Method for manufacturing a motor vehicle body composed of sub-modules

Abstract

This invention relates to a method for manufacturing a vehicle body, wherein multiple sub-modules (1, 2, 3, 11) are joined together. To provide a method for manufacturing a vehicle body that is particularly simple and precise in terms of manufacturing technology, a vehicle bottom (3), a front structure (1), a rear structure (2), and corresponding side beams (11), composed of multiple lightweight structural elements such as lightweight structural panels (13) or lightweight structural beams (13h), are joined together as sub-modules in a clamping process. Furthermore, this invention relates to a vehicle body formed from the joined sub-modules (1, 2, 3, 11).

Description

Technical Field

[0001] This invention relates to a method for manufacturing a motor vehicle body according to the preamble of claim 1. Furthermore, this invention relates to such a vehicle body according to the preamble of claim 11. Background Technology

[0002] Such a body structure is already known from DE10239990B4, in which multiple large sub-modules are interconnected.

[0003] Load-bearing structures for vehicle bodies and methods for manufacturing such load-bearing structures are known, for example, from DE19917177B4, and the load-bearing structure includes a vehicle bottom assembled from one or more lightweight structural panels. Summary of the Invention

[0004] The objective of this invention is to provide a method and a vehicle body by means of which the manufacture of the vehicle body is particularly simple and precise in terms of manufacturing technology.

[0005] This task is accomplished according to the invention by a method and vehicle body having the features of claim 1 or claim 10. Advantageous designs, together with advantageous modifications of the invention, are the subject of the dependent claims.

[0006] In order to provide a method for manufacturing vehicle bodies that is particularly simple and precise in terms of manufacturing technology, the present invention joins the vehicle bottom, front structure, rear structure and corresponding side beams, which are composed of multiple lightweight structural elements such as lightweight structural plates or lightweight structural beams, as sub-modules in a clamping process.

[0007] By clamping all the mentioned sub-modules together, a particularly stable, simple, and quick connection of the sub-modules can be created. To this end, the prepared sub-modules (at least the vehicle bottom, front structure, rear structure, and two side beams) are first clamped and positioned on the appropriate manufacturing equipment, and then connected to each other by suitable joining methods, especially welding methods, and further, especially gas shielded welding methods. This results in a correspondingly stable and dimensionally accurate design for the vehicle body, whose manufacturing is also particularly simple and rapid. In particular, the uniform width dimensions of the sub-modules are measured here so that these sub-modules can be connected to the corresponding lateral side beams with the straightest possible joint seams, especially weld seams.

[0008] An advantageous embodiment of the invention further specifies that the lightweight structural elements, such as lightweight structural panels or lightweight structural beams, extend in the transverse direction of the vehicle, are arranged successively in the longitudinal direction of the vehicle, and are joined together to form an assembly of the vehicle bottom. This selective orientation of the lightweight structural panels in the transverse direction and the successive arrangement of these panels in the longitudinal direction allows for the provision, for example, within a vehicle series, corresponding derivatives or structural variations with different lengths in the longitudinal direction of the vehicle bottom, in a simple yet rigid and stable manner. In particular, different lightweight structural panels can be used, for example, differing in their height relative to the vehicle height direction and / or their width relative to the longitudinal direction of the vehicle, or also, for example, in their respective shapes, material choices, or wall thicknesses, thus achieving scalability of the bottom structure or vehicle bottom in a simple manner.

[0009] In another embodiment of the invention, at least one corresponding lightweight structural element, such as a lightweight structural plate or a lightweight structural beam, is arranged on the rear end of the front vehicle structure and / or the front end of the rear vehicle structure. This lightweight structural element is directly joined to the assembly of the vehicle floor. This joining is particularly achieved by connecting the lightweight structural element, such as a lightweight structural plate or a lightweight structural beam, on the front vehicle structure and / or the rear vehicle structure side to the adjacent lightweight structural element, such as a lightweight structural plate or a lightweight structural beam, of the assembly of the vehicle floor. At least one corresponding joint seam between the front vehicle structure and / or the rear vehicle structure and the vehicle floor extends, particularly in the lateral direction of the vehicle.

[0010] Furthermore, it is advantageous to machine the lightweight structural elements such as lightweight structural panels or beams of the vehicle bottom assembly on their outer sides during clamping after joining. This common lateral machining of all the lightweight structural panels of the assembly allows for a particularly simple and cost-effective vehicle bottom on which side beams can be easily installed after machining. Moreover, the machining performed only during clamping ensures that the two outer sides of the assembly or vehicle bottom are very simply parallel to each other and manufactured at a corresponding angle relative to the vehicle's lateral direction, preferably at least substantially 90°.

[0011] In another embodiment of the invention, the side beam is joined laterally to corresponding lightweight structural elements such as lightweight structural panels or lightweight structural beams of the vehicle's underbody, front structure, and / or rear structure. This results in a particularly advantageous composite of the vehicle's underbody, front structure, and / or rear structure, achieved by means of the side beam.

