Method for manufacturing a structural component, method for manufacturing a backrest for a vehicle seat, structural component and vehicle seat frame

Abstract

A method for producing a structural component (2), characterized by: - ​​arranging a fiber structure (G) and at least one metal part (24A-24F) together in a consolidation tool (4), - consolidating the fiber structure (G) by applying pressure and heat to the fiber structure (G) and the at least one metal part (24A-24F) in the consolidation tool (4) to form a fiber composite part (21) firmly connected to the at least one metal part (24A-24F) and thus forming the structural component (2), wherein reinforcing fibers from the fiber structure (G) are impregnated and compacted with matrix material during consolidation, and - injection molding of injection molding material onto the structural component (2) to form at least one injection-molded structure (25), wherein the at least one injection-molded structure (25) comprises at least one section of the fiber composite part (21) and at least one section of the at least one metal part (24A, 24C) covered.

Description

[0001] The invention relates to a method for manufacturing a structural component according to claim 1 and to a structural component.

[0002] In conventional structural components, such as those of a vehicle seat frame, for example, a structural component of a backrest section, a tubular element in the form of a transverse tube typically extends between the frame members of the backrest section. This tube is usually made of steel and serves to provide sufficient stiffness and strength to the backrest section, particularly with regard to strength requirements in a crash. Such a steel tube is generally heavy and contributes significantly to the overall weight of the vehicle seat.

[0003] Under load, a seat frame is subjected to torsional moments, bending stresses, and also tensile and compressive loads. Structural elements of the seat frame are designed to absorb and transfer these loads. It is important to note that loads on the seat frame can vary significantly locally, so measures are implemented at particularly stressed locations to absorb and transfer load forces and moments.

[0004] From DE 10 2006 012 699 A1, a three-dimensional structure of a backrest of a motor vehicle is known, which has an area made of a plastic reinforced with non-directional long fibers and an area made of a plastic reinforced with multidimensionally directional long fibers.

[0005] From DE 10 2010 051 180 A1, a shell of a seat backrest made of blown plastic is known, which is hollow and flat overall and has a tubular stiffening element, preferably made of metal, but optionally also of a composite material.

[0006] From DE 20 2014 004 095 U1, a cross member for a vehicle seat is known, which comprises a tubular body and is designed as a hollow body. The cross member comprises a plastic material.

[0007] In DE 10 2008 055 103 A1 a seat structure is described in which a frame made of profile steel and a flat element designed as a base body made of a lightweight material are manufactured, wherein the frame and the base body are connected to each other via at least one adhesive connection.

[0008] The object of the present invention is to provide a method for manufacturing a structural component and a structural component that is easy to manufacture and has high stability despite its lightweight construction.

[0009] This problem is solved by a method having the features of claim 1.

[0010] A method for manufacturing a structural component, particularly for a vehicle seat or a vehicle door, is then described. The method comprises arranging a fiber structure and at least one metal part, in particular a steel part, together in a consolidation tool. Furthermore, the method comprises consolidating the fiber structure by applying pressure and heat to both the fiber structure and the metal part in the consolidation tool to form a fiber-reinforced composite component that is firmly connected to the at least one metal part and thus forms the structural component, such that after consolidation the structural component is formed with the (consolidated) fiber-reinforced composite component, which is firmly, in particular by a metallurgical bond, connected to the at least one metal part.

[0011] This method allows for the production of a structural component that, through the use of a fiber-reinforced composite material, is both exceptionally lightweight and stable, while also enabling targeted force distribution. Furthermore, the manufacturing of this structural component is particularly straightforward because the consolidation of the fiber-reinforced composite and the creation of the strong bond between the composite and the metal part can be performed in the same step and using the same tool. The metal part can also serve as a connection to another component. For example, it is unnecessary to consolidate the fiber structure in the consolidation tool and then insert the resulting fiber-reinforced composite part into another tool to attach a metal part. Additionally, the application of pressure and heat within the consolidation tool results in a particularly robust bond with the metal part.

[0012] The fiber-reinforced composite component and the metal component are in contact with each other, particularly over a surface area. The manufactured fiber-reinforced composite component comprises, for example, continuous fibers embedded in a matrix, primarily thermoplastic polymer, and is designed, for example, as an organosheet. Continuous fibers are generally understood to be fibers with a long length, for example, greater than 50 mm. Accordingly, the fiber-reinforced composite component, for example, has fibers with a length of more than 50 mm. Such continuous fibers contribute to the high strength of the structural component and can be made of various fiber materials such as glass, aramid, or carbon.

[0013] Before consolidation, the fiber structure comprises, for example, loose fibers or consists of loose fibers, such as a woven fabric. At least some of these fibers are reinforcing fibers. After consolidation, these reinforcing fibers are embedded in a (rigid) polymer matrix.

[0014] At least one metal part (and / or the fiber structure) can be coated with an adhesive, particularly before the consolidation step, e.g., before being arranged in the consolidation tool. The adhesive then creates a bond between the fiber composite part and the metal part and is designed, for example, to be activated by heat. Alternatively or additionally, the surface of the metal part can be roughened, e.g., by grinding and / or a chemical process.

[0015] Alternatively or additionally, the metal part (and / or the fiber structure) can be provided with an adhesion promoter, particularly before the consolidation step, e.g., before being arranged in the consolidation tool, and especially across its entire surface. This allows for a particularly strong bond between the fiber-reinforced composite part and the metal part. The adhesion promoter forms, for example, chemical bonds that hold the fiber-reinforced composite part and the metal part together. The adhesion promoter can be designed to be activated by heat, e.g., by separate tamping and / or by the heat in the consolidation tool.

[0016] In a further training, the fiber structure and the metal part are arranged in the consolidation tool in such a way that a side of the metal part coated with the adhesion promoter is in contact with the fiber structure or is brought into contact with it during the consolidation step, so that a particularly strong bond is formed.

