Structural element, structural component, transport device, road vehicle and method for manufacturing a structural element

Abstract

Supporting structural element, in particular for a structural component, wherein the structural component may preferably be a support, e.g. a crossbeam, of a transport device, wherein the transport device may e.g. be a vehicle, wherein the supporting structural element contains a plastic material, consists of a plastic material and / or is made of a plastic material, wherein the plastic material comprises a foamed section and a solid section.

Description

[0001] The present invention relates to a supporting structure element, a structural component, a transport device, a road vehicle and methods for producing a supporting structure element.

[0002] Particularly, but not only, in connection with increasing electromobility, there is a need for particularly lightweight, yet mechanically highly resilient plastic components, especially for supports, e.g., cross members.

[0003] It became apparent that conventional plastic components often do not meet the increasing demands on weight and mechanical strength at the same time.

[0004] To meet the increasing demands on mechanical strength, reinforcement elements can be integrated or higher-strength plastics can be used. However, this requires significantly more effort in the production of the plastic components. Furthermore, plastic components reinforced in this way often have a significantly higher mass than unreinforced plastic components.

[0005] The present invention is based on the object of providing an improved structural component, e.g. in the form of a beam or a cross member, an improved component therefor and a transport device obtainable using the structural component with particularly low manufacturing costs.

[0006] The object is achieved according to the invention by the supporting structure element according to the relevant independent claim.

[0007] The supporting structure element can, in particular, be a supporting structure element for a structural component. The structural component can preferably be a beam. The beam can, for example, be a cross member. The structural component can, in particular, be a beam, e.g., a cross member, of a transport device. The transport device can, for example, be a vehicle.

[0008] The cross member can be aligned or installed in the transport device, e.g., in the vehicle, particularly orthogonally to the vehicle's longitudinal axis and / or the direction of travel. This can mean, in particular, that a straight line extending from a first end zone to a second end zone of the supporting structure element forms an angle of 65° to 90°, preferably 75° to 90°, e.g., 80° to 90°, to the vehicle's longitudinal axis and / or the direction of travel when the cross member is installed in the transport device, e.g., in the vehicle.

[0009] The term “in particular” is used in this description and the appended claims to describe optional features.

[0010] The supporting structure element may contain a plastic material, consist of a plastic material and / or be made of a plastic material.

[0011] The supporting structure element may contain a plastic material. The supporting structure element may consist of a plastic material. The supporting structure element may be made of a plastic material.

[0012] The plastic material contains in particular a polymer or a mixture of different polymers.

[0013] Preferably, the plastic material may contain one or more additives.

[0014] Additives include, in particular, reinforcing agents, fillers, flame retardants, colorants, heat stabilizers, light stabilizers, antioxidants, stabilizers, plasticizers, blowing agents, lubricants, antistatic agents and impact modifiers.

[0015] It can be particularly advantageous if the plastic material contains at least one propellant.

[0016] It can be particularly advantageous if the plastic material contains at least one reinforcing material.

[0017] The at least one reinforcing material may comprise fibers, e.g., glass fibers, carbon fibers, polymer fibers, or plant fibers.

[0018] The plastic material includes a foamed section and a compact section.

[0019] Preferably, the plastic material is foamed in the foamed section and less foamed in the compact section than in the foamed section or not foamed.

[0020] A degree of foaming and / or a foaming rate of the plastic material is preferably greater in the foamed section of the plastic material by a factor of at least 1.1, particularly preferably of at least 1.2, most preferably of at least 1.5, for example of at least 2, than in the compact section of the plastic material.

[0021] A foaming rate is understood here in particular as a degree of volume increase during foaming of the plastic material.

[0022] In the foamed section of the plastic material, a gas content, based on a total volume of the foamed section, is preferably at least 10 vol.%, particularly preferably at least 25 vol.%, for example at least 50 vol.%.

[0023] In the compact section of the plastic material, a gas content, based on a total volume of the compact section, is preferably at most 10 vol.%, particularly preferably at most 5 vol.%, for example at most 3 vol.%.

