Side impact protection, motor vehicle door with such side impact protection and method for manufacturing such side impact protection

Abstract

Side impact protection (1) with an extruded profile (3) and a tubular profile (5), wherein - the pipe profile (5) comprises a fiber composite material, wherein in particular a reinforcing fiber is selected from a group consisting of aramid fibers, an aramid fabric, an aramid braid, carbon fibers, glass fibers, polyester fibers and a mixture of a plurality of textile fibers, wherein in particular a plastic matrix comprises a thermosetting plastic, wherein - the extruded profile (3) extends along a first axial direction (7.1), wherein - the pipe profile (5) extends along a second axial direction (7.2), wherein - the first axial direction (7.1) and the second axial direction (7.2) are aligned at least nearly parallel to each other, wherein - the extruded profile (3) has an extruded profile length (9.1) measured along the first axial direction (7.1), wherein - the pipe profile (5) has a pipe profile length (9.2) measured along the second axial direction (7.2), wherein - the extruded profile (3) has an extruded profile cross-section orthogonal to the first axial direction (7.1), wherein the extruded profile cross-section has an extruded profile incircle with an extruded profile diameter (13.1), wherein - the pipe profile (5) has a pipe profile cross-section with a pipe profile diameter (13.2) orthogonal to the second axial direction (7.2), wherein - the pipe profile diameter (13.2) is at most as large as the extruded profile diameter (13.1), wherein - the extruded profile (3) surrounds the pipe profile (5), wherein - the pipe profile (5) is arranged completely within the extruded profile (3), wherein - the extruded profile length (9.1) is greater than the pipe profile length (9.2), wherein - a first end (21.1) of the extruded profile (3) is designed such that a displacement of the tube profile (5) relative to the extruded profile (3) in the first axial direction (7.1) in the direction of the first end (21.1) is limited, wherein - a second end (21.2) of the extruded profile (3) opposite the first end (21.1) is designed such that a displacement of the tube profile (5) relative to the extruded profile (3) in the first axial direction (7.1) in the direction of the second end (21.2) is limited, characterized by the fact that - the extruded profile (3) has a cover element at the first end (21.1) and / or at the second end (21.2) which is designed to at least partially cover the extruded profile (3), wherein - the lid element is designed as a crimp tab (23).

Description

[0001] The invention relates to a side impact protection system, a motor vehicle door with such side impact protection, and a method for manufacturing such side impact protection.

[0002] It is known that an electrically powered vehicle is usually heavier than a comparable vehicle with an internal combustion engine due to the necessary batteries. Therefore, it is advantageous to construct the body of an electrically powered vehicle using lightweight materials. Furthermore, in lightweight construction, the body incorporates aluminum at least partially. Side impact protection made of aluminum is disadvantageous because aluminum lacks sufficient mechanical stability, particularly with regard to elongation. Side impact protection made of steel is disadvantageous because steel's material density is too high, making the side impact protection too heavy.

[0003] Furthermore, German patent application DE 10 2008 012 853 A1 discloses a motor vehicle seat with a support element arranged laterally on the seat for transmitting forces between a side structure of the motor vehicle and the seat in the event of a side impact. The support element serves to adjust the properties of the seat. A disadvantage of this seat is that it does not prevent an object from penetrating the vehicle.

[0004] German patent application DE 199 14 344 A1 discloses a side impact beam for a motor vehicle. The side impact beam has at least two load-bearing elements connected to each other by a fiber-reinforced composite (FRC) tensile structure, wherein the tensile structure comprises endless, highly elongated fibers embedded in a matrix. A disadvantage of this design is that the side impact beam cannot be adapted modularly to different requirements.

[0005] German patent application DE 10 2021 006 162 A1 further discloses a motor vehicle door with variable side-crash properties. The door comprises a door frame which has a cavity below a window opening, in which a reinforcing element extends approximately in the longitudinal direction of the vehicle. A disadvantage of this door is that additional parts, particularly reinforcing elements, are installed that are not fixed within the cavity and thus generate disruptive noise. Furthermore, contact corrosion and / or crevice corrosion may occur. Another disadvantage is the additional assembly effort required for the reinforcing elements.

