Composite component and manufacturing method thereof

Abstract

The invention relates to a composite component (1) comprising a hollow structure (3) and a foamed component (5) inserted in the hollow structure (3), a gap (15) being formed between the hollow structure (3) and the foamed component (5), in which a tension active enhancing structure (17) is connected to the foamed component (5) and an end (19) of the tension active enhancing structure (17) is connected to the hollow structure (3), the foaming component (5) is not in contact with the hollow structure (3), and the gap (15) is formed between the hollow structure (3) and the foaming component (5). The invention also relates to a method for producing the composite component.

Description

[0001] manual

[0002] The present invention relates to a composite component including a hollow structure and a foaming component inserted into the hollow structure, and wherein a gap is formed between the foaming component and the hollow structure.

[0003] For example, in the automotive industry, foamed components inserted into hollow structures are used as reinforcement inserts for mechanical reinforcement or as energy absorbing inserts to absorb energy in the event of a collision. Due to the construction of the vehicle chassis, the foamed component is usually inserted into the hollow structure before painting. Therefore, during the cationic electrophoretic painting process, a gap must be maintained between the foamed component and the hollow structure. In order to achieve sufficient corrosion stability, all metal surfaces are coated with an anticorrosive. In order to apply the anticorrosive on all surfaces, the vehicle chassis is treated by cationic electrophoretic painting. During cationic electrophoretic painting, the vehicle chassis is immersed in an immersion bath, which contains a coating liquid with an anticorrosive.

[0004] During the immersion of the vehicle chassis in the immersion bath, the coating liquid reaches all free surfaces and the corrosion inhibitor is deposited on these free surfaces. The coating liquid also flows into the gap between the hollow structure and the foamed component, so that the coating liquid can also be applied to those surfaces of the hollow structure adjacent to the foamed component.

[0005] To provide the gap, currently spacer points are formed on the outer surface of the foaming component. For example, the spacer points have the form of spherical domes to minimize the contact area between the foaming component and the hollow structure. Alternatively, the gap is provided by using an adhesive pad that defines the gap and keeps the foaming component at a desired distance from the surface of the hollow structure.

[0006] In addition to inserting the foaming component into the hollow structure, it is also known, for example from EP-A 2 383 170, to use an insert part made of a material with high tensile strength, which can be inserted into the hollow profile or U-shaped profile and whose ends can be connected to the hollow profile or U-shaped profile for reinforcing the hollow profile or U-shaped profile. In order to achieve the reinforcing properties, a certain distance must be provided between the insert part and the hollow profile or U-shaped profile. This distance is achieved by a spacing element, which rests on one side against the profile and on the other side against the insert part.

[0007] One object of the present invention is to provide a composite component comprising a hollow structure and a foam component, which allows simple fixing of the foam component with a continuous gap between the foam component and the hollow structure and also additionally improves the performance of the composite component, in particular with regard to energy absorption. Another object of the present invention is to provide a method for making such a composite component.

[0008] This object is achieved by a composite component, which includes a hollow structure and a foaming component inserted in the hollow structure, a gap is formed between the hollow structure and the foaming component, wherein a tension active reinforcement structure is connected to the foaming component, and the end of the tension active reinforcement structure is connected to the hollow structure in a way that the foaming component does not contact the hollow structure and a gap is formed between the hollow structure and the foaming component.

[0009] Surprisingly, by using a tensile active reinforcing structure, in particular, the energy absorption properties of the composite component can be further improved, even without providing a spacing element, which rests on one side against the hollow structure and on the other side against the tensile active reinforcing structure. In addition, by connecting the ends of the tensile active reinforcing structure to the hollow structure, the fixing of the foamed component in the hollow structure can be simplified.

[0010] As part of the present invention, more than one tensile active reinforcement structure may be used to better accommodate different mechanical loads.