[0017] Optionally, at least part of the fiber structure (before the consolidation step) consists of or comprises hybrid yarn. The hybrid yarn includes polymer fibers and reinforcing fibers, e.g., made of glass, carbon fibers (CF), basalt, or aramid. For example, the polymer fibers consist of polyamide (PA), polypropylene (PP), or polyethylene terephthalate (PET). Upon heating, the polymer fibers can melt and form a matrix of the fiber-reinforced composite, either partially or completely, which further simplifies the manufacturing process and ensures a particularly uniform distribution of the matrix material.

[0018] For example, the fiber structure comprises one or more (separate) fiber braids. Each of these (separate) fiber braids can be formed in the form of a braided tube. The fiber braids, particularly in the form of braided tubes, or alternatively, for example, as planar structures, can be arranged one above the other and / or within each other to form the fiber structure. The fiber structure can thus form a (completely closed) tube structure. Fiber braids in the form of braided tubes can be designed for a specific load (torsion, bending, or tensile / compressive load), whereby loads from different directions can be absorbed and absorbed by superimposing different fiber braids. Locally increased stiffness and elsewhere reduced stiffness can be achieved via the fiber braids, so that, for example, targeted compliance can also be specified.In one embodiment, the fiber structure can, for example, consist of at least five or at least ten layers, each with a fiber braid. Alternatively or additionally, the fiber structure can comprise a braid, woven fabric, non-woven fabric, knitted fabric, and / or embroidered fabric. This allows for the fulfillment of further functions with particularly simple manufacturing. In particular, hybrid yarn with the same or identical polymer as the fiber braid(s) can be used. Different layers of the fiber structure (and the fibers of the resulting fiber-reinforced composite component) can differ from one another, especially in the formation of fiber braids. The layers can also differ in their fiber density, fiber material, and / or the thickness (i.e., diameter) of the fibers.

[0019] The process can further include the injection molding of injection molding material onto the structural component to form at least one injection-molded structure. It can be provided that the at least one injection-molded structure abuts the fiber-reinforced composite part (at least) with a section, rests against it, and / or covers the fiber-reinforced composite part (or at least a section thereof). Alternatively or additionally, it can be provided that the at least one injection-molded structure abuts the at least one metal part (at least) with a section, rests against it, and / or covers the at least one metal part (or at least a section thereof). The at least one injection-molded structure can rest against a surface of the metal part and / or at least partially cover the surface facing away from the fiber-reinforced composite part.The injection-molded structure can thus (additionally) secure the metal part to the fiber-reinforced composite part, particularly by means of a positive fit. For example, the injection-molded structure is formed in the form of a stiffening rib. The injection molding process is carried out, for example, in an injection mold. The consolidated structural component can be inserted into the injection mold.

[0020] Optionally, the process includes attaching another component to the at least one metal part. This additional component can be permanently, detachably, or permanently connected to the at least one metal part, for example, by welding, soldering, riveting, crimping, clamping, and / or screwing. The secure and reliable connection of fiber-reinforced composites to other components often presents a challenge, for example, because drilling screw holes can sever fibers, which generally weakens the material. By firmly and, in particular, over a large area, bonding the metal part to the fiber-reinforced composite part, it is securely held in place and, in turn, allows for welding to another metal part and / or the easy drilling of screw holes.

[0021] According to one aspect, a method for manufacturing a backrest for a vehicle seat is provided. It is provided that the backrest is manufactured with at least one structural element, which is produced in the method according to any embodiment described herein. Furthermore, other parts of the vehicle seat, e.g., a seat section, or other vehicle components, such as a vehicle door or a bumper, can also be manufactured using the structural element produced by the method described herein.

[0022] According to one aspect, a structural component is provided, comprising a fiber-reinforced composite part and at least one metal part, which are held together by a material bond and / or an adhesive bond. Optionally, the fiber-reinforced composite part may have the form of a hollow profile, at least in some sections. The hollow profile, e.g., a cross tube of a seat frame, can significantly contribute to a weight reduction compared to a steel cross tube and can be securely connected to the metal part by the material bond, in particular an adhesive bond. The structural component is, for example, manufactured or manufacturable according to the method in any embodiment described herein. The metal part serves, for example, as reinforcement and / or as an interface or connecting element to another component.

[0023] At least one metal part can protrude from the fiber-reinforced composite part (in particular, project beyond the fiber-reinforced composite part in at least one direction). This can provide an interface to another component. Alternatively or additionally, the metal part can protrude locally from the fiber-reinforced composite part (for example, between two sections of the metal part that are in contact with the fiber-reinforced composite part), e.g., in the form of a raised section. Such a raised section can also serve as an interface. For example, a weld can be created on a protruding section of the metal part, e.g., using laser welding, without damaging the fiber-reinforced composite part.

[0024] Optionally, at least one metal part is formed in a flat shape, for example, as a sheet metal part, especially as a metal strip. This allows for a flat and particularly strong adhesive bond. Alternatively, the metal part can also be in the form of a metal wire or a metal mesh.

[0025] At least one metal part (or another metal part connected to the fiber composite part in the same way) can be profiled. This makes it possible to use a flat and lightweight yet particularly rigid metal part.

[0026] Furthermore, at least one metal part can be designed in the form of a bracket, e.g., for the detachable attachment of a child car seat, and can, for example, form a loop. In particular, the loop can protrude laterally from the fiber composite part (e.g., in the form of a tube). For example, two such brackets can form an Isofix mount. Alternatively or additionally, such a bracket can form a top tether loop.

[0027] At least one metal part, or another metal part, can form a fitting component of a fitting assembly or firmly connect the fiber-reinforced composite component to a fitting component of a fitting assembly. In this way, a secure connection of the fitting to a structural element predominantly made of a fiber-reinforced composite material is possible.

[0028] The structural element can be firmly connected to a frame, such as a seat frame or a backrest frame, by means of at least one metal part. This allows the frame to be securely attached.

[0029] According to one aspect, a structural component is provided, optionally according to any embodiment described herein and / or manufactured or manufacturable according to the method according to any embodiment described herein. The structural component comprises a fiber-reinforced composite part and at least one metal part, which are held together by an adhesive bond comprising an adhesion promoter. The adhesion promoter enables a particularly strong bond.

[0030] According to one aspect, a vehicle seat frame is provided which includes at least one structural component according to any design described herein.

