Structural element for motor vehicle, in particular for motorcycle, motor vehicle and method for producing such structural element

Abstract

The invention relates to a structural element (1) for a motor vehicle, comprising at least one rheocasting component (3) made of a metallic material.

Description

Field of the Invention

[0001] The present invention relates to a structural element for a motor vehicle, in particular for a motorcycle, as described in the preamble of claim 1. Furthermore, the present invention relates to a motor vehicle comprising at least one such structural element. The present invention also relates to a method for manufacturing a structural element for a motor vehicle, in particular for a motorcycle, as described in the preamble of claim 10. Background Art

[0002] A known frame structure for an electric motorcycle can be derived from US 9 598 132 B2. Furthermore, EP 2589 528 A1 discloses a motorcycle comprising a frame and an engine fixed to the frame. Summary of the Invention

[0003] The object of the present invention is to create a structural element for a motor vehicle, a motor vehicle comprising at least one such structural element, and a method for manufacturing such a structural element, such that a particularly small weight and favorable mechanical properties of the structural element can be achieved.

[0004] The above object is solved according to the present invention by a structural element having the features of claim 1, by a motor vehicle having the features of claim 9, and by a method having the features of claim 10. Advantageous embodiments are the subject matters of the dependent claims.

[0005] A first aspect of the present invention relates to a structural element for a motor vehicle. This means that the motor vehicle has the structural element in its fully manufactured state. The motor vehicle is preferably a single-track motor vehicle having exactly two wheels arranged one behind the other, i.e., successively, in the vehicle longitudinal direction of the motor vehicle. Thus, the motor vehicle can be, for example, a single-track motorcycle having exactly two wheels arranged one behind the other, in particular successively, in the vehicle longitudinal direction of the motorcycle. Furthermore, it is conceivable that the motor vehicle is a three-wheeler, in particular a two-track three-wheeler, and thus a motor vehicle having exactly three wheels, in particular a two-track motor vehicle, so that, for example, the motor vehicle can be configured as a motorcycle with a sidecar or can be configured as a three-wheeler.

[0006] The structural element can in particular be understood as a load-bearing member. The structural element has a metallic material. For example, the metallic material is a light metal, i.e., a light metal alloy, in particular an aluminum alloy.

[0007] In order to achieve a particularly small weight of the structural element and at the same time particularly advantageous mechanical properties at present, according to the present invention, the structural element has at least one rheocasting member formed of a metallic material. The rheocasting member, also referred to as the first rheocasting part, should be understood as a member made by rheocasting, i.e., by the rheocasting process. Rheocasting is also known as Rheocasting (in English) and is a casting process in which the metallic material as the casting material is processed not in a completely liquid state but in a semi-solid or semi-liquid state. In rheocasting, for example, a billet formed of a metallic material that is initially completely solid is provided. However, then, instead of producing a liquid melt from this billet, the billet, also referred to as the blank, is so to speak electromagnetically kneaded / forged, and thus processed by electromagnetic waves so that the billet reaches the above-mentioned semi-solid or semi-liquid state, thus reaching a state similar to jelly or cooled soft-serve ice cream. In this state, for example, the blank is pressed into a mold or die by means of a piston as in die-casting and thus shaped, and thereby the rheocasting member is manufactured from the blank. Thereby, a particularly small wall thickness, also referred to as the wall thickness, of the rheocasting member can be achieved and the same or even better material properties can be achieved compared to conventional members. Therefore, the weight of the structural element can generally be kept particularly small, and particularly advantageous mechanical properties of the structural element can be achieved. In particular, a wall thickness of up to 3.5 mm or even less than 3.5 mm can be achieved while achieving particularly advantageous mechanical properties.

[0008] In order to enable the structural element to have a particularly small weight and to achieve particularly advantageous mechanical properties of the structural element, in one embodiment of the present invention, it is provided that at least 30% of the volume and / or mass of the structural element is formed by the rheocasting member.

[0009] Another embodiment is characterized in that the structural element is configured as a frame of a motor vehicle. This embodiment is based on the recognition that the frame of a motor vehicle makes a decisive contribution to the total weight of the motor vehicle, so that by configuring the structural element as the frame, the weight of the motor vehicle can be made particularly small.