[0024] The density of the plastic material in the foamed section is preferably lower by a factor of at least 1.2, more preferably at least 2, for example at least 2.5, than in the compact section of the plastic material. This may mean, in particular, that the density of the plastic material in the foamed section must be multiplied by at least this factor to calculate the density of the plastic material in the compact section.

[0025] It can be particularly advantageous if the plastic material is injection-moldable and / or the supporting structure element is manufactured from the plastic material by injection molding.

[0026] The plastic material may be injection-moldable. Alternatively, or in addition to the possibility of the plastic material being injection-moldable, the supporting structure element may be manufactured from the plastic material by injection molding.

[0027] The supporting structure element may preferably be an injection-molded plastic part.

[0028] The support structure element is not limited with regard to its shape. In general, the support structure element can have a significantly greater extent in two mutually orthogonal directions than in a third direction orthogonal to the first and second directions.

[0029] The supporting structure element can, for example, be plate-shaped.

[0030] It may be advantageous if the supporting structure element has a significantly greater extent in one direction than in two directions that are orthogonal to each other and to the first direction.

[0031] The supporting structure element can, for example, be beam-shaped or rod-shaped, and can optionally be curved.

[0032] It may be advantageous if a maximum longitudinal dimension of the support structure element, measured in a longitudinal direction, is at least 250% of a maximum transverse dimension of the support structure element, measured orthogonally to the longitudinal direction. The maximum longitudinal dimension may preferably be at least 350%, e.g., at least 400%, of the maximum transverse dimension.

[0033] The greatest longitudinal extent of the supporting structure element can, in particular, correspond to the length of a section of a straight line extending through the two furthest apart points of the supporting structure element. This straight line can run in the direction of the longitudinal extent.

[0034] The maximum transverse dimension of the supporting structure element, measurable orthogonally to the longitudinal direction of extension, can be determined in a plane oriented orthogonally to the longitudinal direction of extension. To measure the maximum transverse dimension of the supporting structure element, the entire supporting structure element can be projected into this plane by orthogonal projection. The maximum transverse dimension of the supporting structure element can be a maximum transverse dimension measurable in this projection of the supporting structure element.

[0035] It can be advantageous if the supporting structure element has a recess.

[0036] It is preferred if the recess extends orthogonally to the longitudinal direction into the plastic material. The statement that the recess extends orthogonally to the longitudinal direction into the plastic material may, in particular, mean that the recess extends into the plastic material at an angle of 75 to 90°, in particular 80 to 90°, e.g., 85 to 90°, to the longitudinal direction.

[0037] Preferably, the recess may extend into the plastic material down to a bottom of the recess.

[0038] The recess can preferably be defined by the floor and wall elements.

[0039] The wall elements can have wall surfaces. Preferably, at least two wall surfaces of at least two wall elements can face each other. The facing wall surfaces can preferably run at least approximately parallel to each other.

[0040] If facing wall surfaces extend at least approximately parallel to each other, the two wall surfaces can preferably be inclined relative to each other by a maximum of 10°, particularly preferably by a maximum of 6°, e.g., by a maximum of 3°. For example, the wall surfaces extending at least approximately parallel to each other can be inclined relative to each other by 1° to 3°. In particular, they can be inclined relative to each other such that the distance between the facing wall surfaces is greater at a greater distance from the bottom of the recess than closer to the bottom of the recess.

[0041] The mutually facing wall surfaces can preferably run at least approximately parallel to each other in at least one section of the supporting structure element.

[0042] The foamed portion of the plastic material may be present in the bottom of the recess.

[0043] The foamed section can be separated from the remaining plastic material. To separate the foamed section, the plastic material can be cut. To separate the foamed section, the plastic material can be cut at the edges of the floor where the floor meets the wall elements. The cuts can be made in such a way that the resulting cut surfaces represent extensions of the wall surfaces.

[0044] Such separation of the foamed section is not desired in connection with the invention. Reference is made to this only for a more detailed description of the invention, e.g., the degree of foaming, the foaming rate, the density, and / or the gas content.

