Profile arrangement with a closed profile carrier

Abstract

Profile arrangement (10), with a closed profile carrier (14) for a motor vehicle structure, wherein the profile carrier (14) has a first hole (16) on a first side (18) and a second hole (20) on a second side (22) opposite the first side (18), wherein a reinforcing part (12) is arranged in the first hole (16) and in the second hole (20) of the profile support (14), characterized in that the holes (16, 20) produced in the profile support (14) are designed such that a hole edge of the holes (16, 20) adjacent to an outer side (24) of the profile support (14) is inclined inwards.

Description

[0001] The present invention relates to a profile arrangement with a closed profile beam for a motor vehicle structure, wherein the profile beam has a first hole on a first side and a second hole on a second side opposite the first side, wherein a reinforcing part is arranged in the first hole and in the second hole of the profile beam, and to a method for producing the profile arrangement, wherein the method comprises the following: extruding and / or hydroforming a closed profile beam, making holes in the profile beam, inserting a reinforcing part in the holes of the profile beam and connecting the reinforcing part to the profile beam.

[0002] Profile arrangements for motor vehicle structures are disclosed, for example, in the generic DE 103 15 690 B4, EP 1 324 908 B1, US 2 327 585 A, DE 698 00 544 T2 and DE 916 152 B.

[0003] In current vehicle structures, it has become a challenge to gain space within the vehicle to implement components that absorb impact energy generated during a vehicle collision. Conventional designs for absorbing high-energy impacts typically incorporate structures made of high-strength materials, such as various high-strength steels. These tubular structures can be designed as vehicle beams, or they can be positioned separately longitudinally of the vehicle to absorb the energy of a longitudinal collision. However, such designs are prone to laterally buckling when the load is offset, that is, when the load is not concentric with the tube.However, due to the limited space available in the vehicle and the limited frame selection, improving the axial strength of such structures tends to increase the degree of lateral instability of the tubes.

[0004] Other conventional designs include crush cans or crush tubes (crash cans, crash tubes, crush cans, crush tubes) that are welded or mechanically attached to one end of a beam and a vehicle bumper, as shown, for example, in US 5 876 ​​078 A. The crush cans or crush tubes implemented as above tend to buckle laterally when the load is not concentric with the tube.

[0005] As in the Fig. 1 and Fig. 2, a crush tube assembly 110 is shown. The crush tube assembly 110 includes a tube 118 disposed within a deep-drawn longitudinal profile 116 but does not extend the underlying structure. The tube 118 is welded into the longitudinal profile 116, and then a deep-drawn closure profile is subsequently connected to the longitudinal profile 116 to create a closed longitudinal member 120. The prior art crush tube assembly 110 requires a two-piece, deep-drawn profile member 120, which is generally heavier and more expensive. Furthermore, such a design results in longer assembly or manufacturing time.

[0006] As shown, other systems may also be used to absorb impact energy, including a complete redesign of a motor vehicle body structure, such as the vehicle body structure described in US Pat. No. 6,312,038 B1. Such designs may include longitudinal extensions of the vehicle structure frame to accommodate one or more energy-absorbing members.

[0007] However, such redesigns are more expensive to develop and are incompatible with currently manufactured vehicles, regardless of the area of ​​the vehicle where increased energy absorption is desired. In particular, currently manufactured vehicles may not have the necessary packaging space to accommodate a larger number of absorbing members or tubes.

[0008] The object of the invention is to overcome the disadvantages of the prior art and to provide a profile arrangement which is easy to manufacture and which can be designed with low weight and high strength.

[0009] This problem is solved by the features of claims 1 and 11. Fig. 1 is a partial perspective view of an open body structure with a prior art reinforcement member. Fig. 2 is a partial perspective view of a closed body structure with a reinforcement part according to the prior art. Fig. 3 is a partial perspective view of a closed profile beam with holes and the corresponding anti-crush tube. Fig. 4 is a partial cross-sectional view of a closed profile beam with the in the holes of the closed profile beam of Fig. 1 installed anti-crushing tube. Fig. Figure 5 is an enlarged partial cross-sectional view of a closed profile beam with the anti-crush tube installed in the holes of the closed profile beam. Fig. Figure 6 is an enlarged fragmentary cross-sectional view of a closed profile beam with a nut and bolt and the anti-crush tube installed in the holes of the closed profile beam. Fig. Figure 7 is a partial cross-sectional view of a closed profile beam with the anti-crush tube installed in the holes of the closed profile beam using a projection welding process. Fig. 8 is a flow diagram illustrating one embodiment of a method for manufacturing a reinforced closed profile assembly.