[0006] DE 36 06 024 A1 discloses a vehicle door, particularly for passenger cars, comprising at least one impact profile made of a light metal alloy, which is fixed at both ends of the vehicle door and is provided with two profile walls arranged at a distance from each other. It is designed to exhibit, at low weight, a high degree of dimensional stability – especially torsional stiffness – with sufficient compensation capacity for the impact deformation energy, while also being easy to manufacture and handle. For this purpose, the profile walls, together with a pair of connecting transverse walls, enclose a profile chamber and project beyond the outer surfaces of the transverse walls, forming bead sections. Furthermore, a second axis of symmetry, running parallel to the profile walls and perpendicular to them, is associated with a third axis of symmetry running between the profile walls.

[0007] DE 10 2005 041 894 A1 discloses a support element, in particular in a motor vehicle, which has a hollow profile with a closed cross-section, wherein a reinforcing element is arranged in the hollow profile, wherein the reinforcing element is designed as a deformation element and the hollow profile has a square or corner-free shape in cross-section, wherein the reinforcing element at least partially rests in a form-fitting manner against each of the inner sides of the side walls forming the shape of the hollow profile.

[0008] DE40 26 459 A1 discloses a door reinforcement tube with high strength, toughness, and deformation energy as an impact beam for installation in the door of a motor vehicle, in particular a passenger car. To develop a door reinforcement tube that is lighter when using a cost-effective steel alloy and while meeting the required mechanical properties, it is proposed that the door reinforcement tube consist of a base tube with a reinforced section extending over a certain length in the middle region of the base tube.

[0009] DE 10 2015 218 406 A1 proposes a side door for a vehicle, in particular a motor vehicle, with at least one tubular impact protection element. This impact protection element extends in the longitudinal direction (x-direction) of the vehicle and is subjected to axial loading and buckling in the event of a frontal crash. Advantageously, the at least one tubular impact protection element has at least one tubular stiffening element arranged within it, primarily stiffening the potential buckling area of ​​the impact protection element. This stiffening element is arranged at least sectionally at a distance from the inner surface of the impact protection element and is fixed within the impact protection element by means of an inflating structural foam.

[0010] The invention is therefore based on the objective of creating a side impact protection system, a motor vehicle door with such side impact protection, and a method for manufacturing such side impact protection, whereby the aforementioned disadvantages are at least partially eliminated, preferably avoided.

[0011] The problem is solved by providing the present technical teaching, in particular the teaching of the independent claims as well as the embodiments disclosed in the dependent claims and the description.

[0012] The problem is solved, in particular, by creating a side impact protection system with an extruded profile and a tubular profile. The extruded profile extends along a first axial direction. The tubular profile extends along a second axial direction and comprises a fiber-reinforced composite material. The first and second axial directions are aligned at least nearly parallel to each other. Furthermore, the extruded profile has a length measured along the first axial direction, and the tubular profile has a length measured along the second axial direction. The extruded profile has a cross-section orthogonal to the first axial direction, wherein the cross-section includes an incircle with a diameter of [diameter value missing in original text].The tubular profile has a cross-section perpendicular to the second axial direction with a tubular profile diameter that is at most as large as the extruded profile diameter. The extruded profile surrounds the tubular profile, which is completely enclosed within the extruded profile. Advantageously, the tubular profile, particularly due to the fiber-reinforced composite material, increases the stiffness and stability of the extruded profile and thus also the side impact protection. Furthermore, contact corrosion between the extruded profile and the tubular profile is advantageously prevented by the fiber-reinforced composite material.

[0013] In particular, the extruded profile has a continuous recess extending along the first axial direction. Thus, the extruded profile is designed primarily as an elongated hollow body.

[0014] In the context of the present technical teaching, the extruded profile cross-section is a cross-section of the continuous recess of the extruded profile extending along the first axial direction.

[0015] In particular, the extruded profile cross-section is square.

[0016] In the context of the present technical teaching, the pipe profile diameter is an outer diameter of the pipe profile.

[0017] In particular, the fiber-reinforced composite material comprises at least one reinforcing fiber and at least one polymer matrix. Specifically, the at least one reinforcing fiber is selected from a group consisting of aramid fibers, an aramid woven fabric, an aramid braid, carbon fibers, glass fibers, polyester fibers, and a mixture of multiple textile fibers. Additionally, the at least one polymer matrix comprises a thermosetting polymer.