[0010] In another particularly advantageous embodiment of the present invention, the structural element is configured as a rear-wheel swing arm for a motor vehicle. The rear-wheel swing arm of a motor vehicle can also make a decisive contribution to the total weight of the motor vehicle, so that now the weight of the motor vehicle can be made particularly small by the present invention. Therefore, for example, in the fully manufactured state of the motor vehicle, one of the aforementioned wheels of the motor vehicle is configured as the rear wheel of the motor vehicle, particularly as the only rear wheel, and is rotatably held on the rear-wheel swing arm. Thereby, in particular, the unsprung mass of the motor vehicle can be made particularly small.

[0011] In order to achieve particularly advantageous properties of the rheocast component and thus of the structural element as a whole in a particularly weight - favorable manner, in a further design of the present invention it is provided that the rheocast component has at least or exactly one rib for strengthening the rheocast component.

[0012] In a further particularly advantageous embodiment of the present invention, the structural element has a first rheocast component and at least or exactly one second rheocast component which is arranged in addition to the first rheocast component, is separately formed from the first rheocast component and is connected to the first rheocast component, in particular directly. Quite preferably, the structural element has exactly two rheocast components, namely the first rheocast component and the second rheocast component. Thus, a small weight and particularly advantageous mechanical properties of the structural element can be achieved. In addition, the structural element can be manufactured in a demand - compliant, time - and cost - favorable manner. The foregoing and following explanations regarding the first rheocast component can also be transferred to the second rheocast component without any problems, and vice versa.

[0013] The rheocast components are connected to each other, in particular directly, form - fit and / or force - fit and / or material - fit.

[0014] It has been shown to be particularly advantageous here that the rheocast components are welded to each other, in particular directly to each other and thus connected to each other, in particular directly to each other. Thereby, particularly advantageous properties of the structural element can be achieved in a particularly weight - and cost - favorable manner.

[0015] Furthermore, it is conceivable that the rheocast components are screwed to each other.

[0016] It is particularly advantageous that the rheocast components are adhesively bonded to each other, in particular directly to each other and thus connected to each other, in particular directly to each other.

[0017] Finally, it has been shown to be particularly advantageous that the rheocast component itself, i.e., when observed alone, forms a hollow cross - section, in particular an open hollow cross - section, having at least or exactly one opening, such that the hollow cross - section is open on the side where the opening is arranged. In particular, the opening which is configured as a through - opening is at least mainly and thus at least more than half, in particular completely, closed by a closing element which is separately formed from the rheocast component, is arranged in addition to the rheocast component and is connected to the rheocast component, in particular directly, in particular by welding and / or adhesively bonding and / or screwing. Thereby, a particularly high stiffness can be achieved in a particularly weight - favorable manner.

[0018] The closing element can be formed integrally and thus from a single piece. This is to be understood as meaning that the closing element is not composed of a plurality of separately formed and interconnected parts, but rather the closing element is formed from a single piece and is thus constituted as a single block or formed from a single block. Alternatively, it can be envisaged that the closing element is constituted as a multi-piece component, such that the closing element has, for example, a plurality, i.e. at least or exactly two, separately formed and interconnected, in particular directly interconnected, in particular welded and / or glued and / or screwed together parts and is formed from these parts.

[0019] In order to be able to achieve particularly advantageous mechanical properties of the structural element in a particularly cost- and weight-favorable manner, in a further embodiment of the invention it is provided that the rheocast components are not mirror-symmetrical with respect to one another.

[0020] Preferably, the closing element is constituted as a component different from the rheocast component, so that preferably the closing element is not produced by rheocasting. Preferably, the closing element is formed from the aforementioned metallic material or from a different additional metallic material, in particular from steel or a steel alloy. The closing element can be formed from a light metal alloy, in particular an aluminum alloy. For example, the rheocast component is constituted as a sheet metal component, in particular a sheet metal component different from the rheocast component.

[0021] A second aspect of the invention relates to a motor vehicle having at least one structural element according to the first aspect of the invention. The advantages and advantageous embodiments of the first aspect of the invention can be regarded as the advantages and advantageous embodiments of the second aspect of the invention, and vice versa.

[0022] A third aspect of the invention relates to a method for manufacturing a structural element for a motor vehicle, which is also referred to simply as a vehicle or a motor vehicle. In the method according to the third aspect of the invention, the structural element is manufactured from a metallic material.