[0010] The present disclosure provides an effective structure and method for incorporating a reinforcement member into a closed profile structure.

[0011] Now on Fig. Referring to Figure 3, an embodiment of the reinforced closed profile assembly 10 is shown. It is understood that the closed profile beam 14 can be manufactured by a variety of means, such as hydroforming and / or extrusion. The profile assembly 10 includes a closed profile beam 14. Closed here means that the profile beam is constructed in one piece in cross-section, i.e., has a circumferential profile, unlike beams consisting of two or more part shells and then subsequently joined.

[0012] The profile carrier 14 has a first hole or a first opening 16 on a first side 18 and a second hole or a second opening 20 on a second side 22 opposite the first side 18. As shown in the Fig. 3 and Fig. As shown in Figure 5, the holes or openings 16, 20 created in the profile beam 14 are configured such that the outer side 24 of the closed profile beam 14 is inclined inward. This configuration allows for a smooth outer side 24 and further facilitates the installation of a reinforcement member 12. The inclined outer part 26 can guide the reinforcement member 12 into position.

[0013] The reinforcement member 12 may have an inner surface 62 and an outer surface 64. The reinforcement member 12 may be arranged in the first and second holes 16, 20 of the closed profile beam 14 such that the reinforcement member 12 is inserted through the first or second hole 16, 20 of the profile beam 14.

[0014] As in Fig. 3, the reinforcement member 12 may extend along the height or width of the profile beam 14. The example of Fig. Figure 3 shows the reinforcement member 12 as a tube 12', wherein the tube 12' has a circular cross-section. However, it is understood that the reinforcement member 12 may also have a different configuration, such as a square configuration or a differently shaped configuration (an oval, etc.). Although the reinforcement member 12 in Fig. 3 is a closed profile (a circular tube), the reinforcing part 12 may also have an open profile, such as one or more holders (not shown) that may extend from the first opening 16 to the second opening 20.

[0015] Now on Fig. 5, the reinforcement member 12 may include a portion 28 of the reinforcement member 12 that extends beyond an outer side 24 of the profile beam 14 to allow sufficient structural support for welding the reinforcement member 12 to the profile beam 14. Alternatively, the reinforcement member 12 may extend on the first side 18 as well as on the second side 22 to the outer side 24 of the profile beam 14, as shown in Fig. 4 shown.

[0016] In one example, the reinforcement member 12 may be secured to the first opening 16 and the second opening 18 via a projection welding process or other welding process (spot welding, etc.) on the profile beam 14. The reinforcement member 12 may be secured to the profile beam 14 using mechanical fasteners (60 in Fig. 6) or adhesives to the profile beam 14. Additional reinforcement components (not shown) may be attached to the first opening 16 and / or second opening 20 to properly attach the reinforcement member 12 to the profile beam 14.

[0017] Now on Fig. 6, an example of a mechanical fastener 60 is shown. A threaded bolt 34 may be used with a washer or reinforcement 48. A bolt 50 may then be inserted through the reinforcement member 12, the first opening 16, and the second opening 20. An additional reinforcement 52 may be implemented at the second opening 20 with a nut 54 used to secure the bolt 50 and the reinforcements 48, 52 in position. Regardless of whether additional mechanical reinforcement components are implemented, the reinforcement member 12 may be operatively configured such that the reinforcement member 12 engages the first opening 16 (or first hole) and the second opening 20 (or second hole) of the profile beam 14.

[0018] Again on the Fig. 3 - 7, the profile beam 14 can be designed in many ways as a vehicle structure, such as a chassis beam 14', a roof beam (not shown), a B-pillar (not shown), a front roof cross member (not shown), etc. The profile beam 14 and the reinforcement member 12 can be made of the same material, such as aluminum. As in Fig. 5, the longitudinal axis 32 of the reinforcement member 12 may be substantially perpendicular to a longitudinal axis 30 of the profile beam 14. It will be appreciated that this configuration allows the entire reinforced closed profile assembly 10 to better absorb energy in the event of a crash or collision.