[0011] The hollow structure can be a closed hollow structure, such as a tube or a closed passage, or an open hollow structure, such as a U-shaped profile. If the hollow structure is a closed hollow structure, the hollow structure can have any cross-sectional geometry, such as a circle, a triangle, a rectangle or any other polygonal shape. In addition to these channel-like geometries, the cross-sectional geometry of the closed passage can also include grooves or can have irregular cross-sectional areas. If the hollow structure is an open hollow structure, in this case, in addition to the U-shape, the hollow structure can also have any cross-sectional shape, such as a V-shape, a W-shape or a shape with grooves. In addition, no matter whether the hollow structure is an open hollow structure or a closed hollow structure, the cross-sectional shape can change along the hollow structure.

[0012] The hollow structure may be made of any suitable material, for example of metal or an optionally reinforced polymer. Preferably, the hollow structure is made of metal, in particular of steel or aluminium.

[0013] The foamed component is preferably made of polymer foam. However, in addition to polymer foam, any other foaming material, such as metal foam or glass foam, can also be used to make the foamed component.

[0014] Suitable polymers for making the foamed component may be, for example, polyurethanes or polyamides.Preferably, the polymer foam is a polyamide foam, for example a polyamide foam based on polyamide 6, polyamide 6 / 6.36, polyamide 12, polyamide 610, polyamide 6 / 66, polyamide 6.12 or a copolyamide.

[0015] Preferably, the polyamide is a polyamide such as described in WO-A 2020 / 016102 or a copolyamide such as described in WO-A 2021 / 052881.

[0016] Thus, the polyamide may be, for example, a polyamide prepared by polymerization of:

[0017] (i) 15 to 84% by weight of at least one lactam,

[0018] (ii) 16 to 85 wt. % of a monomer mixture comprising

[0019] (ii1) at least one C 32 -C 40 Dimer acid, and

[0020] (ii2) at least one C4-C 12 diamine,

[0021] wherein the monomer mixture comprises 45 mol% to 55 mol% of component (ii1) and 55 wt% to 45 wt% of component (ii2) based on the total amount of the monomer mixture, and component (i)

[0022] The sum of (i) and (ii) is 100 wt%.

[0023] If the polyamide is a copolyamide, the polyamide may be, for example, a polymer mixture comprising:

[0024] (A) 5 to 75% by weight of at least one copolyamide prepared by polymerizing:

[0025] (A1) 15 to 84% by weight of at least one lactam,

[0026] (A2) 16 to 85 wt% of a monomer mixture comprising

[0027] (M1) at least one C 32 -C 40 Dimer acid, and

[0028] (M2) at least one C4-C 12 diamine,

[0029] wherein the sum of components A1 and A2 is 100% by weight, and

[0030] (B) 25 to 95% by weight of at least one polyamide different from the copolyamide (A).

[0031] The polyamide (B) may be selected from the group consisting of polycaprolactam (PA6), polybutylene adipamide (PA4.6), polyhexamethylene adipamide (PA6.6), polyhexamethylene sebacamide (PA6.10), polyhexamethylene dodecanoamide (PA6.12), poly-11-aminoundecanoamide (PA11), polylaurolactam (PA12), polymethylene adipamide (PAMXD 6), polypentamethylene sebacamide (PA510), 6T / Z (Z = lactam), 6T / 6I / XY, 6T / XT (X = linear or branched C4-C 18 -diamine), XT (X=C4-C 18 -diamine), PA PACM 12 (PACM = p-diaminodicyclohexylmethane), PAMACM 12 (MACM = 3,3-dimethyl-p-diaminodicyclohexylmethane), PA MPMD 6 (MPMD = 2-methylpentamethylenediamine), PA MPMD T, PA MPMD 12, polyhexamethyleneisophthalamide (PA 6I), polyhexamethyleneisophthalamide co-hexamethyleneterephthalamide (PA 6I / 6T), PA 6-3-T (a mixture of terephthalic acid polyamide and 2,2,4- and 2,4,4-trimethylhexamethylenediamine), polybutadiene sebacamide (PA 4.10), polydecanediamine sebacamide (PA 10.10), polypentamethylene sebacamide (PA 5.6), PA 6 / 66 and PA 66 / 6, PA 6Y (Y = C4-C 18 -diacids) and their transamidation products.

