Lightweight component with structural parts and a reinforcing part arranged between them.

Abstract

Lightweight component (1) comprising a first structural part (2), a second structural part (3) and a reinforcement part (4) arranged between the two structural parts (2, 3), wherein the reinforcement part (4) is bonded to at least one of the structural parts (2) by a heat-expanded structural foam (5), characterized in that the reinforcement part (4) is additionally positively connected to one of the structural parts (2) in at least one local area (10), wherein the reinforcement part (4) is designed as a hybrid component and the reinforcement part (4) as a hybrid component is formed at least in essential parts from thermoplastic material, which is reinforced in parts with continuous fibers and in parts with short and / or long fibers.

Description

[0001] The invention relates to a lightweight component comprising a first structural part, a second structural part and a reinforcement part arranged between the two structural parts, wherein the reinforcement part is bonded to at least one of the structural parts by means of a heat-expanded structural foam.

[0002] Such a lightweight component, preferably used in the body of a motor vehicle, in particular in a vehicle pillar, is known from DE 10 2009 051460 A1. In this lightweight component, the two structural parts made of sheet steel are welded together, and the reinforcement part, arranged within the structural parts and positioned precisely by means of holders, is bonded to the structural parts by means of a heat-curable structural adhesive. In the further manufacturing process, the structural adhesive is heated in a paint oven of a multi-stage painting process and cures, in particular after cathodic dip coating (e-coating).

[0003] In DE 10 2010 023 073 A1, a structural part of a vehicle body is described, comprising a molded metal part and a reinforcing plastic part, which has a shape corresponding to the molded part in sections and is connected to the molded part at least in sections for structural reinforcement.

[0004] DE 10 2007 022 385 A1 describes a hybrid component which has a hollow component in the form of a shell and a plastic insert component, wherein the plastic insert component has connecting elements in the form of snap-in connecting elements which can be fixed in connecting elements in the hollow component in the form of snap openings.

[0005] The object of the present invention is to further develop a lightweight component of the type mentioned above in such a way that the materially bonded structural foam connection has a high performance capability.

[0006] The problem is solved by a lightweight component designed according to the features of claim 1.

[0007] In the lightweight component according to the invention, the reinforcing element is not only bonded to at least one of the structural parts by the expanded structural foam, but is also positively connected to one of the structural parts in at least one local area. This supporting positive-locking area, or several supporting positive-locking areas, increases the performance of the material-bonded structural foam connection.

[0008] The respective structural component(s) are preferably designed as shell components. In particular, the structural components comprise at least one outer shell component and at least one inner shell component of a vehicle column. The vehicle column is manufactured using a shell construction method and therefore consists of at least one or more components on the inner shell side and at least one outer shell component, as well as the reinforcing component arranged between the two shell components.

[0009] The structural components, in particular the shell components of the column, are preferably made of fiber-reinforced plastic, light metal or steel.

[0010] It is considered particularly advantageous from a structural point of view if the reinforcement element is designed with a ribbed construction. Particularly high strength of the reinforcement element can be achieved if it is designed as a hybrid component. This is also characterized by its low weight. In particular, the reinforcement element as a hybrid component is made, at least in substantial part, of thermoplastic material, which is reinforced partly with continuous fibers and partly with short and / or long fibers.

[0011] Preferably, the reinforcement part is bonded to at least one of the structural parts by means of a structural foam that has been expanded by heat in a KTL (cathodic dip coating) drying process.

[0012] The positive-locking connection between the reinforcement element and the structural element can be designed in various ways. For example, the reinforcement element and the structural element can be fixed to each other, particularly against shear forces. Alternatively, the positive-locking connection can be designed so that the two components are fixed to each other in all directions.

[0013] It is particularly intended that the structural component to which the reinforcement component is positively connected has a recess for the passage of the reinforcement component. This allows the positive connection of the components to be achieved in a particularly simple manner. The recess is specifically designed as a hole or passage in the structural component. It is entirely within the scope of the invention that the reinforcement component is positively connected to several structural components.

