a node element
  • FIG. 4 shows a perspective view of a motor vehicle structural component according to an embodiment of the invention, in which three FRP structures are connected by means of a node element,
  • Fig. 5 is a perspective view of three FRP structures, the two
  • the motor vehicle structural component according to the invention consists of several, but at least two semifinished components and at least one cast node element.
  • the semifinished components used may be a fiber-plastic composite pultrudate, hereinafter also referred to as FRP structure, which corresponds in particular to the desired lightweight construction of a motor vehicle through an internal hollow volume and through the force flow-oriented arrangement of the reinforcing fibers.
  • FRP structure fiber-plastic composite pultrudate
  • the manufacturing method according to the invention enables the economical joining by direct pouring of the FRP structures into the knots in exact positioning to each other while compensating component distortions. It ensures the correct introduction of force and power transmission. Due to the very high fiber content of the pultrusion profiles, load-optimized structures can be realized by means of this simplified joining technique with maximum material utilization and consistent lightweight construction.
  • FIG. 1 a shows the connection region of a motor vehicle structural component in which an FRP pultrudate is joined together by means of a cast node 3 approximately at an angle with another FRP pultrudate 1 '.
  • FRP pultrudates 1, 1 ' only the connecting ends are shown, which are surrounded by the node element 3.
  • the major part of the FRP profiles is (not shown figuratively) outside of the enveloping casting node 3. In this way, the motor vehicle structural component is provided with optimum strength with the greatest possible weight savings.
  • the casting material is preferably a light metal alloy and in particular an aluminum or magnesium alloy. Since only the connection ends of the FRP structures 1, 1 'are cast, the temperature input into the FRP profile is lower than when the FRP pultrudate is completely encapsulated. In order to ensure a good bond between the FRP pultrudates 1, 1 'and the cast node 3, it is conceivable to provide the FRP profiles 1, 1' with additional fiber windings 10, for example, which form the profiles 1, 1 'on the outer wall 2 give some roughness. Alternatively, an adhesion-promoting coating may be provided on the outer wall 2. Since the semi-finished components 1, 1 'are fiber-reinforced, they do not have to be subjected to internal pressure during the casting process despite their internal hollow volume 5.
  • a cast barrier 4 close to the connection end in the hollow volume 5 before the casting process in order to allow the cast material to penetrate only to a certain degree into the inner hollow volume 5 along the inner wall 2 'and thus to provide a particularly good form fit and to prevent the unwanted pouring of the semi-finished component 1, 1 '.
  • the FRP pultrudate in this joining region is made solid or at least thicker in wall thickness in order to better withstand the pressure casting process or to form a casting barrier.
  • FIG. 1 b shows a joint of two FRP pultrusions 1, 1 'by means of a node element 3, which substantially corresponds to that of FIG. 1 a, but here there is a reinforcement of the casting node 3 with a fiber preform 6.
  • the fibers may be metal fibers, carbon fibers, glass fibers, aramid or other common reinforcing fibers.
  • the preform 6 can be a prefabricated textile preform 6, wound on a sand core, for example, which is inserted together with the FRP pultrudates 1, 1 'into a casting mold for forming the node element 3, so that not only the Connecting end portions of the FRP pultrudate 1, 1 ', but also the textile preform 6 is surrounded by the aluminum or magnesium casting material.
  • the mold is equipped with a cavity corresponding to the shape of the knot to be formed.
  • the FRP pultrusions will extend into the cavity of the casting mold, so that they can be enveloped accordingly.
  • the FRP pultrusions can be fixed during the casting process, this can be done via appropriate tool parts or, for example, by a mold core piece, which also represents the casting barrier.
  • FIG. 2 shows an alternative node element 3, which is not cast around the connection end of the FRP pultrudate, but rather forms a pin which extends into a recess of the FRP pultrudate bounded by the inner wall 2 " 4, which may for example also be provided by an adhesive
  • the node element 3 corresponding passage openings 8,8 ', in which can be inserted pins or screws.
  • the passage openings 8 'on the FVK pultrudate 1, 1' can be provided with radially and concentrically around the passage opening 8 'arranged reinforcing structures, which prevent an interruption of the power flow in the FVK pultrudate 1, 1' through the passage openings 8 'and in the area reinforce the passage openings.
  • FIG 3 shows a further alternative joint line between node element 3 and FRP pultrudate 1, 1 ', here the connecting wall 2 is stepped.
  • through-openings 8 in the node element 3 and through openings in the FRP pultrudate 1, 1 are not visible here 'provided to strengthen the connection.
  • the contact area between node element 3 and the wall 2 of the FVK pultrudate is provided with an adhesive.
  • FIG. 4 shows a detail of a motor vehicle structural component, in which three semifinished components 1, 1 ', 1 "of a node element 3 are connected, where the positive connection between the respective FRP pultrudates 1, 1', 1" and the node element takes place via a pin-shaped section extending from the node element 3, which extends into a recess of the respective pultrudate 1, 1 ', 1 "bounded by the inner wall 2".
  • the fiber composite plastic pultrudate can exhibit fibers deposited at 0 °, 90 ° and ⁇ 45 °, while radial and circumferentially concentric fiber reinforcement structures are provided around the passage openings 8 'in which screws 11 can be arranged.
  • a cast barrier 4 which may also be made of adhesive, may be provided.
  • the node element may, as mentioned above, be cast from an aluminum or magnesium alloy, but it may also be an RTM node.
  • the casting material is formed from an injection-moldable reinforcing fiber-matrix-plastic mixture.
  • FIG. 5 shows three FRP pultrudate structures 1, 1 ', 1 ", two of which are each connected by means of a node element 3.
  • the node elements 3 allow any, angled arrangement of the various FRP pultrudates to one another, and can therefore also even be executed differently in their design and, for example, to save weight cavities 12 or webs 13 for connecting other structures respectively.
  • An adhesive bead 9 is provided at the contact points between the respective FRP pultrudates and the knots 3.
  • a screw 1 1 is provided in the joining area to secure the connection here.
  • FIG. 6 shows a particular embodiment of the connection between the node element 3 and the FRP pultrudate 1, with which a defined bead of adhesive 9 between the node element 3 and the FRP structure 1 can be realized with the aid of spacers 7, 7 '.
  • Dams 7 are provided on the inner wall 2 'of the FRP profile 1, which serve as spacers, while the cast-in node 3 is cast with four existing spacers T, which are each received between two dams. Between the remaining dams 7, the adhesive bead 9 is introduced.
  • the node element comprises a fiber reinforcement, which also has a fiber composite plastic powder rutate with fiber directions in 0 °, 90 °, ⁇ 45 °, ⁇ 60 °, etc. quasi-isotropic.
  • hole reinforcements can of course also hole reinforcements, be provided radially and concentrically circular around the passage openings. This preform is inserted together with the pultruded semi-finished components in the cavity of the mold and encapsulated by a casting material in the manner described.
  • Cast-in inserts can be used to form the passage openings in the cast node element.
  • This may be, for example, sleeves or internal threads, which are formed for example of metal. This ensures that the knot, which forms a positive fit with the semi-finished products in any case, can additionally be fastened to the semifinished product so that the formed component has the desired stability in the knot region.
  • a removable mandrel such as a sand core, may be used.