[0032] An advantage of using polyamide foam is that such foamed components made of polyamide foam are temperature-stable, in particular with regard to the temperatures occurring during the coating process.

[0033] The polymer of the polymer foam may contain additives, such as reinforcing additives, dyes, plasticizers, stabilizers (e.g. UV stabilizers) and / or flame retardants, in order to set the properties of the polymer foam. If the polymer used for the polymer foam contains reinforcing additives, these may be, for example, short fibers or powdered additives, such as talc. If short fibers are used, the fibers may be, for example, carbon fibers, glass fibers, aramid fibers or mineral fibers.

[0034] The foaming component can be made of open-cell foam or closed-cell foam. In addition, the secondary foaming component can also be made of a combination of open-cell foam and closed-cell foam, and contain open cells and closed cells. The foam made of the foaming component can be a particle foam or a continuous foam, preferably a particle foam.

[0035] The foaming component may have any cross-sectional shape, provided that the shape allows the foaming component to be inserted into the hollow structure and a gap can be formed between the inner wall of the hollow structure and the surface of the foaming component. The foaming component may have a cross-sectional shape corresponding to the cross-sectional shape of the hollow structure but slightly smaller. These corresponding shapes allow a regular gap to be formed between the hollow structure and the forming component. However, depending on the desired characteristics of the composite component, the foaming component may also have a cross-sectional shape that is different from the cross-sectional shape of the hollow structure, such as providing a groove or protrusion in the foaming component at a position where there is no groove or protrusion in the hollow structure.

[0036] The active tensile reinforcement structure used in the composite component is preferably made of a material that can reinforce the composite component if a bending load acts on the composite component. Suitable materials are, for example, metals that allow elastic deformation or act like a spring. Suitable materials for the active tensile reinforcement structure are, for example, continuous fiber reinforced polymers or preferably metals. For example, preferred metals for making the active tensile reinforcement structure are steel or aluminum. The material of the active tensile reinforcement structure is preferably made of the same material as the hollow structure, because this facilitates the mechanical connection (e.g. welding) between the two.

[0037] The tension active reinforcing structure may have any suitable shape. Preferably, the tension active reinforcing structure is a beam, a bar or a rod. Thus, the shape of the tension active reinforcing structure is such that at least two ends of the tension active reinforcing structure protrude from the foaming component.

[0038] In the composite component, the foam component is connected to the tension active reinforcement structure. In order to connect them, the tension active reinforcement structure is preferably integrated into the foam component, so that the foam component at least partially surrounds the tension active reinforcement structure. Alternatively, the tension active reinforcement structure can also be connected to one surface of the foam component, so that in the composite component, one surface of the tension active reinforcement structure is facing the inner surface of the hollow structure. However, preferably, the foam component surrounds the tension active reinforcement structure so that only the end of the tension active reinforcement structure protrudes from the foam component.

[0039] The protruding end is shaped so that the end can be connected to the hollow structure, and after the end is connected to the hollow structure, a gap is formed between the foaming component and the hollow structure, wherein the gap preferably surrounds the entire foaming component so that there is no contact between the foaming component and the hollow structure. To this end, the end may be, for example, S-shaped, U-shaped, or may include a portion pointing to the inner surface of the hollow structure and a second portion behind the portion pointing to the inner surface of the hollow structure, the second portion being aligned parallel to the surface of the hollow structure to allow the second portion to be connected to the hollow structure.

[0040] In order to connect the ends of the active tension reinforcement structure to the hollow structure, any connection method known to a person skilled in the art can be used. Suitable connection methods are, for example, threading, riveting, gluing, welding, brazing or a combination thereof. In particular, if the active tension reinforcement structure and the hollow structure are made of metal (in particular steel or aluminum), the ends of the active tension reinforcement structure are welded or brazed to the hollow structure. Welding, brazing or gluing the ends of the active tension reinforcement structure to the hollow structure has the additional advantage that the connection is a material bond and therefore, if the composite assembly is subjected to cationic electrophoretic painting for applying a preservative, there is no need to apply a preservative to the portion of the hollow structure to which the end is attached and the portion of the end of the active tension reinforcement structure attached to the hollow structure.

