Wooden vehicle structural components and manufacturing methods

Abstract

The present invention relates to a wooden vehicle structural member (100) having an elongated base (110) made of solid wood (V), the base having at least one force-introducing region (111, 112) of greater strength formed by partial compression of the solid wood (V), wherein at least one transition between the force-introducing region (111, 112) of greater strength and an adjacent region of lesser strength is configured as a strength transition region (115) having a continuous and / or graded strength transition. The invention also relates to a method of manufacturing a wooden vehicle structural member (100) having an elongated base (110) made of solid wood (V) having at least one force-introducing region (111, 112) of greater strength formed by partial compression of the solid wood (V).

Description

Technical Field

[0001] The present invention relates to a wooden vehicle structural component and a method for manufacturing such a vehicle structural component. Background Technology

[0002] The vehicle structural components discussed here are motor vehicle components with higher stiffness and / or strength requirements, such as beams or internal reinforcements typically not visible in the vehicle body or other vehicle parts. These vehicle structural components are currently mostly made of metal or composite materials. Wooden vehicle structural components have long been developed to improve environmental and climatic balance and can also meet current requirements.

[0003] A door interior structure with an integrated door anti-collision beam is known from DE 10 2018 120 190 A1. This door interior structure can be made of wood, which has many advantages. Summary of the Invention

[0004] Based on existing technology, this invention proposes a wooden vehicle structural component and a method for manufacturing the wooden vehicle structural component. For both subjects of the invention, advantageous extensions and designs are similarly derived from the following description (which also explicitly includes exemplary and optionally described features) and the accompanying drawings. The following description is therefore applicable, in its meaning, to both inventive subjects.

[0005] The vehicle structural components according to the invention are made of wood, specifically solid wood, and therefore can also be referred to as wood structural components or vehicle wood structural components. These wood structural components or vehicle wood structural components have an elongated, particularly beam-shaped, solid wood or timber matrix, specifically referring to a one-piece (i.e., integrally made) or monolithic matrix. Laminates or plywood, particleboard, etc., are clearly not solid wood in the sense of this invention. Preferably, the wood fibers extend or are distributed at least primarily or substantially in the longitudinal direction of the matrix.

[0006] According to the invention, the solid wood matrix is ​​formed with at least one force-introducing region, which is formed by local compression / compaction of the solid wood, and has (locally) greater strength than at least one adjacent region of the matrix (i.e., the closest region or the region almost next to it), i.e., greater mechanical material strength, etc., particularly having at least twice the strength. This force-introducing region is particularly located at the axial end of an elongated matrix.

[0007] Preferably, the solid wood matrix has at least two force-introducing regions formed by the local compression of the solid wood, wherein the force-introducing regions have (local) greater strength, particularly at least twice the strength, compared to adjacent regions of the matrix. Specifically, two such force-introducing regions are provided at the axial ends of the elongated matrix.

[0008] In this force-introducing region, local, that is, locally restricted compression is preferably designed to be transverse to the longitudinal direction or longitudinal extension of the matrix, and especially transverse to the fiber orientation of the wood fibers, wherein the force-introducing region (relative to the adjacent region) preferably also has a smaller cross-section.

[0009] In addition to compression, the force-inducing area can also be impregnated. This specifically means treating solid wood or wood materials (hereinafter referred to simply as timber) with an impregnating substance or the like, which preferably penetrates into the timber. Such impregnation can, for example, increase strength, reduce flammability, and / or reduce moisture absorption. Preferably, impregnation is performed only in the force-inducing area and, if necessary, in the strength transition area (see below). Preferably, the impregnating substance is applied before compression, as will be explained in more detail below.

[0010] Furthermore, according to the present invention, at least one transition region between a force-introducing region with greater strength and an adjacent region with less strength is designed as a strength transition region having a continuous and / or graded strength transition. Such a strength transition region may also be referred to as a strength transition zone. This avoids or at least reduces abrupt changes in strength.

