Method for manufacturing a chassis component and such a chassis component

Abstract

Method for manufacturing a chassis component (14) in which a component body (17) is made of a fiber-reinforced plastic, in which a connecting part (2) is connected to the component body (17), wherein a fastening section (10) of the connecting part (2) is fastened in an end section (5) of the component body (17) and a connecting section (11) of the connecting part (2) projects out of the end section (5), wherein the component body (17) is formed from a fiber semi-finished product (1) impregnated with a plastic matrix (16), and in order to fasten the fastening section (10) in the end section (5) the fastening section (10) is first arranged within the fiber semi-finished product (1) in an arrangement step, characterized in thatthat a rod-like or tubular fiber semi-finished product (1) is used and in the assembly step the fastening section (10) is inserted or inserted into an end face (6) or tube opening of the end section (5) of the fiber semi-finished product (1) and subsequently in an impregnation step the fiber semi-finished product (1) is impregnated with the plastic matrix (16).

Description

[0001] The invention relates to a method for manufacturing a chassis component, wherein a component body is made of a fiber-reinforced plastic, and wherein a connecting part is attached to the component body, a fastening section of the connecting part being fixed in an end section of the component body, and a connecting section of the connecting part projecting from the end section. The invention further relates to a chassis component manufactured according to such a method, wherein a component body is made of a fiber-reinforced plastic, a connecting part is attached to the component body, a fastening section of the connecting part being fixed in an end section of the component body, and a connecting section of the connecting part projecting from the end section.

[0002] Such a method or chassis component is known from DE 10 2010 049 565 A1. In this case, the chassis component is designed as a torsion bar spring for a vehicle. A connecting element is partially inserted into each end of a tubular component body to create a positive fit. Alternatively, it is disclosed that the connecting element can be bonded and / or injection-molded to the tubular component body. For example, the connecting element and the tubular component body can be overmolded together with a plastic material.

[0003] A chassis component designed as a torsion bar spring is also known as a stabilizer. Stabilizers or torsion bar springs are widely used in automotive engineering, particularly in chassis construction, for their role as roll stabilizers. These components are primarily subjected to torsion, especially torsion and / or bending, and reduce the roll of a vehicle. To stabilize the vehicle's body, stabilizers can be positioned between the wheels on an axle. When the wheels on an axle compress alternately, stabilizers distribute the axle load, ensuring a uniform load distribution. This can positively influence a vehicle's handling, for example, by maintaining the coefficients of friction of the wheels on the same axle at nearly identical levels.

[0004] The ends of known stabilizers can typically be arranged and / or supported by pendulum supports on a separate component, such as a wheel-guiding element like a wheel carrier or a wheel-guiding link. The pendulum supports can be designed as separate components. A connecting element can join the component body or stabilizer body and the pendulum support. This connecting element can thus act as an intermediate piece between the pendulum support on the one hand and the stabilizer body on the other.

[0005] The object of the invention is to further develop a method and / or a chassis component of the type mentioned above in such a way that the assembly effort is reduced and / or a connection between the connecting part and the component body can be implemented both securely and easily. Preferably, the proportion of individual parts to be assembled during the manufacture of the chassis component and / or the number of process steps during the manufacture of the chassis component should be reduced. In particular, an alternative embodiment should be provided.

[0006] The problem underlying the invention is solved by a method according to claim 1 and / or by means of a chassis component according to claim 12. Preferred embodiments of the invention are found in the dependent claims and in the following description.

[0007] The process is designed for manufacturing a chassis component, particularly for the chassis of a motor vehicle. A component body is produced from a fiber-reinforced plastic. A connecting element is attached to the component body. For this purpose, a fastening section of the connecting element is secured in an end section of the component body. A connecting section of the connecting element protrudes from the end section of the component body. The component body is formed from a fiber semi-finished product impregnated with a plastic matrix. To secure the fastening section in the end section, the fastening section is first positioned within the fiber semi-finished product in an assembly step. Subsequently, in an impregnation step, the fiber semi-finished product is impregnated with the plastic matrix.