[0041] The use of a reinforcement structure may improve the anti-corrosion coating process of a hollow structure because it allows anti-corrosion liquids and other liquids to flow cleanly through the gap and may therefore improve the anti-corrosion effect.

[0042] A method for making such a composite component, the composite component comprising a hollow structure and a foaming component inserted into the hollow structure, a gap being formed between the hollow structure and the foaming component, the method comprising:

[0043] (a) forming a hollow structure;

[0044] (b) forming a foam component with an inserted tension active reinforcing structure, wherein an end of the tension active reinforcing structure protrudes from the foam component;

[0045] (c) Attaching the ends of the tension active reinforcement structure to the hollow structure.

[0046] The hollow structure may be formed by any method known to those skilled in the art for forming a hollow structure. If the hollow structure is an open hollow structure, the hollow structure may be formed, for example, by bending a flat sheet into a desired shape.

[0047] If the hollow structure is a closed hollow structure, the hollow structure can be formed by any method known to those skilled in the art for forming profiles, such as by roll forming or by making at least two profile segments by extrusion and connecting these profile segments. Other techniques for forming the hollow structure are pultrusion or extrusion to form closed profiles without welding.

[0048] If the hollow structure is formed by making at least two profile segments and connecting these profile segments, the connection can be achieved by any connection known to the person skilled in the art. For example, the profile segments can be connected by welding, gluing, brazing, screwing or riveting. In particular, if the profile segments are connected by screwing or riveting, the profile segments can be arranged so that parts of the walls of the profile segments overlap and the rivets or screws are guided through the overlapping walls. Alternatively, it is also possible to provide each profile segment with a flange and connect the flanges to form the hollow structure.

[0049] If a closed hollow structure is formed by roll forming, a profile is first formed from a coil. By forming the profile, the sheet edges of the coil are bent so that they abut. After the profile is formed, the abutting edges are welded, thereby producing a closed hollow structure.

[0050] The extrusion method for making hollow structures can also be used to make open hollow structures or closed hollow structures. The advantage of forming hollow structures by extrusion is that, since the metal is pressed through a die, any shape of profile can be produced, including shapes that cannot be produced by roll forming or bending.

[0051] In a second step, which can be performed independently of the formation of the hollow structure, a foamed component with an inserted tension active reinforcing structure is formed. The hollow structure and the foamed component with an inserted tension active reinforcing structure can be produced simultaneously or in steps, wherein if the components are produced one after the other, the hollow structure can be produced first and then the foamed component with an inserted tension active reinforcing structure, or alternatively, the foamed component with an inserted tension active reinforcing structure can be formed first and then the hollow structure. Furthermore, in particular, if a plurality of composite components are to be produced, it is also possible to form all required hollow structures and all required foamed components with an inserted tension active reinforcing structure individually and, after the individual components have been produced, to connect all foamed components with an inserted tension active reinforcing structure to the hollow structure.

[0052] In order to make a foamed component with an inserted tensile active reinforcing structure, the tensile active reinforcing structure is usually first formed. For example, the tensile active reinforcing structure can be formed by casting or preferably by pressing or deep drawing methods.

[0053] If the foaming component is made of continuous foam, in order to make the foaming component, the tension active reinforcement structure is preferably placed in a mold, and then a foaming agent containing a polymer melt or a reactant and a foaming agent for preparing a polymer are injected into the mold, and the foaming component is formed in the mold. In the mold, the foaming agent expands and forms a polymer foam. If the reactant for preparing the polymer is injected into the mold, the reactant reacts during expansion and forms a polymer. If the polymer is thermosetting, it is particularly preferred to inject the reactant into the mold. For thermoplastic polymers, it is preferred to inject a foaming agent containing a polymer into the mold. In this case, the melt of the polymer is injected into the mold, and the foaming component is made by an injection molding method.