[0045] Preferably, the degree of foaming, the foaming rate, the density and the gas content can relate to the foamed section that can be separated or separated from the remaining plastic material.

[0046] It may be advantageous if the supporting structure element has at least one intermediate element. The intermediate element can be, for example, a partition wall element. The intermediate element can divide the recess into several recess sections.

[0047] It can be particularly advantageous if the supporting structure element has intermediate elements. These intermediate elements can be partition wall elements, for example. The intermediate elements can divide the recess into several recess sections.

[0048] It is preferred if the plastic material extends into at least one of the intermediate elements. It is particularly preferred if at least one of the intermediate elements also contains the plastic material, consists of the plastic material, and / or is manufactured from the plastic material.

[0049] At least one intermediate element, e.g. at least one partition wall element, can rise orthogonally to the longitudinal direction from the bottom of the recess.

[0050] The at least one intermediate element, e.g. the at least one partition wall element, can preferably rise out of the bottom of the recess at an angle of 60° to 90° to the bottom.

[0051] At least one intermediate element, e.g., at least one partition wall element, can preferably protrude from the bottom of the recess and be connected to at least one of the wall elements. Preferably, the at least one intermediate element, e.g., partition wall element, is connected to the two wall elements.

[0052] It may be particularly preferred if the foamed section, the compact section, the wall elements and at least one intermediate element are formed in one piece from the plastic material.

[0053] It can be particularly advantageous if the foamed section of the plastic material is located in the recess. The foamed section of the plastic material can, for example, be located at the bottom of the recess.

[0054] It is preferred if the foamed portion of the plastic material is present in at least one of the recessed portions. For example, the foamed portion of the plastic material can be present in at least one of the recessed portions at the bottom of the recess.

[0055] It may be advantageous if the foamed section is a first foamed section and the plastic material comprises a second foamed section.

[0056] It is preferred if the plastic material comprises further foamed sections in addition to the first foamed section and the second foamed section.

[0057] Preferably, the first foamed section and the second foamed section can be separated by an intermediate element, e.g., a partition wall element. The intermediate element separating the first foamed section and the second foamed section can be an intermediate element protruding from the bottom of the recess.

[0058] It may be advantageous if the first foamed section and the second foamed section form parts of a continuous foamed zone of the plastic material, which foamed zone extends continuously from one side of the intermediate element to the other side of the intermediate element and through the first and second foamed sections.

[0059] The continuous foamed zone may also extend through one or more additional foamed sections that may be present.

[0060] It may be advantageous if the foamed section of the plastic material is present in the recess, e.g. at the bottom of the recess.

[0061] It is preferred if the first foamed portion of the plastic material is present in at least a first of the recess portions, e.g. at the bottom of the recess in the at least one first of the recess portions, and the second foamed portion of the plastic material is present in at least a second of the recess portions, e.g. at the bottom of the recess in the at least one second of the recess portions.

[0062] It may be advantageous if the support structure element extends from a first end zone to a second end zone. It is preferred if the plastic material extends from the first end zone to the second end zone. It is particularly preferred if the end zones are connection zones at which the support structure element can be connected to other support structure elements.

[0063] Preferably, the end zones can be spaced apart along the longitudinal direction. The largest longitudinal dimension of the support structure element measurable in the longitudinal direction can be measured from the first end zone to the second end zone.

[0064] Depending on the shape of the supporting structure element, different shapes of the end zones are conceivable. For example, if the supporting structure element is a substantially plate-shaped supporting structure element, the end zones can be formed on opposite edges of the supporting structure element.

[0065] For example, if the supporting structure element is rod-shaped or beam-shaped, the end zones may be formed at the ends of the supporting structure element.

[0066] It may be advantageous if the supporting structure element does not extend straight from the first end zone to the second end zone.

[0067] A course of the supporting structure element from the first end zone to the second end zone can be described in particular with reference to a straight line connecting the two end zones.

[0068] It is preferred if the support structure element is deflected in at least one direction along the path from the first end zone to the second end zone relative to a straight line connecting the two end zones. Preferably, the support structure element can be deflected in at least one first direction and in at least one second direction along the path from the first end zone to the second end zone relative to this line.