[0008] It is advantageous that the fastening section of the connecting element, due to its arrangement within the fiber semi-finished product, can interact with the fiber semi-finished product. This results in a particularly strong and / or resilient connection between the component body and the connecting element. Preferably, a curing step follows the impregnation step, in which the injected plastic matrix hardens.

[0009] In particular, during the assembly step, the fastening section of the connecting element is surrounded by the fiber semi-finished product and / or by fibers of the fiber semi-finished product. The fastening section of the connecting element can be embedded in the fiber semi-finished product within its fibers. Preferably, the fastening section is coaxially surrounded and / or enclosed by the fiber semi-finished product and / or by its fibers. Thus, the fiber semi-finished product, especially its fibers, and the fastening section of the connecting element can interact at least partially and / or be in direct contact with each other. This enables a particularly strong and durable connection between the connecting element and the component body.

[0010] According to a further development process, the fastening section has a positive locking profile and / or at least one positive locking element. The positive locking profile and / or positive locking element can be formed by means of recesses, protrusions, openings, and / or suitable contours. In particular, during the impregnation step, the positive locking profile and / or the positive locking element is embedded in the plastic matrix and / or encased in the plastic matrix. This allows at least one positive locking connection to be achieved between the fastening section of the connecting part and the end section of the component body.

[0011] The connecting element can be made of metal. The plastic matrix can be a thermoset plastic. Alternatively, the connecting element can also be made of fiber-reinforced or non-fiber-reinforced plastic. With a suitable material selection for the connecting element, a metallurgical bond between the connecting element material and the plastic matrix can also be achieved.

[0012] According to a further embodiment, the fiber semi-finished product assumes, at least partially in the area of ​​the interlocking profile and / or the interlocking element, a shape corresponding to, and in particular cooperating with, the interlocking profile and / or the interlocking element during the assembly step and / or the impregnation step. This means that not only the material of the plastic matrix interacts with the interlocking profile and / or the interlocking element to form the interlock, but also the fiber semi-finished product or its fibers. This results in a stronger and more resilient connection between the connecting part and the component body. Preferably, the fiber semi-finished product is arranged at least partially in at least one recess of the interlocking profile and / or the interlocking element. The interlocking profile and / or the interlocking element can be formed by a sequence of alternating recesses and protrusions.For example, the positive locking profile can be wavy and / or ribbed.

[0013] Preferably, the fiber semi-finished product is formed dry in the assembly step. A braided core with layers of woven or braided fiber fabric woven around it can be used as the fiber semi-finished product. The fiber semi-finished product can be made of long fibers or continuous fibers. The braided core can be made of continuous fibers extending longitudinally along the component body. To enable the fastening section to be inserted into the end section of the component body, the braided core can be expanded beforehand using a mandrel. Alternatively, a fiber semi-finished product can be made without a braided core or at least without a permanently retained braided core.

[0014] According to an alternative embodiment, which is also conceivable independently of the present application, the fiber semi-finished product can be impregnated or pre-impregnated before the assembly step. In particular, the fiber semi-finished product can be designed as a so-called prepreg material or fiber-matrix semi-finished product. In this case, however, the plastic matrix, especially the thermoset plastic, is not cured during the assembly step. The curing step only takes place after the assembly step. Preferably, pressing and / or hardening takes place during the curing step. This can be carried out in a forming tool. This also allows the connecting element to be permanently bonded to the component body.

[0015] According to a further development, a rod-like or tubular fiber semi-finished product is used. In particular, the fiber semi-finished product can have a round, circular, oval, and / or ellipsoidal cross-section. Preferably, in the assembly step, the fastening section is inserted or inserted into an end face or tube opening of the end section of the fiber semi-finished product. When the fastening section is inserted or inserted, the fiber semi-finished product can expand in the region of the end section, in particular radially outwards to the axial longitudinal extent of the fiber semi-finished product, so that the fastening section can be received in the end section.

[0016] Preferably, in the impregnation step, a positive fit and / or a material bond is created between the end section of the component body and the attachment section of the connecting part. In particular, at least a positive fit is achieved between the attachment section of the connecting part and the end section of the component body. With a suitable material selection for the connecting part, a material bond between the material of the connecting part and the plastic matrix can, preferably additionally, be achieved.