[0023] In order to be able to achieve particularly advantageous mechanical properties of the structural element as well as a particularly low weight, in the third aspect of the invention it is provided that the structural element is manufactured by rheocasting. The advantages and advantageous embodiments of the first and second aspects of the invention can be regarded as the advantages and advantageous embodiments of the third aspect of the invention and vice versa. Description of the Drawings

[0024] Further details of the invention emerge from the following description of the preferred embodiments and the accompanying drawings. Here:

[0025] Figure 1 A schematic perspective view, shown in partial section, of a first embodiment of a structural element configured as a rear wheel swing arm for a motor vehicle;

[0026] Figure 2Shows another schematic perspective view of the structural element according to the first embodiment;

[0027] Figure 3 Shows another schematic perspective view of the structural element according to the first embodiment; and

[0028] Figure 4 Shows a schematic side view of a second embodiment of the structural element. Detailed Description

[0029] In the figures, identical or functionally identical elements are provided with the same reference signs.

[0030] Figure 1 A first embodiment of the structural element configured as a rear wheel swing arm 1 for a motor vehicle is shown in a schematic perspective view with a partial cutaway. This means that the motor vehicle has a rear wheel swing arm 1 in its fully manufactured state. Here, the motor vehicle, also referred to as a vehicle or a motor vehicle, is for example a land vehicle configured as a single-track motorcycle, so that preferably the motor vehicle has exactly two wheels. The wheels of the motor vehicle are also simply referred to as wheels and are arranged one behind the other, i.e., successively, in the longitudinal vehicle direction of the motor vehicle. The wheels are ground contact elements via which the motor vehicle is supported or can be supported downward in the vertical vehicle direction of the motor vehicle on the ground. If the motor vehicle travels along the ground and the motor vehicle is supported downward on the ground via the ground contact elements in the vertical vehicle direction of the motor vehicle, then the ground contact elements roll on the ground, especially directly on the ground. The motor vehicle has a frame configured separately from the rear wheel swing arm 1, for example, the drive engine of the motor vehicle is connected to this frame. The rear wheel swing arm 1 is also simply referred to as a swing arm and is pivotally supported on the frame, for example, about a pivot axis S relative to the frame. In addition, the motor vehicle has, for example, a fork configured separately from the swing arm and separately from the frame, which is pivotally supported on the frame about a steering axis relative to the frame. The first of the wheels is the front wheel of the motor vehicle, which is rotatably held on the fork. The second of the wheels is the rear wheel of the motor vehicle, which is rotatably held on the swing arm about the wheel rotation axis D exemplified in Figure 1 . The rear wheel can swing together with the swing arm about the pivot axis S relative to the frame, and the front wheel can pivot together with the fork about the steering axis relative to the frame. By pivoting the fork and the front wheel relative to the frame and about the steering axis, the front wheel and thus the motor vehicle can be steered, whereby a turning movement, a change in the direction of travel, and a lane change of the motor vehicle can be achieved, especially during the travel of the motor vehicle.

[0031] From Figure 2It can be seen that the swing arm, for example, has two through openings 2 that are especially aligned with each other, and these two through openings are, for example, penetrated by a shaft. Here, for example, the rear wheel is rotatably supported on this shaft, such that the rear wheel can rotate about the wheel rotation axis D relative to the shaft and relative to the rear wheel swing arm 1 and is thus supported on the shaft above the shaft and thus on the rear wheel swing arm 1. Each through opening 2 is configured as an elongated hole, and the longitudinal extension direction of the elongated hole extends along the vehicle longitudinal direction of the motor vehicle. Thereby, it is possible to adjust, that is, to change, the distance between the wheels extending along the vehicle longitudinal direction and thus the so-called track width of the motor vehicle.

[0032] In order to now achieve a particularly small weight and particularly favorable mechanical properties of the rear wheel swing arm 1, the rear wheel swing arm 1 has exactly two rheo-casting members, namely a first rheo-casting member 3 and a second rheo-casting member 4. The rheo-casting members 3 and 4 are configured to be separate from each other and are directly connected to each other. In the present case, they are connected in such a way that the rheo-casting members 3 and 4 are directly welded to each other. Here, each rheo-casting member 3, 4 is formed of a metallic material. Preferably, the metallic material is a light metal alloy, especially an aluminum alloy. In a first embodiment, at least 30% of the volume and / or mass of the rear wheel swing arm 1, when observed as a whole, is formed by the respective rheo-casting members 3, 4, such that, for example, the sum of the rheo-casting members 3 and 4, that is, when observed together, forms at least 60% of the volume and / or mass of the rear wheel swing arm 1 as a whole.