  • the object according to the invention provides an economically joined motor vehicle structural component made of fiber composite plastic structures, which satisfies the lightweight construction concept and nevertheless allows a correct introduction of force and power transmission.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Composite Materials (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Body Structure For Vehicles (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

The invention relates to a structural motor vehicle component and to a method for producing same. The structural motor vehicle component consists of at least two semi-finished components (1, 1', 1") which are made of a pultruded fibre-plastic composite and are connected by means of a cast node element (3). The semi-finished component (1, 1', 1") comprises at least one inner hollow volume (5) and the node element (3) is positively cast on at least one wall (2, 2') of a connecting end of each of the semi-finished components (1, 1', 1") to be connected. Outside the node element (3), the semi-finished components (1, 1', 1") are free from cast material.

Description

Kraftfahrzeugstrukturbauteil aus mittels eines Knotenelements verbundenen Halbzeug- Bauteilen und Herstellungsverfahren  Motor vehicle structural component made of semi-finished components connected by means of a node element and manufacturing method
Die Erfindung betrifft ein Kraftfahrzeugstrukturbauteil, das aus Halbzeug-Bauteilen besteht, die mittels eines Knotenelements verbunden sind. Ferner betrifft die Erfindung ein entsprechendes Herstellungsverfahren. The invention relates to a motor vehicle structural component, which consists of semi-finished components, which are connected by means of a node element. Furthermore, the invention relates to a corresponding manufacturing method.
Bislang werden Strukturelemente aus Faserverbund-Kunststoff wie etwa Pultrudate oder Profile zur Bildung eines Kraftfahrzeugstrukturbauteils mit sehr zeitintensiven Fügetechniken, wie etwa dem Kleben und Verschrauben zusammengefügt. Dadurch werden zusätzliches Bauteilgewicht und -kosten erzeugt. Zudem ist es sehr schwierig, die FVK- Strukturelemente maßhaltig zu fügen. So far, structural elements made of fiber composite plastic such as pultrusions or profiles to form a motor vehicle structural component with very time-consuming joining techniques, such as gluing and screwing together. This adds additional component weight and cost. In addition, it is very difficult to fit the FRP structural elements true to size.
Aus der DE 198 22 731 A1 ist ein Verfahren zur Herstellung eines Rahmens für ein Fahrzeug bekannt, bei dem Knotenelement und Träger durch Magnetumformen miteinander verbunden werden. Dort werden die Knotenelemente in einem Gussverfahren hergestellt, um Verbindungsflansche für die Träger auszubilden. An den Flanschen liegen Stutzen vor, die durch das Magnetumformen die formschlüssige Verbindung erzeugen. From DE 198 22 731 A1 a method for producing a frame for a vehicle is known in which node element and carrier are connected to each other by magnet forming. There, the node elements are manufactured in a casting process to form connecting flanges for the carriers. At the flanges, there are sockets, which generate the positive connection by the magnet forming.
Die DE 100 26 981 A1 offenbart einen Hohlträger für eine Kraftfahrzeugkarosserie, der so ausgebildet ist, dass auf fertigungstechnisch einfache Weise eine lastspezifische Gestaltung und vor allem deutliche Gewichtsverringerung erzielt werden kann. Der Hohlträger besteht aus einem vorgefertigten, formgebenden Innenprofilteil und einem äußeren, integral mit dem Innenprofilteil vergossenen, Last aufnehmenden Leichtmetall-Gusskörper. Der Leichtmetall-Gusskörper ist zumindest einseitig mit einem innenprofilfreien, gleichzeitig mit dem Innenprofil vergossenen Endabschnitt versehen, der an einem wieder verwendbaren, werkzeugseitigen, das Innenprofilteil beim Gießvorgang fixierenden Formkernstück ausgeformt ist. DE 100 26 981 A1 discloses a hollow beam for a motor vehicle body, which is designed so that a load-specific design and, above all, significant weight reduction can be achieved in a production-wise simple manner. The hollow carrier consists of a prefabricated, shaping inner profile part and an outer, integrally molded with the inner profile part, load-bearing light metal cast body. The light metal cast body is provided at least on one side with an inner profile-free, simultaneously cast with the inner profile end portion, which is formed on a reusable, tool-side, the inner profile part during the casting process-fixing mold core.
DE 10 2005 050 964 A1 beschreibt ein Strukturteil für eine Karosserie eines Fahrzeugs und Verfahren zu dessen Herstellung, wobei das Strukturteil ein verbessertes Energieabsorptionsverhalten aufweisen soll und dabei relativ leicht ausgebildet werden kann. Dazu weist das Strukturteil, das in einem Gussverfahren einstückig ausgebildet ist, ein integriertes Verstärkungselement auf, das zumindest teilweise aus Verstärkungsfasern ausgebildet ist und positionsgenau in dem Strukturteil angeordnet ist. Die DE 10 2005 050 964 A1 describes a structural part for a body of a vehicle and method for its production, wherein the structural part should have an improved energy absorption behavior and can be relatively easily formed. To For example, the structural part, which is integrally formed in a casting process, has an integrated reinforcing element, which is formed at least partially from reinforcing fibers and is positioned precisely in the structural part. The
Verstärkungsfasern sind von dem metallischen Material umgössen. Das Reinforcing fibers are surrounded by the metallic material. The
Herstellungsverfahren umfasst daher das positionsgenaue Einbringen des Manufacturing process therefore includes the positionally accurate introduction of the
Verstärkungselements in eine geöffnete Gussform, und nach dem Schließen der Gussform das Eingießen eines metallischen Materials in die Gussform, so dass die Verstärkungsfasern von dem metallischen Material umgössen werden. Reinforcing element in an open mold, and after closing the mold, pouring a metallic material into the mold, so that the reinforcing fibers are encapsulated by the metallic material.
Ausgehend von diesem Stand der Technik ist es wünschenswert, das wirtschaftliche Fügen von Faserverbundkunststoff-Strukturen untereinander beziehungsweise das Fügen von Faserverbundkunststoff-Strukturen mit Leichmetall-Strukturen bei korrekter Krafteinleitung und Kraftübertragung zu ermöglichen. Based on this prior art, it is desirable to enable the economical joining of fiber composite plastic structures with each other or the joining of fiber composite plastic structures with Leichmetall structures with the correct introduction of force and power transmission.
Diese Aufgabe wird durch ein Kraftfahrzeugstrukturbauteil mit den Merkmalen des Anspruchs 1 gelöst. This object is achieved by a motor vehicle structural component with the features of claim 1.
Die Aufgabe der Schaffung eines einfachen Verfahrens zum Verbinden von FVK-Struktu- ren mittels eines Knotenelements mit einer möglichst geringen Anzahl von Werkzeugen und Fertigungsschritten wird durch ein Verfahren mit den Merkmalen des Anspruchs 5 gelöst. The object of providing a simple method for connecting FRP structures by means of a node element with the smallest possible number of tools and manufacturing steps is achieved by a method having the features of claim 5.
Weiterbildungen der Gegenstände und des Verfahrens sind in den Unteransprüchen offenbart. Further developments of the objects and the method are disclosed in the subclaims.