[0017] In a further embodiment, the connecting section of the attachment is shielded from the plastic matrix during the impregnation step. This ensures that the connecting section protruding from the end section of the component body is not wetted or coated with the plastic matrix material. In this case, a slight wetting or coating of the connecting section with the plastic matrix material can be tolerated within a tolerance achievable in the manufacturing process. In particular, the connecting section is designed for connection to a chassis element.

[0018] Preferably, a chassis element is connected to the connecting section of the attachment part by means of a joint connection, in particular a ball joint connection. On the one hand, the connecting part is permanently and sufficiently firmly or with sufficient load-bearing capacity connected to the component body by means of the fastening section. On the other hand, the connecting section of the attachment part, which protrudes from the component body, enables the creation of a connection, in particular an articulated one, with the chassis element.

[0019] According to a further development, the chassis component is designed as a stabilizer, and the component body as a stabilizer body. The stabilizer is designed for use in the chassis of a vehicle, particularly a motor vehicle. For this purpose, the stabilizer comprises the stabilizer body, which forms a curved torsion spring. Specifically, a stabilizer body is understood to be an elongated, rod-like, bar-like, and / or tubular body. Thus, the stabilizer body can be hollow or tubular, or made of solid material. In particular, the stabilizer body is designed as a tubular bar or solid bar. Due to the curved design of the stabilizer body, it can be essentially U-shaped, C-shaped, or otherwise curved.In particular, a chassis element connected to the connecting section of the attachment part by means of a joint connection is designed as a pendulum support. Thus, the stabilizer can have at least one pendulum support and at least one attachment part. In particular, the stabilizer has two pendulum supports and two attachment parts. Here, one pendulum support and one attachment part can be arranged at each end of the stabilizer body. In particular, the stabilizer body has two ends facing away from each other and / or spaced apart, at each of which a pendulum support is arranged by means of an attachment part.

[0020] According to a further embodiment, a profile strand with a profile space open on at least one side is used as the connecting element. In particular, fibers of the fiber semi-finished product are arranged within the profile space during the assembly step. Specifically, an opening of the profile space extends, preferably from an open end face of the connecting element, in the axial direction of the profile strand or connecting element. Such a profile space or opening results, for example, in a profile strand with a U-shaped or C-shaped cross-section. It is advantageous here that fibers of the fiber semi-finished product not only adapt to and interact with the outer contour of the fastening section of the connecting element, but that fibers of the fiber semi-finished product are also arranged within the fastening section of the connecting element. This allows the strength and / or...The load-bearing capacity of the connection between the connecting part and the component body is further increased. In particular, during the impregnation step, the plastic matrix penetrates the profile cavity. Preferably, the profile cavity is completely filled by means of the plastic matrix and, in particular, fibers of the fiber semi-finished product.

[0021] A chassis component manufactured according to the inventive method is particularly advantageous, wherein a component body is made of a fiber-reinforced plastic, a connecting part is connected to the component body, a fastening section of the connecting part is attached in an end section of the component body, and a connecting section of the connecting part projects out of the end section, the component body is formed from a fiber semi-finished product impregnated with a plastic matrix, and for fastening the fastening section in the end section, the fastening section is arranged within the fiber semi-finished product, and the fiber semi-finished product is impregnated with the plastic matrix. In particular, the chassis component described here is further developed according to the embodiments explained in connection with the method.

[0022] The invention is explained in more detail below with reference to the figures. Reference numerals refer to identical, similar, or functionally equivalent components or elements. The figures show: Fig. 1 a section of a side view of a fiber semi-finished product and a connecting part for manufacturing a chassis component according to the invention, Fig. 2 a section of a second side view of the fiber semi-finished product after the arrangement of the connecting part in an end section of the fiber semi-finished product for the production of the chassis component according to the invention, Fig. 3 a section of a perspective front view of the fiber semi-finished product after the arrangement of the connection part in an end section of the fiber semi-finished product according to Fig. 2, Fig. 4 a section of a further side view of the chassis component according to the invention with a chassis element connected to the connecting part, and Fig. 5 a schematic flowchart of a method according to the invention.

