Composite component, especially for motor vehicles, and methods for manufacturing such a composite component

Abstract

Composite component (10), in particular for motor vehicles, with at least one profile component (12) having a hollow cross-section (18) circumferentially enclosing a cavity (20), and with at least one further component (16) having an open cross-section receiving area (14) in which the profile component (12) is received over a partial area surrounded by the component (16). where, the profile component (12) is designed as an internal high-pressure forming part, which is connected at least partially to the further component (16) in the receiving area (14), wherein the profile component (12) received within the receiving area of ​​the further component was connected to the further component (16) by enlarging its cross-section at least in certain areas through internal high-pressure forming, characterized by the fact that the composite component (10) is overmolded with a plastic (34) at the location of the receiving area (14) to form a hybrid composite component.

Description

[0001] The invention relates to a composite component, in particular for motor vehicles, of the type specified in the preamble of patent claim 1. Furthermore, the invention relates to a method for producing such a composite component according to the preamble of patent claim 2.

[0002] Such a composite component is already known from DE 100 22 360 A1, which is formed from a profile component and at least one further component. The profile component has a rectangular cross-section enclosing a cavity on the periphery. The at least one further component, which according to DE 100 22 360 A1 is angular and designed to connect two profile components, has a receiving area with an open cross-section, in which the respective profile component is received, surrounded by the further component over a partial area.

[0003] Such composite components typically pose the problem that considerable effort is required to securely bond the components, especially under higher loads. This results in high tool and process costs, which are a major disadvantage, especially in automotive applications.

[0004] The object of the present invention is therefore to create a composite component and a method of the type mentioned at the outset, by means of which a particularly stable, load-adapted connection of the components involved can be realized on the one hand and a cost-effective production on the other.

[0005] This object is achieved according to the invention by a composite component and a method for producing a composite component having the features of patent claims 1 and 2, respectively. Advantageous embodiments with expedient non-trivial further developments of the invention are specified in the remaining patent claims.

[0006] In order to create a composite component in which the profile component and the at least one further component can be connected to one another in a particularly stable and cost-effective manner, it is provided according to patent claim 1 that the profile component is designed as an internal high-pressure formed part which is connected by internal high-pressure forming, at least in some regions, to the further component in its receiving region, which surrounds the profile component. In other words, the invention provides for the profile component received within the receiving region of the further component to be connected to the further component by the latter being enlarged in its cross-section, at least in some regions, by internal high-pressure forming. By means of this cross-sectional enlargement of the profile component, a connection and fastening of the profile component to or with the further component can be achieved in a simple manner, at least as a result of a clamping effect.The particular advantage of such a connection is that it eliminates the need for complex assemblies of the profile component, which is designed as a circumferentially closed hollow profile, and the additional component, for example using a plurality of auxiliary components and / or joining connections such as welded joints. At the same time, the composite component is characterized by the fact that it can be designed to be extremely lightweight. A further advantage is the cost-effective joining technology using internal high-pressure forming. Furthermore, high tooling costs and the large number of tools required, for example, for additional auxiliary components in the form of deep-drawn or stamped parts, can be eliminated. The composite component is therefore suitable for use in motor vehicles and / orMotor vehicles, in particular when only a small or medium number of composite components is required for the respective vehicle design.

[0007] In a further embodiment of the invention, it has proven advantageous if the additional component is a sheet metal profile. Such a sheet metal component can be easily and cost-effectively profiled, particularly by deep drawing, and provided with the receiving area.

[0008] A further advantageous embodiment provides that the receiving area of ​​the further component and the profile component are connected to one another via at least one positive connection. Such a positive connection can be easily produced during internal high-pressure forming and ensures a particularly stable connection between the profile component and the at least one further component. In this context, the two components are particularly well held together if the receiving area of ​​the further component is not rotationally symmetrical. After internal high-pressure forming of the profile component, it conforms to the contour of the receiving area, resulting in a rotationally fixed connection.Further improvements in the adhesion of the components to one another can be achieved by creating undercuts in the contour of the receiving area of ​​the other component, which can be achieved by locally bulging or narrowing the receiving area. The material of the profile component flows around these undercuts during the expanding internal high-pressure process, resulting in a rotationally and axially non-slip hold of the components to one another.

[0009] It is further advantageous if the profile component and the receiving area of ​​the additional component are flush with each other, at least substantially throughout their entire overlap area. This creates a particularly stable and load-bearing connection between the profile component and the at least one additional component. At the same time, this can, for example, easily ensure increased anti-twist protection of the two components.