[0018] In particular, the aramid fabric has a plurality of aramid fibers, the plurality of which are interwoven to form a particularly flat fabric.

[0019] In particular, the aramid mesh has a plurality of aramid fibers, the plurality of which are interwoven to form a particularly tubular three-dimensional mesh.

[0020] In one embodiment, the tube profile is configured such that the reinforcing fibers, in particular the majority of aramid fibers, are arranged almost parallel, preferably parallel, to the second axial direction. Alternatively or additionally, the tube profile is configured such that the reinforcing fibers, in particular the majority of aramid fibers, are arranged along a circumferential direction of the tube profile. Alternatively or additionally, the tube profile comprises an aramid fabric and / or an aramid braid. Preferably, the tube profile comprises at least two reinforcing fibers selected from a group consisting of aramid fibers oriented along the second axial direction, aramid fibers oriented along the circumferential direction, an aramid fabric, and an aramid braid.

[0021] In particular, the first axial direction and the second axial direction are aligned parallel to each other.

[0022] In particular, the extruded profile length is at most 10 cm, preferably at most 5 cm, preferably at most 2 cm, preferably at most 1 cm, greater than the pipe profile length. Alternatively, the pipe profile length is at least 70%, preferably at least 80%, preferably at least 90%, preferably at least 95% of the extruded profile length.

[0023] In particular, the tube profile diameter is at most 5 mm, preferably at most 2 mm, at most 1 mm, at most 0.5 mm, smaller than the extruded profile diameter. Alternatively, the tube profile diameter is at least 80%, preferably at least 90%, preferably at least 95%, preferably at least 97%, preferably at least 99% of the extruded profile diameter.

[0024] In particular, the extruded profile and the tube profile form a clearance fit.

[0025] In one embodiment, the side impact protection has a plurality of extruded profiles and a plurality of tubular profiles, wherein each extruded profile of the plurality of extruded profiles surrounds exactly one tubular profile of the plurality of tubular profiles, with the respective tubular profile being arranged completely within the respective extruded profile.

[0026] In an alternative embodiment, the side impact protection system comprises an extruded profile and a plurality of tubular profiles. In particular, the extruded profile has a plurality of recesses extending along the first axial direction, specifically chambers extending along the first axial direction, wherein the recesses, specifically the chambers, have a square cross-section when viewed orthogonally to the first axial direction. A tubular profile from the plurality of tubular profiles is arranged in at least two of the recesses, specifically in at least two of the chambers.

[0027] This makes it advantageously possible to adapt the side impact protection modularly, in particular by means of different geometric and material designs, to different load requirements and / or to different legal requirements, especially in different markets.

[0028] According to a further development of the invention, the extruded profile and the tube profile are designed such that an inner surface of the extruded profile and an outer surface of the tube profile contact each other along at least four lines extending along the first axial direction and / or the second axial direction. Advantageously, this results in a positive-locking arrangement of the extruded profile and the tube profile.

[0029] According to a further development of the invention, the extruded profile is made of aluminum. Advantageously, such an extruded profile is lighter than a steel component, resulting in a lightweight side impact protection system overall. Furthermore, it is advantageously possible to reduce or eliminate thermal stresses between the side impact protection and an aluminum vehicle door. In addition, it is advantageously possible to achieve corrosion protection without the need for additional wax, seam sealant, or coatings.

[0030] In particular, the extruded profile comprises an aluminum-magnesium-silicon alloy, especially an aluminum alloy of the 6xxx group. Alternatively, the extruded profile consists of an aluminum-magnesium-silicon alloy, especially an aluminum alloy of the 6xxx group.

[0031] According to a further development of the invention, the inner surface of the extruded profile and the outer surface of the pipe profile are bonded together using a particularly heat-foaming plastic. Advantageously, the plastic can be used to close any gap and / or play between the extruded profile and the pipe profile. Furthermore, it is advantageously possible to permanently fix the pipe profile within the extruded profile. In addition, crevice corrosion of the extruded profile, particularly in wet areas, is advantageously prevented.

[0032] In particular, the hot-foaming plastic comprises at least one thermoplastic, especially ethylene vinyl acetate. Additionally, the hot-foaming plastic comprises, in particular, glass fibers and / or at least one dye. Alternatively or additionally, the hot-foaming plastic comprises, in particular, at least one compound that decomposes upon heating and transitions into a gaseous state.