[0023] Fig. Figure 1 shows a section of a side view of a fiber semi-finished product. 1 and a connecting part 2 for manufacturing a chassis component according to the invention. The fiber semi-finished product 1 In this embodiment, the fiber semi-finished product is formed dry. 1 has a braided core that is not clearly visible here 3 up. To the braided core 3 are multiple layers 4 woven from continuous fibers in the form of a fiber mesh. For clarity, not all layers are shown. 4 marked with a reference number. From the semi-finished fiber product 1 This is merely the end section. 5 of the fiber semi-finished product 1 depicted.

[0024] One end face 6 of the final section 5 is a front face 7 of the connecting part2 facing the front. 7 of the connecting part 2 In this embodiment, the design is open. Starting from the open end face. 7 of the connecting part 2 an opening extends 8 in the axial direction of the connecting part 2 . Across the open front 7 and the opening 8 is a profile space 9 of the connecting part 2 accessible. In this embodiment, the connecting part is 2 designed as a profile strand with a U-shaped cross-section.

[0025] The connecting part 2 has a fastening section 10 up. The fastening section 10 is located in the area of ​​semi-finished fiber products 1 facing end of the connecting part 2 . In one of the fiber semi-finished products 1 The connecting part has a facing away area. 2a connecting section 11 up. The connecting section 11 Only a partial excerpt is shown here.

[0026] The fastening section 10 features a positive locking profile 12 in this embodiment, the positive locking profile 12 by means of a wave-like surface contour of the connecting part 2 in the fastening section 10 realized. Furthermore, the connecting part features 2 In this embodiment, several positive locking elements are used. 13 in this embodiment, the positive locking elements 13 Each is designed as a perforation or hole. For the sake of clarity, not all positive locking elements are shown. 13 provided with a reference mark.

[0027] To manufacture the chassis component, the fastening section is assembled in one step. 10 within the final section5 of the fiber semi-finished product 1 arranged. For this purpose, the front side 7 of the connecting part 2 into the front 6 of the final section 5 of the fiber semi-finished product 1 plugged in or inserted.

[0028] Fig. Figure 2 shows a section of a second side view of the fiber semi-finished product. 1 after arranging the connecting part 2 in the final section 5 of the fiber semi-finished product 1 for manufacturing the chassis component according to the invention. Due to the arrangement of the fastening section 10 of the connecting part 2 within the final section 5 of the fiber semi-finished product 1 is the fastening section 10 into the fiber semi-finished product 1 or in fibers of the fiber semi-finished product 1 of the final section 5 embedded. In this embodiment, fibers of the fiber semi-finished product are also incorporated. 1through the open front 7 of the connecting part 1 and the opening 8 into the profile room 9 inside.

[0029] Fig. Figure 3 shows a section of a perspective front view of the fiber semi-finished product. 1 after arranging the connecting part 2 in the final section 5 of the fiber semi-finished product 1 according to Fig. 2. It can be seen here that the fibers of the fiber semi-finished product 1 due to the arrangement of the fastening section 10 in the final section 5 are expanded or displaced outwards. Alternatively, the braided core can 2 of the fiber semi-finished product 1 before arranging the fastening section 10 in the final section 5 for example, widened using a mandrel.

[0030] After arranging the fastening section 10 in the final section 5 according to the Fig. 2 and Fig. 3. An impregnation step takes place in which the fiber semi-finished product 1 The material is impregnated with a plastic matrix. The plastic matrix then hardens in a curing step. This results in the formation of the chassis component according to the invention, as shown below. If required, a post-processing step, such as machining and / or surface treatment, can follow the curing step.

[0031] Fig. Figure 4 shows a section of another side view of the chassis component according to the invention. 14 In this embodiment, the chassis component 14 by means of the connecting part 2 with a chassis element 15 connected. Here, the chassis element is 15 Only a partial view is shown. The fiber semi-finished product 1 together with the injected and cured plastic matrix, it forms 16a component body 17 From the final section 5 of the fiber semi-finished product 1 or of the component body 17 the connecting section protrudes 11 of the connecting part 2 out of here.