[0012] Furthermore, it is advantageous that the corresponding side beams are composed of two interconnected profile elements, one of which has an insertion area extending along its length, which is inserted into a receiving groove extending along the entire length of the other profile element. This allows the bottom structure to be manufactured with particular precision, and more specifically, especially when the width of the side beams is set according to the width of the lightweight structural panel assembly. Based on the width of the manufactured vehicle bottom, the bottom structure, along with the vehicle bottom and the side beams arranged laterally on the vehicle bottom, can thus be dimensionally uniform by the width of the corresponding side beams.

[0013] Furthermore, a side beam is provided, which can be easily adapted to the corresponding boundary conditions of the vehicle and the underbody structure. Therefore, for example, one of the two profile elements can be designed differently depending on the vehicle type, structure, weight, etc., to achieve a particularly simple adaptability of the side beam for, for example, a sedan or a convertible. Thus, for example, it is conceivable that, depending on whether the vehicle is a sedan or a convertible, one of the profile elements can be manufactured with a thinner or thicker wall thickness or a different material.

[0014] Furthermore, it has proven advantageous to set the width of the side beams by forming them before joining them to the assembly of the lightweight structural panels. This means that the total width of the bottom structure is preferably set in such a way that the assembly of the lightweight structural panels and the two side beams are individually or coordinated in their widths. This is particularly simple to achieve in terms of manufacturing technology.

[0015] An advantageous embodiment of the invention further specifies that the lightweight structural panel assemblies are butt-connected to the corresponding side beams, and that the lightweight structural panels are connected to the corresponding side beams via corresponding welds in the areas of their respective upper and lower cover walls. This results in a particularly stable and rigid connection between the side beams and the lightweight structural panel assemblies.

[0016] Furthermore, it is advantageous that adjacent lightweight structural panels are joined to their corresponding cover walls at their opposing end sides via corresponding projecting flanges within the regions of their opposing cover walls. This results in a particularly advantageous double-shear composite of lightweight structural members to be joined via two separate flange connections, these flange connections being arranged at a spacing that approximately corresponds, and particularly closely, to, the spacing of the cover walls to be joined. Therefore, tensile and compressive forces can be extremely well borne via the respective two flange connections, resulting, for example, a particularly rigid and stable vehicle bottom, or enabling the vehicle bottom to be particularly advantageously connected to lightweight structural beams such as side beams, front or rear crossbeams, or central passageways in its edge regions.

[0017] This allows for advantageous possibilities in connecting various structural components by offsetting the corresponding flange connections, for example, through cold or hot joining, or also by using mechanical connecting devices such as semi-hollow self-piercing rivets or flow-drilled forming screws. In cold joining, adhesion is particularly considered, and in hot joining, especially for components constructed from extruded metal profiles, such as aluminum extruded profiles, single-sided welding, such as shielded gas welding or laser welding, is particularly considered.

[0018] The advantages described in conjunction with the method according to the invention also apply to the vehicle body according to the invention.

[0019] Further features of the invention are derived from the claims, drawings, and description of the drawings. The features and combinations thereof mentioned above in the specification, as well as those mentioned below in the description of the drawings and / or shown separately in the drawings, may be used not only in the combinations given separately, but also in other combinations or individually. Attached Figure Description

[0020] The invention will now be described in more detail with reference to preferred embodiments and the accompanying drawings. It is shown that:

[0021] Figure 1a b, c, and d are perspective top and bottom views of the vehicle body and corresponding partial perspective views in the front and rear areas of the vehicle bottom, the vehicle body having a bottom structure having a vehicle bottom joined by a plurality of lightweight structural plates, wherein the lightweight structural plates are oriented in the transverse direction of the vehicle with their longitudinal extensions and are arranged successively to each other in the longitudinal direction of the vehicle.

[0022] Figure 2a , 2b It is a corresponding cross-sectional view of the vehicle body in the bottom structural region along a section plane extending in the longitudinal direction or the height direction of the vehicle.

[0023] Figure 3 It is an additional partial cross-sectional view of the bottom of the vehicle along a section plane that extends in the longitudinal or height direction of the vehicle.

[0024] Figure 4 These are three schematic and three-dimensional cross-sectional views through the bottom of the vehicle, which has multiple corresponding lightweight structural panels that allow for scaling of the vehicle's length.

[0025] Figure 5 It is a corresponding cross-sectional view through the bottom structure of the vehicle along a corresponding section plane extending in the longitudinal direction or the height direction of the vehicle, wherein the corresponding cross-sectional view is formed according to... Figure 4 The bottom of the vehicle, scaled along its length,

[0026] Figure 6a , 6b It is a corresponding partial cross-sectional view of the corresponding crossbeam region at the front or rear end of the vehicle bottom, along the corresponding section plane extending in the longitudinal direction or the height direction of the vehicle.