[0069] It is preferred if the recess of the support structure element is deflected in at least one direction along the path from the first end zone to the second end zone relative to a straight line connecting the two end zones. Preferably, the recess of the support structure element can be deflected in at least one first direction and in at least one second direction along the path from the first end zone to the second end zone relative to this path.

[0070] It is preferred if the base of the depression is deflected in at least one direction along the path from the first end zone to the second end zone relative to a straight line connecting the two end zones. Preferably, the base of the depression can be deflected in at least one first direction and in at least one second direction along the path from the first end zone to the second end zone relative to this line.

[0071] The at least one first direction and the at least one second direction in which the support structure element, the recess of the support structure element or the bottom of the recess of the support structure element is deflected in the course from the first end zone to the second end zone with respect to this distance can preferably form an angle of at least 5° and at most 175°, particularly preferably an angle of at least 15° and at most 165°, very particularly preferably an angle of at least 40° and at most 140°, e.g. an angle of at least 45° and at most 135°.

[0072] It may be particularly advantageous if the support structure element does not extend straight from the first end zone to the second end zone and is deflected, for example, in at least one direction or in at least one first and at least one second direction, as described above with reference to the route.

[0073] Supporting structure elements shaped in this way can particularly advantageously determine the shape of structural components, e.g., cross members in vehicles, especially passenger cars. In modern vehicles, efficient use of available installation space is important. Particularly in the area of ​​the cross member, a path deflected in different directions from a driver-side end to a passenger-side end is often desired, since the vehicle is to be equipped on the driver side, in particular, with control devices, and on the passenger side, there is often a desire to provide devices to increase driving comfort, such as entertainment systems.

[0074] The installation space requirements of the various devices installed on both sides, the driver and passenger sides, vary. A supporting structure element that does not extend straight from the first end zone to the second end zone and is deflected, for example, in a first direction and a second direction relative to a straight line connecting the two end zones, can optimally accommodate the different installation space requirements. At the same time, the invention opens up the possibility of providing the foamed and compact sections in such a way that the rigidity can be specifically increased in areas subject to higher loads.

[0075] It may be advantageous if the depression and / or at least one depression section is surrounded by wall elements, wherein at least one section of the surfaces of the wall elements coincides with a lateral surface of a prism.

[0076] A prism is referred to herein solely for the purpose of defining the shape of the recess and / or at least one recess section. The prism can, in particular, be a body with two parallel-shifted polygons. The number of vertices of the parallel-shifted polygons is not limited. It can be, for example, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12, preferably 3 or 4.

[0077] The number of vertices can be infinite. For example, a circle or an oval can be considered a polygon with an infinite number of vertices. References to a prism here can mean a solid with two parallel polygons, where the number of vertices of the polygons can be arbitrarily large and the polygons can be, for example, circular or oval.

[0078] It may be preferred if the prism is a body with two parallel quadrilaterals, whereby the corners can optionally be rounded.

[0079] It can be particularly advantageous if a plurality of recessed sections are each surrounded by a plurality of wall elements, wherein at least one section of the respective surfaces of the wall elements surrounding a recessed section coincides with a respective lateral surface of a prism.

[0080] It can be particularly advantageous if the surfaces of wall elements coincide with the outer surface of a prism, since a foamed section of the plastic material can then be obtained under particularly controlled conditions. In particular, a volume expansion of an expansion zone of the plastic material can then be brought about in a particularly controlled manner by deliberately moving an expansion body, which has an expansion body section, within the recess. This is especially true if at least some of the surfaces of the expansion body section also coincide with the outer surface of the prism.

[0081] The object is achieved according to the invention by the structural component according to the relevant independent claim.

[0082] The structural component can, in particular, be a beam. The beam can, for example, be a cross member.

[0083] The structural component can, in particular, be a support for a transport device. The support can, for example, be a cross member for a transport device.

[0084] The transport device can, for example, be a vehicle.

