EP1687194A1

EP1687194A1 - Component, particularly a lightweight hybrid component

Info

Publication number: EP1687194A1
Application number: EP04803199A
Authority: EP
Inventors: Gregor Specht
Original assignee: Behr GmbH and Co KG
Current assignee: Mahle Behr GmbH and Co KG
Priority date: 2003-11-19
Filing date: 2004-11-19
Publication date: 2006-08-09
Also published as: DE102004056102C5; US20070145188A1; DE102004056102A1; CN1882470A; JP2007511413A; DE102004056102B4; WO2005049411A1

Abstract

The invention relates to a component (1) comprising a particularly shell-shaped base carrier (2) and at least one core element (6). The aim of the invention is to provide an improved component (1), wherein an intermediate layer (5) is inserted in between the base carrier (2) and the core element (6) in order to compensate tolerances, resulting in a positive power flow via the intermediate layer (4) and improved tolerance compensation.

Description

Component, in particular hybrid component in lightweight construction

The invention relates to a component, in particular a hybrid component with a shell-shaped base support and at least one core element.

Such components, e.g. a pipe or cross member are used in vehicle construction, but also in appropriate design in aircraft. An existing example of a pipe cross member is usually made due to the better modulus of elasticity, exclusively made of metal, wherein, for example, a deep drawn from sheet steel or aluminum sheet body welded to rivets, riveted or screwed. The component has correspondingly large wall thicknesses, so that a sufficient bending, buckling and torsional rigidity and a sufficient pressure load is given. This results in a high weight and cost disadvantages. The component can be used in principle for air flow, for example, for an air conditioner. Here, the problem arises that can easily deposit unwanted condensation on the metal pipes.

Furthermore, a component is known which has a two-shell construction with welded-in webs for stabilization. Such a component is For example, from DE 197 20 902 known. The component is very expensive to manufacture and has a high weight.

EP 0 370 342 discloses a lightweight component which can be used as a carrier in a motor vehicle and has a hybrid construction which has a shell-shaped basic body preferably made of metal, in the interior of which reinforcing ribs are arranged. The reinforcing ribs consist of injected plastic and are connected to the metal base body at discrete connection points, in that the plastic penetrates through apertures arranged in the metal part and extends beyond the surfaces of the apertures. The metal base body is U-shaped, and the reinforcing ribs enforce the interior of the body to achieve high rigidity and strength. This known hybrid component has an advantageously low weight while maintaining sufficient strength, rigidity and load capacity.

From DE 200 08 201 U, a cross member in hybrid construction with a shell-like base body which is stiffened by an injected Kunststoffvemp- pung known. The plastic ribs are formed in such a way that a plastic tube serving as an air duct can be inserted in a form-fitting manner. Such introduction of a channel is expensive because the channel must be made separately and inserted in one step. The thus adapted in shape ribs lose stability.

Based on this prior art, the present invention seeks to provide a lightweight component and a method for its production, which has improved properties and is inexpensive.

The object is achieved by a component comprising a shell-shaped base support and at least one core element, wherein the base carrier has at least one closing seam and is connected to the core element via at least one tolerance-compensating intermediate layer.

Furthermore, the invention relates to a method for producing a component according to the invention, in which the tolerance compensating intermediate layer is placed on the inside of the non-closed base support and at least one core element is applied to the intermediate layer, the base support is closed and via a suitable joining technique along one or more Closing seams permanently connected.

Furthermore, the invention relates to the use of the component according to the invention in vehicles or aircraft.

Advantageous developments are the subject of the dependent claims.

The invention is based on the idea of providing a low-cost, stable lightweight component which has a high modulus of elasticity (called E modulus for short) and at the same time low weight and low thermal conductivity. The component comprises a stable shell-shaped base support, for example made of metal and a Kemele- element, for example made of plastic. The inside of the base carrier and the core element are connected via at least one tolerance compensating intermediate layer.

With the component numerous material and surface combinations are possible. This leads to a high flexibility in the production of the component and a high flexibility in its uses.

Furthermore, by means of the production method, a cohesive bonding of the metallic base carrier and the core element via adhesion is possible. Lich. The tolerance compensation is preferably achieved by intermediate layers such as adhesive. The manufacturing process and the component produced therewith enable a simple modeling of the composite system in the component by a uniform stress distribution in the case of adhesive intermediate layers. Furthermore, the component has a high surface resistance moment since a closed, as thin as possible metal base support surrounds the core elements. The base support is not limited to a straight base support, but may also assume a shape in the plan view, as they may occur, for example, in floor groups or area stiffening parts of vehicles or aircraft.

Furthermore, the component leads to a space savings, since in the base support, for example in cavities formed by the base carrier guide elements such as air guide elements or lines can be performed. By a special base support structure such as recesses in the form of holes in the base support core elements can escape to the outside, which, for example, mechanical integration such as the screwing of an airbag are possible. The special composite structure of the component and the method of manufacture also allow a fast and inexpensive generation of prototypes, which is of great importance in vehicle production in particular. This is achieved, among other things, by the low tool costs and tool change costs, since a modular design with core elements can be selected. As a result, flexible solutions, for example, given left and right halves, which in turn allows small injection or forming tools.