[0027] Figure 7a , 7b These are exploded perspective views and perspective views of a vehicle body according to the present invention. The vehicle body is composed of multiple sub-modules, which are in the form of a vehicle bottom, front structure, rear structure and corresponding side beams, which are composed of multiple lightweight structural elements such as lightweight structural plates or lightweight structural beams. These sub-modules are joined together in clamping.

[0028] Figure 8 This is a three-dimensional view of the vehicle's underside, which is assembled from lightweight structural panels.

[0029] Figure 9a , 9b It is a cross-sectional view along a section plane extending in the vehicle height direction or vehicle lateral direction through the corresponding bottom structure with side beams and vehicle bottom according to the invention.

[0030] Figure 10 It is a cross-sectional view along a section plane extending in the vehicle height direction and the vehicle lateral direction, passing through the side beams of the bottom assembly.

[0031] Figure 11a , 11b It is similar to passing through the side beam. Figure 10 The corresponding cross-sectional views also illustrate the connection of the side beams to the bottom of the vehicle.

[0032] Figure 12a , 12b It is similar to an attachment that passes through the side beam. Figure 11a The corresponding cross-sectional views of b, further illustrating the connection of the corresponding support elements arranged on the upper side of the vehicle bottom to the side beams,

[0033] Figure 13 It is a bottom view of the bottom structure of the vehicle bottom, on the lower side of which a sealing member for the battery housing is arranged, and a partial cross-sectional view of the bottom assembly in the sealing member area, with sections extending in the longitudinal and height directions of the vehicle.

[0034] Figure 14 It is a partial cross-sectional view along a section extending in the lateral and vertical directions of the vehicle, passing through the bottom assembly and the battery housing arranged below the bottom of the vehicle, wherein the seal is visible between the bottom of the vehicle and the battery housing. Detailed Implementation

[0035] exist Figure 1a and 1b The vehicle body is shown in both a top view and a bottom view, comprising a front structure 1 and a rear structure 2, with a vehicle bottom 3 extending between them. The front structure 1 extends rearward in the longitudinal direction of the vehicle to a front end wall 4, which separates the front structure 1 from the passenger compartment 5. In the area of ​​the front structure 1, for example, corresponding longitudinal supports / engine mounts 6 and upper longitudinal supports 7 are visible at the height of the corresponding fender mounts, extending rearward to corresponding front door pillars 8, which laterally surround the front end wall 4.

[0036] The rear longitudinal bracket 9 is basically shown from the rear vehicle structure 2. It extends above the rear wheel inside the corresponding wheel arch 10 and its front end connects to the rear end of the corresponding side beam 11, which extends along the entire length of the vehicle bottom 3 between the front and rear wheel arches 10. Furthermore, corresponding blank structural members, such as the crossbeams of the rear bottom structure 12, extend between each rear longitudinal bracket 9.

[0037] As specifically referred to below Figure 7a and 7b As will be explained in more detail, the vehicle body is formed by joining together multiple sub-modules, namely the vehicle bottom 3, the front vehicle structure 1, the rear vehicle structure 2, and the corresponding side beams 11.

[0038] exist Figure 1c and Figure 1c The diagram shows corresponding partial perspective views of the front and rear areas of the vehicle's underside 3. A longitudinal structure 31 is provided here, constructed in accordance with or having similar reinforcement properties as a central passageway. Figure 1a The front longitudinal structure 31, connected to the bottom 37 of the pedal on the front end wall 4, includes two profile elements 33 extending relative to each other in the vehicle's longitudinal direction. These profile elements are constructed as extruded profiles extending in the vehicle's longitudinal direction. In the connection area to the bottom 37 of the pedal, an additional, generally triangular profile element 34 is positioned above the corresponding profile element 33, providing additional reinforcement. Furthermore, the two profile elements 34 are interconnected by at least one transverse element 35.

[0039] The longitudinal structure 31 or the corresponding profile element 33 also connects the corresponding lightweight structural plate 13 on the upper side, the profile element bridging the opening 18 in the vehicle bottom 3. Figure 4 The longitudinal structure 31 acts particularly in the longitudinal direction of the vehicle to reinforce the bottom 3 of the vehicle.

[0040] According to Figure 1dThe longitudinal structure 31 shown includes corresponding profile elements 36, which are particularly used for corner reinforcement between the lightweight structural plate 13 of the vehicle bottom 3 and the extruded profile 13 configured as a heel element 32. The profile element 36 is also configured as an extruded profile.

[0041] Figure 2a , 2b 3 is shown in a cross-sectional view along a plane extending in the longitudinal direction or the height direction of the vehicle, according to Figure 1a and Figure 1b 3. The bottom of the vehicle. Figure 4 In addition, three schematic and three-dimensional cross-sectional views are used to illustrate the scaling possibilities of the vehicle bottom 3, which will be described in more detail below.

[0042] exist Figures 1a to 4 As can be seen from the overview, the vehicle bottom 3 is composed of multiple lightweight structural elements such as lightweight structural plates 13 or lightweight structural beams, which are oriented in the transverse direction of the vehicle and arranged sequentially on each other in the longitudinal direction of the vehicle.