[0085] The structural component comprises a supporting structure element according to the invention described herein and at least one connecting element and / or at least one reinforcing element.

[0086] The structural component may preferably comprise at least one connecting element and at least one reinforcing element.

[0087] The structural component may preferably comprise at least one connecting element or at least one reinforcing element.

[0088] The at least one connecting element comprised by the structural component can at the same time be at least one reinforcing element.

[0089] In the context of the invention, a connecting element is, in particular, an element that enables the structural component to be connected to another component of the transport device. The connecting element can preferably have an opening or recess into which a fastening element, e.g., a bolt or a screw, can be received. The connecting element can be, for example, a sleeve. The opening or recess of the connecting element can have a thread on an inner wall of the opening or recess.

[0090] The reinforcing element can reinforce the supporting structure element. For example, the reinforcing element can increase the rigidity of the supporting structure element, e.g., the flexural rigidity or torsional rigidity of the supporting structure element. The reinforcing element can, for example, be a flat or rod-shaped metal element.

[0091] Of course, the connecting element can also act as a reinforcing element. For example, the connecting element can enable a more secure connection between the structural component and the other component of the transport device. This is accompanied by a reinforcing effect.

[0092] It may be advantageous if the structural component comprises several connecting elements, e.g. at least two connecting elements.

[0093] It is preferred if the at least one connecting element and / or the at least one reinforcing element does not consist of the plastic material.

[0094] The at least one connecting element can preferably consist entirely or partially of a steel or an aluminum alloy.

[0095] Preferably, the at least one connecting element and / or the at least one reinforcing element can be arranged at one of the end zones, e.g. at one of the connecting zones.

[0096] It may be particularly advantageous if at least one first connecting element is arranged at the first end zone and at least one second connecting element is arranged at the second end zone.

[0097] The first connecting element and the second connecting element can preferably each be configured as described herein for the connecting element. The first end zone and the second end zone of the supporting structure element can then each function as a connecting zone.

[0098] The at least one connecting element and / or the at least one reinforcing element can preferably be connected to the plastic material in a material-locking and / or form-locking manner.

[0099] Preferably, the first connecting element can be connected to the plastic material in a material-locking and / or form-fitting manner at the first end zone and the second connecting element can be connected to the plastic material in a material-locking and / or form-fitting manner at the second end zone.

[0100] Preferably, the plastic material can extend around the connecting element. It may be particularly preferred if the plastic material extends around the first connecting element in the first end zone and the plastic material extends around the second connecting element in the second end zone.

[0101] If the plastic material extends around the connecting element, this can in particular mean that the plastic material extends around the connecting element in at least one plane that intersects the connecting element. Preferably, an opening or recess in the connecting element, which can preferably serve to accommodate a fastening element, is not covered by the plastic material.

[0102] Preferably, the connecting element can be embedded in the plastic material and / or surrounded by the plastic material.

[0103] The object is achieved according to the invention by the transport device according to the relevant independent claim.

[0104] The transport device can, for example, be a vehicle.

[0105] The vehicle can be a land vehicle, an aircraft, e.g. an airplane, or a watercraft, e.g. a ship.

[0106] Preferably, the vehicle can be a land vehicle. The land vehicle can be a road vehicle or a rail vehicle. Preferably, the vehicle is a road vehicle.

[0107] The transport device comprises a support structure element according to the invention described herein and / or a structural component according to the invention described herein. It may be particularly advantageous if the transport device comprises a structural component according to the invention described herein.

[0108] It may be advantageous if the structural component is a support, e.g. a cross member, of the transport device.

[0109] It may be advantageous if the transport device is a road vehicle and the structural component is a cross member arranged between an interior of the road vehicle and a space located in front of or behind the interior in the direction of travel. It may be advantageous if the structural component is a cross member arranged between an interior and an engine compartment of the road vehicle.

[0110] The interior can in particular form the passenger area of ​​the road vehicle.

[0111] The space located in front of the interior in the direction of travel can preferably contain at least one motor and / or at least one energy storage device.