Eine erste Ausführungsform bezieht sich auf ein Kraftfahrzeugstrukturbauteil, das aus zwei oder mehreren Halbzeug-Bauteilen besteht, die mittels eines gegossenen Knotenelements verbunden sind. Die Halbzeug-Bauteile bestehen aus einem Faser-Kunststoff- verbund-Pultrudat, und weisen zumindest ein innen liegendes Hohlvolumen auf. Erfindungsgemäß ist das Knotenelement an zumindest einer Wandung eines Verbindungsendes jedes der zu verbindenden Halbzeug-Bauteile formschlüssig angegossen, während die Halbzeug-Bauteile außerhalb des Knotenelements frei von Gussmaterial sind. Der wesentliche Anteil des Kraftfahrzeugstrukturbauteils wird also durch die FVK-Bauteile gebildet, die einfach über einen an ihren Verbindungsenden angegossenen Knoten gefügt sind. So können die Vorteile des sehr hohen Fasergehalts und der belastungsgerechten Strukturen der FVK-Bauteile durch Verbindung über einen kostengünstigen Gussknoten unter Ausgleich von Bauteiltoleranzen und Beibehaltung der richtigen Krafteinleitung und Kraftübertragung bei der Herstellung von Kraftfahrzeugstrukturbauteilen genützt werden und erlauben eine Optimierung von Kosten und Leichtbau. A first embodiment relates to a motor vehicle structural component, which consists of two or more semi-finished components, which are connected by means of a cast node element. The semi-finished components consist of a fiber-plastic composite pultrudate, and have at least one internal hollow volume. According to the invention, the node element is molded onto at least one wall of a connecting end of each of the semi-finished components to be connected in a form-fitting manner, while the semi-finished component outside the node element is free of casting material. The essential part of the motor vehicle structural component is thus formed by the FRP components which are simply joined via a node cast on at their connecting ends. Thus, the advantages of the very high fiber content and the load-oriented structures of the FRP components can be utilized by connection via a low-cost casting node while compensating for component tolerances and maintaining the correct introduction of force and power transmission in the manufacture of automotive structural components and allow optimization of costs and lightweight construction.
Das angegossene Knotenelement kann dabei in einen Hohlraumabschnitt eindringen, der an den Verbindungsenden der Halbzeug-Bauteile vorliegt, alternativ oder zusätzlich kann das Knotenelement eine Außenwandung der Verbindungsenden der Halbzeug-Bauteile umschließen, beziehungsweise dort zur Anlage kommen. The molded node element can penetrate into a cavity portion which is present at the connecting ends of the semi-finished components, alternatively or additionally, the node element can enclose an outer wall of the connecting ends of the semi-finished components, or come to rest there.
Ferner kann vorgesehen sein, dass das Knotenelement und die Halbzeug-Bauteile Durchtrittsöffnungen für Verbindungsstifte aufweisen. Das Knotenelement hat die Durchtrittsöffnungen in dem Bereich, in dem es an den Verbindungsenden der Halbzeug-Bauteile zur Anlage kommt; entsprechend liegen die Durchtrittsöffnungen der Halbzeug- Bauteile auch an den Verbindungsenden vor und sind mit den Durchtrittsöffnungen des Knotenelements kongruent. Furthermore, it can be provided that the node element and the semi-finished components have passage openings for connecting pins. The node element has the passage openings in the area in which it comes to rest at the connecting ends of the semifinished components; Accordingly, the passage openings of the semifinished components are also present at the connection ends and are congruent with the passage openings of the node element.
Eine weitere Ausführungsform sieht vor, dass in einem Bereich, in dem das Knotenelement an die Wandung eines Verbindungsendes angrenzt, eine Kleberaupe vorliegt. A further embodiment provides that in a region in which the node element adjoins the wall of a connection end, there is an adhesive bead.
Ein erfindungsgemäßes Verfahren zum Verbinden von zwei oder mehr Halbzeug-Bauteilen mittels eines Knotenelements bezieht sich auf Halbzeug-Bauteile aus einem Faser- Kunststoffverbund-Pultrudat, das zumindest ein innen liegendes Hohlvolumen aufweist. Das Knotenelement wird aus einem Gussmaterial gebildet. Dazu werden zunächst die zu verbindenden Halbzeug-Bauteile positionsgenau in eine Gussform eingelegt. Es wird dabei jeweils das Verbindungsende der zu verbindenden Halbzeug-Bauteile derart in Bezug zu einer Kavität der Gussform eingelegt, dass das Verbindungsende wenigstens an die Kavität angrenzt. Die Kavität dient zur Ausbildung der Form des Knotenelements. A method according to the invention for connecting two or more semifinished component parts by means of a node element relates to semifinished component parts made of a fiber-plastic composite pultrudate which has at least one internal hollow volume. The node element is formed from a cast material. For this purpose, the semi-finished components to be joined are first of all placed in a precise position in a casting mold. In each case, the connection end of the semi-finished component parts to be connected is inserted in relation to a cavity of the casting mold such that the connecting end adjoins at least the cavity. The cavity serves to form the shape of the node element.
Hierauf folgt das Schließen der Gussform und das Einbringen des Gussmaterials in die Kavität, wobei eine oder mehrere Wandungen des Verbindungsendes der entsprechenden Halbzeug-Bauteile mit dem Gussmaterial angegossen werden. Durch erstarren Lassen des Gussmaterials zur Ausbildung des Knotenelements bildet sich ein Formschluss zwischen der Wandung der jeweiligen Verbindungsenden und dem Knotenelement. Das erfindungsgemäße Verbindungsverfahren des direkten Angießens einer Knotenstruktur an die FVK-Strukturen senkt die Anzahl der benötigten Werkzeuge sowie die Anzahl der Fertigungsschritte bei der Herstellung komplexer Kraftfahrzeug-Strukturbauteile deutlich. Zudem kann eine auf das Bauteil ausgeübte Kraft besser in die Struktur eingeleitet und weiter übertragen werden und somit der Werkstoff besser ausgenutzt werden. This is followed by closing the mold and introducing the casting material into the cavity, casting one or more walls of the connection end of the respective semifinished component with the casting material. By solidifying the cast material to form the node element, a positive connection between the wall of the respective connecting ends and the node element is formed. The connection method according to the invention of the direct casting of a node structure onto the FRP structures reduces the number of tools required and the number of Manufacturing steps in the production of complex automotive structural components significantly. In addition, a force exerted on the component can be better introduced into the structure and transferred further and thus the material can be better utilized.
In einer Ausführungsform ist es auch denkbar, dass sich die Verbindungsenden der zu verbindenden Halbzeug-Bauteile in die Kavität der Gussform hinein erstrecken, so dass das gebildete Knotenelement die Verbindungsenden der zu verbindenden Halbzeug- Bauteile umschließt. Die weiteren Bauteilabschnitte sind erfindungsgemäß frei von Gussmaterial. In one embodiment, it is also conceivable that the connecting ends of the semi-finished component parts to be joined extend into the cavity of the casting mold, so that the node element formed encloses the connecting ends of the semi-finished component parts to be joined. The further component sections are according to the invention free of casting material.
Bei dem Gussmaterial kann es sich um eine Leichtmetall-Legierung wie beispielsweise eine Aluminium- oder Magnesium-Legierung handeln, es ist aber auch ein spritzgießfäh- iges Verstärkungsfaser-Matrix-Kunststoffgemisch denkbar. The cast material may be a light metal alloy, such as an aluminum or magnesium alloy, but it is also an injection-moldable reinforcing fiber-matrix-plastic mixture conceivable.