[0033] In a first embodiment, each rheo-casting member 3, 4 is configured as a respective shell element, also simply referred to as a shell, such that each rheo-casting member 3, 4 is configured as a rheo-casting shell. Each shell itself, that is, when observed individually, has a respective open hollow cross-section H. The rheo-casting members 3 and 4 are assembled, that is, connected to each other, such that the hollow cross-sections H of the shells face each other. Here, the rheo-casting members 3 and 4 themselves, that is, when observed individually, form or delimit a hollow cross-section 5, also referred to as an overall hollow cross-section, which has at least one opening 6 configured as a through opening, such that the hollow cross-section 5 itself, that is, when observed individually, is open at the side SE pointing rearward in the vehicle longitudinal direction of the motor vehicle and thus rearward in the vehicle longitudinal direction of the motor vehicle. In the fully manufactured state of the motor vehicle, the side SE faces the rear wheel, such that the hollow cross-section 5 itself, that is, when observed individually, is open toward the rear wheel.

[0034] From Figure 2It can be seen that in the first embodiment, the hollow cross-section 5 is closed by a closing element 7 which is formed separately from the rheocasting members 3 and 4, is provided in addition to the rheocasting members 3 and 4 and is currently directly connected to the rheocasting members 3 and 4. In the first embodiment, the closing element 7 is a closing metal plate and is thus configured as a metal plate member. In particular, the closing element 7 is formed of steel or of the aforementioned light metal alloy, in particular an aluminum alloy, or of another light metal alloy different from the aforementioned light metal alloy, in particular another aluminum alloy. In the first embodiment, the closing element 7 is configured as multi-part, wherein the closing element 7 has two, in particular exactly two, closing parts 8 and 9. The closing parts 8 and 9 are configured separately from one another and are connected to one another, in particular directly connected to one another, in particular welded to one another. In particular, the closing element 7 is welded to the rheocasting members 3 and 4, in particular directly welded, and is thus connected to the rheocasting members 3 and 4, in particular directly connected. From Figure 1 and Figure 2 it can be seen that the rheocasting members 3 and 4, which are configured as a rheocasting shell and whose inner sides face one another, are welded to one another on their inner sides, in particular directly welded to one another and are thus connected to one another, in particular directly connected to one another and thereby form a hollow cross-section 5 which is open towards the rear wheel and which is at least mainly and thus at least more than half, currently completely, closed by the closing element 7. In particular, a high torsional and bending stiffness of the rear wheel swing arm 1 can thus be achieved in a particularly weight-advantageous manner. Preferably, the rheocasting members 3 and 4 are configured non-mirror-symmetrical with respect to one another.

[0035] The rear wheel swing arm 1 has a first support portion 10 by means of which the rear wheel swing arm 1 can be pivotally supported or can be supported on the frame about a pivot axis S relative to the frame. The support portion 10 is formed partly by the rheocasting member 3 and partly by the rheocasting member 4. In addition, the rear wheel swing arm 1 has a first connecting device 11 which is formed partly by the rheocasting member 3 and partly by the rheocasting member 4. By means of the connecting device 11, Figure 3 it can be seen that a pressure support 12 which is formed separately from the rear wheel swing arm 1 is connected, in particular hingedly connected, to the rear wheel swing arm 1, currently for example such that the pressure support 12 is pivotally supported on the rear wheel swing arm 1 about a pivot axis relative to the rear wheel swing arm 1. For example, the pivot axis extends parallel to the pivot axis S. In addition, the rear wheel swing arm 1 has Figure 4A second connecting device 13 can be seen, which is formed, for example, partly by the rheocasting member 3 and partly by the rheocasting member 4. By means of the connecting device 13, the spring and / or damping element 14 of the motor vehicle is connected, in particular articulated, to the rear wheel swing arm 1, in particular such that the spring and / or damping element 14 is pivotally supported on the rear wheel swing arm 1 relative to the rear wheel swing arm 1 about a second axis of rotation. For example, the axes of rotation extend parallel to one another, and preferably the axes of rotation are spaced apart from one another. In addition, the second axis of rotation is spaced apart from the pivot axis S and the wheel axis D, and the first axis of rotation is spaced apart from the pivot axis S and the wheel axis D.

[0036] In Figure 3 the illustrated embodiment, the spring and / or damping element 14 is a shock absorber strut. The rear wheel swing arm 1 is supported on the frame in a vibration-damping and / or damping manner via the spring and / or damping element 14, such that the pivoting movement of the rear wheel swing arm 1 and thus of the rear wheel about the pivot axis S and relative to the frame is vibration-damped and / or damped by means of the spring and / or damping element 14. In particular, for example, the pressure starting from the rear wheel swing arm 1 can be transmitted to the spring and / or damping element 14 via the pressure support 12, whereby, for example, the spring and / or damping element 14 can be compressed. Figure 3 The aforementioned frame of the motor vehicle, which is shown in a partially cut-away view, is denoted by 15 in Figure 3 .