[0031] The fiber-reinforced composite component of at least one structural element can form a transverse tube and / or a vertical tube of the vehicle seat frame. The forces and torques occurring during normal use and / or in a crash can be safely transferred via the structural element, and in particular via the fiber-reinforced composite component of the structural element.

[0032] According to another aspect, a vehicle seat is provided with the structural component.

[0033] The underlying concept of the invention will be explained in more detail below with reference to the exemplary embodiments shown in the figures. The figures show: Fig. 1. A description of a method for manufacturing a structural component; Fig. 2 a view of a seat frame of a vehicle seat with a structural component of a backrest sub-assembly in the form of a reinforcing tube element; Fig. 3 a separate view of the structural element according to Fig. 2; Fig. 4 a view of a backrest for a vehicle seat with the structural element according to Fig. 3; Fig. 5A and Fig. 5B Views of further embodiments of the structural element according to Fig. 3 and its connection to a frame; Fig. 6A a view of a pipe element with an adapter; Fig. 6B a cross-sectional view of the Fig. 6A; Fig. 7A a view of a fiber composite part with loops; Fig. 7B a view of a wrapped fiber composite part with loops; Fig. 8A to Fig. 8C Views of a fiber composite part in the form of a pipe element with a toothed part positively connected to it; Fig. 9A a view of an embodiment of a structural element having a reinforcement formed locally by rings of metal; Fig. 9B a longitudinal section view through the structural element according to Fig. 9A; Fig. 10A a view of an embodiment of a structural element with ribbon structures; Fig. 10B a longitudinal section view through the structural element according to Fig. 10A; Fig. 11 A a view of another embodiment of a structural element with a band structure; Fig. 11 B a longitudinal section view through the structural element according to Fig. 11A; Fig. 12A a view of an embodiment of a fiber composite part having three different layers with different fiber weaves; Fig. 12B a longitudinal section view through the fiber composite part according to Fig. 12A; Fig. 13A a view of another embodiment of a fiber composite part having three different layers with different fiber weaves; Fig. 13B a ​​longitudinal section view through the fiber composite part according to Fig. 13A; Fig. 14A a view of yet another embodiment of a fiber composite part, which has three different layers with different fiber weaves; Fig. 14B a longitudinal section view through the fiber composite part according to Fig. 14A; Fig. 15A a view of yet another embodiment of a fiber composite part, which has three different layers with different fiber weaves; Fig. 15B a longitudinal section view through the fiber composite part according to Fig. 15A; Fig. 16 a view of yet another embodiment of a fiber composite part, which has three different layers with different fiber weaves; Fig. 17A a view of a fiber composite part with a shape other than a cylindrical shape; Fig. 17B a sectional view along line AA according to Fig. 17A; Fig. 17C a sectional view along line BB according to Fig. 17A; Fig. 18A a view of a hybrid yarn with a round cross-section; and Fig. 18B a view of a hybrid yarn with a rectangular cross-section.

[0034] Fig. Figure 1 shows a method for manufacturing a structural component 2 with a fiber composite part formed from a fiber composite material 21 and at least one, in this case several, metal parts firmly attached to it 24A .

[0035] The process involves providing at least one fiber structure. G and at least one metal part 24A .

[0036] The fibrous structure G In the present example, this is achieved by a first fiber network. M1 and a separate (distinct) second fiber network M2 , each formed by a braided tube. Both fiber braids. M1 , M2The braided tubes are each provided in the form of a hybrid tube with hybrid yarn and then layered on top of each other, e.g., pushed inside one another. One braided tube is positioned (coaxially) inside the other. This forms a braided tube package. The individual layers of braided tubes can be fixed to each other for positional security, e.g., by local welding. For this purpose, one or more infrared welding points (IR points) and / or ultrasonic welding points (US points) can be used, as shown in Fig. 1 schematically represented. Furthermore, in the present example, a hose is shown 42 or another expanding agent is inserted into the braided hoses, e.g. in the innermost one.

[0037] Every metal part 24A will be dealt with by a liability mediator H (alternatively or additionally with an adhesive) K) provided, in this case coated with it. For this purpose, for example, a polyolefinic adhesion promoter, a silane adhesion promoter and / or another metal-organic compound can be used as an adhesion promoter. Alternatively, metal parts pre-coated accordingly can also be used. Optionally, the metal parts are or are 24A with a plasma treatment, in particular plasma coating, e.g. a PlasmaPlus coating.

[0038] The metal parts 24A are each formed in the form of a sheet metal strip. For example, the metal parts 24A cut from a coiled steel strip. The metal parts are present. 24A Made of steel, they can also be referred to as steel bands or steel patches. Alternatively, the metal parts can 24AIt can also be made of aluminum, titanium, or another metal. Optionally, a band with reinforcing metal fibers is provided.

[0039] The fibrous structure G is together with at least one metal part, here with the several (specifically two) metal parts 24A (and with the hose) 42 ) into a consolidation tool 4 Each one is used in conjunction with the liability mediator. H provided side of each of the steel bands 24A a section of the fibrous structure G turned towards, in particular brought into contact with it. In the present case, the consolidation tool comprises 4 two tool halves 40 , 41 , which can be opened and closed to control the fibrous structure G with the metal parts 24A (and the hose) 42 to insert.

[0040] The fibrous structure is then G and the metal parts 24Ajointly and simultaneously subjected to pressure and heat (with increased pressure and heat compared to the environment) to form the fibrous structure G to consolidate. Through consolidation, reinforcing fibers are extracted from the fiber structure. G impregnated and compacted with matrix material. In the example shown, the hose is used for this purpose. 42 inflated and a heater 43 on one or both tool halves 40 , 41 is activated. This expands the package until it reaches a shaping contour of the consolidation tool. 4 (e.g., a variothermal tool of the consolidation tool). The hose pushes the material outwards.

[0041] The heating system 43 heats the fiber braids M1 , M2 of the package for creating a material-bonded connection between the fiber braids M1 , M2forming the fiber composite part 21 . By means of the hose 42 The pressure exerted (by the expanding agent) will cause the fiber networks to become M1 , M2 compressed. The finished fiber composite part 21 at least one of the fiber networks is shown. M1 first layer formed and one formed by the second fiber network M2 A second layer is formed, which is bonded together by a material connection.