[0033] According to a further development of the invention, the extruded profile length is greater than the pipe profile length. A first end of the extruded profile is designed such that displacement of the pipe profile relative to the extruded profile in the first axial direction towards the first end is limited. Additionally, a second end of the extruded profile, opposite the first end, is designed such that displacement of the pipe profile relative to the extruded profile in the first axial direction towards the second end is limited. Advantageously, this makes it possible to fix the pipe profile within the extruded profile with respect to the first axial direction.

[0034] In particular, the first end and / or the second end has a narrowing and / or a deformation such that the incircle diameter of the first end and / or the second end is smaller than the pipe profile diameter.

[0035] According to the invention, the extruded profile has a cover element at the first end and / or at the second end, which is designed to at least partially cover the extruded profile. In particular, the cover element is designed as a crimp tab.

[0036] The problem is also solved by creating a motor vehicle door with at least one side impact protection device according to the invention or at least one side impact protection device according to one or more of the embodiments described above. In connection with the motor vehicle door, the advantages that have already been explained in connection with the side impact protection device become particularly apparent.

[0037] The problem is also solved by providing a method for manufacturing a side impact protection device according to the invention or a side impact protection device according to one or more of the embodiments described above. In this method, the extruded profile extending along a first axial direction and the tubular profile extending along a second axial direction are arranged such that the first axial direction and the second axial direction are aligned at least nearly parallel to each other and that the extruded profile surrounds the tubular profile. The advantages of this method are particularly evident in the context of the side impact protection device already described. Furthermore, such a side impact protection device can advantageously be manufactured cost-effectively.

[0038] In particular, the first axial direction and the second axial direction are aligned parallel to each other.

[0039] According to a further development of the invention, at least one thermosetting plastic is inserted between the extruded profile and the pipe profile. The thermosetting plastic is then foamed. Advantageously, this closes any gap and / or play between the extruded profile and the pipe profile. Furthermore, it advantageously fixes the pipe profile permanently within the extruded profile.

[0040] In particular, the side impact protection, especially the heat-foaming plastic, is subjected to heat to cause the plastic to foam and thus bond the extruded profile and the tube profile together. Specifically, the side impact protection is treated for a predetermined duration at a predetermined temperature or with a predetermined temperature profile.

[0041] According to a further development of the invention, the extruded profile and the tube profile are additionally arranged such that a first end of the extruded profile and a second end of the extruded profile, opposite the first end, project beyond the tube profile in the first axial direction. The first end of the extruded profile is machined such that displacement of the tube profile relative to the extruded profile in the first axial direction towards the first end is limited. Furthermore, the second end of the extruded profile is machined such that displacement of the tube profile relative to the extruded profile in the first axial direction towards the second end is limited.

[0042] According to the invention, the first end of the extruded profile is crimped. Alternatively or additionally, the second end of the extruded profile is crimped.

[0043] The invention will be explained in more detail below with reference to the drawing.

[0044] This shows: Fig. 1 a schematic representation of a first embodiment of a side impact protection system, Fig. 2 a schematic representation of a second embodiment of the side impact protection, and Fig. 3 a flowchart of an embodiment of a method for manufacturing side impact protection.

[0045] Fig. Figure 1 shows a schematic representation of a first embodiment of a side impact protection device 1 in two sectional views. The side impact protection device 1 comprises an extruded profile 3 and a tubular profile 5. The extruded profile 3 extends along a first axial direction 7.1. The tubular profile 5 extends along a second axial direction 7.2 and comprises a fiber-reinforced composite material. The extruded profile 3 surrounds the tubular profile 5, with the tubular profile 5 being arranged completely within the extruded profile 3.

[0046] Fig. Figure 1 a) shows a sectional view of the side impact protection 1, wherein the section plane is aligned almost parallel, preferably parallel, to the first axial direction 7.1 and / or the second axial direction 7.2. The first axial direction 7.1 and the second axial direction 7.2 are aligned at least almost parallel, preferably parallel, to each other. Furthermore, the extruded profile 3 has an extruded profile length 9.1 measured along the first axial direction 7.1, and the tubular profile 5 has a tubular profile length 9.2 measured along the second axial direction 7.2.

[0047] The dotted lines in Fig. 1 a) represent cut edges and / or visible edges of the extruded profile 3 and the tube profile 5.