[0112] The space behind the interior in the direction of travel can, for example, be a trunk.

[0113] The direction of travel is the direction in which the road vehicle moves when it moves forward.

[0114] The object is achieved according to the invention by the method for producing a supporting structure element according to the relevant independent claim.

[0115] The supporting structure element can preferably be a supporting structure element according to the invention as described herein. The method for producing a supporting structure element can preferably be a method for producing the supporting structure element according to the invention as described herein.

[0116] In the process for producing a supporting structure element, - a foamable plastic material is introduced into a cavity of a tool and - a foamed section of the plastic material is produced by a volume expansion of an expansion zone of the plastic material introduced into the cavity.

[0117] The cavity of the tool can, for example, be a cavity of an injection molding tool. The foamable plastic material can, for example, be introduced into the cavity of the injection molding tool.

[0118] The foamable plastic material can be physically or chemically foamable.

[0119] The foamable plastic material can, for example, be a foamable plastic melt. The foamable plastic material can be introduced into the cavity by injecting the foamable plastic melt.

[0120] It can be advantageous if a foamable plastic material melt is injected into a cavity of an injection molding tool.

[0121] Preferably, the foamable plastic material melt may contain one or more additives.

[0122] Additives include, in particular, reinforcing agents, fillers, flame retardants, colorants, heat stabilizers, light stabilizers, antioxidants, stabilizers, plasticizers, blowing agents, lubricants, antistatic agents and impact modifiers.

[0123] It can be particularly advantageous if the foamable plastic material melt contains at least one blowing agent.

[0124] It can be particularly advantageous if the foamable plastic material melt contains at least one reinforcing material.

[0125] The at least one reinforcing material may comprise fibers, e.g., glass fibers, carbon fibers, polymer fibers, or plant fibers.

[0126] The method for producing the supporting structure element may preferably be an injection molding method for producing the supporting structure element.

[0127] The tool has a volume expansion device which comprises an expansion body extending at least partially into the cavity of the tool.

[0128] The volume expansion of the expansion zone of the plastic material is caused or promoted by an expansion movement of the expansion body.

[0129] The method for producing the support structure element may preferably be a method for producing a support structure element according to the invention described herein, which has the recess.

[0130] The plastic material melt may extend around the expansion body or around an expansion element of the expansion body such that the expansion body defines a recess of the plastic material or the expansion element of the expansion body defines a recess portion of the plastic material.

[0131] The expansion movement can preferably be carried out such that the foamed portion of the plastic material is formed at the bottom of the recess or recess portion and the amplitude of the expansion movement can preferably be set such that the foamed portion of the plastic material does not completely fill the recess or recess portion.

[0132] It may be advantageous if the expansion body has an expansion element, and the plastic material melt extends around the expansion element such that the expansion element of the expansion body defines a recessed section of the plastic material. The expansion movement is preferably carried out such that the foamed section of the plastic material is formed at the bottom of the recessed section. The amplitude of the expansion movement is preferably set such that the foamed section of the plastic material does not completely fill the recessed section.

[0133] It can be particularly advantageous if the expansion body comprises several expansion elements. The expansion elements can be spaced apart from one another by intermediate recesses, which can, for example, be gap-shaped.

[0134] Preferably, the plastic material melt can extend around a plurality of spaced-apart expansion elements of the expansion body such that the expansion elements define a plurality of recessed sections of the plastic material. Preferably, the expansion movement is carried out such that a plurality of foamed sections of the plastic material are formed at the bottom of the respective recessed section. Preferably, the amplitude of the expansion movement is set such that the foamed sections of the plastic material do not completely fill the recessed sections or at least several of the recessed sections.

[0135] This procedure can be particularly advantageous since the intermediate recesses can be used to produce intermediate elements described herein, in particular partition wall elements described herein, and only a few expansion bodies, at best only one expansion body, are required in order to be able to produce many recessed sections, many intermediate elements and many foamed sections and many compact sections with minimal technical and time expenditure.