[0043] Here, especially from Figures 2a to 4 It is identifiable that, in the current embodiment, the corresponding lightweight structural elements, such as lightweight structural panels 13 or lightweight structural beams, are constructed as extruded profiles, such as aluminum extruded profiles, having corresponding cover walls 14, 15, between which corresponding cavities 17 are formed by webs 16. The extruded profiles or cavities 17 of the lightweight structural elements, such as lightweight structural panels 13 or lightweight structural beams, therefore also extend in the transverse direction of the vehicle along their longitudinal extensions.

[0044] Especially from Figure 4 It can be identified here that multiple lightweight structural elements, such as lightweight structural panels 13 or lightweight structural beams, extending generally horizontally in the lateral direction of the vehicle, are arranged successively to form the vehicle bottom 3 of a corresponding length, depending on what is to be achieved for the derivative or structural variant of the corresponding vehicle series. Therefore, based on experience, the vehicle bottom 3, also known as the main bottom or bottom center, is longer in a 4-door or 5-door sedan than, for example, in a 3-door coupe or convertible.

[0045] Therefore, especially here from Figure 4 It is identifiable that, by arranging different numbers of lightweight structural panels 3 successively in the longitudinal direction of the vehicle, the vehicle bottom 3 is scalable in its length relative to the longitudinal direction of the vehicle. And according to... Figure 4 In the lower embodiments, for example, six lightweight structural panels 13 are used, which is nine lightweight structural panels 13 in the middle embodiments and seven lightweight structural panels 13 in the uppermost embodiments.

[0046] from Figure 4 Furthermore, it is identifiable that the corresponding lightweight structural panels 13 can exhibit different shapes or forms in cross-section. While some of the lightweight structural panels 13 have a uniform thickness and, for example, only one row of cavities 17, there are also lightweight structural elements such as lightweight structural panels 13h or lightweight structural beams that have, for example, a larger height cross-section and two overlapping rows of cavities 17. These lightweight structural elements are used, for example, as crossbeams or seat crossbeams.

[0047] In addition, Figure 4 A corresponding lightweight structural panel 13ö can be identified in which a corresponding opening 18 is introduced into one of the cover walls 14. These openings 18 can be used for various purposes, such as for fastening corresponding parts or components, or for laying parts, wiring, cables, etc. inside the cavity 17, or for at least partially accommodating components inside the corresponding lightweight structural panel 13ö.

[0048] By using a unified lightweight structural panel 13 that is not only used across structural variations but also in multiple derivatives or structural variations of the vehicle series, and by using lightweight structural elements such as lightweight structural panels 13 or lightweight structural beams that are specifically designed for one or more derivatives or structural variations of the vehicle series, therefore, according to Figure 4 In a simple way, it is possible to assemble a desired vehicle bottom 3 with a corresponding length, so as to provide a vehicle bottom 3 for, for example, a longer vehicle, such as a sedan, or for a shorter vehicle, such as a coupe or convertible.

[0049] The corresponding lightweight structural panels 13 can be connected to each other, for example by means of mechanical connecting devices or by means of other components, such as load-bearing components, like side beams 11.

[0050] exist Figure 3 and Figure 4 and Figure 6a and Figure 6b The overview reveals connections between lightweight structural elements such as lightweight structural panels 13 or lightweight structural beams, with corresponding cross-sectional views of the front and rear ends of the vehicle bottom 3 shown along the respective cross-sectional planes extending in the longitudinal or height direction of the vehicle.

[0051] Therefore, for example from Figure 6b It can be identified how the lightweight structural panel 13 and the lightweight structural beam 13h, which is currently constructed as a crossbeam or heel element 32, are assembled, and how the vehicle bottom 3 transitions to the rear bottom at the heel element at the rear end of the vehicle bottom.

[0052] Therefore, it can be identified that the two lightweight structural elements 13, 13h have corresponding protruding flanges 21 or 22 in the regions of their opposing wide sides or cover walls 14, 15 (which extend parallel to each other on both sides) at their mutually facing end sides 19, 20, which are configured for engagement. These flanges are connected to the corresponding cover walls 14, 15 of the corresponding adjacent lightweight structural elements 13, 13h in the case of constructing corresponding flange connections or joint connections 23, 24. The corresponding flanges 21, 22 can here be at least substantially located in one plane, as is the case in flange 21 and its corresponding cover wall 14.

[0053] For example, a joint connection can be provided between the respective flanges 21, 22 and their respective cover walls 14, 15. Similarly, a corresponding joint connection can exist between the respective end sides 19, 20 of the two lightweight structural plates 13, 13h. Furthermore, it can be recognized that this type of double shear connection with the two flange connections 23, 24 is suitable for achieving tolerance compensation in the longitudinal direction of the vehicle, depending on how the two end sides 19, 20 are spaced relative to each other. Thus, the flanges 21, 22 are configurable relative to the corresponding cover walls 14, 15, wherein the spacing between the mutually facing end sides 19, 20 varies.

