Reinforcing element for reinforcing structural element

Abstract

A reinforcement element for reinforcing a structural element in a motor vehicle, the reinforcement element comprising: a carrier; an expandable material at least partially disposed on the carrier; at least two securing elements connected to the carrier, each comprising a metal tab having a substantially flat central portion for welding, the securing elements being arranged such that the reinforcing element can be secured to the structural element by a welded connection between the tab and the structural element; wherein the metal tab is surrounded by the material of the carrier; wherein the fastening element is arranged in the peripheral region of the carrier.

Description

[0001] The invention relates to a reinforcing element for reinforcing a structural element and to a system for reinforcing a structural element in a motor vehicle.

[0002] Components such as the bodies and / or frames of transport and transmission devices (in particular water or land vehicles or aircraft) often have structures with cavities in order to enable lightweight construction. However, these cavities give rise to various problems. Depending on the type of cavity, the cavity must be sealed in order to prevent the ingress of moisture and dirt (which may cause corrosion of the component). It is often also desirable to substantially reinforce the cavity, and therefore the component, but to keep the weight low. It is often also necessary to stabilize the cavity, and therefore the component, in order to reduce noise that would otherwise propagate along or through the cavity. Many of these cavities have irregular shapes or compact dimensions, making it difficult to properly seal, reinforce and damp the cavity.

[0003] In particular, in automotive construction, but also in aircraft and ship construction, cavities are sealed and / or soundproofed with sealing elements (flaps) or reinforced with reinforcing elements (reinforcements).

[0004] Figure 1 The vehicle body is schematically shown. In this case, the vehicle body 10 has various structures with cavities, such as pillars 14 and carriers or brackets 12. These structural elements 12, 14 with cavities are typically sealed and / or reinforced using sealing and / or reinforcement elements 16, respectively.

[0005] Figure 2 A known concept for reinforcing such a structural element with a cavity in a motor vehicle is schematically represented. In this example, an expandable material 13 is arranged on the surface of a carrier element 11. In this example embodiment, the carrier element 11 has an irregularly shaped cross section.

[0006] This reinforcement element 16 according to the prior art has welding tabs 15 for fixing the carrier to the structural element by means of a welded connection.

[0007] A disadvantage of this type of reinforcement element 16 is that its welding tabs 15 are exposed, which can lead to damage during production, transportation, or handling. Furthermore, this type of welding tab is subject to less-than-ideal production quality and repeatability. Another disadvantage is that the design options for this type of welding tab are limited due to the need to integrate the metal tab into the polymer material of the carrier. Consequently, not all areas of the carrier are suitable for the placement of such tabs.

[0008] The object of the present invention is therefore to provide an improved device of the type mentioned at the outset, which allows a better connection of a carrier to a structural element. Furthermore, the device should be easy to design, have improved manufacturability, quality and reproducibility, and be better protected against damage during production, transport and handling.

[0009] This object is achieved by a reinforcing element for reinforcing a structural element in a motor vehicle, the reinforcing element comprising: a carrier; an expandable material, which is at least partially arranged on the carrier; at least two fixing elements connected to the carrier, the fixing elements each comprising a metal tab, the metal tab having a substantially flat central portion suitable for welding, and the fixing elements being arranged such that the reinforcing element can be fixed to the structural element by a welded connection between the tab and the structural element; wherein the metal tab is surrounded by material of the carrier; and the fixing elements are arranged in a peripheral region of the carrier.

[0010] The advantage of this solution is that, because the metal tabs are integrated into the carrier material, they are protected from mechanical influences. This integration into the carrier material further improves moldability and manufacturability, as the position of the tabs is tightly defined within the mold form. Consequently, these components can be produced with improved quality and tighter tolerances in the tab area.

[0011] The core concept of the present invention is that, because the tabs are integrated into the material of the carrier, there is greater design freedom for the location of the fixing elements (welding tabs), as the location of the tabs is no longer limited to specific suitable areas of the carrier where welding tabs can be placed as in the prior art. This allows for more options when designing the component and ultimately allows for optimized and higher-performance components.

[0012] In one exemplary embodiment, the metal tab is dome-shaped. The term "dome-shaped" is also understood to mean conical, meaning curved. In other words, the metal tab is arched, having a shape or structure with a curve at the top or bottom.