[0019] On Fig. 7, the reinforcement member 12 may be projection welded (using a projection welding device 68) into the profile beam 14. Furthermore, it is understood that the reinforcement member 12 may be positioned by TIG / MIG welding or spot welding. With respect to projection welding and Fig. 7, the reinforcement member 12 may be projection welded at the first opening 16 and the second opening 20, as in Fig. 7. Furthermore, in this exemplary embodiment, the reinforcement member 12 may have a thread 60 on its inner surface 62, which allows a screw (not shown) to be screwed directly into the profile assembly 10. Accordingly, the (in Fig. 7 not shown) screw must be anchored in the profile arrangement via the thread 60 and, since no nut is required for the connection, may not have to extend completely through the reinforcing part 12.

[0020] Now on Fig.Referring to Figure 8 of the present disclosure, a flow diagram is shown illustrating a method for manufacturing a profile assembly 10. The method includes the first step of hydroforming a vehicle body structure (step 36). The second step includes forming, e.g., by punching or the like, openings 16, 20 in the profile beam 14 (step 38). It is understood that forming the openings 16, 20 may occur during the hydroforming process or thereafter. As mentioned, the openings or holes may further be plastically expanded. The third step includes installing a reinforcement member 12 in the openings (into the first opening and the second opening) 16, 20 (step 40). This third step of installing the reinforcement member 12 in the profile beam 14 may also include engaging the reinforcement member 12 with the profile beam 14.The fourth step involves fastening the reinforcement part 12 in the profile support 14 (step 42).

[0021] The step of attaching the reinforcement member 12 to the profile beam 14 may further comprise projection welding the reinforcement member 12 to the profile beam 14. In yet another embodiment, the step of attaching the reinforcement member 12 to the profile beam 14 may comprise implementing mechanical fasteners for attaching the reinforcement member 12 to the profile beam 14.

Claims

[1] Profile arrangement (10), with a closed profile carrier (14) for a motor vehicle structure, wherein the profile carrier (14) has a first hole (16) on a first side (18) and a second hole (20) on a second side (22) opposite the first side (18), wherein a reinforcing part (12) is arranged in the first hole (16) and in the second hole (20) of the profile support (14), characterized by , that the holes (16, 20) produced in the profile support (14) are designed such that a hole edge of the holes (16, 20) adjacent to an outer side (24) of the profile support (14) is inclined inwards. [2] Profile arrangement (10) according to claim 1, characterized by that the reinforcing part (12) is attached to the closed profile support (14) by a projection welding process. [3] Profile arrangement (10) according to claim 1 or 2, characterized by that the reinforcing part (12) is a hollow tube. [4] Profile arrangement (10) according to one of the preceding claims, characterized by that the profile support (14) is a chassis support. [5] Profile arrangement (10) according to one of the preceding claims, characterized by that the profile support (14) and the reinforcement part (12) are made of aluminum. [6] Profile arrangement (10) according to one of the preceding claims, characterized by that the reinforcing part (12) is shaped to engage with the first hole (16) and the second hole (20). [7] Profile arrangement (10) according to one of the preceding claims, characterized by that a longitudinal axis of the reinforcing part (12) runs perpendicular to a longitudinal axis of the profile carrier (14). [8] Profile arrangement (10) according to one of the preceding claims, characterized by that a part of the reinforcing part (12) extends beyond an outer side (24) of the profile carrier (14). [9] Profile arrangement (10) according to one of the preceding claims, characterized by that the reinforcement part (12) is attached to the profile support (14) via a MIG welding process, a TIG welding process or a spot welding process. [10] Profile arrangement (10) according to claim 3 characterized by that the hollow tube has a thread (60) on the inside (62). [11] A method for producing a profile arrangement (10) according to any one of the preceding claims, the method comprising: Extruding and / or hydroforming (36) a closed profile beam (14); Making (38) holes (16, 20) in the profile support (14); Inserting (40) a reinforcing part (12) into the holes (16, 20) of the profile support (14); and Connecting (42) the reinforcing part (12) to the profile support (14), characterized by that the holes (16, 20) are formed such that a hole edge of the holes (16, 20) adjacent to an outer side (24) of the profile support (14) is inclined inwards. [12] Method for producing a profile arrangement (10) according to claim 11, characterized by that the reinforcing part (12) is a hollow tube. [13] Method for producing a profile arrangement (10) according to claim 11 or 12, characterized by that the holes (16, 20) in the profile support (14) are formed to engage with the reinforcing part (12).

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