[0054] Furthermore, it can be identified that a connection exists between the two lightweight structural panels 13 and 13h via two flange connections 23 and 24 spaced apart from each other at the heights of the respective cover walls 14 and 15, thereby allowing the entire vehicle underside to be subjected to tensile or compressive forces, for example, in the planes of the respective cover walls 14 and 15. The sandwich-like double-wall design of the respective lightweight structural elements 13 and 13h in the joint area thus provides a particularly rigid and stable connection for the respective lightweight structural elements 13 and 13h. The double-shear connection of the respective lightweight structural elements 13 and 13h shown here can of course be applied to all lightweight structural panels, for example, with… Figure 4 The lightweight structural panels shown in connection with this.

[0055] Figure 5 The bottom structure is shown in three cross-sectional views along a corresponding section plane extending in the longitudinal direction of the vehicle or in the height direction of the vehicle, according to Figure 5 It can be identified again based on Figure 4 Vehicle bottoms of varying lengths. In particular, it can be identified that the front and rear ends of the vehicle bottom 3 are respectively provided with corresponding lightweight structural elements 13 or crossbeam elements 27, 28 in the form of lightweight structural beams / extruded profiles.

[0056] The corresponding beam elements 27 and 28 are exemplarily designed to be in conjunction with... Figure 6a and 6bThe connection described in relation to the corresponding lightweight structural plate 13 of the vehicle bottom 3 is achieved here. The transition from the vehicle bottom 3 to the end wall 4 is particularly achieved here via the front crossbeam element 27, which may be, for example, a sheet metal forming element, a cast structural element, or also constructed of lightweight structural plate. The connection between the corresponding crossbeam element 27 and the end wall 4 is achieved, for example, by a joint connection or by a mechanical connecting device. The corresponding front longitudinal bracket / engine mount 6 is also supported and secured here, for example, on the front crossbeam element 27.

[0057] The rear crossbeam element 28 (where the vehicle bottom 3 transitions into the rear bottom 29) is also constructed as an extruded profile, a multi-cavity profile, or a lightweight structural panel. The height of this crossbeam element 28 can be variably configured. The crossbeam element 28 is connected to the rear bottom 29 (which can be constructed, for example, by a sheet metal forming element, a metal casting, or also by multiple lightweight structural panels) via appropriate joint connections and / or mechanical connecting devices.

[0058] Figure 7a and 7b An exploded perspective view and a perspective view of a vehicle body according to the present invention are shown. The vehicle body includes multiple sub-modules in the form of a vehicle bottom 3 (constructed from multiple lightweight structural panels 13 or lightweight structural beams 13h and other lightweight structural elements), a front vehicle structure 1, a rear vehicle structure 2, and side beams 11. These sub-modules are engaged with each other in a clamping manner.

[0059] From the basis Figure 7a In the exploded view, it can be identified that the front crossbeam element 27 is constructed as a component of the front vehicle structure 1. Here, the crossbeam element 27 extends between the ends 60 of corresponding rear structural elements, such as the engine mount / longitudinal bracket 6, which are internally connected to the laterally corresponding side beams 11 after assembly, as is particularly evident in... Figure 7b As explained in the document, the crossbeam element 27 is joined, for example, by welding or similar means to the rear end 60 of the engine mount / longitudinal support 6.

[0060] The rear crossbeam element 28 is constructed as a component of the rear vehicle structure 2 and is welded or joined, for example, to the front end of the longitudinal support 9 and / or other structural elements of the rear vehicle structure 2.

[0061] To connect sub-modules 1, 2, 3, and 11, these sub-modules are oriented / positioned and fixed relative to each other in a common clamp within a corresponding manufacturing device. Sub-modules 1, 2, 3, and 11 are then joined together, particularly by welding. Here, the crossbeam elements 27 and 28 of the front vehicle structure 1 or the rear vehicle structure 2 are connected to each other, for example, by joining. Figure 6a and 6bWelding is performed in the manner described. The vehicle bottom 3 or its lightweight structural component 13 is joined to the side beam 11, for example, by welding, such as by joining... Figure 9a and 9b As described, the side beam 11 engages with the corresponding lateral end sides 61, 62, 63 of the lightweight structural elements such as the lightweight structural plate 13 or lightweight structural beam 13h of the vehicle bottom 3, the front vehicle structure 1, and / or the rear vehicle structure 2. Furthermore, the rear end 60 of the front engine mount / longitudinal bracket 6 also engages with the inner side of the side beam 11 on its outer side. This results in a highly rigid and stable composite of submodules 1, 2, 3, and 11 in a desired manner.

[0062] Furthermore, by clamping together all sub-modules 1, 2, 3, and 11, these sub-modules can be joined together very quickly. Moreover, the preferred uniform width of sub-modules 1, 2, and 3 enables the formation of corresponding, preferably straight-line-extending joints, particularly welds, between the side beam 11 and sub-modules 1, 2, and 3.