In einer Verfahrensvariante, in der das innen liegende Hohlvolumen des Halbzeugs-Bauteils am Verbindungsende offen liegt, so dass das Halbzeug-Bauteil so in oder an der Kavität angeordnet ist, dass das Hohlvolumen in die Kavität mündet und so einen Strömungspfad für das Gussmaterial bereitstellt, wird vor dem Schritt des positionsgenauen Einlegens des Halbzeug-Bauteils eine Gussbarriere in das Hohlvolumen eingebracht, die nahe dem Verbindungsende angeordnet wird und damit ein weiteres Eindringen des Gussmaterials in das Hohlvolumen verhindert. Das Guss-Knotenelement bleibt somit auf den Bereich der Verbindungenden beschränkt. Dort kann ein massiver Abschnitt ausgebildet werden. In a variant of the method in which the internal hollow volume of the semifinished component is open at the connection end, so that the semifinished component is arranged in or on the cavity such that the hollow volume opens into the cavity and thus provides a flow path for the casting material, a casting barrier is introduced into the hollow volume before the step of positionally accurate insertion of the semi-finished component, which is arranged near the connection end and thus prevents further penetration of the casting material into the hollow volume. The cast node element thus remains limited to the area of the connection ends. There, a massive section can be formed.
In einer weiteren Verfahrensausführungsform ist vorgesehen, dass vor dem Einbringen des Gussmaterials in die Kavität eine Fasern aufweisende Preform in der Kavität angeordnet wird. Bei den Fasern kann es sich um Metall-Fasern, Carbon-Fasern, Glasfasern und/oder Textil- insbesondere Aramid-Fasern handeln. Dabei kommt zumindest eine der Wandungen der Verbindungsenden der zu verbindenden Halbzeug-Bauteile an der Preform zur Anlage, die im nachfolgenden Schritt beim Einbringen des Gussmaterials von dem Gussmaterial durchdrungen und/oder umgössen wird. Bei dieser Preform kann es sich um eine einen Formkern, insbesondere um eine einen Sandkern umgebende Faser- Preform handeln. Durch die Preform, die Verstärkungsfasern aufweist, wird das Knotenelement verstärkt. In a further method embodiment, it is provided that, prior to introduction of the casting material into the cavity, a preform having fibers is arranged in the cavity. The fibers may be metal fibers, carbon fibers, glass fibers and / or textile, in particular aramid fibers. In this case, at least one of the walls of the connecting ends of the semi-finished component parts to be joined comes to rest on the preform, which in the subsequent step is penetrated and / or encapsulated by the casting material during introduction of the casting material. This preform can be a shaped core, in particular a fiber preform surrounding a sand core. Due to the preform having reinforcing fibers, the node element is reinforced.
Auch ohne die Verwendung einer Faser aufweisenden Preform ist es denkbar, dass vor dem Einbringen des Gussmaterials in die Kavität ein Formkern wie etwa ein Sandkern in die Kavität eingebracht wird, um das dort auszubildende Knotenelemente mit einem innen liegenden Hohlraum auszustatten, um weiter dem Leichtbaugedanken Rechnung zu tragen. Even without the use of a fiber having preform, it is conceivable that prior to introducing the casting material into the cavity, a mold core such as a sand core in the cavity is introduced in order to equip the node elements to be formed there with an internal cavity in order to further take into account the concept of lightweight construction.
Schließlich sieht eine Ausführungsform vor, dass an dem Verbindungsende des Halbzeug-Bauteils Dämme an einer Innewandung bereitgestellt sind, während die Kavität der Gussform derart ausgebildet ist, dass Distanzhalter ausgeformt werden, die eine Form aufweisen, um zwischen zwei Dämmen aufgenommen zu werden, wobei zwischen den Dämmen, in denen kein Distanzhalter aufgenommen wird, Kleberaupen eingebracht werden. Finally, an embodiment provides that at the connecting end of the semi-finished component dams are provided on an Innewandung while the cavity of the mold is designed such that spacers are formed having a shape to be received between two dams, between the dams, in which no spacer is added, adhesive beads are introduced.
Diese und weitere Vorteile werden durch die nachfolgende Beschreibung unter Bezug auf die begleitenden Figuren dargelegt. Der Bezug auf die Figuren in der Beschreibung dient der Unterstützung der Beschreibung und dem erleichterten Verständnis des Gegenstands. Gegenstände oder Teile von Gegenständen, die im Wesentlichen gleich oder ähnlich sind, können mit denselben Bezugszeichen versehen sein. Die Figuren sind lediglich eine schematische Darstellung einer Ausführungsform der Erfindung. These and other advantages are set forth by the following description with reference to the accompanying figures. The reference to the figures in the description is to aid in the description and understanding of the subject matter. Articles or parts of objects which are substantially the same or similar may be given the same reference numerals. The figures are merely a schematic representation of an embodiment of the invention.
Dabei zeigt: Showing:
Fig. 1a eine Seitenschnittansicht des Fügebereichs zwischen zwei Faserkunst- stoffverbund-Pultrudaten und einem Gussknotenelement,  1a is a side sectional view of the joining region between two fiber-plastic composite pultrudates and a cast node element,
Fig. 1 b eine Ansicht entsprechend Fig. 1a, jedoch mit einer Faser aufweisenden  Fig. 1 b is a view corresponding to Fig. 1a, but with a fiber having
Preform im Knotenelement,  Preform in the node element,
Fig. 2 eine perspektivische Draufsicht auf den Fügebereich zwischen einem  Fig. 2 is a perspective top view of the joining region between a
weiteren FVK-Pultrudat und einem Knotenelement nach einer weiteren Ausführungsform der Erfindung,  another FRP pultrudate and a node element according to a further embodiment of the invention,
Fig. 3 eine perspektivische Draufsicht auf eine weitere Ausführungsform zweier mittels eines Knotenelements verbundener FVK-Strukturen,  3 shows a perspective top view of a further embodiment of two FVK structures connected by means of a node element,
Fig. 4 eine perspektivische Ansicht auf ein Kraftfahrzeug-Strukturbauteil gemäß einer Ausführungsform der Erfindung, bei dem drei FVK-Strukturen mittels eines Knotenelements verbunden sind,  4 shows a perspective view of a motor vehicle structural component according to an embodiment of the invention, in which three FRP structures are connected by means of a node element,
Fig. 5 eine perspektivische Ansicht auf drei FVK-Strukturen, die über zwei  Fig. 5 is a perspective view of three FRP structures, the two
Knotenelemente verbunden sind,  Node elements are connected,
Fig. 6 eine perspektivische Schnittansicht durch ein Verbindungsende einer FVK- Struktur mit eingegossenem Knotenelement-Teil, in dem mittels Distanzhalter die Realisierung definierter Kleberaupen zwischen Gussknotenelement und der FVK-Struktur ermöglicht ist. Das erfindungsgemäße Kraftfahrzeug-Strukturbauteil besteht aus mehreren, zumindest jedoch aus zwei Halbzeug-Bauteilen und wenigstens einem gegossenen Knotenelement. Bei den verwendeten Halbzeug-Bauteilen kann es sich um ein Faser-Kunststoffverbund- Pultrudat handeln, nachfolgend auch FVK-Struktur genannt, das durch ein innen liegendes Hohlvolumen und durch die kraftflussgerechte Anordnung der Verstärkungsfasern insbesondere der angestrebten Leichtbauweise eines Kraftfahrzeugs entspricht. Zur Fertigung komplexerer Kraftfahrzeugstrukturen müssen mehrere solcher FVK-Strukturen miteinander gefügt werden, eine zeitintensive Klebetechnik erhöht das Bauteilgewicht sowie die Kosten und ist aufgrund der fertigungsbedingten Maßabweichungen der FVK- Strukturen schwierig. 6 shows a perspective sectional view through a connecting end of an FRP structure with a cast-in node element part, in which the realization of defined adhesive beads between the cast node element and the FRP structure is made possible by means of spacers. The motor vehicle structural component according to the invention consists of several, but at least two semifinished components and at least one cast node element. The semifinished components used may be a fiber-plastic composite pultrudate, hereinafter also referred to as FRP structure, which corresponds in particular to the desired lightweight construction of a motor vehicle through an internal hollow volume and through the force flow-oriented arrangement of the reinforcing fibers. For the production of more complex motor vehicle structures several such FRP structures must be joined together, a time-consuming adhesive technique increases the weight of the component and the cost and is difficult due to the production-related deviations in the FRP structures.