[0042] Optionally, hybrid yarn is used, which provides the entire matrix material. This is done in the consolidation tool. 4The polymer fibers of the hybrid yarn are melted, impregnating the reinforcing fibers of the hybrid yarn. To provide additional matrix material, one or more polymer sheaths, films, tubes, and / or fiber structures can optionally be arranged on the braided tube assembly, for example, inside, outside, and / or between the braided tubes. In the combined consolidation process, this material forms at least part of the matrix of the composite material, particularly in the form of a continuous fiber-reinforced organosheet. Because the final matrix material is already present in the braided tube assembly, particularly short cycle times can be achieved, which can enable or simplify mass production.

[0043] The application of heat further consolidates the fiber structure. G (especially through the liability mediator) H ) a connection between the respective metal part 24Aand the fiber composite part 21 It forms, in particular, an adhesive bond that is strong and cannot be undone without damage. Furthermore, during consolidation, matrix material can consolidate the metal part. 24A partially or completely flow around the components, thus contributing to a firm connection.

[0044] In this way, the consolidation is achieved in just one step and with just one tool, the consolidation tool. 4 , both the fibrous structure G consolidated, as well as the metal parts 24A firmly attached to the fiber composite part produced in the process 21 connected. Through joint consolidation with the metal parts 24A The reinforcing fibers can adhere particularly well to the metal parts. 24A apply. For example, the metal parts press 24A(generally at least one metal part) in the consolidation process the reinforcing fibers (slightly) enclose and / or the reinforcing fibers wrap around at least one edge of the metal parts 24A This allows for a particularly secure connection of these parts made of different materials in a particularly simple and quick manner.

[0045] The in Fig. 1 exemplary, completed fiber composite part 21 of the structural element 2 consists of organosheet. According to the procedure according to Fig. 1. Hollow profiles can be produced in particular, but other shapes are also possible.

[0046] The fiber braids are optional. M1 , M2 similar. For example, a long fiber braid is cut into several pieces to create the multiple separate fiber braids. M1 , M2 to provide. Alternatively, the fiber braids can be used. M1 , M2They may differ, for example, in their braiding technique (with regard to braiding angle, additional support threads and / or incorporated bands), in their fiber composition (e.g., they have different reinforcing fibers and / or polymer fibers, e.g., different reinforcing fibers or mixtures of different reinforcing fibers, each e.g., selected from glass, CF, basalt and aramid) and / or in their volume fraction of polymer fibers.

[0047] The completed structural element 2 It is designed to form a load-bearing structure or part thereof (thus providing structure). In this case, the structural element is... 2 with the fiber composite part 21 It is installed in the form of a tubular body in a vehicle seat and forms part of a vehicle seat frame.

[0048] Optionally, the liability mediator H additionally tempered, e.g. before consolidation.

[0049] Optionally, after consolidation, e.g. in an injection mold, injection molding material is applied to the structural component. 2 The structural element can be injection-molded to form at least one molded-on structure. 2 It is inserted into the injection mold as a pre-product. The at least one molded-on structure is then formed in such a way that it is applied section by section to the fiber-reinforced composite part. 21 borders and is partially attached to at least one metal part 24A adjacent. This procedural step is shown, for example, by the transition of the right-hand sub-image into Fig. 1 to Fig. 5B.

[0050] The completed structural element 2 can then be connected to other components, particularly through the at least one metal part 24A a durable connection can be established.

[0051] A in Fig. 2. Exemplary vehicle seat frame 1A vehicle seat comprises a seat component assembly. 10 and one via a fitting arrangement 13 around a pivot axis D swiveling to the seat assembly 10 arranged backrest sub-assembly 11 The seat assembly 10 forms a seating area 100 for a vehicle occupant and is, for example, equipped with a longitudinal adjustment device 12 Can be connected to or is connected to a vehicle floor. The backrest sub-assembly. 11 can be achieved by pivoting around the pivot axis D in their inclined position relative to the seat assembly 10 can be adjusted to set a comfortable seating position for a vehicle occupant or to adjust the vehicle seat frame 1 for example, to put it into a flat position, for example to provide additional storage space in the vehicle.

[0052] The vehicle seat frame 1It can, for example, form a front seat in a vehicle. However, it is also conceivable and possible that such a vehicle seat frame is part of a vehicle's rear seating arrangement (in the second or third row of seats).

[0053] In the example shown, the backrest sub-assembly 11 a structural section 110 on which a cushion can be arranged to provide a backrest. On the structural section 110 is a structural component 2 arranged which forms a transverse tube. The structural element 2 connects frame parts 111 , 112 , here in the form of essentially perpendicular to the pivot axis D extended longitudinal beams, together and stiffening the structural section 110 such that the structural section 110 the backrest sub-assembly 11Acting load forces and moments are absorbed and directed towards the seat assembly. 10 can be derived.

[0054] Such a cross tube has so far usually been designed as a steel tube to ensure sufficient rigidity on the vehicle seat frame. 1 to provide. However, this entails that the weight of the vehicle seat frame 1 significantly increased.

[0055] At the in Fig. 2 vehicle seat frames shown 1 is therefore the structural element 2 according to the procedure Fig. 1 manufactured. The structural element 2 includes a fiber composite component 21 , which is made of a fiber composite material (in particular organosheet), and is shown in a separate figure in Fig. 3 shown. The fiber composite part 21 extends lengthwise along a longitudinal axis Land is designed in the form of a hollow profile, specifically a tube body. The longitudinal axis L extends along the vehicle seat frame 1 parallel to the pivot axis D The tube body contains an inner lumen. 20 It is hollow and therefore has a pivot axis. D through the lumen 20 Because the pipe body is made of a fiber composite material, the structural element can 2 They are designed to be lightweight, so that the weight of the vehicle seat frame is reduced. 1 The overall reduction can be achieved.

[0056] The structural element 2 Each component is furthermore firmly attached to the fiber composite part by means of an adhesive bond. 21 connected metal parts 24A in the form of steel strips. The metal parts 24A stand from the fiber composite part 21 (on the seat frame) 1 essentially perpendicular to the pivot axis D) and enable a particularly durable connection of the fiber composite part 21 with other parts of the backrest sub-assembly 11 e.g. the structural section 110 and / or the frame parts 111 , 112 .