[0063] Finally, within the engagement range of submodules 1, 2, 3, and 11, additional structural elements, such as components 33 and 34, or fastening shoes 64 for the B-pillar, can also be engaged.

[0064] according to Figure 9a and Figure 9b Specifically, the corresponding side beam 11 and its connection to the vehicle bottom 3 are shown. Figure 9a A cross-section through the bottom structure is visible in the region of the longitudinal structure 31. Figure 9b A cross-section through the bottom structure is shown in the region of the elevated lightweight structural panel 13h, which is here constructed as a seat crossbeam.

[0065] Furthermore, it is explicitly stated here that the vehicle bottom 3 or its lightweight structural plate 13 is butt-connected to the corresponding side beam 11, and is connected to the corresponding side beam 11, for example, not only in the area of ​​the upper cover 14 but also in the area of ​​the lower cover 15, for example, by corresponding welds. The side beam 11 is based on... Figures 10 to 12b For example, it consists of corresponding profile elements 46 and 47, which are constructed as extruded profiles extending horizontally in the longitudinal direction of the vehicle.

[0066] Figure 8 The vehicle bottom 3, assembled from lightweight structural panels 13, is shown in a perspective view. Particularly visible here are the reassembly of lightweight structural panels 13, 13h of different heights, wherein the lighter structural panel 13h with greater height forms a crossbeam, such as a seat crossbeam.

[0067] The manufacturing method of this bottom structure is characterized by firstly joining lightweight structural panels 13, 13h, which are arranged sequentially in the longitudinal direction of the vehicle and extend horizontally in the transverse direction, together to form an assembly, namely the vehicle bottom 3. Subsequently, the assembly of the lightweight structural panels 13 is machined laterally, i.e., on the outer side 44 of the lightweight structural panels 13 facing the side beam 11. In particular, the end / outer side 44 of the lightweight structural panels 13 is here milled to be planar and constructed at a corresponding angle, particularly 90° relative to the horizontal line. This... Figure 8 The planes are represented by dashed lines.

[0068] Currently, particularly in the middle length region of the vehicle bottom 3, additional lateral support elements 45 are arranged on the upper side of the lightweight structural plate 13. These additional support elements are used not only for fastening and connecting the vehicle bottom 3 to the laterally corresponding side beams 11, but are also fastened on the upper side of the corresponding lightweight structural plate 13, for example, by welding.

[0069] These support elements 45 are also machined together with the end / outer side 44 of the vehicle bottom 3 and subsequently form a plane with the end / outer side 44 of the vehicle bottom 3.

[0070] Figure 10 The side beam 11 is shown in a cross-sectional view along a plane extending in the vehicle height and lateral directions, connecting to the outer-machined vehicle bottom 3. At least along its length, preferably along its entire length, the corresponding side beam 11 is formed by two profile elements 46, 47, which are formed from extruded profiles, particularly of a metallic material. Currently, one of the profile elements 46, arranged on the inner side facing the center of the vehicle, has an insertion region 48 extending along its entire length, which is inserted into a receiving groove 49 extending along the entire length of the other profile element 47. The profile element 46 with the insertion region 48 is here arranged on the inner side of the side beam 11, and the profile element 47 with the receiving groove 49 is arranged on the outer side of the side beam 11.

[0071] A head region 50 is connected to the insertion area 48 of the corresponding profile element 46, and this head region is supported against the wall 51 of the corresponding defining receiving groove 49 of another profile element 47. For this purpose, the head region 50 has corresponding support webs 52, 53, which are supported against the wall 51 of the other profile element 47. The support webs 52, 53 are arranged to project towards the external profile element 47 at the upper and lower ends of the head region 50 relative to the vehicle height direction.

[0072] The receiving groove 49 extends across approximately the entire width of the outer profile element 47, such that only the outer wall of the outer profile element 47 defines the receiving groove 49 on the outside.

[0073] The lengths of the supporting webs 52 and 53 are machined relative to the vehicle's transverse direction to set the width b of the side beam 11. In other words, the lengths of the supporting webs 52 and 53 are determined, for example, by milling, so that the total width b of the side beam 11, or the assembly of the profile elements 46 and 47, can be set. Furthermore, the wall 54 of the head region 50 facing the center of the vehicle can be machined relative to the vehicle's transverse direction to set the width b of the side beam 11. This can be done, in particular, by milling.

[0074] The two profile elements 46, 47 are preferably connected to each other by joining, especially by welding, and even more particularly by shielded gas welding. For this purpose, the two profile elements 46, 47 are welded to each other, particularly in the region supporting the webs 52, 53, at corresponding joints 55, 56.

[0075] The internal profile element 46 is preferably selected from a high or highest quality material. The external profile element 47 is selected from a medium to highest quality material, wherein, for example, the stiffness of the side beam 11 is determined by the external profile element 47, wherein the external profile element is made of a correspondingly varying wall thickness or from other materials. Thus, for example, for a closed vehicle, the wall thickness of the profile element 47 is selected to be less than that for a convertible.