Das erfindungsgemäße Herstellungsverfahren ermöglicht das wirtschaftliche Fügen durch direktes Eingießen der FVK-Strukturen in den Knoten in exakter Positionierung zueinander unter Ausgleich von Bauteilverzügen. Es gewährleistet die korrekte Krafteinleitung und Kraftübertragung. Durch den sehr hohen Fasergehalt der Pultrusionprofile lassen sich mittels dieser vereinfachten Fügetechnik unter maximaler Werkstoffausnutzung und bei konsequentem Leichtbau belastungsgerechte Strukturen realisieren. The manufacturing method according to the invention enables the economical joining by direct pouring of the FRP structures into the knots in exact positioning to each other while compensating component distortions. It ensures the correct introduction of force and power transmission. Due to the very high fiber content of the pultrusion profiles, load-optimized structures can be realized by means of this simplified joining technique with maximum material utilization and consistent lightweight construction.
Fig. 1 a zeigt den Verbindungsbereich eines Kraftfahrzeug-Strukturbauteils, in dem ein FVK-Pultrudat mittels eines Gussknotens 3 näherungsweise im Winkel mit einem weiteren FVK-Pultrudat 1 ' zusammengefügt ist. Von den FVK-Pultrudaten 1 ,1 ' sind lediglich die Verbindungsenden dargestellt, die durch das Knotenelement 3 umgössen sind. Der Hauptanteil der FVK-Profile liegt jedoch (figurativ nicht dargestellt) außerhalb des umhüllenden Gussknotens 3. Auf diese Weise wird das Kraftfahrzeug-Strukturbauteil mit optimaler Festigkeit bei größtmöglicher Gewichtseinsparung bereitgestellt. 1 a shows the connection region of a motor vehicle structural component in which an FRP pultrudate is joined together by means of a cast node 3 approximately at an angle with another FRP pultrudate 1 '. Of the FRP pultrudates 1, 1 ', only the connecting ends are shown, which are surrounded by the node element 3. However, the major part of the FRP profiles is (not shown figuratively) outside of the enveloping casting node 3. In this way, the motor vehicle structural component is provided with optimum strength with the greatest possible weight savings.
Bei dem Gussmaterial handelt es sich vorzugsweise um eine Leichtmetall-Legierung und insbesondere um eine Aluminium- oder Magnesium-Legierung. Da lediglich die Verbindungsenden der FVK-Strukturen 1 ,1 ' angegossen werden, ist der Temperatureintrag in das FVK-Profil geringer, als wenn das FVK-Pultrudat vollständig umgössen wird. Um eine gute Bindung zwischen FVK-Pultrudaten 1 , 1 ' und dem Gussknoten 3 zu gewährleisten, ist es denkbar, die FVK-Profile 1 ,1 ' beispielsweise mit zusätzlichen Faserwicklungen 10 auszustatten, die den Profilen 1 ,1 ' an der Außenwand 2 eine gewisse Rauhigkeit verleihen. Alternativ kann an der Außenwand 2 eine haftungsunterstützende Beschichtung vorgesehen sein. Da die Halbzeug-Bauteile 1 ,1 ' faserverstärkt sind, müssen sie trotz ihres innen liegenden Hohlvolumens 5 während des Gussvorgangs nicht mit Innendruck beaufschlagt werden. Allerdings ist es günstig, vor dem Gussprozess eine Gussbarriere 4 nahe dem Verbindungsende in dem Hohlvolumen 5 anzuordnen, um das Gussmaterial nur bis zu einem gewissen Grad in das innen liegende Hohlvolumen 5 entlang der Innenwandung 2' eindringen zu lassen und somit einen besonders guten Formschluss bereitzustellen und um das unerwünschte Ausgießen des Halbzeug-Bauteils 1 ,1 ' zu verhindern. The casting material is preferably a light metal alloy and in particular an aluminum or magnesium alloy. Since only the connection ends of the FRP structures 1, 1 'are cast, the temperature input into the FRP profile is lower than when the FRP pultrudate is completely encapsulated. In order to ensure a good bond between the FRP pultrudates 1, 1 'and the cast node 3, it is conceivable to provide the FRP profiles 1, 1' with additional fiber windings 10, for example, which form the profiles 1, 1 'on the outer wall 2 give some roughness. Alternatively, an adhesion-promoting coating may be provided on the outer wall 2. Since the semi-finished components 1, 1 'are fiber-reinforced, they do not have to be subjected to internal pressure during the casting process despite their internal hollow volume 5. However, it is favorable to arrange a cast barrier 4 close to the connection end in the hollow volume 5 before the casting process in order to allow the cast material to penetrate only to a certain degree into the inner hollow volume 5 along the inner wall 2 'and thus to provide a particularly good form fit and to prevent the unwanted pouring of the semi-finished component 1, 1 '.
Denkbar sind allerdings auch Varianten, bei denen das FVK-Pultrudat in diesem Fügebereich massiv oder zumindest mit dickerer Wandstärke ausgebildet ist, um dem Druck- gussprozess besser standhalten zu können oder um eine Gussbarriere zu bilden. However, variants are also conceivable in which the FRP pultrudate in this joining region is made solid or at least thicker in wall thickness in order to better withstand the pressure casting process or to form a casting barrier.
Fig. 1 b zeigt eine Fügestelle zweier FVK-Pultrudate 1 ,1 ' mittels eines Knotenelements 3, die im Wesentlichen der aus Fig. 1a entspricht, allerdings liegt hier eine Verstärkung des Gussknotens 3 mit einer Faserpreform 6 vor. 1 b shows a joint of two FRP pultrusions 1, 1 'by means of a node element 3, which substantially corresponds to that of FIG. 1 a, but here there is a reinforcement of the casting node 3 with a fiber preform 6.
Bei den Fasern kann es sich um Metallfasern, Carbon-Fasern, Glas-Fasern, Aramid- o- der anderen gängigen Verstärkungsfasern handeln. Bei der Preform 6 kann es sich um eine vorgefertigte, beispielsweise auf einen Sandkern kraftschlussgerecht aufgewickelte Textil-Preform 6 handeln, die zusammen mit den FVK-Pultrudaten 1 ,1 ' in eine Gussform zur Bildung des Knotenelements 3 eingelegt wird, so dass nicht nur die Verbindungsendbereiche des FVK-Pultrudats 1 ,1 ', sondern auch die Textil-Preform 6 von dem Aluminiumoder Magnesium-Gussmaterial umgössen wird. The fibers may be metal fibers, carbon fibers, glass fibers, aramid or other common reinforcing fibers. The preform 6 can be a prefabricated textile preform 6, wound on a sand core, for example, which is inserted together with the FRP pultrudates 1, 1 'into a casting mold for forming the node element 3, so that not only the Connecting end portions of the FRP pultrudate 1, 1 ', but also the textile preform 6 is surrounded by the aluminum or magnesium casting material.