[0010] In a further advantageous embodiment, the receiving area of ​​the additional component and the profile component are connected to each other via at least one mechanical fastener, for example, a flow-drill screw, a pentaflow screw, a nail, or a rivet. Such a mechanical fastener can be used particularly where the mechanical load on the interconnected components is particularly high. The additional mechanical connection can thus additionally ensure that appropriate strength and rigidity are provided in places where the finished composite component is subject to high mechanical loads.

[0011] According to the invention, the composite component is overmolded with a plastic at the location of the receiving area to form a hybrid composite component. The plastic thus makes it easy to create additional functional areas and connection points of the composite component. Furthermore, the plastic can easily be used to form a stiffener or stiffening structure to impart additional stability to the hybrid composite component. The overmold and thus the additional stiffener are preferably applied to the additional component so that thinner wall thicknesses can be provided therein without any loss of rigidity, thereby reducing the overall weight of the composite component. The overmold and internal high-pressure forming are provided in a single common tool in a simple and process-economical manner, which also avoids repositioning tolerances between tools.

[0012] The advantages described above in connection with the composite component according to the invention apply equally to the method according to patent claim 2. This is further characterized in that the internal high-pressure forming of the profile component and the provision of the composite component with a plastic are produced in one and the same manufacturing process, for example in a combined internal high-pressure forming and injection molding process.

[0013] Further advantages, features and details of the invention will become apparent from the following description of a preferred embodiment and from the single figure.

[0014] This shows, in a sequence of six process steps, the process for producing the composite component, which is shown in individual process steps in a respective cross-sectional view, wherein it can be seen that at least one profile component with a hollow cross-section enclosing a cavity on the circumference is arranged in a receiving area of ​​a further component in the form of a sheet metal component, said receiving area having an open cross-section, and is connected to this by internal high-pressure forming, at least in regions, wherein the composite component is subsequently provided with a plastic to form a hybrid composite component.

[0015] According to the method for producing a composite component 10 shown in the single figure in a sequence of six method steps, in the first method step indicated by number 1, a profile component 12 is initially arranged in a corresponding receiving area 14 of another component 16 in the form of a sheet metal component. In the illustration according to number 1, it can be seen that the profile component 12 in this case comprises a tubular hollow cross-section 18, which surrounds or encloses a corresponding cavity 20 on the outer circumference.

[0016] The corresponding receiving area 14 of the component 16 is in the present case formed in a U-shape, namely by three one-piece sheet metal legs 22 of the component 16. A further sheet metal leg 24 is connected to one of the sheet metal legs 22.

[0017] As can be seen in the figure according to the first method step with the number 1, the profile component 12 is first positioned in the receiving area 14 having the open cross-section. This can take place when the components 12 and 16 are inserted into the internal high-pressure forming tool explained below, or even outside the tool. As can be seen from the illustration with the number 1, the sheet metal legs 22 are spaced from one another such that their distance approximately corresponds to the diameter of the profile component 12. If necessary, a clamping of the profile component 12 within the receiving area 14 is implemented in order to enable a pre-fixing of the two components 12, 16 to one another.

[0018] In the process step according to No. 2, the final pre-positioning of the profile component 12 in the receiving area of ​​the component 16 having the open cross-section is then shown.

[0019] According to the third method step - as can be seen from the illustration with the number 3 - the profile component 12 is subjected to internal high pressure. For this purpose, the profile component 12 placed in the corresponding internal high pressure forming tool is sealed with appropriate stamps and filled with a pressure medium - for example, water, an emulsion, or a gas. Subsequently, the profile component 12 - as can be seen from the third method step according to number 3 - is formed by applying internal high pressure, expanding it accordingly, until it assumes the illustrated, essentially square or rectangular contour. In the present exemplary embodiment, the profile component 12 is formed by applying internal high pressure until it and the receiving area 14 of the further component 16 are flush with one another, at least essentially over their entire overlap area.However, it should be considered within the scope of the invention that such full-surface contact is not absolutely necessary, but that the profile component 12 may only partially abut the corresponding receiving area 14. It can also be seen from the illustration according to No. 3 that, as a result of the internal high-pressure forming, the profile component 12 and the receiving area 14 of the further component 16 are connected to one another via a plurality of, in this case, three positive-locking connections 26. For this purpose, the sheet metal legs 22 have respective recesses or bulges 28 into which corresponding wall areas 30 of the profile component 12 are permanently pressed.