[0032] In this embodiment, the chassis component 14 designed as a stabilizer. Accordingly, the component body is 17 as a stabilizer body forming a torsion spring 17 realized. The chassis element 15 It is designed as a pendulum support. The connecting part enables this. 2 by means of its end section 5 outstanding connecting section 11 the realization of a suitable connection with the chassis element 15 In this embodiment, the connecting section 11 a cone 18 a ball stud 19 screwed in. This involves a ball joint. 20of the ball stud 19 articulating within the chassis element 15 mounted. Alternatively, other connection methods for a pendulum support or other chassis element are also possible. 15 at the connecting section 11 conceivable.

[0033] Fig. Figure 5 shows a schematic flowchart of a method according to the invention. The process sequence is illustrated by way of example using the embodiment described above. Fig. 1 to Fig. 4 explained.

[0034] After starting the process according to step S10, a fiber semi-finished product is produced. 1 Produced according to step S11. For the production of the fiber semi-finished product. 1 The braided core will be 3 with multiple layers 4 Woven with fiber braids. In every position 4 There are at least two braiding directions, resulting in multiple fiber strands within one layer. 4 are intertwined. The braided core 3In this embodiment, it consists of a unidirectional path extending in the axial direction of the fiber semi-finished product. 1 Extending continuous fibers. Alternatively, a braided core can also be used. 3 They can be made from a different material or material composition. According to another alternative, the braiding core is removed after the fiber semi-finished product has been produced. This allows the fiber semi-finished product to have a tubular shape.

[0035] Following step S11, or alternatively parallel to or preceding it, the connection part is carried out according to step S12. 2 with the fastening section 10 provided. In this embodiment, the connecting part is 2 It is made of a metal. Furthermore, in this embodiment, the connecting part is 2 It is designed as an open, U-shaped profile strand in cross-section. Alternatively, other open or closed designs of the connection part are also possible.2 conceivable.

[0036] According to step S13, the fastening section is arranged in one arrangement step. 10 in a final section 5 of the fiber semi-finished product 1 . Here, the fastening section 10 within the fiber semi-finished product 1 of the final section 5 arranged. The fibers of the fiber semi-finished product 1 in this case, they at least partially adapt to the positive locking profile. 12 and / or the positive locking elements 13 of the fastening section 10 and interact with it. Furthermore, when arranging the fastening section, the following occur: 10 in the final section 5 Fibers of the fiber semi-finished product 1 into the profile room 9 of the fastening section 10 .

[0037] Subsequently, in step S14, the fiber semi-finished product is impregnated in an impregnation step. 1with the plastic matrix 16 . Here, the plastic matrix exhibits 16 a thermoset plastic. In the impregnation step S14, the interlocking profile is formed. 12 into the plastic matrix 16 embedded, encased, or enclosed by it. At the same time, the plastic matrix penetrates. 16 into the form-locking elements designed as openings 13 one. The plastic matrix then hardens. 16 in a single curing step. Through the formation of the positive fit between the fastening section. 10 and the final section 5 is the connecting part 2 fixed and immovable with and in relation to the component body 17 tied together.

[0038] During the impregnation of the fiber semi-finished product 1 will the connecting section 11 of the connecting part 2 from the plastic matrix 16shielded. This ensures that the connection section 11 from the component body 17 stands out.

[0039] The chassis component thus produced can then be used 14 by means of a suitable design of the connecting section 11 with a chassis element 15 , for example, a pendulum support. The method according to the invention ends with step S15. Reference symbol list 1 Fiber semi-finished product 2 Connection part 3 braided core 4 layers 5 Final section 6 Front face of the end section 7 Front side of the connection part 8 Opening 9 Profile room 10 Mounting section 11 Connecting section 12 Positive locking profile 13 Positive locking element 14 Chassis component 15 Chassis element 16 plastic matrix 17 component bodies 18 cones 19 ball studs 20 ball joints QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] DE 102010049565 A1

[0002]