Die Gussform ist mit einer Kavität ausgestattet, die der Form des zu bildenden Knotens entspricht. Bei den in Fig. 1a und 1 b dargestellten Knotenelementen 3' werden die FVK- Pultrudate in die Kavität der Gussform hineinreichen, sodass sie entsprechend umgössen werden können. Dabei können die FVK-Pultrudate während des Gussvorgangs fixiert werden, dies kann über entsprechende Werkzeugteile oder beispielsweise durch ein Formkernstück geschehen, das gleichzeitig die Gussbarriere darstellt. The mold is equipped with a cavity corresponding to the shape of the knot to be formed. In the node elements 3 'illustrated in FIGS. 1 a and 1 b, the FRP pultrusions will extend into the cavity of the casting mold, so that they can be enveloped accordingly. In this case, the FRP pultrusions can be fixed during the casting process, this can be done via appropriate tool parts or, for example, by a mold core piece, which also represents the casting barrier.
Fig. 2 zeigt ein alternatives Knotenelement 3, das nicht um das Verbindungsende des FVK-Pultrudats herum gegossen ist, sondern quasi einen Zapfen bildend sich in eine durch die Innenwandung 2" begrenzte Ausnehmung des FVK-Pultrudats hinein erstreckt. Diese Ausnehmung kann durch eine Gussbarriere 4 begrenzt sein, die beispielsweise auch durch einen Klebstoff geschaffen sein kann. Um die Verbindung zwischen dem FVK-Pultrudat 1 und dem Knoten 3 zu verstärken, können sowohl das FVK-Pultrudat 1 ,1 ' als auch das Knotenelement 3 korrespondierende Durchtrittsöffnungen 8,8' aufweisen, in die sich Stifte bzw. Schrauben einführen lassen. Die Durchtrittsöffnungen 8' am FVK- Pultrudat 1 ,1 ' können dabei mit radial und konzentrisch um die Durchtrittsöffnung 8' angeordneten Verstärkungsstrukturen versehen sein, die eine Unterbrechung des Kraftflusses im FVK-Pultrudat 1 ,1 ' durch die Durchtrittsöffnungen 8' unterbinden und im Bereich der Durchtrittsöffnungen verstärken. 2 shows an alternative node element 3, which is not cast around the connection end of the FRP pultrudate, but rather forms a pin which extends into a recess of the FRP pultrudate bounded by the inner wall 2 " 4, which may for example also be provided by an adhesive In order to strengthen the connection between the FRP pultrudate 1 and the knot 3, both the FRP pultrudate 1, 1 'can be provided. as well as the node element 3 corresponding passage openings 8,8 ', in which can be inserted pins or screws. The passage openings 8 'on the FVK pultrudate 1, 1' can be provided with radially and concentrically around the passage opening 8 'arranged reinforcing structures, which prevent an interruption of the power flow in the FVK pultrudate 1, 1' through the passage openings 8 'and in the area reinforce the passage openings.
Fig. 3 zeigt eine weitere alternative Fügelinie zwischen Knotenelement 3 und FVK-Pultrudat 1 ,1 ', hier stellt sich die Verbindungswandung 2 stufenförmig dar. Auch hier sind Durchtrittsöffnungen 8 im Knotenelement 3 und hier nicht zu sehende Durchtrittsöffnungen im FVK-Pultrudat 1 ,1 ' vorgesehen, um die Verbindung zu verstärken. Generell ist es auch denkbar, dass der Kontaktbereich zwischen Knotenelement 3 und der Wandung 2 des FVK-Pultrudats mit einem Klebstoff versehen wird. 3 shows a further alternative joint line between node element 3 and FRP pultrudate 1, 1 ', here the connecting wall 2 is stepped. Here too, through-openings 8 in the node element 3 and through openings in the FRP pultrudate 1, 1 are not visible here 'provided to strengthen the connection. In general, it is also conceivable that the contact area between node element 3 and the wall 2 of the FVK pultrudate is provided with an adhesive.
Fig. 4 zeigt einen Ausschnitt eines Kraftfahrzeug-Strukturbauteils, bei dem drei Halbzeug- Bauteile 1 ,1 ',1 " eines Knotenelements 3 verbunden sind. Hier findet der Formschluss zwischen den jeweiligen FVK-Pultrudaten 1 ,1 ',1 " und dem Knotenelement über einen sich von dem Knotenelement 3 erstreckenden zapfenförmigen Abschnitt statt, der sich in eine durch die Innenwandung 2" begrenzte Ausnehmung des jeweiligen Pultrudats 1 ,1 ', 1 " erstreckt. 4 shows a detail of a motor vehicle structural component, in which three semifinished components 1, 1 ', 1 "of a node element 3 are connected, where the positive connection between the respective FRP pultrudates 1, 1', 1" and the node element takes place via a pin-shaped section extending from the node element 3, which extends into a recess of the respective pultrudate 1, 1 ', 1 "bounded by the inner wall 2".
Das Faserverbund-Kunststoff-Pultrudat kann, wie gezeigt, mit 0°, 90° und ± 45° abgelegte Fasern ausweisen, während um die Durchtrittsöffnungen 8', in denen Schrauben 1 1 angeordnet werden können, radiale und umfänglich konzentrische Faserverstärkungsstrukturen vorgesehen sind. Auch hier kann zur Begrenzung der Ausnehmung in dem FVK-Pultrudat eine Gussbarriere 4, die auch aus Klebstoff sein kann, vorgesehen sein. As shown, the fiber composite plastic pultrudate can exhibit fibers deposited at 0 °, 90 ° and ± 45 °, while radial and circumferentially concentric fiber reinforcement structures are provided around the passage openings 8 'in which screws 11 can be arranged. Again, to limit the recess in the FRP pultrudate, a cast barrier 4, which may also be made of adhesive, may be provided.
Das Knotenelement kann, wie oben erwähnt, aus einer Aluminium- oder Magnesium- Legierung gegossen sein, es kann sich aber auch um einen RTM-Knoten handeln. Dabei wird das Gussmaterial aus einem spritzgießfähigen Verstärkungsfaser-Matrix-Kunststoffgemisch gebildet. The node element may, as mentioned above, be cast from an aluminum or magnesium alloy, but it may also be an RTM node. The casting material is formed from an injection-moldable reinforcing fiber-matrix-plastic mixture.
Fig. 5 zeigt drei FVK-Pultrudat-Strukturen 1 ,1 ', 1 " von denen jeweils zwei mittels eines Knotenelements 3 verbunden sind. Die Knotenelemente 3 lassen dabei eine beliebige, gewinkelte Anordnung der verschiedenen FVK-Pultrudate zueinander zu, und können daher auch selbst in ihrer Ausgestaltung unterschiedlich ausgeführt sein und beispielsweise zur Gewichtseinsparung Hohlräume 12 oder Stege 13 zur Anbindung weiterer Strukturen aufweisen. An den Kontaktstellen zwischen den jeweiligen FVK-Pultrudaten und den Knoten 3 ist eine Kleberaupe 9 vorgesehen. Auch ist zur Sicherung der Verbindung hier eine Verschraubung 1 1 im Fügebereich vorgesehen. 5 shows three FRP pultrudate structures 1, 1 ', 1 ", two of which are each connected by means of a node element 3. The node elements 3 allow any, angled arrangement of the various FRP pultrudates to one another, and can therefore also even be executed differently in their design and, for example, to save weight cavities 12 or webs 13 for connecting other structures respectively. An adhesive bead 9 is provided at the contact points between the respective FRP pultrudates and the knots 3. Also, a screw 1 1 is provided in the joining area to secure the connection here.