[0054] If the foamed component is made of particle foam, the foamed component with the inserted tension-active reinforcement structure can be formed, for example, by placing the tension-active reinforcement structure into a mold, injecting expanded polymer beads into the mold and connecting the expanded polymer beads to form the foamed component. The particle foam is preferably made of a thermoplastic polymer. In order to connect the expanded polymer beads, superheated steam is usually injected into the mold under pressure. The surface of the expanded polymer beads begins to melt due to the superheated steam, so that the expanded polymer beads are welded together to form the particle foam.

[0055] After the hollow structure and the foamed component with the inserted tension active reinforcing structure are fabricated, the hollow structure and the foamed component with the inserted tension active reinforcing structure are connected.

[0056] In order to connect the foamed component with the inserted tension active reinforcement structure to the hollow structure, the end of the tension active reinforcement structure protruding from the foamed component can be attached to the hollow structure. The end of the tension active reinforcement structure can be attached to the hollow structure by welding, gluing, screwing, riveting, brazing or a combination thereof. Preferably, the end of the tension active reinforcement structure is attached to the hollow structure by welding, gluing or brazing, in particular by welding.

[0057] The composite component produced in this way can be further processed, for example coated.

[0058] Typically, the composite component is part of a larger structure, such as a part of a vehicle chassis. In this case, the composite component and other parts are connected to form a larger structure, and subsequently, the larger structure can be subjected to a coating process. If the larger structure is a vehicle chassis, the vehicle chassis is usually cationic electrophoretic painted before the color paint is sprayed onto the vehicle to apply a preservative to the chassis. In order to dry and cure the coating, the chassis is passed through a drying oven after each coating step. Due to the temperatures in the drying oven and the temperatures in the cationic electrophoretic painting bath, the foamed component needs to be made of a temperature-stable material. Therefore, temperature-stable polyamides are preferably used to form the composite component.

[0059] Embodiments of the invention are shown in the drawings and are explained in more detail in the following description.

[0060] In the attached picture:

[0061] Figure 1 A three-dimensional schematic diagram showing a hollow structure and a foaming component to be inserted into the hollow structure;

[0062] Figure 2 Schematically illustrates a hollow structure with an embedded composite component made of a foamed component with an inserted tensile active reinforcement structure;

[0063] Figure 3 A foamed component with an embedded tension active reinforcement structure under bending load is shown;

[0064] Figures 4a to 4d Different possible cross-sectional shapes of the foaming component are shown;

[0065] Figure 5 Simulated force-displacement curves of a hollow structure, a hollow structure with a foaming component, a hollow structure with a tension active reinforcement structure, and a hollow structure with a foaming component and a tension active reinforcement structure are shown.

[0066] Figure 1 The hollow structure and the foaming component to be inserted into the hollow structure are schematically shown.

[0067] The composite component 1 comprises a hollow structure 3 and a foamed component 5. In the embodiment shown here, the hollow structure 3 comprises a first profile segment 7 and a second profile segment 9, which are connected to form a closed hollow profile 3. In order to connect the first profile segment 7 and the second profile segment 9, each of the first profile segment 7 and the second profile segment 9 comprises a flange 11, which is placed one on top of the other and connected. In order to connect the flange 11, screws or rivets can be used, for example. In addition, the flanges can also be connected by welding, brazing or gluing.

[0068] In addition to using Figure 1 In addition to the flanges shown, the first profile segment 7 and the second profile segment 9 can also be connected by sliding one profile segment into the other profile segment so that a part of the walls of the first profile segment and the second profile segment touch and connecting the first profile segment and the second profile segment by screwing, riveting, gluing, brazing or welding. If the first profile segment and the second profile segment are connected by welding or brazing, it is also possible to position the profile segments edge to edge and connect the edges.

[0069] After the hollow structure 3 has been formed, the foaming component 5 is inserted into the hollow structure 3 , as indicated here by arrow 13 .

[0070] Figure 2 A schematic cross-sectional view of a composite component 1 is shown.