[0037] From Figure 1 it can be seen that the respective rheocasting members 3, 4 can have a rib structure 16, in particular on or at their respective inner sides. In a first embodiment, the rib structure 16 has a plurality of ribs, at least two of which cross one another. In a first embodiment, two of the first ribs cross one another, and two of the second ribs cross one another. The first ribs that cross one another are denoted by 17 and the second ribs that cross one another are denoted by 18. The ribs 17 form a first rib pair, and the ribs 18 form a second rib pair, and these rib pairs are arranged successively in the vehicle longitudinal direction of the motor vehicle. By means of the ribs 17 and 18 and thus by means of the rib structure 16, the respective rheocasting members 3, 4 are strengthened, such that a particularly high rigidity of the respective rheocasting members 3, 4 and thus of the rear wheel swing arm 1 can be ensured in a manner that is favorable for weight and structural space.

[0038] Figure 4A second embodiment of the rear wheel swing arm 1 is shown in a schematic side view. Taking the rheocast member 3 as an example, it can be seen that the difference between the second embodiment and the first embodiment lies especially in that the respective rheocast members 3, 4 each have ribs, especially exactly one rib 19, on their respective inner sides, and the respective rheocast members 3, 4 are strengthened by means of these ribs. Here, the rib 19 extends at least substantially in the vehicle longitudinal direction of the motor vehicle, so that the rib 19 is a longitudinal rib. In summary, it can be seen that the rib 19 or the rib structure 16 is a rib part or also referred to as a rib part, and the respective rheocast members 3, 4 are strengthened by their respective rib parts. In addition, it can be seen that the respective rheocast members 3, 4 are respective casting shells made by rheocasting, that is, by the rheocasting process. Thereby, a favorably small wall thickness of the respective rheocast members 3, 4 can be achieved, and particularly favorable material properties of the respective rheocast members 3, 4 can be achieved.

[0039] List of reference signs

[0040] 1 Rear wheel swing arm

[0041] 2 Through-opening

[0042] 3 Rheocast member

[0043] 4 Rheocast member

[0044] 5 Hollow cross-section

[0045] 6 Opening

[0046] 7 Closing element

[0047] 8 Closing part

[0048] 9 Closing part

[0049] 10 Support site

[0050] 11 First connecting device

[0051] 12 Pressure support

[0052] 13 Second connecting device

[0053] 14 Spring and / or damping element

[0054] 15 Frame

[0055] 16 Rib structure

[0056] 17 First rib

[0057] 18 Second rib

[0058] 19 Rib

[0059] D Wheel axle

[0060] H Hollow cross-section

[0061] S Pivot shaft

[0062] SE Side

Claims

1. Structural element (1) for a motor vehicle, characterized in that The structural element (1) has at least one rheocast component (3) formed of a metallic material.

2. The structural element (1) according to claim 1, characterized in that, At least 30% of the volume and / or mass of the structural element (1) is formed by the rheocast component (3).

3. The structural element (1) according to claim 1 or 2, characterized in that, The structural element (1) is configured as a frame (15) for a motor vehicle.

4. The structural element (1) according to claim 1 or 2, characterized in that, The structural element (1) is configured as a rear wheel swing arm (1) for a motor vehicle.

5. The structural element (1) according to one of the preceding claims, characterized in that, The rheocast component (3) has at least one rib (17, 18, 19) for reinforcing the rheocast component (3).

6. The structural element (1) according to one of the preceding claims, characterized in that, The structural element (1) has a rheocast component (3) as a first rheocast component (3) and at least one second rheocast component (4) arranged in addition to the first rheocast component (3), configured separately from the first rheocast component (3) and connected to the first rheocast component (3).

7. The structural element (1) according to claim 6, characterized in that, The respective rheocast components (3, 4) are welded and / or bonded to one another and are thus connected to one another.

8. The structural element (1) according to claim 6 or 7, characterized in that, The respective rheocast components (3, 4) form a hollow cross-section (5) with at least one opening (6), which opening is closed at least mainly by a closing element (7) configured separately from the rheocast components (3, 4), arranged in addition to the rheocast components (3, 4) and connected to the rheocast components (3, 4).

9. A motor vehicle, comprising at least one structural element (1) according to one of the preceding claims.

10. A method for manufacturing a structural element (1) for a motor vehicle, in which the structural element (1) is manufactured from a metallic material, characterized in that The structural element (1) is manufactured by rheocasting.

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