[0013] In an embodiment, the metal tab is substantially circular, or has an elliptical cross section. The metal tab may have a polygonal cross section.

[0014] In an embodiment, the metal tab may have a coin-shaped substantially flat central portion. In particular, the metal tab may have a coin-like shape.

[0015] This has the advantage that, due to the specific shape, the welding tip is guided to the desired welding point during the welding process.

[0016] In one exemplary embodiment, the metal tab has a border region lying in a plane that is offset parallel to the plane of the substantially flat central portion. In other words, the plane of the substantially flat central portion is offset parallel to the plane of the border region. This means that the tab can be shaped as a frustum, in particular a truncated cone or a truncated pyramid.

[0017] In one example embodiment, the border region of the metal tab comprises an edge having a constant width around the tab, the width measuring from 1 mm to 5 mm, preferably from 2 mm to 4 mm.

[0018] In an embodiment, the edge is arranged in the plane of the border area.

[0019] This has the advantage that, due to this edge configuration, the metal tabs can be optimally integrated into the material of the carrier.

[0020] In an example embodiment, the diameter of the metal tab measures from 15 mm to 45 mm, preferably from 20 mm to 40 mm.

[0021] In one example embodiment, the carrier and expandable material are products of an injection molding process.

[0022] In one example embodiment, the injection molding process defines the stretching direction of the carrier.

[0023] In an exemplary embodiment, an axis perpendicular to the substantially flat central portion of the at least one tab makes an angle of 2° to 20°, preferably 5° to 15°, to the stretching direction of the carrier.

[0024] In one embodiment, the carrier comprises a longitudinal axis.The substantially flat central portion of the at least one tab makes an angle of 2° to 90°, in particular 5° to 45°, in particular up to 20°, in particular 5° to 15° to the longitudinal axis of the carrier.

[0025] This has the advantage that, due to the possible angle between the stretching direction or longitudinal axis and the axis of the tab, the reinforcing element can be designed more freely, since the orientation of the tab can be adapted to the corresponding area of ​​the structural element.

[0026] In one exemplary embodiment, the carrier forms a flange that at least partially surrounds the edge region of the metal tab. This allows the tab to be embedded in the carrier. The flange also allows the tab to be securely fixed to the carrier.

[0027] In one example embodiment, the carrier constructs a gusset that strengthens the connection between the flange and the rest of the carrier.

[0028] This has the advantage that, due to the gusset, the mechanical robustness of the tab can be further increased.

[0029] In an exemplary embodiment, the expansion ratio of the expandable material is greater than 100% and less than 800%, in particular greater than 200% and less than 700%, in particular greater than 250% and less than 600%.

[0030] In principle, different types of materials can be used as expandable material. For example, the following commercially available adhesives can be used: -911, -940, -941, -942, -943, -951 and -955.

[0031] In one example embodiment, the expandable material is capable of curing at a temperature exceeding 120°.

[0032] In one exemplary embodiment, the carriers are manufactured by a two-component injection molding process, on which the expandable materials are respectively arranged.

[0033] This has the advantage that a cost-effective device can thus be produced.

[0034] In an exemplary embodiment, the carrier comprises plastic, fiber-reinforced plastic (in particular carbon fiber-reinforced plastic or glass fiber-reinforced plastic) or a combination of these materials.

[0035] The object set at the outset is also achieved by a system for reinforcing a structural element in a motor vehicle, wherein the system comprises a structural element; a reinforcing element as described above, wherein the reinforcing element is arranged in the structural element; and an expansion material connecting the carrier to the structural element.

[0036] Details and advantages of the invention will be described below based on exemplary embodiments and with reference to the accompanying schematic drawings, in which:

[0037] Figure 1 An example diagram of a vehicle body is shown;

[0038] Figure 2 shows a schematic diagram of an example reinforcing element according to the prior art;

[0039] Figures 3a to 4c A schematic diagram of an example reinforcement element is shown;

[0040] Figures 5a to 5c A schematic diagram showing an example fixing element; and

[0041] Figure 6a and6b A schematic diagram of an example metal tab is shown.

[0042] Figure 3a and 3b A first exemplary embodiment of a reinforcing element 16 is shown. In this case, Figure 3a A first side of the reinforcing element 16 is shown. Figure 3b The other side of the reinforcing element 16 is shown, which is substantially the same as Figure 3a The first side is opposite. Figure 3b In the embodiment shown, the reinforcing element 16 is fastened to the structural elements 12 , 14 by means of a welded connection.