[0014] The reinforcement element can be designed differently in the area of ​​the recess in the structural part, in particular as a form-fitting dome or as a form-fitting dome with an integrated spacer element. Specifically, before the structural foam expands, a defined distance of 1 to 5 mm is established between the reinforcement element and the structural parts by means of the spacer element, which, for example, has the shape of a spacer nose, in order to ensure sufficient wetting of the structural parts, especially the steel sheets, during the cathodic dip coating (KTL) bath for corrosion protection.

[0015] The reinforcing element is positively connected to the structural component or the steel sheet with the recess(s), particularly by hot riveting / forming the form-fitting dome(s). The gap is then bridged by expanding structural foam in the e-coating dryer.

[0016] The function of the spacer element or the spacer nose can be integrated into the form-fitting dome, for example by a stepped design of the respective form-fitting dome.

[0017] According to a preferred embodiment of the invention, the spacer element or the form-fitting dome penetrating the recess is deformed in the region of its free end. Preferably, the structural part in the region of the recess, on the outside of the lightweight component, has an indentation into which the spacer element or the form-fitting dome is deformed in the region of its free end.

[0018] The lightweight component according to the invention and its further development are characterized by a reduced weight, a stabilized cross-section, and a defined pre-fixation of the two components relative to each other. Furthermore, simplified tolerance compensation is ensured by the foam insert, and the performance of the material-bonded structural foam connection is increased by supporting form-fitting areas.

[0019] Further features of the invention will become apparent from the dependent claims, the accompanying drawing and the description of the preferred embodiments shown in the drawing, without being limited thereto.

[0020] It shows: Fig. 1 A view of a lightweight component, shown over a partial length of the lightweight component, illustrating with respect to a first structural part and a reinforcement part connected to it, thus without a second structural part of the lightweight component connected to the first structural part, Fig. 2 a section AA through the arrangement according to Fig. 1, however, through the entire lightweight component, thus also through the second structural part, Fig. 3 a section BB through the arrangement according to Fig. 1, however, through the entire lightweight component, thus also through the second structural part, Fig. 4. a section CC through the arrangement according to Fig. 1, however, through the entire lightweight component, thus also through the second structural part, Fig. 5 a view D according to Fig. 2 of a sub-area of ​​the lightweight component, Fig. 6 a view E according to the Fig. 3 and Fig. 4 of a sub-area of ​​the lightweight component, Fig. 7 a section through a lightweight component which, compared to the embodiment according to the Fig. 1 to 6 is modified, with a representation of a form-closing dome, according to the representation in Fig. 2, Fig. 8 compared to the embodiment according to Fig. 7. Modified design of the form-fitting dome with integrated function of a spacer element or a spacer nose, Fig. 9 a section through a lightweight component which, compared to the embodiment according Fig. 3 is modified, with a representation of a form-locking dome, according to the representation in Fig. 3, Fig. 10 compared to the embodiment according to Fig. 9. Modified design of the form-locking dome with integrated function of a spacer element or a spacer nose. Character description

[0021] The Fig. Figures 1 to 6 show the design of a partial length of a lightweight component 1. This lightweight component 1 is, in particular, a vehicle pillar of a passenger car, for example, an A-pillar of an open vehicle (convertible or roadster).

[0022] The lightweight component 1 comprises a first structural part 2, a second structural part 3, and a reinforcement part 4 arranged between the two structural parts 1 and 2. The reinforcement part 4 is bonded to the structural part 2, which is an outer shell of the lightweight component 1 or the vehicle column, by means of a heat-expanding structural foam 5. The structural part 3 forms an inner shell of the lightweight component or the vehicle column. The structural part 2 is provided with several recesses 6 in the form of holes or passages for the passage of the reinforcement part 4. In the area of ​​these recesses 6, i.e., in these local areas, the reinforcement part 4 is positively connected to the structural part 2. This positive connection is designed differently according to the illustrated sub-areas of the lightweight component 1.