[0057] Optionally, part of the seat assembly is also available. 10 according to the procedure Fig. 1 manufactured, e.g. a cross tube 14 The cross tube 14 connects side panels of the seat assembly 10 each other.

[0058] Fig. Figure 4 shows a possible connection of the structural element. 2 to a schematically represented frame 27 a backrest sub-assembly, e.g. the backrest sub-assembly 11 according to Fig. 2. Two according to Fig. 3 with the fiber composite part designed in the form of a hollow profile 21 bonded metal parts in the form of a steel strip each 24Astand from the fiber composite part 21 off. The steel bands 24A are each attached at several points to a longitudinally standing bending beam, here a vertical profile 270 of the frame 27 fastened. In this case, the vertical profiles are made of metal, e.g., steel, and the steel bands 24A are at the attachment points 26 with the vertical profiles 270 screwed together, as in Fig. 4. Example at one of the attachment points 26 illustrated. Alternatively, it can be provided that the steel bands 24A at the attachment points 26 are welded to the vertical profiles 720.

[0059] Through the secure connection of the steel bands 24A with the fiber composite part 21 Can comparatively large loads, especially torques, be transferred from the backrest sub-assembly to a low overall weight? 11about the structural element 2 into the seat assembly 10 to be initiated. 24A If organosheet strips are provided, these would usually have to be different compared to steel strips. 24A have a greater thickness, which is not feasible in some applications due to space constraints.

[0060] When using the procedure according to Fig. Furthermore, relatively short production times are possible, which allows for mass production.

[0061] The vertical profiles 270 are attached to their structural element 2 far-facing ends via a cross-section 271 connected to each other, e.g. welded. Alternatively, it is also possible to connect the cross-section. 271 and / or the vertical profiles 270 to bind with a fiber composite component, in particular using the method according to Fig. 1. For example, the cross-section 271with steel bands corresponding to the fiber composite part 21 and with the procedure according to Fig. 1 will be provided.

[0062] Furthermore, it is possible that at least one metal part, such as the steel bands, may be affected. 24A , two fiber composite parts (e.g. the fiber composite part 21 and a vertical profile 270 (made of a fiber composite material) are firmly connected to each other by joining two fiber structures. G and that at least one metal part is placed together in the consolidation tool 4 are inserted so that the metal part is firmly bonded to both formed fiber composite parts.

[0063] Fig. 5A shows this on the frame 27 assembled structural element 2 according to Fig. 4, whereas in contrast at least one of the metal parts (of the steel bands) 24A ) not as in Fig. 4 shows that it is not flat, but profiled. The steel band has this feature. 24A a profiling 243 on, which in this example extends along a longitudinal direction of the steel strip 24A This makes it possible to further increase bending stiffness.

[0064] Furthermore, the profiling 243 a local elevation where the metal part 24A and the fiber composite part 21 A gap exists. The local elevation is present between areas of the metal part. 24A arranged that are in contact with the fiber composite part 21 This makes it possible to access the metal part. 24A to create a welded connection with another component in the area of ​​elevation, e.g. by means of laser welding, without the fiber composite part 21 to be damaged by the associated heat input. In the example according to Fig. 5A is thus a screw dome 28A attached to the metal part 24A welded on.

[0065] Fig. 5B shows this on the frame 27 assembled structural element 2 according to Fig. 4, in contrast to this, additional stiffening ribs are injection-molded. 25 are planned. Some of the stiffening ribs 25 extend (only) over the fiber composite part 21 and the metal part (the steel band) 24A Other, alternative or additional stiffening ribs 25 extend (only) over the metal part (the steel band) 24A ) and part of the frame 27 Other, alternative or additional stiffening ribs 25 extend over the metal part (the steel band) 24A ), the fiber composite part 21 and part of the frame 27 .

[0066] Fig. 6A and Fig. Figure 6B shows an embodiment of the fiber composite part. 21 in the form of a tube body, in which one end of the fiber composite part 21 during the consolidation process with a form-fitting contour 217 was provided with the form-fitting contour 217 The present design is star-shaped. It features a corresponding form-fitting contour. 240 metal part, for example in the form of an adapter 24B , fits snugly on the end 22 and is firmly connected to it as a result of the consolidation process. After inserting the adapter. 24B and the fibrous structure G into the consolidation tool 4 The fiber composite part 21 during consolidation (according to Fig. 1) the form-fitting contour 240 of the adapter 24.

[0067] The adapter 24B serves to connect the fitting arrangement 13 (see Fig. 2) to the fiber composite part 21 The adapter 24B It consists, for example, of steel and is equipped with a fitting. 130 the fitting order 13 firmly connected, in this case welded (e.g., after consolidation). Therefore, it is possible to remove the structural element. 2 with the fiber composite part 21 to train and yet create a welded joint with metal parts, such as the fitting part 130 to be made of steel. This allows for particularly easy connection to existing structures and to structures that, for specific reasons, must or should be made of metal.

[0068] The fitting 130 represents a backrest-fixed fitting component that is relative to a seat-fixed fitting component of the fitting arrangement 13 The adapter is rotatable. 24B It can be directly subjected to pressure. The structural element 2 encompasses both ends22 , 23 of the fiber composite part 21 one adapter each 24B according to Fig. 6A, Fig. 6B.

[0069] Alternatively or additionally to the connection to the fitting arrangement 13 can the adapter 24B the fiber composite part 21 Seal (at the respective end), e.g. airtight.

[0070] Fig. 7A shows an embodiment in which the fiber composite part 21 (Several, specifically two) metal parts in the form of metal brackets 24C (alternatively, just a metal bracket) 24C ) by a procedure according to Fig. 1. Adhesive bonding and additionally reinforced by (optional) stiffening ribs 25 are connected by overmolding the metal brackets 24C on the fiber composite part 21 have been formed using injection molding material.