Fig. 6 zeigt eine besondere Ausführungsform der Verbindung zwischen Knotenelement 3 und FVK-Pultrudat 1 , mit dem sich eine definierte Kleberraupe 9 zwischen dem Knotenelement 3 und der FVK-Struktur 1 mit Hilfe von Distanzhaltern 7,7' realisieren lässt. An der Innenwandung 2' des FVK-Profils 1 sind dabei Dämme 7 bereitgestellt, die als Distanzhalter dienen, während der eingegossene Knoten 3 mit vorliegend vier Distanzhaltern T eingegossen wird, die jeweils zwischen zwei Dämmen aufgenommen werden. Zwischen den übrigen Dämmen 7 wird die Kleberaupe 9 eingebracht. 6 shows a particular embodiment of the connection between the node element 3 and the FRP pultrudate 1, with which a defined bead of adhesive 9 between the node element 3 and the FRP structure 1 can be realized with the aid of spacers 7, 7 '. Dams 7 are provided on the inner wall 2 'of the FRP profile 1, which serve as spacers, while the cast-in node 3 is cast with four existing spacers T, which are each received between two dams. Between the remaining dams 7, the adhesive bead 9 is introduced.
Schließlich ist es denkbar, dass das Knotenelement eine Faserverstärkung umfasst, die ebenfalls ein Faser-Verbund-Kunststoffpultrudat mit Faserrichtungen in 0°, 90°, ± 45°, ± 60° etc. quasi-isotrop aufweist. Dort können selbstverständlich auch Lochverstärkungen, radial und konzentrisch kreisförmig um die Durchtrittsöffnungen vorgesehen sein. Diese Preform wird zusammen mit den pultrudierten Halbzeug-Bauteilen in die Kavität der Gussform eingelegt und durch ein Gussmaterial auf die beschriebene Weise umgössen. Finally, it is conceivable that the node element comprises a fiber reinforcement, which also has a fiber composite plastic powder rutate with fiber directions in 0 °, 90 °, ± 45 °, ± 60 °, etc. quasi-isotropic. There can of course also hole reinforcements, be provided radially and concentrically circular around the passage openings. This preform is inserted together with the pultruded semi-finished components in the cavity of the mold and encapsulated by a casting material in the manner described.
Zur Bildung der Durchtrittsöffnungen im gegossenen Knotenelement können eingegossene Einlagen verwendet werden. Dabei kann es sich beispielsweise um Hülsen oder Innengewinde handeln, die beispielsweise aus Metall ausgebildet sind. Damit wird sicher gestellt, dass der Knoten, der ohnehin einen Formschluss mit den Halbzeugen bildet, zusätzlich an dem Halbzeug befestigt werden kann, so dass das gebildete Bauteil im Knotenbereich die gewünschte Stabilität aufweist. Cast-in inserts can be used to form the passage openings in the cast node element. This may be, for example, sleeves or internal threads, which are formed for example of metal. This ensures that the knot, which forms a positive fit with the semi-finished products in any case, can additionally be fastened to the semifinished product so that the formed component has the desired stability in the knot region.
Zur Bildung eines Hohlraums im Knotenelement, um den Knoten leichter zu gestalten, kann ein entfernbarer Formkern, beispielsweise ein Sandkern, verwendet werden. To form a cavity in the node member to make the node lighter, a removable mandrel, such as a sand core, may be used.
Damit stellt der erfindungsgemäße Gegenstand ein wirtschaftlich gefügtes Kraftfahrzeugstrukturbauteil aus Faserverbundkunststoff-Strukturen bereit, das dem Leichtbaugedanken genügt und dennoch eine korrekter Krafteinleitung und Kraftübertragung ermöglicht. Thus, the object according to the invention provides an economically joined motor vehicle structural component made of fiber composite plastic structures, which satisfies the lightweight construction concept and nevertheless allows a correct introduction of force and power transmission.

Claims

Patentansprüche claims
1. Kraftfahrzeugstrukturbauteil, das aus zumindest zwei Halbzeug-Bauteilen (1 , 1 ', 1 ") aus einem Faser-Kunststoffverbund-Pultrudat besteht, die mittels eines gegossenen Knotenelements (3) verbunden sind, 1. motor vehicle structural component, which consists of at least two semi-finished components (1, 1 ', 1 ") of a fiber-plastic composite pultrudate, which are connected by means of a cast node element (3),
wobei das Halbzeug-Bauteil (1 ,1 ', 1 ") zumindest ein innen liegendes Hohlvolumen (5) aufweist, dadurch gekennzeichnet, dass  wherein the semifinished component (1, 1 ', 1 ") has at least one internal hollow volume (5), characterized in that
das Knotenelement (3) an zumindest einer Wandung (2,2') eines Verbindungsendes jedes der zu verbindenden Halbzeug-Bauteile (1 ,1 ',1 ") formschlüssig angegossen ist, wobei  the node element (3) is molded on at least one wall (2, 2 ') of a connecting end of each of the semi-finished component parts (1, 1', 1 ") to be connected in a form-fitting manner, wherein
die Halbzeug-Bauteile (1 ,1 ',1 ") außerhalb des Knotenelements (3) frei von  the semifinished components (1, 1 ', 1 ") outside of the node element (3) free from
Gussmaterial sind.  Casting material are.
2. Kraftfahrzeugstrukturbauteil nach Anspruch 1 , 2. Motor vehicle structural component according to claim 1,
dadurch gekennzeichnet, dass  characterized in that
das Knotenelement (3) in an den Verbindungsenden der Halbzeug-Bauteile (1 ,1 ',1 ") vorliegenden Hohlraumabschnitten und/oder um eine Wandung der Verbindungsenden der Halbzeug-Bauteile (1 ,1 ',1 ") zur Anlage kommt.  the node element (3) comes into contact with cavity sections present at the connection ends of the semifinished component parts (1, 1 ', 1 ") and / or around a wall of the connection ends of the semifinished component parts (1, 1', 1").
3. Kraftfahrzeugstrukturbauteil nach Anspruch 1 oder 2, 3. motor vehicle structural component according to claim 1 or 2,
dadurch gekennzeichnet, dass  characterized in that
das gegossene Knotenelement in einem Bereich, in dem es an den Verbindungsenden zur Anlage kommt, Durchtrittsöffnungen (8) für Verbindungsstifte aufweist, und dass  the molded node element in a region in which it comes to rest at the connecting ends, having passage openings (8) for connecting pins, and that
das Verbindungsende der Halbzeug-Bauteile (1 ,1 ',1 ") korrespondierende  the connecting end of the semi-finished components (1, 1 ', 1 ") corresponding
Durchtrittsöffnungen (8') zur Aufnahme der Verbindungsstifte aufweist. Having passage openings (8 ') for receiving the connecting pins.
4. Kraftfahrzeugstrukturbauteil nach zumindest einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass 4. Motor vehicle structural component according to at least one of claims 1 to 3, characterized in that
zumindest eine Kleberaupe (9) in einem Bereich zwischen dem gegossenen Knotenelement (3) und der Wandung (2,2') eines der Verbindungsenden  at least one bead of adhesive (9) in a region between the cast node element (3) and the wall (2, 2 ') of one of the connecting ends
vorgesehen ist.  is provided.