[0023] Reinforcement part 4 is designed as a reinforcement insert. In particular, the representation of the Fig. Figure 1 shows that the reinforcement element 4 has a ribbed design. The reinforcement element 4 is a hybrid component. This hybrid component is formed, at least in substantial part, from a thermoplastic material reinforced partly with continuous fibers and partly with short and / or long fibers. Specifically, the reinforcement element 4 consists of a woven or non-woven fabric, a thermoplastic matrix in which the woven or non-woven fabric is embedded – referred to as organosheet 7 – and ribs 8 made of plastic with short or long fiber reinforcement. The structural foam 5 is arranged between the continuous fiber-reinforced thermoplastic 7 and the structural element 2.

[0024] Structural parts 2 and 3, or shells of the lightweight component 1 or column, are made of fiber-reinforced plastic, light metal or steel.

[0025] The reinforcement part 4 is manufactured, in particular, in an injection molding machine in which the preheated, continuous fiber-reinforced thermoplastic 7 is formed in a closing operation and back-injected with short- or long-fiber-reinforced plastic. The structural foam 5 is then applied, also by injection molding. The continuous fiber-reinforced thermoplastic 7 contains recesses 9 corresponding to the recesses 6, through which short- or long-fiber-reinforced plastic is injected for the interlocking domes 10, which may optionally have spacer elements 11 or spacer lugs. Alternatively, the recesses 9 in the continuous fiber-reinforced thermoplastic 7 can be created during the manufacturing process of the reinforcement part 4, for example, by displacing the continuous fiber-reinforced thermoplastic 7 with needles.In principle, it is also possible not to provide any recesses and to inject the plastic directly through the continuous fiber reinforced thermoplastic 7.

[0026] The form-fitting domes 10 create, as with the different cuts according to the Fig. 2, Fig. 3 and Fig. Figure 4 illustrates a positive fit in local areas between the reinforcing part 4 and the structural part 2. Preferably, the structural part 2 is provided with an indentation 12 in the area of ​​the recesses 6 through which the positive-fit domes 10 pass.

[0027] Does the respective form-closing dome 10 penetrate the structural part 2 according to the design as per the Fig. 2 and Fig. 5, the unit formed by the structural foam 5, the continuous fiber-reinforced thermoplastic 7, and the ribs 8, and the structural part 2 are fixed to each other, particularly under shear force. If the positive-locking connection is designed such that the positive-locking dome 10 is riveted in the area of ​​its side located on the outside of the lightweight component 1, as is the case for the embodiment according to the Fig. 3, Fig. 4 and Fig. As illustrated in Figure 6, the aforementioned unit and the structural part 2 are fixed to each other in all directions. The hot-stitched or formed end 13 of the form-locking dome 10 is received by the indentation 12.

[0028] The reinforcing element 4 is arranged in a ribbed design between the two structural parts 2 and 3, i.e., the two shells. The reinforcing element 4 is bonded or glued to the structural part 2 by the structural foam 5, which expands due to heat during the KTL drying process, and is positively connected to the structural part 2 at least in one local area, or, according to the exemplary embodiment, in several local areas.