[0071] The metal brackets 24CEach of them forms a loop. 241 The loops 241 They are used, for example, to secure a child car seat, e.g., for an Isofix system. Alternatively, one or more such loops can be used. 241 They are used for guiding a seat belt and / or for transmitting belt force. The metal brackets 24C are made of steel.

[0072] The metal brackets 24C are examples at both ends of the fiber composite part 21 arranged.

[0073] Fig. 7B shows a further training, according to which the metal bracket(s) 24C the fiber composite part 21 Simply or multiple times surrounded. This allows for a particularly high load-bearing capacity.

[0074] The Fig. 8A to Fig. Figure 8C shows another embodiment of the structural component. 2 with the fiber composite part 21, in which a connection is made between the ends of the fiber composite part 21 horizontal section of the fiber composite part 21 during the consolidation process with a form-fitting contour 217 was provided with the form-fitting contour 217 is exemplarily star-shaped (see Fig. 8B). With the form-fitting contour 217 A metal part is positioned, here exemplified in the form of a toothed part. 24D , positively engaging. The toothed part 24D encompasses the fiber composite part 21 and is therefore glued in place. The toothed part 24D has an interlocking design 242 on, in this case an externally circumferential toothing, e.g. for coupling to a drive. The fiber composite part 21 It can, for example, serve as a shaft, e.g. for an optional height adjustment mechanism of the vehicle seat. 1 The toothed part 24D For example, it represents a gear or forms a tooth segment.

[0075] On both sides (viewed in the axial direction) of the form-fitting contour 217 of the fiber composite part 21 Each section has a circular cross-section (see Fig. 8C). To the gear part 24D To secure axially, the fiber composite part 21 on both sides of the form-fitting contour 217 optional extensions 218 on, which protrude outwards (radially) in relation to axially adjacent areas.

[0076] For example, the gear part 24D before the consolidation process on the fiber structure G deferred and held in place by the consolidation process in a materially and form-fitting manner (especially rotationally resistant).

[0077] Instead of the toothed part 24D A metal part without teeth can also be used accordingly. Fig. 8A can be attached and, for example, welded to another metal part. Furthermore, instead of a toothed connection, a lever can be connected to the metal part.

[0078] Fig. 8A further shows two parts made of fiber composite material. 21 mounted screw domes 28B , 28C The screw bosses 28B , 28C Are there any metal parts present (alternatively, the screw bosses could be used)? 28B , 28C but can also be made from other materials). The screw bosses 28B , 28C (Metal parts) are between loose fibers of the (not yet consolidated) fiber structure before consolidation. G One of the screw bosses has been inserted. 28B(A metal part) is pushed through the fiber mesh (and, in the example shown, provided with protrusions on both sides for additional positive locking). Due to the loose fibers, which are not yet impregnated with matrix material, it is possible to move them without damaging them. For this purpose, the metal part to be inserted, in this case the screw bosses, can be... 28B , 28C , are subjected to a vibration. The screw bosses 28B , 28C are then formed together with the fibrous structure G consolidated. The screw bosses 28B , 28C This allows for particularly safe application to the consolidated fiber composite part 21 to be held. One of the screw bosses 28C(A metal part) is only pushed through the upper layers of the fibers and rests on deeper layers of the fibers. This allows for a particularly secure, material-bonded connection due to consolidation. At least one of the screw bosses 28B , 28C or at least one corresponding to one of the screw bosses 28B , 28C on a fiber composite part 21 The attached metal part can also be used without another metal part (such as the toothed part). 24D ) on the fiber composite part 21 be attached.

[0079] At a Fig. 9A, Fig. 9B illustrated embodiment of a structural component 2 are on the outside of an outer surface 216 (corresponding to the outside of a layer) 212 a fiber network M3 ) of the fiber composite part 21 Rings 24Emade of metal, e.g. steel or aluminium, arranged, which in this case form the ends 22 , 23 of the fiber composite part 21 comprehensively along a circumferential direction U surrounded and thus at the ends 22 , 23 provide additional reinforcement. The rings 24E are together with the fiber network M3 into the consolidation tool 4 were inserted and subjected to pressure and heat, so that through each inner side of the rings 24E The applied adhesive creates a particularly strong adhesive bond between the rings. 24E and the fiber composite part 21 is available.

[0080] In the embodiment according to Fig. 10A, Fig. 10B are on the outside of the (single- or multi-layer) fiber composite part 21 Band structures, specifically in the form of tapes 24Fmade of metal, e.g., steel or aluminum. In this embodiment, the tapes are 24F parallel to the longitudinal axis L longitudinally extended. In this case, therefore, a special reinforcement is applied along the longitudinal axis. L on the fiber composite part 21 provided.

[0081] In the embodiment according to Fig. 11A, Fig. In contrast, 11B extends a tape 24F spirally around the outer surface 216 of the fiber composite part 21 around.

[0082] The fiber composite part 21 It is optionally designed in multiple layers. As will be explained below using different examples, the fiber composite part is 21Formed by different layers that have similar or different, overlapping fiber networks. The shape, arrangement, and orientation of the fiber networks in the layers relative to each other can be used to modify the fiber-reinforced composite part. 21 A specific stiffness – possibly varying locally and depending on the direction – can be set to specifically absorb forces and moments.

[0083] At a Fig. 12A and Fig. In the embodiment shown in 12B, the fiber composite part has 21 of the structural element 2 (in the form of a pipe element) three layers 210 , 211 , 212 with different fiber battles M1 , M2 , M3 up. The fiber networks M1 , M2 , M3 are each characterized by intersecting fibers F formed and overlap in such a way that a first, innermost fiber network is created. M1a first layer 210 radially within a second fiber network M2 a second layer 211 and the second fiber network M2 the second layer 211 in turn radially within a third fiber network M3 a third layer 212 is arranged. The fiber networks M1 , M2 , M3 In the illustrated embodiment, they differ in their axial length such that the outermost, third layer 212 axially shorter than the second layer 211 and these in turn are axially shorter than the first layer 210 is trained. The third layer 212 is with its third fiber network M3 this is located in the middle of the structural element 2 arranged, and the second layer 111 is in turn centered on the third layer 212 , so that the structural element 2 It is reinforced in the middle.