5. Verfahren zum Verbinden von zumindest zwei Halbzeug-Bauteilen (1 ,1 ',1") aus einem Faser-KunststofTverbund-Pultrudat, mittels eines Knotenelements (3) aus einem Gussmaterial, zu einem Kraftfahrzeugstrukturbauteil, wobei das Halbzeug- Bauteil (1 ,1 ',1 ") zumindest ein innen liegendes Hohlvolumen (5) aufweist, umfassend die Schritte 5. A method for joining at least two semifinished components (1, 1 ', 1') made of a fiber-plastic composite pultrudate, by means of a node element (3) made of a cast material, to a motor vehicle structural component, wherein the semifinished component (1, 1 ', 1 ") has at least one internal hollow volume (5), comprising the steps
a) Einlegen der zu verbindenden Halbzeug-Bauteile (1 ,1 ', 1 ") positionsgenau in eine Gussform, wobei jeweils ein Verbindungsende der zu verbindenden Halbzeug- Bauteile (1 ,1 ', 1") zumindest an eine Kavität der Gussform angrenzt, wobei die Kavität eine Form zur Ausbildung des Knotenelements (3) bereitstellt,  a) insertion of the semifinished product components (1, 1 ', 1 ") to be joined with exact position in a casting mold, wherein in each case one connecting end of the semifinished component (1, 1', 1") to be connected adjoins at least one cavity of the casting mold, wherein the cavity provides a shape for forming the node element (3),
b) Schließen der Gussform,  b) closing the mold,
c) Einbringen des Gussmaterials in die Kavität, wobei zumindest an eine Wandung (2,2') des Verbindungsendes der zu verbindenden Halbzeug-Bauteile (1 ,1 ', 1 ") das Gussmaterial angegossen wird,  c) introduction of the casting material into the cavity, the casting material being cast on at least one wall (2, 2 ') of the connecting end of the semi-finished component parts (1, 1', 1 ") to be joined,
d) erstarren Lassen des Gussmaterials, wobei sich das Knotenelement (3) ausbildet und wobei ein Formschluss zwischen der Wandung (2,2') und dem Knotenelement (3) bereitgestellt wird.  d) solidifying the casting material, wherein the node element (3) is formed and wherein a positive connection between the wall (2,2 ') and the node element (3) is provided.
6. Verfahren nach Anspruch 5, 6. The method according to claim 5,
wobei sich die Verbindungsenden der zu verbindenden Halbzeug-Bauteile (1 , 1 ', 1 ") in die Kavität der Gussform hinein erstrecken.  wherein the connecting ends of the semi-finished component parts (1, 1 ', 1 ") to be joined extend into the cavity of the casting mold.
7. Verfahren nach Anspruch 5 oder 6, wobei das Gussmaterial ein Gussmaterial aus der Gruppe ist, die eine Leichtmetalllegierung, insbesondere eine Aluminium- oder Magnesiumlegierung oder ein spritzgießfähiges Verstärkungsfaser-Matrixkunst- stoffgemisch ist. 7. The method of claim 5 or 6, wherein the casting material is a cast material from the group which is a light metal alloy, in particular an aluminum or magnesium alloy or an injection-moldable reinforcing fiber matrix plastic mixture.
8. Verfahren nach einem der Ansprüche 5 bis 7, wobei zumindest ein Halbzeug- Bauteil (1 ,1 ',1 ") mit innen liegendem Hohlvolumen (5) so in oder an der Kavität angeordnet ist, dass sich das Hohlvolumen (5) in die Kavität erstreckt und einen Strömungspfad für das Gussmaterial bereitstellt, umfassend die Schritte 8. The method according to any one of claims 5 to 7, wherein at least one semifinished component (1, 1 ', 1 ") with an internal hollow volume (5) is arranged in or on the cavity, that the hollow volume (5) in extending the cavity and providing a flow path for the casting material, comprising the steps
- vor Schritt a), dem positionsgenauen Einlegen des Halbzeug-Bauteils (1 , 1 ',1 ") mit innen liegendem Hohlvolumen (5), Einbringen einer Gussbarriere (4) in das Hohlvolumen (5) nahe dem Verbindungsende.  - Before step a), the positionally accurate insertion of the semi-finished component (1, 1 ', 1 ") with internal hollow volume (5), introducing a casting barrier (4) in the hollow volume (5) near the connecting end.
9. Verfahren nach einem der Ansprüche 5 bis 8 9. The method according to any one of claims 5 to 8
umfassend die Schritte  comprising the steps
- vor Schritt b), vor dem Einbringen des Gussmaterials in die Kavität, Anordnen einer Faser aufweisenden Preform (6), insbesondere einer Metall-Fasern, Carbon- Fasern, Glasfasern, Textil- insbesondere Aramid-Fasern aufweisenden Preform (6) in der Kavität, wobei zumindest eine der Wandungen (2,2') der Verbindungsenden der zu verbindenden Halbzeug-Bauteile (1 ,1 ',1 ") an der Preform (6) zur Anlage kommt,  - Before step b), prior to introducing the casting material into the cavity, arranging a preform having fiber (6), in particular a metal fibers, carbon fibers, glass fibers, textile in particular aramid fibers having preform (6) in the cavity in which at least one of the walls (2, 2 ') of the connection ends of the semifinished component parts (1, 1', 1 ") to be connected comes to rest against the preform (6),
- und wobei in Schritt c) ferner die Preform (6) von dem Gussmaterial durchdrungen und/oder umgössen wird.  - And wherein in step c) further, the preform (6) is penetrated by the casting material and / or encapsulated.
10. Verfahren nach Anspruch 9, 10. The method according to claim 9,
wobei die Preform (6) einen Formkern, insbesondere einen Sandkern umgibt.  wherein the preform (6) surrounds a mold core, in particular a sand core.
1 1. Verfahren nach einem der Ansprüche 5 bis 8 1 1. A method according to any one of claims 5 to 8
umfassend die Schritte  comprising the steps
- vor Schritt b), vor dem Einbringen des Gussmaterials in die Kavität, Einlegen eines Formkerns, insbesondere einen Sandkerns, in die Kavität.  - Before step b), before introducing the casting material into the cavity, inserting a mold core, in particular a sand core, into the cavity.
12. Verfahren nach einem der Ansprüche 5 bis 8 12. The method according to any one of claims 5 to 8
wobei an dem Verbindungsende des Halbzeug-Bauteils (1 , 1 1 ") an einer  wherein at the connection end of the semifinished component (1, 1 1 ") on a
Innenwandung eine Mehrzahl von Dämmen (7) bereitgestellt ist, und  Inner wall a plurality of dams (7) is provided, and
wobei die Kavität der Gussform eine Form zur Bereitstellung von Distanzhaltern (7') aufweist, wobei ein Distanzhalter (7') eine Form aufweist, um zwischen zwei Dämmen (7) aufgenommen zu werden,  the cavity of the mold having a shape for providing spacers (7 '), a spacer (7') having a shape to be received between two dams (7),
und wobei zwischen den Dämmen (7) an dem Verbindungsende Kleberaupen (9) bereitgestellt werden.  and wherein between the dams (7) at the connection end adhesive beads (9) are provided.
PCT/EP2011/004886 2010-11-09 2011-09-30 Structural motor vehicle component comprising semi-finished components connected by means of a node element, and production method WO2012062391A1 (en)

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EP3165428A1 (en) * 2015-11-06 2017-05-10 Audi Ag Node structure for a vehicle body, method for its preparation and car body with at least one node structure

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