[0071] In this composite component, the foam component 5 is located in the hollow structure 3 in such a way that a gap 15 is formed between the foam component 5 and the hollow structure 3. The gap 15 is thus formed so that the entire surface of the foam component 5 does not contact the hollow structure 3.

[0072] In order to place the foaming component 5 in the hollow structure 3, a tension active reinforcing structure 17 is used. The tension active reinforcing structure 17 is embedded in the foaming component 5, and only the end 19 protrudes from the foaming component 5. The end 19 includes a portion 21 pointing to the inner surface 23 of the hollow structure 5 and a second portion 25 aligned parallel to the inner surface 23 of the hollow structure 3.

[0073] In order to fix the foaming component 5 in the hollow structure 3, the second part 25 of the end 19 is fixed to the inner surface 23 of the hollow structure 3. The fixing of the second part 25 of the end 19 can be achieved by any fixing method known to those skilled in the art, such as threading, riveting, welding, brazing or gluing, wherein welding, brazing or gluing is preferred.

[0074] When the composite assembly is impacted, the active tensile reinforcement structure 17 and the foaming component 5 support the hollow structure 5 to absorb energy. The active tensile reinforcement structure 17 is preferably located in the hollow structure 3 so that the active tensile reinforcement structure 17 bends in the direction of the side of the hollow structure 5 where the second part 25 is installed. Figure 3 Such a deformation is shown by way of example for a foam component 5 having an embedded tensile active reinforcement structure 17 .

[0075] During the impact 27, the composite component 1 including the foam component 5 and the tensile active reinforcement structure 17 deforms and absorbs the impact energy by this deformation. The tensile active reinforcement structure 17 and the foam component 5 support the energy absorption properties of the composite component and, in particular, increase the load that the composite component can absorb before its final failure. On the side where the impact occurs, the foam component is compressed and compressive stresses act on the foam component and the tensile active reinforcement structure, while on the opposite side, tensile stresses act on the foam component and the tensile active reinforcement structure.

[0076] In addition, if Figure 3As shown, the tension active reinforcement structure 17 is placed in the normal stress area under bending in the foam component 5. In this way, although the tension active reinforcement structure 17 is bending, it is still allowed to absorb high tension forces because, due to the compressive strength of the foam component 5, the tension active reinforcement structure 17 remains in place and contributes to the bending stiffness.

[0077] If there are multiple load directions which differ in the location of the tension and compression distribution, more than one reinforcing structure is preferably used to ensure that at least one of these reinforcing structures is under tension in the event of mechanical loading.

[0078] Figures 4a to 4d Different shapes of foaming components that can be inserted into the rectangular hollow structure 3 are shown.

[0079] exist Figure 4a and Figure 4b In the embodiment, the foaming component has a rectangular cross-sectional shape with rounded corners. By using the foaming component 5 having such a shape, a gap with substantially uniform width can be achieved between the foaming component 5 and the hollow structure 3.

[0080] In addition to the tension active reinforcing structure 17 for providing a gap between the foaming component 5 and the hollow structure 3 , an additional spacer 29 for adjusting the gap 15 may be arranged between the hollow structure 3 and the foaming component 5 .

[0081] In particular, in order to reduce the mass of the composite component, it may be advantageous to form recesses 31 in the surface of the foamed component 5, for example as Figure 4c and Figure 4d By providing the grooves, although the mass of the foam component 5 is reduced, the energy absorption characteristics of the foam component 5, especially the supporting function, still exist.

[0082] exist Figure 5 In the figure, force-displacement curves of a hollow structure 3, a hollow structure 3 with a foaming component 5, a hollow structure 3 with a tension active reinforcement structure 17, and a hollow structure 3 with a foaming component 5 and a tension active reinforcement structure 17 are shown to emphasize the mechanical improvements that can be achieved through the invention.

[0083] exist Figure 5 In the graph, the abscissa 33 represents the magnitude of the displacement in mm, and the ordinate 35 represents the magnitude of the force in N.