[0048] Fig. 1 b) shows a sectional view of the side impact protection 1 along the dashed line 11 from Fig. 1 a), wherein the cutting plane is oriented orthogonally to the first axial direction 7.1 and / or the second axial direction 7.2. The extruded profile 3 has an extruded profile cross-section orthogonal to the first axial direction 7.1, wherein the extruded profile cross-section has an incircle with an extruded profile diameter 13.1. The tube profile 5 has a tube profile cross-section orthogonal to the second axial direction 7.2 with a tube profile diameter 13.2, wherein the tube profile diameter 13.2 is at most as large as the extruded profile diameter 13.1. Preferably, the tube profile diameter 13.2 and the extruded profile diameter 13.1 are the same.

[0049] Preferably, the extruded profile 3 and the tube profile 5 are designed such that an inner surface 15.1 of the extruded profile 3 and an outer surface 15.2 of the tube profile 5 touch at least four lines 17 extending along the first axial direction 7.1 and / or the second axial direction 7.2.

[0050] Preferably, the extruded profile comprises 3 aluminum. Alternatively or additionally, the extruded profile comprises, in particular, an aluminum-magnesium-silicon alloy, especially an aluminum alloy of the 6xxx group. Alternatively, the extruded profile consists of an aluminum-magnesium-silicon alloy, especially an aluminum alloy of the 6xxx group.

[0051] Preferably, the inner surface 15.1 of the extruded profile 3 and the outer surface 15.2 of the tube profile 5 are bonded together by means of a particularly heat-foaming plastic 19. The heat-foaming plastic 19 is in Fig. 1 b) represented as a hatched area.

[0052] Preferably, the extruded profile length 9.1 is greater than the tube profile length 9.2. Furthermore, preferably a first end 21.1 of the extruded profile 3 is configured such that a displacement of the tube profile 5 relative to the extruded profile 3 in the first axial direction 7.1 in the direction of the first end 21.1 is limited. Additionally, preferably a second end 21.2 of the extruded profile 3 opposite the first end 21.1 is configured such that a displacement of the tube profile 5 relative to the extruded profile 3 in the first axial direction 7.1 in the direction of the second end 21.2 is limited.

[0053] In particular, the first end 21.1 and / or the second end 21.2 each have a crimp tab 23.

[0054] Fig. Figure 2 shows a schematic representation of a second embodiment of the side impact protection 1.

[0055] Identical and functionally equivalent elements are provided with the same reference symbols in all figures, so reference is made to the preceding description.

[0056] The side impact protection 1 comprises an extruded profile 3 and a plurality of tubular profiles 5, in particular a first tubular profile 5.1 and a second tubular profile 5.2. The extruded profile 3, in particular, has a plurality of recesses 25. Furthermore, the first tubular profile 5.1 is arranged in a first recess 25.1. Additionally, the second tubular profile 5.2 is arranged in a second recess 25.2.

[0057] Fig. Figure 3 shows a flowchart of an embodiment of a method for manufacturing side impact protection 1.

[0058] In a first step S1, the extruded profile 3 extending along the first axial direction 7.1 and the tubular profile 5 extending along a second axial direction 7.2 are arranged such that the first axial direction 7.1 and the second axial direction 7.2 are aligned at least nearly parallel to each other and that the extruded profile 3 surrounds the tubular profile 5. The side impact protection 1 is thereby maintained.

[0059] In an optional second step S2, at least one hot-foaming plastic 19 is inserted between the extruded profile 3 and the pipe profile 5. Subsequently, in a third step S3, the hot-foaming plastic 19 is foamed.

[0060] In an optional preparatory step S0, the first end 21.1 of the extruded profile 3 is processed such that displacement of the tube profile 5 relative to the extruded profile 3 in the first axial direction 7.1 in the direction of the first end 21.1 is limited. In particular, the first end 21.1 of the extruded profile 3 is crimped.

[0061] In an optional fourth step S4, the second end 21.2 of the extruded profile 3 is processed such that displacement of the tube profile 5 relative to the extruded profile 3 in the first axial direction 7.1 towards the second end 21.2 is limited. In particular, the second end 21.2 of the extruded profile 3 is crimped.

[0062] Specifically, the fourth step S4 is performed after the third step S3. Alternatively, the fourth step S4 is performed after the second step S2 and before the third step S3.