[0011] The following description partially relates to strength transition regions, and the relevant description should generally apply to embodiments having multiple strength transition regions, which may be designed identically or differently within the scope of the invention. Thus, for example, two strength transition regions may be provided, connecting the force-introducing region to their respective adjacent regions. Furthermore, the vehicle structural member according to the invention may have multiple force-introducing regions (formed by local compression of solid wood), particularly at least two force-introducing regions (see above), which may be designed identically or differently. Preferably, the transition between a force-introducing region with greater strength and at least one corresponding adjacent region with less strength is designed as a strength transition region with a continuous and / or graded strength transition.

[0012] Preferably, within the strength transition region, the strength changes continuously, i.e., almost smoothly (without abrupt changes), and / or preferably in stages across multiple strength levels (i.e., at least two levels), particularly with respect to the longitudinal direction of the matrix. This avoids or at least reduces sudden or abrupt strength transitions. A continuous strength transition can be combined with a staged strength transition. In the case of a staged strength transition, it is preferably configured such that adjacent strength levels or strength segments differ in strength by at least 10%. The strength transition region can have a length (relative to the longitudinal direction of the matrix) of 10 mm to 100 mm, preferably 20 mm to 75 mm, and especially 30 mm to 60 mm.

[0013] Preferably, the strength transition section, particularly a continuous and / or graded strength transition section, is formed in the strength transition region through geometric adaptation and / or through adaptation of the wood structure or wood properties. In other words, the strength transition, particularly a continuous and / or graded strength transition, can be achieved in the strength transition region through geometric adaptation and / or through adaptation of the wood structure. Geometric adaptation specifically refers to special configurations, such as stepped, rounded, and / or sloping transition profiles, to connect a typically smaller cross-sectional area of ​​force introduction with an adjacent area of ​​larger cross-section. Adaptation of the wood structure specifically refers to variations in the compression and / or impregnation of solid wood or timber, i.e., creating different compressions and / or impregnations in the strength transition region. These two measures can be explicitly combined with each other.

[0014] The force-introducing region is preferably created by applying external extrusion pressure using a suitable extrusion process, particularly by applying external extrusion pressure only locally. Preferably, the strength transition region is also created by applying external extrusion pressure using a suitable extrusion process, particularly by applying external extrusion pressure only locally. To apply the extrusion pressure, an extrusion tool is preferably used, which is particularly configured to simultaneously create at least one force-introducing region and at least one corresponding strength transition region.

[0015] The force-introducing region may have at least one formed hole, which in particular serves as a fixing hole. Preferably, the hole is formed simultaneously with the formation of the force-introducing region (by compressing the solid wood, etc.), for example, by means of a punch. No cutting drilling process is involved, thus avoiding damage to the wood structure or interruption of the wood fibers. For reinforcement, a metal ring or similar object can be additionally pressed into the formed hole.

[0016] Additional functional elements can be incorporated into the matrix, particularly those located outside the force-introducing and strength transition regions. These additional functional elements include, for example, fastening elements, connecting elements, supporting elements, retaining elements, reinforcing elements, and distance-maintaining elements. Preferably, these additional functional elements are produced by directly injecting plastic (especially fiber-reinforced plastic) into the wood matrix; that is, the functional elements are directly injected injection-molded elements, but their strength is preferably lower than that of the force-introducing region formed from wood. The matrix may be constructed with recesses, especially shaped recesses or similar structures, in relevant areas to achieve a shape-locking connection of the injected plastic.

[0017] The timber structural member according to the invention is particularly constructed as a dashboard crossbeam of a motor vehicle. In other words, the timber structural member according to the invention is preferably a dashboard crossbeam, as shown, for example, in the accompanying drawings. Prior art in this regard can be found, for example, in DE 10 2008 021 103 A1, DE 20 2011 110 441U1, and EP 2 499 038 B1. However, the timber structural member according to the invention can also be, for example, a transmission bracket.

[0018] The method or manufacturing method according to the invention enables the manufacture of vehicle structural components from wood, the vehicle structural components having an elongated base made of solid wood, the base having at least one force-introducing region of high strength formed by local compression of the solid wood or timber, and, if necessary, at least one (corresponding) strength transition region. Preferably, the component to be manufactured or already manufactured is a vehicle structural component according to the invention, and in particular a dashboard crossbeam. The foregoing description similarly applies to the method.