[0084] At a Fig. 13A and Fig. In contrast, in the embodiment shown in 13B, a reinforcement is provided at one end. 22 of the fiber composite part 21 Provided. The axially shortest, third layer. 212 is with its third fiber network M3 to this end 22 arranged. The second layer as well. 211 extends to the end 22 , however, in the direction of the other end 23 about the third layer 212 outwards, but is axially shorter than the first layer 210 , which extends to the end 23 extends. In the area of ​​the end. 22 is the structural element 2 thus through the superimposition of fiber networks M1 , M2 , M3 the different positions 210 , 211 , 212 Specifically reinforced. Furthermore, targeted flexibility can be achieved in the end area in this way. 23to be provided for energy management in the event of a crash (in the sense of a deformation element).

[0085] In yet another instance, in Fig. 14A, Fig. In the embodiment shown in 14B, the fiber composite part is 21 reinforced again in the middle, with the innermost layer being the 210 The second layer is axially shortest and centrally located. 211 is axially longer than the first layer 210 , but shorter than the third layer 212 By overlapping the layers 210 , 211 , 212 in the middle of the fiber composite part 21 This results in targeted reinforcement in the center of the fiber composite part. 21 provided. In addition, targeted compliance can be provided on both sides at the ends in this way for energy management in the event of a crash (in the sense of a deformation element).

[0086] The exemplary embodiment according to Fig. 15A, Fig. 15B is similar in the arrangement of layers. 210 , 211 , 212 in relation to each other according to the exemplary embodiment Fig. 12A, Fig. 12B, wherein in this embodiment the inner layer 210 formed by two braided tubes that are spaced axially apart in the middle 213 are arranged relative to each other. In this way, flexibility can be achieved, if necessary, in the center of the fiber composite part. 21 be created.

[0087] The embodiment according to Fig. 16 corresponds to the embodiment shown in Fig. 12A, Fig. 12B, in this case into the fiber mesh M2 the second layer 211 additional stiffening fibers 214 in the form of along a stiffening direction V are embedded in longitudinally extended continuous fibers. In this embodiment, the second layer 211thus through the additional embedding of stiffening fibers 214 stiffened so that along the direction of extension V the stiffening fibers 214 an additional, direction-dependent stiffness in the fiber composite part 21 is provided.

[0088] In the different embodiments, the fiber braids are M1 , M2 , M3 to form the multi-layered structure from braided tubes, which are applied section by section or along the entire length of the fiber composite part. 21 overlap. The orientation of the fibers F the different fiber networks M1 , M2 , M3 This can vary, so that the fibers F different fiber networks M1 , M2 , M3For example, they are aligned at an oblique angle to each other. In this way, a predetermined directional dependency can be achieved for absorbing forces and moments on the fiber-reinforced composite component. 21 be hired.

[0089] Similarly, the fiber networks can M1 , M2 , M3 in the density and / or strength of their fibers F differ. Additionally or alternatively, at least some of the fibers can F the fiber networks M1 , M2 , M3 They may also be made from different materials, for example glass, aramid or carbon.

[0090] The fibers F the fiber networks M1 , M2 , M3 They can be formed, for example, by continuous fibers, i.e., particularly long fibers with a length preferably of (significantly) greater than 50 mm.

[0091] The fiber networks M1 ,M2 , M3 They are made, for example, from hybrid yarn, i.e., a mixture of glass and polymer fibers. For the integral, material-bonded connection in the production of the fiber-reinforced composite part. 21 can the superimposed fiber braids M1 , M2 , M3 in the form of braided hoses, in this case in consolidation tools 4 They are heated and partially melted, resulting in a material-bonded connection between the braided tubes.

[0092] Alternatively or additionally, the fiber braids can M1 , M2 , M3 These include, for example, glass, carbon, or aramid fibers. The fiber braids M1 , M2 , M3 are used to manufacture the fiber composite part 21 layered on top of each other and then combined (in situ) in the consolidation tool 4polymerized, resulting in an integral, one-piece fiber composite part 21 results.

[0093] In the Fig. 12A, Fig. 12B to Fig. The fiber composite part shown in 16 illustrated embodiments has 21 of the structural element 2 It has an essentially cylindrical shape with a circular cross-section. In contrast, the outer shape of the structural element is less pronounced. 2 at the in Fig. 17A, Fig. 17B, Fig. The embodiment shown in 17C differs from a cylindrical shape and varies along the longitudinal axis. L as well as circumferentially around the longitudinal axis L This allows for the shaping of the fiber composite part. 21 specifically for attachment to the structural section 110 , for example the backrest sub-assembly 11, adapted, whereby structures can be created via flattened surface sections, for example, to which attachments, such as adapter parts for connection with fittings, can be attached. 13 , can be attached. Regarding the shaping of the fiber composite part. 21 The (direction-dependent) stiffness can also be adjusted so that torsional moments and bending loads can be applied to the fiber composite part in a targeted manner. 21 can be recorded.

[0094] In each of the embodiments described herein, the fiber composite part can be manufactured using the following methods: 21 Hybrid yarn 3 can be used. The hybrid yarn 3 includes matrix-forming fibers, e.g. thermoplastic polymer fibers 30 , and reinforcing fibers 31 The polymer fibers 30 They consist of materials such as PA, PP and / or PET. The reinforcing fibers 31They consist of materials such as glass, CF, basalt and / or aramid.

[0095] Fig. Figure 18A shows a possible arrangement of polymer fibers 30 and reinforcing fibers 31 in a hybrid yarn 3 The polymer fibers 30 and reinforcing fibers 31 They are (in cross-section) essentially evenly distributed. The distribution can, for example, be chaotic.

[0096] Fig. Figure 18B shows an alternative arrangement of polymer fibers. 30 and reinforcing fibers 31 in a hybrid yarn 3 The polymer fibers are involved here. 30 and reinforcing fibers 31 Ordered. It consists of several flat layers of polymer fibers. 30 and reinforcing fibers 31 intended. In this case, several layers of polymer fibers enclose each other. 30 multiple layers of reinforcing fibers 31 .