[0020] The profile component 12 thus forms a stabilizing and stiffening insert for the additional component 16, particularly in places that require reinforcement due to mechanical stress or at connection points. The profile component 12 can serve as a support in the motor vehicle as well as a frame or frame element.

[0021] From the further method steps according to Nos. 4 and 5, it can be seen that following the internal high-pressure forming of the profile component 12, this is connected to the further component 16 via at least one mechanical connecting means 32. In the present exemplary embodiment, this mechanical connecting means 32 is a screw, which is introduced, for example, using the flow-hole screw forming method or a so-called flow-drill method. By means of this mechanical connecting means 32, the insert or the profile component 12 is thus additionally secured to the component 16, whereby particularly high forces can be absorbed by the connection. Although this measure increases the weight of the assembly, this increase is slight and, in terms of a disadvantageous assessment, negligible compared to the benefit of increased reinforcement.

[0022] In the particular embodiment shown here, the insert or profile component 12 and the component 16, which form the composite component 10, are additionally overmolded with a plastic 34 at the location of the receiving area 14. In the present case, this is done in particular in a combined internal high-pressure forming and injection molding process, which can be performed in one and the same tool. In this case, it can be seen from the illustration in No. 6 that the entire composite component 10 is overmolded on the outside with plastic 34, thus forming a hybrid composite component composed of the metal parts 12, 16 and the plastic 34.

[0023] The plastic can also be used to create connecting contours, consoles and functional, filigree structures that do not have to meet the high demands on mechanical strength like the rest of the composite component.

[0024] Overall, it can be seen from the figure that the internal high-pressure forming process, by influencing the combination of a circumferentially closed hollow profile with an open sheet metal profile, makes it possible to specifically adapt the composite component to the loads and to integrate receptacles for elements located in the force flow, such as bushings, etc., into the reinforcement structure. The positive connection with the profile component 12 enables an additional connection of the profile component 12 or the insert with the component 16. Flow hole forming screwing enables a screw connection without pre-drilling, in which the inserted screw 32 or similar connecting means drills or cuts the through hole and the thread itself. This combines three work steps into one. With the Pentaflow process, the hole provided for this purpose does not have to be present; rather, it is formed during the process.This facilitates the positioning of the components 12, 16 relative to one another. It is to be considered within the scope of the invention that instead of a single component 16, several metallic deep-drawn sheets or the like can also be provided. It is furthermore particularly advantageous if the receiving area 14 of the component 16 surrounds at least approximately 180° of the circumference of the hollow cross-section 18 of the profile component 12, as this allows a particularly favorable connection between the components 12, 16 to be realized. However, it is to be considered within the scope of the invention that, if necessary, a smaller area of ​​the circumference of the hollow cross-section 18 of the profile component 12 can also be surrounded by the receiving area 14. The flow drill method can also be used, by means of which a thread is formed into the hollow profile and / or sheet metal profile, after which a corresponding screw is screwed in as a connecting and stiffening element.

Claims

[1] Composite component (10), in particular for motor vehicles, with at least one profile component (12) with a hollow cross-section (18) surrounding a cavity (20) on the circumference, and with at least one further component (16) with an open cross-section having a receiving area (14), in which the profile component (12) is received over a partial area surrounded by the component (16) where, the profile component (12) is designed as an internal high-pressure forming part, which is at least partially connected to the further component (16) in the receiving area (14), wherein the profile component (12) received within the receiving area of the further component was connected to the further component (16) by the fact that the latter was enlarged in its cross-section at least in some areas by internal high-pressure forming, characterized by , that the composite component (10) is overmolded with a plastic (34) at the location of the receiving area (14) to form a hybrid composite component. [2] Method for producing a composite component (10), in particular for motor vehicles, in which at least one profile component (12) with a hollow cross-section (20) surrounding a cavity (18) on the circumference is arranged in a receiving area (14) of a further component (16) having an open cross-section and is connected to the latter, wherein the profile component (12) received within the receiving area of the further component was connected to the further component (16) by the fact that the latter was enlarged in its cross-section at least in some areas by internal high-pressure forming, characterized by , that the composite component (10) is overmolded with a plastic (34) at the location of the receiving area (14) to form a hybrid composite component.

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