[0136] It may be particularly advantageous if the method for producing the support structure element is a method for producing a support structure element according to the invention described herein, which has a recess, wherein the recess and / or at least one recess section is surrounded by wall elements, wherein at least a section of the surfaces of the wall elements coincides with a lateral surface of a prism. Preferably, the expansion body can have an expansion body section, wherein at least a portion of the surfaces of the expansion body section coincides with a lateral surface of a prism.

[0137] The expansion body portion may be a portion of an expansion element of the expansion body.

[0138] When at least one part of the surfaces of the expansion body section coincides with the lateral surface of a prism, the expansion movement causes a displacement of the expansion body section, which occurs along the surfaces of wall elements formed from the plastic material that face the expansion body section.

[0139] The foamed section of the plastic material can then be produced by a particularly precisely controllable volume expansion of an expansion zone present in the bottom of the recess.

[0140] The surface of the expansion body section that coincides with the lateral surface of a prism can define the section of the wall element surfaces that coincides with a lateral surface of a prism. The base areas of the two prisms referred to to define the surfaces of the wall elements and the expansion body section can be identical.

[0141] The method for producing the supporting structure element can be a method for producing the structural component, the support, or the cross member. Preferably, at least one reinforcing element or at least one connecting element can be arranged in the cavity in at least one position, and the supporting structure element can be formed in contact with at least one surface of the at least one reinforcing element or the at least one connecting element.

[0142] The tool can preferably have two mold halves. It can be advantageous if the expansion body is guided on at least one of the mold halves in such a way that the expansion movement can be carried out, in particular with the desired amplitude.

[0143] Features described in connection with an object according to the invention can of course also represent features of another object described herein. Objects according to the invention include, in particular, the supporting structure element, the structural component, the carrier, the cross member, the transport device, the road vehicle, and the method for producing a supporting structure element.

[0144] Further preferred features and / or advantages of the invention are the subject of the following description and the drawings of exemplary embodiments.

[0145] The drawings show: Fig. 1: a structural component; Fig. 2: another view of the structural component from Fig. 1; Fig. 3: a perspective view of a section through the Fig. 1 and Fig. 2 structural component shown; Fig. 4: another view of the section from Fig. 3; Fig. 5: a perspective view of the structural component from Fig. 1 and Fig. 2; Fig. 6: another perspective view of the structural component from the Fig. 1, Fig. 2 and Fig. 5; Fig. 7: an enlarged view of the cut surface from Fig. 3 before a volume expansion of an expansion zone; Fig. 8: an enlarged view of the cut surface from Fig. 3; Fig. 9: a perspective view of an expansion body for producing the structural component according to Fig. 1 to 8; Fig. 10: a schematic sectional view with the expansion body arranged in the recess before the volume expansion; Fig. 11: a schematic representation with the expansion body arranged in the recess after volume expansion and Fig. 12: a schematic representation of expansion elements of the expansion body from Fig. 9.

[0146] Identical or functionally equivalent elements are provided with the same reference numerals in all figures.

[0147] The Fig. Figure 1 shows a structural component 100. The structural component 100 is a support 102. The support 102 is a cross member 104 for a transport device. The transport device can be, for example, a vehicle, in particular a road vehicle.

[0148] The structural component 100 comprises a supporting structure element 106.

[0149] The supporting structure element 106 contains a plastic material 108. The Fig. The supporting structure element 106 shown in Figure 1 consists of the plastic material 108. It is manufactured from the plastic material 108 according to a method according to the invention described herein.

[0150] The plastic material 108 is an injection-moldable plastic material 110. The supporting structure element 106 is made from the plastic material 108 by injection molding.

[0151] Also the Fig. 2 shows the structural component 100 from Fig. 1.

[0152] The supporting structure element 106 has a largest longitudinal extent 114 measurable in a longitudinal direction 112. This is in Fig. 1, in which the longitudinal direction is oriented transversely to the viewer’s line of sight.

[0153] The supporting structure element 106 has a maximum transverse dimension 116 that can be measured orthogonally to the longitudinal direction 112. The maximum transverse dimension 116 is in Fig. 2 shown.