[0019] The method according to the invention includes at least the following steps, particularly in the following order: - providing a prefabricated, especially pre-classified, elongated wooden piece made of solid wood, the base of which should be made;

[0020] - By applying, especially locally, external compressive force to the wooden piece (in the so-called extrusion process), a force-introducing area is created, in which the solid wood or timber is compressed in the relevant area and thereby (locally) increases its strength;

[0021] -As mentioned above, additional functional components may be added as appropriate, especially for injection molding;

[0022] - The substrate may be surface treated as appropriate, wherein the surface treatment may also be performed before the functional elements are set, and / or at least one laminate layer may be applied, in particular, bonded, which is especially for improving quality or texture, and / or at least one plastic layer and / or fiber composite layer may be applied, which is especially for improving quality or texture and / or improving strength.

[0023] Specifically, no wood cutting is included, except for the possibility of length adaptation.

[0024] Preferably, the wood fibers of the elongated wooden piece extend at least primarily or substantially in the longitudinal direction of the piece. The wooden piece is preferably—especially provided as a semi-finished product—cut timber, square timber, or similar articles.

[0025] The resulting force can be introduced into the region with uniform or varying intensity, that is, with different intensities or locally different intensities.

[0026] Compression is preferably achieved by means of a pressing tool, in which the wooden part is placed completely or partially. The pressing tool may be mounted in a press, locking device, or the like. External compressive force (see below) is then applied to the wood using the pressing tool. It may be specified that the wooden part is compressed integrally and, where appropriate, deformed or bent (e.g., to form a bend), where at least one force-introducing area and, where appropriate, at least one strength transition area are thus approximately over-compressed.

[0027] When at least one force-introducing region is generated, preferably, at least one strength transition region is also generated almost simultaneously in the same process or production step, wherein the relevant areas of the wooden part are preferably compressed in a variable manner, so that different compressions or locally different compressions are achieved in the relevant areas. In particular, the extrusion tool used for this purpose is accordingly constructed and, for example, has multiple tool sections, which can be used to apply different extrusion forces locally or in sections (local extrusion forces). In addition, at least one hole can also be formed in at least one force-introducing region. For this purpose, the extrusion tool for extrusion or compression can be constructed, for example, with at least one punch or the like.

[0028] Prior to compression, at least one area of ​​the wooden part corresponding to the force-introducing region may be moistened with a wetting agent (e.g., water or steam) (in the so-called wetting process) and / or treated with an impregnating substance (in the so-called impregnation process). The relevant area or multiple relevant areas of the wooden part may, for example, be sprayed or immersed in a basin or pool. This is similarly applied to at least one intensity transition area. The relevant area or multiple relevant areas may also be varied in terms of wetting and / or impregnation, particularly in such a way that different moisture or impregnating agent contents are produced within the relevant areas, i.e., impregnated in different ways.

[0029] Preferably, the provided wooden part is inspected in at least one region or segment corresponding to the force input area and, if appropriate, in at least one region or segment corresponding to the strength transition area, and the subsequent wetting, impregnation, and / or extrusion processes are controlled or regulated based on the values ​​detected therein. When inspecting the wooden part, individual characteristics such as its fiber orientation (especially in terms of irregularity and inclusions), temperature, density, and / or wood moisture content or wood humidity can be detected, with particular determination of the corresponding values. Furthermore, environmental conditions such as room temperature and air humidity and / or other production conditions can be detected and taken into account during the wetting, impregnation, and / or extrusion processes. The wetting, impregnation, and / or extrusion processes can then be personalized to the characteristics or properties of the corresponding wooden part, for example, by adapting or adjusting the amount of wetting agent or impregnation substance, temperature, and / or application time for each relevant region or segment, and by adapting or adjusting the extrusion pressure, especially localized extrusion pressure, extrusion time, and / or extrusion temperature, especially localized extrusion temperature. Preferably, the inspection and control or adjustment are performed automatically in a process executed with the aid of artificial intelligence (KI process). Based on this inspection, unsuitable wooden parts can also be rejected.