The core elements may also perform tasks such as directing and isolating air streams, integrating components located outside the metal base support, and / or stiffening the structure with reinforcements of metal. Under schalenformigen metal base support in the context of the invention are in particular single or multi-part base support made of metal or metal compositions with high modulus to understand. Preferably, the component, ie the composite element comprises a base support made of steel. The metal base support may have a special surface with different structures or attached materials, for example a surface with holes. The holes in the base support allow the core elements to escape outward, allowing for integration. Integrations within the meaning of the invention are to be understood as meaning, for example, mechanical integrations. Particularly suitable are mechanical integrations, such as airbags and / or a steering column.

In a further embodiment, at least one core element is arranged in the component with the basic carrier in the component. The core element may preferably be a functional component made of plastic or metal, such as steel. Preferably, the core element is a plastic element. The plastic has a low weight and low thermal conductivity. The core element can be one or more parts. Preferably, the core elements can perform tasks such as directing and isolating air streams, integrating components located outside the metal base support, or stiffening the structure by metal reinforcements in the core elements. The component may be measured strip adjacent to the core element in addition electrical wires, conductive traces, fiber optic cables, sensors, strain ^'and / or _(electronic chips.

Furthermore, the base support has at least one closing seam. The closing seam can largely enclose the space formed from metal base support and core elements. A short interruption of the closing seam can be particularly disadvantageous in stress-relieved areas be possible, for example, to lead a wiring harness from the inside out or vice versa.

The closing seam preferably has at least one joint. The base support is preferably closed via the closing seam with suitable joining technology. Particularly preferably, the base support is closed by welding, soldering, gluing, clinching, screws and / or rivets on the closing seam. In a further embodiment, the base support is closed by a combination of gluing and clinching.

Preferably, the closing seam, in particular during welding, soldering by clinching or gluing, has a thickness corresponding to the thickness of the closed base support. In joining methods, such as rivets or screws, the thickness of the closing seam should preferably not exceed ten times the thickness of the closed base support.

The connection of the basic carrier with the core elements is largely via tolerances balancing liners. Tolerances compensating intermediate layers in the sense of the invention are preferably to be understood as intermediate layers which comprise adhesives and sealants, double-sided adhesive tape and / or sealing or foam strips. Particularly suitable tolerances compensating intermediate layers are, for example, polyurethane adhesives.

The component is not limited to a straight base support, but may also assume a different shape in plan view. Other shapes in the sense of the invention may be shapes, as occur, for example, in floor groups or flat depression parts of vehicles or aircraft. In the method for producing the component, the tolerance-compensating intermediate layer is introduced at the beginning onto the inside of a non-closed basic carrier and at least one core element is applied to the intermediate layer. The open base support is then closed and connected permanently via a suitable joining technique along one or more closing seams. Optionally, in addition, for example, electrical lines, conductor tracks, fiber optic cables, sensors, strain gauges and / or electronic chips can be inserted or glued.

The method for producing the component is composed of the following method steps:

I) presence of one or more base beams which are not closed, II) introduction of at least one tolerance compensating intermediate layer, III) introduction of at least one core element and / or optionally other elements such as electrical lines, tracks, fiber optic cables, sensors, strain gauges and / or electronic chips, IV) closing the open base support, V) permanently connecting the closed base support via a suitable joining technique along one or more closing seams.

The component can be used in any technical field. The component is particularly preferably used in vehicle and aircraft construction. The component can contain, for example, as instrument panel support, all brackets and air ducts and a part of the air conditioner. Embodiments of the invention will be explained in more detail with reference to a drawing. Show:

FIG. 1 is a perspective view of a component with a closing seam;

FIG. 2 is a plan view of a component with two Schiießnähten,

FIG. 3 shows a detailed view of a closing seam of a component,

FIG. 4 shows a detailed view of a closing seam with an enforcing connection,

FIGS. 5 I) to 5 V) schematically show the sequence of a method for producing a component with a base carrier and a closing seam,

FIGS. 6 I) to V) schematically show the sequence of a method for producing a component with two basic carriers and two closing seams.

In the following the invention with reference to embodiments with reference to the drawings will be explained in detail. Corresponding parts are provided in all figures with the same reference numerals.

FIG. 1 shows a rectangular embodiment of a component 1, for example a crossbeam for a vehicle or an aircraft. The component 1 comprises a base support 2. On the inside of the base support 2, a core element 6 is introduced with the interposition of a tolerance compensating intermediate layer 4. As a basic support 2 is for example a metallic body or a metallic profile, in particular a cup-shaped metal profile. The core element 6 is the lightweight construction of the component 1 made of plastic. As a liner 4 is preferably a layer of adhesive provided. Alternatively, the intermediate layer 4 may be formed as a double-sided adhesive tape and / or sealing or foam strips. That is, the base support 2 is connected via the intermediate layer 4 with the core element 6. The base support 2 may also be permanently connected along a closing seam 8 via joints 10.