Claims

[1] Side impact protection (1) with an extruded profile (3) and a tubular profile (5), wherein - the pipe profile (5) comprises a fiber composite material, wherein in particular a reinforcing fiber is selected from a group consisting of aramid fibers, an aramid fabric, an aramid braid, carbon fibers, glass fibers, polyester fibers and a mixture of a plurality of textile fibers, wherein in particular a plastic matrix comprises a thermosetting plastic, wherein - the extruded profile (3) extends along a first axial direction (7.1), wherein - the pipe profile (5) extends along a second axial direction (7.2), wherein - the first axial direction (7.1) and the second axial direction (7.2) are aligned at least nearly parallel to each other, wherein - the extruded profile (3) has an extruded profile length (9.1) measured along the first axial direction (7.1), wherein - the pipe profile (5) has a pipe profile length (9.2) measured along the second axial direction (7.2), wherein - the extruded profile (3) has an extruded profile cross-section orthogonal to the first axial direction (7.1), wherein the extruded profile cross-section has an extruded profile incircle with an extruded profile diameter (13.1), wherein - the pipe profile (5) has a pipe profile cross-section with a pipe profile diameter (13.2) orthogonal to the second axial direction (7.2), wherein - the pipe profile diameter (13.2) is at most as large as the extruded profile diameter (13.1), wherein - the extruded profile (3) surrounds the pipe profile (5), wherein - the pipe profile (5) is arranged completely within the extruded profile (3), wherein - the extruded profile length (9.1) is greater than the pipe profile length (9.2), wherein - a first end (21.1) of the extruded profile (3) is designed such that a displacement of the tube profile (5) relative to the extruded profile (3) in the first axial direction (7.1) in the direction of the first end (21.1) is limited, wherein - a second end (21.2) of the extruded profile (3) opposite the first end (21.1) is designed such that a displacement of the tube profile (5) relative to the extruded profile (3) in the first axial direction (7.1) in the direction of the second end (21.2) is limited, characterized by , that - the extruded profile (3) has a cover element at the first end (21.1) and / or at the second end (21.2) which is designed to at least partially cover the extruded profile (3), wherein - the lid element is designed as a crimp tab (23). [2] Side impact protection (1) according to claim 1, wherein the extruded profile (3) and the tube profile (5) are designed such that an inner surface (15.1) of the extruded profile (3) and an outer surface (15.2) of the tube profile (5) touch at least four lines (17) extending along the first axial direction (7.1) and / or the second axial direction (7.2). [3] Side impact protection (1) according to one of the preceding claims, wherein the extruded profile (3) comprises aluminium. [4] Side impact protection (1) according to one of the preceding claims, wherein the inner surface (15.1) of the extruded profile (3) and the outer surface (15.2) of the tube profile (5) are bonded together by means of a particularly heat-foaming plastic (19). [5] Motor vehicle door with at least one side impact protection (1) according to one of the preceding claims. [6] Method for manufacturing a side impact protection device (1) according to any one of claims 1 to 4, wherein the extruded profile (3) extending along a first axial direction (7.1) and the tubular profile (5) extending along a second axial direction (7.2) are arranged such that the first axial direction (7.1) and the second axial direction (7.2) are aligned at least nearly parallel to each other and that the extruded profile (3) surrounds the tubular profile (5), wherein - the extruded profile (3) and the tube profile (5) are additionally arranged such that a first end (21.1) of the extruded profile (3) and a second end (21.2) of the extruded profile (3) opposite the first end (21.1) project beyond the tube profile (5) in the first axial direction (7.1), wherein - the first end (21.1) of the extruded profile (3) is processed in such a way that a displacement of the tube profile (5) relative to the extruded profile (3) in the first axial direction (7.1) in the direction of the first end (21.1) is limited, wherein - the second end (21.2) of the extruded profile (3) is processed in such a way that a displacement of the tube profile (5) relative to the extruded profile (3) in the first axial direction (7.1) in the direction of the second end (21.2) is limited, characterized by , that - the first end (21.1) and / or the second end (21.2) of the extruded profile (3) are crimped. [7] Method according to claim 6, wherein a hot-foaming plastic (19) is inserted between the extruded profile (3) and the tube profile (5), wherein the hot-foaming plastic (19) is subsequently foamed.

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