[0030] Furthermore, based on the inspection of the wooden parts, it is possible to select areas or sections particularly suitable for force introduction areas and / or strength transition areas, or to change the position of related areas or sections, wherein, if necessary, the length of the wooden parts (which may have extra length or may be semi-finished products not ready for assembly) needs to be adapted accordingly. However, the provided wooden parts preferably already have a (axial) length corresponding to the base of the vehicle structural component to be manufactured, so that subsequent length matching is no longer required.

[0031] Furthermore, vehicle-specific requirements can be considered for the wetting, impregnation, and / or extrusion processes, and appropriate controls or adjustments can be made, similar to those described above. This allows for the alternating manufacture of different vehicle structural components or variations thereof in the same production equipment, such as dashboard crossbeams for different vehicle types. Attached Figure Description

[0032] The invention is described in detail below with reference to the schematic diagrams in a non-limiting manner. The features shown in the drawings and / or described below can also be used, independently of specific combinations of features, as general features of the invention and accordingly modify the invention. Furthermore, features of different implementation possibilities can be combined to form other implementation possibilities.

[0033] Figure 1 A wooden vehicle structural member with two force-introducing areas is shown.

[0034] Figure 2Show Figure 1 The first implementation possibility of force introduction area on vehicle structural components.

[0035] Figure 3 Show Figure 1 The second implementation possibility of force introduction area on vehicle structural components.

[0036] Figure 4 Show Figure 1 The third implementation possibility of force introduction area on vehicle structural components.

[0037] Figure 5 Showing the method used to generate based on Figure 4 The extrusion tool and extrusion process in the force-introducing area.

[0038] Figure 6 Showing the manufacturing process Figure 1 The method for constructing vehicle structural components involves multiple steps. Detailed Implementation

[0039] exist Figure 1 The vehicle structural member 100 shown is, for example, a dashboard crossbeam. The vehicle structural member or dashboard crossbeam 100 has an elongated base 110, which is formed in one piece from a solid piece of wood V, and may have, for example, a circular or polygonal, especially rectangular, cross section. Force-introducing regions 111 and 112 are respectively constructed at its axial ends, where the solid wood V or solid wood material M has locally greater strength due to compression. Force-introducing regions 111 and 112 serve as fixing or connecting sections for securing the structural member 100 to the vehicle body (e.g., an A-pillar), and for this purpose also have at least one formed hole or fixing hole 113, which, for example, enables a threaded connection. The base 110 may have additional such force-introducing regions.

[0040] Figure 2 With the help of Figure 1 The force-introducing region 112 on the right side of the vehicle structural member 100 exemplifies a first implementation possibility. Another force-introducing region 111 or the other axial end of the base 110 can be constructed identically or in a mirror-symmetrical manner. That is, the following descriptions and considerations are generally applicable and not limiting.

[0041] There exists a transition region 112, which has a higher strength in the matrix 110, and an adjacent region 114, which has a relatively lower strength. This transition region is configured as a strength transition region or strength transition area 115. This transition region belongs to the force-introducing region 112 to a certain extent and connects the compressed force-introducing region 112 with the uncompressed or less compressed adjacent region 114. That is, there is exactly one strength transition region 115 between adjacent regions 112 and 114, such that the two adjacent regions 112 and 114 are not directly adjacent but indirectly adjacent to each other through the strength transition region 115. For illustration, the regions that differ in their mechanical properties are divided by dashed lines, where the line distribution shown is only for simplified observation.

[0042] Within the strength transition region 115, the strength transition is achieved such that the material strength F or similar mechanical properties (e.g., stiffness or hardness) of the wood M continuously and / or progressively increases toward the force input region 112, as indicated by the arrows. This is achieved here by a geometric fit in the form of a sloping transition profile 116 formed on multiple sides or around the perimeter between adjacent regions 112, 114.