[0043] In this exemplary embodiment, the reinforcing element 16 has an elongated shape and comprises a carrier 11 on which is arranged an expandable material 13. At both ends of the carrier 11, the reinforcing element 16 has fixing elements 2. Each of these fixing elements 2 has a metal tab 3 surrounded by the material of the carrier 11.

[0044] Figure 4a and 4b A second exemplary embodiment of the reinforcing element 16 is shown. In this case, Figure 4a A first side of the reinforcing element 16 is shown, Figure 4b The second side is shown as being substantially opposite to the first side. Figure 4c In the embodiment, the reinforcing element 16 is arranged in the structural elements 12 , 14 and is fastened to one side of the structural elements 12 , 14 by means of a welded connection.

[0045] Figures 5a to 5c Different exemplary embodiments of the fixing elements 2 are shown. Each fixing element 2 comprises a metal tab surrounded by a flange 4 of the material of the carrier 11. Furthermore, the fixing element 2 comprises a gusset 5, also of the material of the carrier 11, which mechanically reinforces the fixing element 2.

[0046] Figure 6a An example metal tab 3 is shown in greater detail. The tab 3 is dome-shaped and has a substantially flat center portion. The tab's border region lies in a plane that is offset parallel to the plane of the substantially flat center portion. The metal tab's border region includes a constant-width edge around the tab.

[0047] 6 c shows a cross-sectional view of the metal tab 3 from FIG 6 , which is enclosed in a flange 4 of the material of the carrier 11. The flange 4 at least partially surrounds the edge of the dome-shaped metal tab 3.

[0048] Reference Signs List

[0049] 1 System

[0050] 2 Fixing elements

[0051] 3 metal tabs

[0052] 4 flange

[0053] 5 gussets

[0054] 10 Body

[0055] 11 Carrier

[0056] 12 Structural elements

[0057] 13 Expandable Materials

[0058] 14 Structural elements

[0059] 15 Welding tabs

[0060] 16 reinforcement elements

Claims

1. A reinforcement element for reinforcing a structural element in a motor vehicle, comprising: carrier; an expandable material at least partially disposed on the carrier; at least two fixing elements connected to the carrier, each of the fixing elements comprising a metal tab having a substantially flat central portion for welding, the fixing elements being arranged such that the reinforcing element can be fixed to the structural element by means of a welded connection between the tab and the structural element; wherein the metal tab is surrounded by the material of the carrier; and The fixing element is arranged in a peripheral region of the carrier.

2. The reinforcing element according to claim 1, wherein: The metal tab is dome-shaped.

3. The reinforcing element according to any one of claims 1 to 2, wherein: The metal tab has a border region lying in a plane, with the plane of the substantially flat central portion being offset parallel to the plane of the border region.

4. The reinforcing element according to any one of claims 1 to 3, wherein: The border region of the metal tab includes an edge having a constant width around the tab, the width measuring 1 mm to 5 mm.

5. A reinforcing element according to any preceding claim, wherein: The diameter of the metal tabs measures 15mm to 45mm.

6. A reinforcing element according to any preceding claim, wherein: The carrier and expandable material are products obtained by an injection molding process.

7. The reinforcing element according to claim 6, wherein: The injection molding process defines the stretching direction of the carrier.

8. The reinforcing element according to claim 7, wherein: An axis perpendicular to the substantially flat central portion of at least one of the tabs makes an angle of from 2° to 20° with the stretching direction of the carrier.

9. A reinforcing element according to any one of the preceding claims, wherein: The carrier forms a flange which at least partially surrounds a border region of the metal tab.

10. The reinforcing element according to claim 9, wherein: The carrier forms a gusset that strengthens the connection between the flange and the rest of the carrier.

11. A reinforcing element according to any preceding claim, wherein: The expandable material has an expansion ratio greater than 100% and less than 800%.

12. A reinforcing element according to any preceding claim, wherein: The metal tab is substantially circular.

13. A system for reinforcing a structural element in a motor vehicle, the system comprising: Structural elements; The reinforcing element according to any one of claims 1 to 12, wherein the reinforcing element is arranged in the structural element; The expansion material connects the carrier to the structural element.

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