Claims

[1] Method for manufacturing a chassis component (14) in which a component body (17) is manufactured from a fiber-reinforced plastic, in which a connecting part (2) is connected to the component body (17), wherein a fastening section (10) of the connecting part (2) is fastened in an end section (5) of the component body (17) and a connecting section (11) of the connecting part (2) protrudes from the end section (5), characterized by , that the component body (17) is formed from a fiber semi-finished product (1) impregnated with a plastic matrix (16), wherein, in order to fasten the fastening section (10) in the end section (5), the fastening section (10) is first arranged within the fiber semi-finished product (1) in an arrangement step and subsequently, in an impregnation step, the fiber semi-finished product (1) is impregnated with the plastic matrix (16). [2] Method according to claim 1, characterized by, that in the arrangement step the fastening section (10) of the connecting part (2) is surrounded by the fiber semi-finished product (1) and / or the fastening section (10) is embedded in the fiber semi-finished product (1), in particular the fastening section (10) is coaxially surrounded and / or enclosed by the fiber semi-finished product (1). [3] Method according to claim 1 or 2, characterized by , that the fastening section (10) has a positive locking profile (12) and / or at least one positive locking element (13), wherein in the impregnation step the positive locking profile (12) and / or the positive locking element (13) is embedded in the plastic matrix and / or overmolded with the plastic matrix (16). [4] Method according to claim 3, characterized by, that the fiber semi-finished product (1) assumes, at least partially and in the area of ​​the form-locking profile (12) and / or the form-locking element (13), a shape corresponding to, and in particular cooperating with, the form-locking profile (12) and / or the form-locking element (13) in the arrangement step and / or in the impregnation step, preferably the fiber semi-finished product (1) is arranged at least partially in at least one recess of the form-locking profile (12) and / or the form-locking element (13), in particular the form-locking profile (12) and / or the form-locking element (13) is formed by means of a sequence of alternating recesses and protrusions. [5] Method according to any one of the preceding claims, characterized by, that the fiber semi-finished product (1) is formed dry in the arrangement step and / or a braided core (3) with layers (4) of fiber fabric or fiber braid woven around the braided core (3) is used as the fiber semi-finished product (1), preferably a fiber semi-finished product (1) made of long fibers or continuous fibers is used. [6] Method according to any one of the preceding claims, characterized by , that a rod-like or tubular fiber semi-finished product (1), in particular with a round, circular and / or oval cross-section, is used and in the assembly step the fastening section (10) is inserted or inserted into an end face (6) or tube opening of the end section (5) of the fiber semi-finished product (1). [7] Method according to any one of the preceding claims, characterized by, that in the impregnation step a positive connection and / or a material connection is created between the end section (5) of the component body (17) and the fastening section (10) of the connecting part (2). [8] Method according to any one of the preceding claims, characterized by , that in the impregnation step the connecting section (11) is shielded from the plastic matrix (16). [9] Method according to any one of the preceding claims, characterized by , that a chassis element (15) is connected to the connecting section (11) of the connecting part (2) by means of a joint connection, in particular a ball joint connection. [10] Method according to any one of the preceding claims, characterized by, that the chassis component (14) is designed as a stabilizer, the component body (17) as a stabilizer body, in particular a chassis element (15) connected to the connecting section (11) of the connecting part (2) by means of a joint connection is designed as a pendulum support. [11] Method according to any one of the preceding claims, characterized by , that a profile strand with a profile space (9) open on at least one side is used as the connecting part (2), wherein fibers of the fiber semi-finished product (1) are arranged within the profile space (9) in the arrangement step, in particular an opening (8) of the profile space (9) extends, preferably starting from an open end face (7) of the connecting part (2), in the axial direction of the profile strand. [12] Chassis component manufactured according to a method according to one of the preceding claims, wherein a component body (17) is made of a fiber-reinforced plastic, a connecting part (2) is connected to the component body (17), wherein a fastening section (10) of the connecting part (2) is fastened in an end section (5) of the component body (17) and a connecting section (11) of the connecting part (2) projects out of the end section (5), characterized by , that the component body (17) is formed from a fiber semi-finished product (1) impregnated with a plastic matrix (16) and, for the purpose of fastening the fastening section (10) in the end section (5), the fastening section (10) is arranged within the fiber semi-finished product (1) and the fiber semi-finished product (1) is impregnated with the plastic matrix (16).

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