[0097] The mass fraction of the polymer fibers 30 in hybrid yarn3 The percentage is between 30% and 70%. The number of polymer fibers 30 The number of reinforcing fibers in hybrid yarn can be similar to or the same as the number of reinforcing fibers. 31 Alternatively or additionally, for one or more layers 210 , 211 , 212 of the fiber composite part 21 A pure polymer yarn is used.

[0098] The polymer fibers 30 in hybrid yarn 3 form the matrix material for the reinforcing fibers 31 in the fiber composite part 21 .

[0099] The underlying idea of ​​the invention is not limited to the embodiments described above, but can in principle also be realized in a completely different way.

[0100] A structural component of the type described can be used not only on a backrest sub-assembly, but also, for example, on the seat sub-assembly of a vehicle seat. In principle, structural sections can be stiffened using fiber-reinforced composite components, particularly in the form of tubular elements of the type described, whereby the tubular element can extend transversely (along a transverse direction of the vehicle) or vertically (particularly transversely to a pivot axis of the backrest sub-assembly). Reference symbol list 1 vehicle seat frame 10 Seat component assembly 100 Seating area 11 Backrest sub-assembly 110 Structural section 111, 112 Frame part (longitudinal beam) 12 Longitudinal adjustment device 13 Fitting arrangement 130 Fitting part 14 cross tube 2 Structural element 20 internal lumens 21 Pipe body (fiber composite part) 210, 211, 212 Location 213 Strut element 214 stiffening fibers 216 Outer surface 217 Form-fit contour 218 Expansion 22, 23 End 24A steel band (metal part) 24B Adapter (metal part) 24C bracket (metal part) 24D gear part (metal part) 24E Ring (metal part) 24F Tape (metal part) 240 Form-fitting contour 241 loop 242 Gearing 243 Profiling 25 stiffening rib 26 Mounting point 27 frames 270 Vertical profile 271 Cross-section 28A-28C Screw Dome 3 hybrid yarn 30 polymer fiber 31 Reinforcing fiber 4 Consolidation tool 40,41 tool halves 42 hose 43 Heating D Swivel axis F fibers G Fibrous structures H Liability mediator K adhesive L Longitudinal axis M1, M2, M3 fiber braid (braided sleeving) U circumferential direction V Stiffening direction 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 102006012699 A1

[0004] DE 102010051180 A1

[0005] DE 202014004095 U1

[0006] DE 102008055103 A1

[0007]

Claims

[1] Method for manufacturing a structural component (2), characterized by : - Arranging a fiber structure (G) and at least one metal part (24A-24F) together in a consolidation tool (4) and - Consolidation of the fiber structure (G) by applying pressure and heat to the fiber structure (G) and the at least one metal part (24A-24F) in the consolidation tool (4) to form a fiber composite part (21) firmly connected to the at least one metal part (24A-24F) and thus forming the structural component (2). [2] Method according to claim 1, characterized by that at least one metal part (24A-24F) is or will be coated with an adhesive (K). [3] Method according to claim 1 or 2, characterized by that at least one metal part (24A-24F) is or will be provided with an adhesion promoter (H). [4] Method according to claim 3, characterized by, that the fiber structure (G) and the metal part (24A-24F) are arranged in the consolidation tool (4) such that a side of the metal part (24A-24F) provided with the adhesion promoter (H) is in contact with the fiber structure (G) or is brought into contact with it during the consolidation step. [5] Method according to any one of the preceding claims, characterized by , that the fiber structure (G) consists of or comprises hybrid yarn (3) before the consolidation step. [6] Method according to any one of the preceding claims, characterized by , that several separate fiber braids (M1, M2, M3), each formed in the form of a braided tube, are arranged one above the other to form the fiber structure (G). [7] Method according to any one of the preceding claims, characterized by : - Injection molding of injection molding material onto the structural component (2) to form at least one injection-molded structure (25), wherein the at least one injection-molded structure (25) partially covers the fiber composite part (21) and partially covers the at least one metal part (24A, 24C) on a surface facing away from the fiber composite part (21). [8] Method according to any one of the preceding claims, characterized by : - Attaching another component (270, 130, 28A) to at least one metal part (24A, 24B). [9] Method for manufacturing a backrest for a vehicle seat, characterized by that the backrest is manufactured with at least one structural element (2) according to one of the preceding claims. [10] Structural element (2) comprising a fiber composite part (21) and at least one metal part (24A-24F) which are held together by a material bond and / or an adhesive bond, characterized by , that the fiber composite part (21) has at least partially the shape of a hollow profile. [11] Structural element (2) according to claim 10, characterized by , that at least one metal part (24A, 24C) protrudes with a section from the fiber composite part to provide an interface to another component. [12] Structural element (2) according to claim 10 or 11, characterized by , that at least one metal part (24A, 24E, 24F) is in the form of a sheet. [13] Structural element (2) according to claim 10, 11 or 12, characterized by, that at least one metal part (24A) or another metal part held on the fiber composite part (21) by a material-bonded connection and / or an adhesive connection is profiled. [14] Structural element (2) according to any one of claims 10 to 13, characterized by , that at least one metal part (24C) or another metal part held by a material-bonded connection and / or an adhesive connection on the fiber composite part (21) is designed in the form of a bracket for the detachable mounting of a child seat. [15] Structural element (2) according to any one of claims 10 to 14, characterized by , that at least one metal part (24B) or another metal part held by a material-bonded connection and / or an adhesive connection on the fiber composite part (21) forms a fitting part of a fitting arrangement or firmly connects the fiber composite part (21) with a fitting part (130) of a fitting arrangement (13). [16] Structural element (2) according to any one of claims 10 to 15, characterized by , that the structural element (2) is firmly connected to a frame (27) by at least one metal part (24A). [17] Structural element (2), in particular according to one of claims 10 to 16, comprising a fiber composite part (21) and at least one metal part (24A-24F) which are held together by an adhesive bond comprising an adhesion promoter (H). [18] Vehicle seat frame (1), characterized by the structural element (2) according to one of claims 10 to 17. [19] Vehicle seat frame (1) according to claim 18, characterized by , that the fiber composite part (21) of the structural element (2) forms a transverse tube and / or a vertical tube of the vehicle seat frame (1).

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