[0084] The solid line 37 shows the force-displacement curve of the hollow structure 3 without the foaming component 5 and without the tension active reinforcement structure 7, the dotted line 39 shows the force-displacement curve of the hollow structure 3 with the tension active reinforcement structure 7 and without the foaming component 5, the dot-dash line 41 shows the force-displacement curve of the hollow structure 3 with the foaming component 5 and without the tension active reinforcement structure 17, and the dotted line 43 shows the force-displacement curve of the composite component 1 of the present invention having the hollow structure 3, the foaming component 5 and the tension active reinforcement structure 17.

[0085] It can be seen that for the hollow structure 3 without a foaming component and a tension active reinforcement structure, and for the hollow structure 3 with only a tension active reinforcement structure 17, the force that can be absorbed by the structure first increases and then decreases after passing the maximum value, wherein the hollow structure 3 with the tension active reinforcement structure 17 can absorb more force than the hollow structure 3 without any reinforcement components.

[0086] If the hollow structure 3 comprises a foam component 5, the withstanding force reaches a maximum value and only slightly decreases after reaching the maximum value.

[0087] A composite component including a foamed component 5 and a tensile active reinforcing structure 17 can withstand much greater forces than other structures, and even maximum values ​​higher than would be expected by adding additional forces that could be absorbed by only the foamed component 5 or only the tensile active reinforcing structure 17 .

[0088] Since the induced energy is proportional to the integral of the force-displacement curve, the energy absorbed by the component is proportional to the indicated force. Therefore, all previous conclusions apply to both force and absorbed energy.

Claims

1. A composite component (1), comprising a hollow structure (3) and a foaming component (5) inserted into the hollow structure (3), a gap (15) being formed between the hollow structure (3) and the foaming component (5), wherein a tension active reinforcing structure (17) is connected to the foaming component (5), and an end (19) of the tension active reinforcing structure (17) is connected to the hollow structure (3) in such a way that the foaming component (5) does not contact the hollow structure (3), and the gap (15) is formed between the hollow structure (3) and the foaming component (5).

2. The composite component according to claim 1, wherein the hollow structure (3) is made of metal.

3. The composite component of claim 2, wherein the metal is steel or aluminum.

4. The composite component according to any one of claims 1 to 3, wherein the foamed component (5) is made of polymer foam.

5. The composite assembly of claim 4, wherein the polymer foam is one of a polyurethane foam or a polyamide foam.

6. The composite component according to claim 4 or 5, wherein the polymer foam is a particle foam.

7. Composite assembly according to any one of claims 1 to 6, wherein the tensile active reinforcing structure (17) is a beam, a bar or a rod.

8. Composite component according to any one of claims 1 to 7, wherein the tensile active reinforcement structure (17) is made of metal.

9. A method for making a composite component according to any one of claims 1 to 8, the method comprising: (a) forming a hollow structure (3); (b) forming a foam component (5) with an inserted tension active reinforcing structure (17), wherein an end (19) of the tension active reinforcing structure (17) protrudes from the foam component (5); (c) Attaching the end (19) of the tensile active reinforcing structure (17) to the hollow structure (3).

10. The method according to claim 9, wherein the end (19) of the tensile active reinforcement structure (17) is attached to the hollow structure (3) by welding, gluing, screwing, riveting, brazing or a combination thereof.

11. Method according to claim 9, wherein the hollow structure (3) is formed by making at least two profile segments (7, 9) and connecting the profile segments (7, 9) by roll forming or by extrusion.

12. A method according to any one of claims 9 to 11, wherein the foaming component (5) having the inserted tension active reinforcing structure (17) is formed by placing the tension active reinforcing structure (17) into a mold, injecting a foaming agent containing a polymer melt or reactants and a foaming agent for preparing a polymer into the mold, and forming the foaming component (5) in the mold.

13. A method according to any one of claims 9 to 11, wherein the foaming component (5) having the inserted tension active reinforcement structure (17) is formed by placing the tension active reinforcement structure (17) into a mold, injecting expanded polymer beads into the mold, and connecting the expanded polymer beads to form the foaming component (5).

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