Figure 2 shows a multi-part component 1. The base support 2 comprises in this embodiment two closing seams 8, which have a plurality of joints 10 for permanent connection. In addition to the plastic insert or core element 6, further elements 1 2, such as e.g. introduced electrical lines.

Figures 3 and 4 show detailed views of a closing seam 8 of the component 1. In Figure 3, the base support 2 via the closing seam 8 is closed by welding. The thickness 8a of the closing seam 8 corresponds to the thickness or thickness of the connected base support 2 at this point. In Figure 4, the base support 2 via the closing seam 8 is closed by a screw 14. In this case, the base support 2 is formed in two parts, so that the two elements of the basic support 2 are connected to one another in the region of the closing seam 8 with the interposition of the intermediate layer 4 and the core element 6. Thus, the thickness 8a of the closing seam 8 in this embodiment corresponds to the thickness of the two elements, e.g. two half-shells, the base support 2, the thickness of the intermediate layers 4 and the thickness of the Kernele- element. 6

FIGS. 5 I) to V) show the sequence of a method for producing a component 1, for example a pipe carrier, with a one-piece base carrier 2. Adhesive and / or a double-sided adhesive tape and / or a double-sided adhesive tape are inserted into the two half-shells 3 of the base carrier 2. or a sealing or foam strip introduced. The core element 6 is in one of the two Half shells 3 applied to the intermediate layer 4 and the base support 2 via a bending point 16 closed. The base support 2 is permanently connected via the closing seam 8 at the joint 10 with a screw 14. Depending on the type and shape of the intermediate layer 4, the adhesive can be distributed during closing of the base support 2 by mechanical stress in the cavity H formed between the core element 6 and the base support 2, so that a peripheral intermediate layer 4 is formed.

FIGS. 6 I) to 6 V) schematically show the sequence of a method for producing a component 1 with a two-part basic carrier 2. For example, the basic carrier 2 comprises two elements 2 a and 2 b, for example a half-open profile and a lid. Alternatively, the base support 2 may be formed with two half-shells or two other half-profiles. In a two-part embodiment of the base support 2, this has two closing seams 8 for permanent connection. On the insides of the elements 2 a, 2 b of the base support 2, a tolerance-compensating intermediate layer 4 of adhesive, a double-sided adhesive tape and / or a sealing or foam strip is introduced. The core element 6 is applied to the intermediate layer 4 of the one element 2b of the base carrier 2. Then, the other element 2a of the base support 2 is applied to the element 2b and the core element 6 inserted into this and both elements 2a, 2b of the base support 2 permanently connected via the closing seams 8 with screws 14 at the joints 10.

LIST OF REFERENCE NUMBERS

Component basic support, 2b Elements of a basic support Half shell of a basic support Intermediate layer Core element Closing seam Thickness of the closing seam0 Joining point2 Elements4 Screw6 Bending point

Claims

Patent claims

1. component (1), comprising a shell-shaped base support (2) and at least one core element (6), wherein the base support (2) has at least one closing seam (8) and at least one tolerance compensating intermediate layer (4) with the Kernelemenf (6 ) connected is.

2. Component according to claim 1, characterized in that the basic carrier (2) is formed in one or more parts.

3. Component according to claim 1 or 2, characterized in that the closing seam (8) has at least one joint (10).

4. Component according to one of claims 1 to 3, characterized in that the base support (2) by a joining method, in particular welding, soldering, gluing, clinching and / or riveting on the closing seam (8) is closed.

5. Component according to one of claims 1 to 4, characterized in that the closing seam (8) during welding, soldering, clinching or gluing and / or after joining one of the thickness of the closed base support (2) corresponding thickness (8a).

6. Component according to one of claims 1 to 5, characterized in that the thickness (8a) of the closing seam (8) after joining is at most ten times the thickness of the closed base support (2).

7. Component according to one of claims 1 to 6, characterized in that the base support (2) has recesses, in particular partially perforated.

8. Component according to claim 7, characterized in that integrations, in particular at the joints (10) are mounted.

9. Component according to one of claims 1 to 8, characterized in that the core element (6) is a plastic element.

10. Component according to one of claims 1 to 9, characterized in that the tolerances compensating intermediate layer (4) comprises an adhesive and / or sealant, a double-sided adhesive tape and / or sealing or foam strips.

11. Component according to one of claims 1 to 10, characterized in that in addition as elements (12) electrical lines, conductors, fiber optic cables, sensors, strain gauges and / or 'electronic chips are provided.

12. A method for producing a component (1) according to one of claims 1 to 11, wherein on the inside of the cross-sectionally open base support (2) a tolerances compensating intermediate layer (4) is introduced and at least one core element (6) on the intermediate layer (4) is applied, the base support (2) is closed and permanently connected via a suitable joining technique along one or more closing seams (8).

13. The method according to claim 12, characterized in that in addition elements (12) such as electrical lines, conductors, fiber optic cables, sensors, strain gauges and / or electronic chips are introduced.

14. Use of a component (1) according to any one of claims 1 to 12 in vehicles or aircraft.