[0043] Preferably, both the force introduction region 112 and the strength transition region 115 are generated by applying external compressive force (or external local compressive force), as will be explained in more detail below. That is, the strength transition region 115 is not simply a result of local compression of the wood M in the force introduction region 112, but is specifically generated or generated together with prescribed characteristics.

[0044] Within the strength transition region 115, the wood M experiences varying compression and strength by gradually increasing or decreasing in cross-section along the direction of the arrow. In other words, the wood structure is fitted not only by adapting the geometry but also by creating varying compression within the strength transition region 115. Furthermore, it can be specified that a variable impregnation of the wood material M is formed (indicated by dots). That is, the strength transition region 115 can have varying density and / or impregnation along its length (in the direction extending longitudinally along the matrix 110) and / or along its cross-section, thereby forming a continuous and / or graded strength transition section according to a specific design scheme, i.e., a strength transition section including multiple strength levels.

[0045] The strength transition region 115 may also be constructed—in other geometric designs, as appropriate—with substantially uniform strength, which lies between the greater strength of the force introduction region 112 and the smaller strength of the adjacent region 114, so that the strength transition region 115 approximately forms an intermediate strength level.

[0046] Figure 3 and Figure 2 Similarly, another implementation possibility is shown, wherein a sloping transition profile 116 is preferably constructed only on one side, which in particular continues the shape of the force-introducing region 112. Furthermore, similar applications are also applicable to... Figure 2 An explanation of the feasibility of its implementation.

[0047] Figure 4 and Figure 2 Similarly, another implementation possibility is shown, wherein the intensity transition region 115 is constructed with a circular transition profile 117. Furthermore, the intensity transition region 115 includes two partial regions 115a and 115b that differ in intensity or intensity distribution, i.e., similar to two intensity levels or intensity segments. The two partial regions 115a and 115b intersect each other more or less, as indicated by the arcuate dividing line, thus resulting in an intensity variation across the cross-section. A similar approach also applies to... Figure 2 An explanation of the feasibility of its implementation.

[0048] Figure 5 With the help of Figure 4 The illustrated implementation possibilities demonstrate an extrusion process that generates a force-introducing region 112 and a corresponding strength transition region 115 by locally compressing solid wood V or timber M using an extrusion tool 200. The extrusion tool 200 is constructed in segments and has multiple, repeatedly repeated tool segments 210, 220, 230. Different external extrusion forces P1, P2, P3 can be applied locally, i.e., regionally or segmentally, using these tool segments, with a particular preference for p1 > p2 > p3. The extrusion forces P1, P2, P3 can also be referred to as local extrusion forces. Preferably, the local extrusion forces P1, P2, P3 applied using tool segments 210, 220, 230 can be varied or adjusted, thereby individually coordinating the extrusion process. Specifically, by varying the extrusion forces P2 and / or P3, the characteristics of the strength transition region 115 can be specifically adjusted.

[0049] The extrusion of solid wood V or wood M can be carried out in a corresponding design of the extrusion tool 200 such that the original cross-sectional shape of the substrate 110 remains unchanged, and is reduced to a smaller cross-section only to a certain extent. However, it is preferably configured such that the cross-sectional shape is changed during or during extrusion, so that the force introduction region 112 has at least partially a different cross-sectional shape from the adjacent region 114, wherein the strength transition region 115 may form a shape transition portion.

[0050] The tool sections 210, 220, and 230 of the extrusion tool 200 may also be equipped with heating devices (not shown), which can each achieve a specific extrusion temperature. Preferably, these heating devices can be controlled or adjusted independently of each other. In particular, the local extrusion temperatures T1, T2, and T3 applied by the tool sections 210, 220, and 230 can be changed or adjusted, thereby allowing for individual coordination of the extrusion process in terms of extrusion temperature.

[0051] For pressing or compressing, undivided pressing tools, especially those with one or more heating devices, can in principle be used. Furthermore, pressing tools can be constructed such that the wooden workpiece to be processed can be inserted as a whole, thereby, for example, producing two [sections / pieces] simultaneously. Figure 1 The force introduction areas 111 and 112 are shown in the figure.