[0076] As already mentioned Figure 9a and 9b As explained, from Figure 11a and 11b It is clearly seen again that the vehicle bottom 3 or its lightweight structural plate 13 is groundedly connected to the corresponding side beam 11, and is connected to the internal profile element 46 of the side beam 11, for example, not only in the region of the upper cover 14 but also in the region of the lower cover 15, via corresponding welds. The lightweight structural plate 13 of the vehicle bottom 3 extends at least substantially at the same height as the insertion region 48 relative to the vehicle height direction, which extends at least substantially through the entire width of the external profile element 47 in the region of the receiving groove 49. This achieves particularly high rigidity of the bottom structure in the event of a lateral collision of the vehicle.

[0077] For example, by specifically designing the cavity around the receiving groove 49 of the external profile element 47, the bending characteristics of the wall defining the receiving groove 49 can be set accordingly, and thus the accident characteristics can be set, especially in the case of a side collision.

[0078] Figure 12a and b show with Figure 10 or Figure 11a and 11bA similar cross-sectional view through the side beam 11 further illustrates the connection of the corresponding support elements 45 arranged on the upper side of the vehicle bottom 3 to the side beam 11. As already described with respect to FIG11, these support elements 45 are, for example, additionally used to fasten and connect the vehicle bottom 3 to the laterally corresponding side beam 11 and are fastened, for example, to the upper side of the corresponding lightweight structural plate 13 by welding.

[0079] Finally, from Figure 12a In section b, a corresponding receiving element 58 for the battery housing 39 of the electric energy storage device for driving the motor vehicle is arranged on the head region 50 of the inner profile element 46. The receiving element 58 is configured as a nut, which is arranged on the slat 59.

[0080] Figure 13 A bottom view of the vehicle bottom structure 3 is shown, in which a sealing member 38 for surrounding the battery housing 39 is arranged on the lower side of the vehicle bottom. It can be particularly identified here that the sealing member 38 is arranged on the inner side of the side beam 11 and the inner side of the corresponding front and rear crossbeams 13h (rear or front). Thus, the sealing member 38 extends on the lower side of the vehicle bottom 3, which is primarily constructed to be flat and have a smooth surface.

[0081] With the help of Figure 13 A partial cross-sectional view, also shown, along a section extending in the longitudinal and height directions of the vehicle through the bottom assembly of the seal 38 region, reveals that, in order to create the lower flange connection 24, the mating region 40 of the corresponding cover wall 14 and the corresponding flange 22 of the cover wall 15 are constructed retracted relative to the cover walls 14, 15 in the region of the flange connection 24, thereby creating a gap 41 between adjacent cover walls 15 of the lightweight structural panels 13, 13h. A weld S is provided, for example, in this gap. This gap 41 is filled here by, for example, a PVC-based filler material 42, resulting in a flat surface 43 with respect to the cover wall 15. The seal 33 can then extend on this flat surface 43, where abrupt changes in height that would cause leakage are avoided.

[0082] The flat orientation of seal 38 in Figure 14 The partial cross-sectional view is illustrated by the bottom assembly and the battery housing 39 arranged below the vehicle bottom 3 along a section extending in the lateral and vertical directions of the vehicle, wherein the seal 38 is visible between the vehicle bottom 3 and the battery housing 39.

[0083] List of reference numerals

[0084] 1. Front vehicle structure

[0085] 2. Rear vehicle structure

[0086] 3. Vehicle bottom

[0087] 4 end walls

[0088] 5 passenger cabins

[0089] 6 longitudinal brackets / engine brackets

[0090] 7 Longitudinal supports

[0091] 8 car door pillars

[0092] 9 longitudinal supports

[0093] 10 wheel covers

[0094] 11 side beams

[0095] 12 Bottom Structure

[0096] 13 Lightweight structural panels

[0097] 14 Cover Wall

[0098] 15 Cover Wall

[0099] 16 webs

[0100] 17 cavity

[0101] 18 openings

[0102] 19 end side

[0103] 20 end side

[0104] 21 flange

[0105] 22 flanges

[0106] 23 Joint Connection

[0107] 24-joint connection

[0108] 25 arrows

[0109] 26 arrows

[0110] 27 crossbeam elements

[0111] 28 crossbeam components

[0112] 29 after bottom

[0113] 30 opening

[0114] 31. Vertical Structure

[0115] 32-pin component

[0116] 33 profile components

[0117] 34 profile components

[0118] 35 horizontal components

[0119] 36 profile components

[0120] 37. Bottom of pedal

[0121] 38 seals

[0122] 39 Battery casing

[0123] 40 joint area

[0124] 41 gap

[0125] 42 Filler Material

[0126] 43 surface

[0127] 44 outer side

[0128] 45 support elements

[0129] 46 profile components

[0130] 47 profile components

[0131] 48 Insertion area

[0132] 49 Reservoir

[0133] 50 head area

[0134] 51 wall

[0135] 52 Supporting Web

[0136] 53 Supporting webs

[0137] 54 walls

[0138] 55 Joint

[0139] 58 housing elements

[0140] 59 strips

[0141] 60 end

[0142] 61 end side

[0143] 62 end side

[0144] 63 end side

[0145] 64 Fastening Shoes

Claims

1. A method for manufacturing a motor vehicle body, wherein, Connect multiple sub-modules (1, 2, 3, 11) together. Its features are, The vehicle bottom (3), front structure (1), rear structure (2) and corresponding side beams (11), which are composed of multiple lightweight structural elements such as lightweight structural plates (13) or lightweight structural beams (13h), are joined together as sub-modules in clamping.