[0029] The discussed basic designs with form-fitting dome 10 without caulking of its end or with caulking of its end are suitable for slightly modified designs of the lightweight component 1 in the Fig. 7 and Fig. Figure 9 illustrates this. For variant 7, the variant shows the following. Fig. 8 and for the variant after Fig. 9 the variant according to Fig.10. A modification of the respective form-locking dome 10 such that it has a spacer element 11 or a spacer nose. Thus, before the expansion of the structural foam, a defined distance of 1 to 5 mm is set between the reinforcement part 4 and the two structural parts 2, 3 by means of the respective spacer element 11, in order to ensure sufficient wetting of the structural parts 2, 3, which are primarily designed as steel sheets, during the e-coating bath for corrosion protection. The reinforcement part 4 is positively connected to the structural part 2 by hot riveting / forming the form-locking domes 10. The gap is subsequently bridged by expanding structural foam 5 during expansion of the structural foam in the e-coating dryer. The function of the spacer elements 11 is integrated into the form-locking domes 10, for example, by a stepped design of the form-locking domes 10. Reference symbol list 1 lightweight component 2 Structural part 3 Structural part 4 Reinforcement part 5 structural foam 6 Exclusion 7 continuous fiber reinforced thermoplastic 8th rib 9 Exclusion 10 Form-closing dome 11 spacer element 12. Imprint 13 End

Claims

[1] Lightweight component (1) comprising a first structural part (2), a second structural part (3) and a reinforcement part (4) arranged between the two structural parts (2, 3), wherein the reinforcement part (4) is bonded to at least one of the structural parts (2) by a heat-expanded structural foam (5), characterized by , that the reinforcement part (4) is additionally connected in at least one local area (10) in a form-fitting manner to one of the structural parts (2), wherein the reinforcement part (4) is designed as a hybrid component and the reinforcement part (4) as a hybrid component is formed at least in essential parts from thermoplastic plastic, which is reinforced in parts with continuous fibers and in parts with short and / or long fibers. [2] Lightweight component (1) according to claim 1, characterized by , that the structural parts (2, 3) are designed as shell parts. [3] Lightweight component (1) according to claim 2, characterized by, that the structural parts (2, 3) are at least one outer shell part (2) and at least one inner shell part (3) of a vehicle column. [4] Lightweight component (1) according to one of claims 1 to 3, characterized by , that the reinforcement part (4) is bonded to at least one of the structural parts (2) by means of a structural foam (5) expanded by heat in a cathodic dip coating drying process. [5] Lightweight component (1) according to any one of claims 1 to 4, characterized by , that the reinforcement part (4) is designed in a ribbed construction. [6] Lightweight component (1) according to any one of claims 1 to 5, characterized by that the reinforcement part (4) and the structural part (2) connected to it are fixed to each other, in particular against shear or in all directions. [7] Lightweight component (1) according to any one of claims 1 to 6, characterized by, that the structural part (2) to which the reinforcing part (4) is positively connected has a recess (6) for the passage of the reinforcing part (4). [8] Lightweight component (1) according to claim 7, characterized by , that the reinforcing part (4) in the area of ​​the recess (6) of the structural part (2) is designed as a form-fitting dome (10) or as a form-fitting dome (10) with an integrated spacer element (11). [9] Lightweight component (1) according to claim 8, characterized by , that the form-closing dome (10) penetrating the recess (6) or the spacer element (11) penetrating the recess (6) is deformed in the area of ​​its free end (13). [10] Lightweight component (1) according to claim 9, characterized by , that the structural part (2) in the area of ​​the recess (6), on the outside of the lightweight component (1), has an indentation (12) into which the form-locking dome (10) or the spacer element (11) is deformed in the area of ​​its free end (13). [11] Lightweight component (1) according to any one of claims 8 to 10, characterized by , that the reinforcement part (4) has corresponding recesses (9) in the structural component (2) through which short- or long-fiber reinforced plastic for the form-locking domes (10) or for the form-locking domes (10) with integrated spacer element (11) is injected. [12] Lightweight component (1) according to claim 11, characterized by , that the recesses (9) are created during the manufacturing process of the reinforcement part (4) by displacing the continuous fiber reinforced thermoplastic material (7) by needles. [13] Lightweight component (1) according to one of claims 8 to 10, characterized by , that short- or long-fiber reinforced plastic for the form-locking domes (10) or for the form-locking domes (10) with integrated spacer element (11) is injected directly through the reinforcement part (4).

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