[0052] Figure 6 Several steps of a preferred method for manufacturing vehicle structural component 100 are shown, the method comprising the following steps:

[0053] - Provide 10 prefabricated, long wooden pieces made of solid wood V;

[0054] - The wooden part 10 is inspected at least in regions 11 and 12 corresponding to the force introduction regions 111 and 112 to be generated—especially including the strength transition region 115—wherein the phase of the wooden part 10 is detected by means of suitable sensors (e.g., camera 300, temperature sensor, humidity sensor, etc.).

[0055] Relevant properties (e.g., fiber orientation, temperature, density, and / or wood moisture), such as Figure 6 As shown in a; - Wetting and / or impregnation processes may be carried out as appropriate, wherein at least area 11 of the wooden component 10,

[0056] 12. Treatment with a wetting agent or impregnating substance S or the like, especially individual treatment based on previously detected characteristics, such as... Figure 6 As shown in b;

[0057] - Perform at least one extrusion process, for example by means of Figure 5 The extrusion tool 200 shown above, wherein solid wood V or wood M is locally compressed at least in regions 11, 12 of the wooden piece 10 by applying external extrusion force P (or local extrusion forces P1, P2, P3), thereby creating, in particular based on previously detected characteristics, individual force-introducing regions 111, 112 and, in particular, simultaneously creating a strength transition region 115, such as... Figure 6 As shown in c; - Additional functional elements 120 may be installed as needed (see c) Figure 1 and Figure 6d), particularly the placement of functional elements of the accessory by directly injecting plastic material onto the substrate 110.

[0058] The holes 113 in the force introduction regions 111, 112 can be formed during or during the extrusion process, as described above. Optionally, a reinforcing ring, particularly a metal reinforcing ring or the like, can then be inserted into the holes 113.

Claims

1. A wooden vehicle structural component (100) having an elongated base (110) made of solid wood (V), the base having at least one force-introducing region (111, 112), characterized in that, The force-introducing regions (111, 112) are formed by applying an external compressive force (P) to locally compress the solid wood (V). Compared with at least one adjacent region (114) of the base (110), the force-introducing regions have greater strength. At least one transition between the force-introducing regions (111, 112) with greater strength and the adjacent regions (114) with less strength is constructed as a strength transition region (115) with a continuous and / or graded strength transition.

2. The vehicle structural component (100) according to claim 1, Its features are, In the strength transition zone (115), a continuous and / or graded strength transition is formed by adapting the geometry and / or by adapting the wood structure.

3. The vehicle structural member (100) according to any one of the preceding claims, Its features are, The strength transition region (115) is created by applying an external compressive force (P).

4. The vehicle structural component (100) according to claim 1 or 2, Its features are, The force-introducing regions (111, 112) have at least one shaped hole (113).

5. The vehicle structural component (100) according to claim 1 or 2, Its features are, Additional functional elements (120) generated by direct injection of plastic are arranged on the substrate (110).

6. The vehicle structural component (100) according to claim 1 or 2, Its features are, The vehicle structural component is designed as a dashboard crossbeam for motor vehicles.

7. A method for manufacturing a wooden vehicle structural member (100), the vehicle structural member having an elongated base (110) made of solid wood (V), the base having at least one force-introducing region (111, 112) of high strength formed by local compression of the solid wood (V), wherein, The method includes the following steps: - Provide a prefabricated long wooden piece (10) made of solid wood (V), the base (110) shall be made from the wooden piece; - By applying external compressive force (P), a force is introduced into the regions (111, 112), thereby compressing the solid wood (V) in the relevant regions (11, 12) and thus locally increasing its strength.

8. The method according to claim 7, Its features are, Before compression, at least one area (11, 12) of the wooden part (10) corresponding to the force-introducing area (111, 112) is treated with impregnation material (S).

9. The method according to claim 7 or 8, Its features are, The provided wooden parts (10) are inspected at least in the areas (11, 12) corresponding to the force-introducing areas (111, 112), and the impregnation and / or extrusion processes are controlled based on the values ​​detected therein.

10. The method according to claim 9, Its features are, When inspecting wooden parts (10), test their fiber orientation, temperature, density and / or wood moisture.

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