2. The method according to claim 1, Its features are, The sub-modules (1, 2, 3, 11) are joined together by welding, especially by protective gas welding.

3. The method according to any one of the preceding claims, Its features are, The lightweight structural elements, such as the lightweight structural plate (13) or lightweight structural beam (13h), are arranged sequentially in the longitudinal direction of the vehicle and connected to form an assembly of the vehicle bottom (3) with their longitudinal extensions extending in the transverse direction of the vehicle.

4. The method according to any one of the preceding claims, Its features are, At least one corresponding lightweight structural element, such as a lightweight structural plate (13) or a lightweight structural beam (13h), is arranged on the rear end of the front vehicle structure (1) and / or the front end of the rear vehicle structure (2), and the lightweight structural element is directly engaged with the assembly of the lightweight structural elements, such as the lightweight structural plate (13) or the lightweight structural beam (13h), of the vehicle bottom (3).

5. The method according to claim 4, Its features are, After the joining, lightweight structural elements such as lightweight structural plates (13) or lightweight structural beams (13h) of the assembly of the vehicle bottom (3) are processed on their outer side (44) in the clamping.

6. The method according to any one of the preceding claims, Its features are, The side beam (11) is joined to the corresponding lateral end sides (61, 62, 63) of the lightweight structural elements such as the lightweight structural plate (13) or lightweight structural beam (13h) of the vehicle bottom (3), the front vehicle structure (1), and / or the rear vehicle structure (2).

7. The method according to any one of the preceding claims, Its features are, The corresponding side beam (11) is formed by two profile elements (46, 47) connected to each other, one of the profile elements (46) having an insertion area (48) extending along its length, which is inserted into a receiving groove (49) extending along the entire length (47) of the other profile element (47).

8. The method according to claim 7, Its features are, The width of the side beam (11) is set by forming before it is joined to the assembly of the lightweight structural plate (13).

9. The method according to any one of the preceding claims, Its features are, The assembly of the lightweight structural elements such as the lightweight structural plate (13) or lightweight structural beam (13h) is connected to the corresponding side beam (11) by butt joint, and the lightweight structural elements such as the lightweight structural plate (13) or lightweight structural beam (13h) are connected to the corresponding side beam (11) by corresponding welds in the areas of their respective upper cover wall (14) and lower cover wall (15).

10. The method according to any one of the preceding claims, Its features are, Adjacent lightweight structural panels (13) are joined to the corresponding cover walls (14, 15) of the adjacent lightweight structural panels (13) in the region of their opposing cover walls (14, 15) on their facing end sides (19, 20) by corresponding protruding flanges (21, 22).

11. A body for a motor vehicle, said body being composed of a plurality of sub-modules (1, 2, 3, 11) joined together. Its features are, The vehicle bottom (3), front structure (1), rear structure (2) and corresponding side beams (11), which are composed of multiple lightweight structural elements such as lightweight structural plates (13) or lightweight structural beams (13h), are joined together as sub-modules in clamping.

12. The vehicle body according to claim 11, Its features are, At least one corresponding lightweight structural plate (13) or lightweight structural beam (13h) or other lightweight structural element is arranged on the rear end of the front vehicle structure (1) and / or the front end of the rear vehicle structure (2), and the lightweight structural element is directly engaged with the assembly of the lightweight structural plate (13) or lightweight structural beam (13h) or other lightweight structural element.

13. The vehicle body according to claim 11 or 12, Its features are, The lightweight structural elements, such as the lightweight structural panels (13) or lightweight structural beams (13h), extend in the transverse direction of the vehicle and are arranged sequentially in the longitudinal direction of the vehicle and joined together to form an assembly of the vehicle bottom (13).

14. The vehicle body according to any one of claims 11 to 13, Its features are, The side beam (11) is joined to the corresponding lateral end (62, 62, 63) of the lightweight structural elements such as the lightweight structural plate (13) or lightweight structural beam (13h) of the vehicle bottom (3), the front vehicle structure (1), and / or the rear vehicle structure (2).

15. The vehicle body according to any one of claims 11 to 14, Its features are, Adjacent lightweight structural panels (13) are joined to the corresponding cover walls (14, 15) of the adjacent lightweight structural panels (13) in the region of their opposing cover walls (14, 15) on their facing end sides (19, 20) by corresponding protruding flanges (21, 22).

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