[0154] The Fig. The view shown in Figure 2 is different from the one shown in Fig. 1 shown view rotated by 90°. In Fig. 2, the viewer's gaze runs along the longitudinal direction 112.

[0155] In the Fig. 1 and Fig. 2, the largest longitudinal extent 114 measurable in the longitudinal direction 112 is approximately 500% of the largest transverse extent 116 measurable orthogonally to the longitudinal direction 112.

[0156] The support structure element 106 extends from a first end zone 118 to a second end zone 120. The plastic material 108 extends from the first end zone 118 to the second end zone 120.

[0157] The support structure element 106 has a recess 122. The recess 122 extends orthogonally to the longitudinal extension direction 112 into the plastic material 108.

[0158] The supporting structure element 106 has many intermediate elements 124. In Fig. 1, only a small proportion of the intermediate elements 124 are provided with a reference symbol.

[0159] Fig. 3 shows the Fig. 1 half of the structural component 100 shown on the right. The Fig. The perspective view shown in Figure 3 clearly shows that at least some of the intermediate elements 124 are intermediate wall elements 126. The intermediate elements 124 divide the recess 122 into a plurality of recess sections 128. To improve clarity, only some of the intermediate elements, the intermediate wall elements, and the recess sections are provided with reference numerals.

[0160] The perspective view of the Fig. 3 shows that the recess 122 extends down to a bottom 130 of the recess 122 into the plastic material 108.

[0161] Fig. 3 also shows that the plastic material 108 includes a foamed portion 132 and a compact portion 134. The foamed portion 132 of the plastic material 108 is present at the bottom 130 of the recess 122.

[0162] The foamed section 132 is a first foamed section 136. The plastic material 108 comprises a second foamed section 138 and, in addition to the first foamed section 136 and the second foamed section 138, further foamed sections 140. For the sake of clarity, not all further foamed sections 140 are provided with reference numerals. The first foamed section 136 and the second foamed section 138 as well as the further foamed sections 140 form portions of a continuous foamed zone of the plastic material, which foamed zone extends continuously from one side of intermediate elements 124 to the other side of intermediate elements 124 and through the first foamed section 136, the second foamed section 138 and further foamed sections 140.

[0163] The first foamed portion 136 of the plastic material 108 is located in a first recessed portion 142. It is located at the bottom 130 of the recess 122 in the first recessed portion 142. The second foamed portion 138 is located in a second recessed portion 144. It is located at the bottom 130 of the recess 122 in the second recessed portion 144.

[0164] Fig. Figure 3 also shows that the structural component 100 includes a connecting element 146. The connecting element 146 is a reinforcing element 148. The connecting element 146 is a sleeve 150, for example, a metal sleeve 152.

[0165] The connecting element 146 is arranged at the first end zone 118.

[0166] The end zones 118 and 120 are connecting zones 154, 156. The first end zone 118 is a first connecting zone 154. The second end zone 120 is a second connecting zone 156.

[0167] The connecting element 146, which is in the Fig. 3, is arranged at the first connection zone 154. The connecting element 146 is connected to the plastic material 108 in a material-to-material and / or form-fitting manner. The plastic material 108 extends around the connecting element 146.

[0168] In Fig. 4 is also in Fig. 3 facing the viewer. The plastic material 108 has pores 158 in the foamed section 132, which are Fig. 4 are indicated schematically.

[0169] Fig. 5 and Fig. 6 show the structural component 100 in two different perspective views. In both views, a straight line connecting the two end zones 118 and 120 is shown. The supporting structure element 106 is oriented in a first direction 160 in the course from the first end zone 118 to the second end zone 120, relative to this straight line. Fig. 5, and in a second direction 162, which is Fig. 6 is indicated, deflected.

[0170] The Fig. 7 and Fig. 8 serve in particular to illustrate the method according to the invention described herein.

[0171] In the method according to the invention, a foamable plastic material is introduced, e.g. a foamable plastic material melt is injected, into a cavity of a tool not shown here, e.g. into a cavity of an injection molding tool. In this case, the Fig. 7 indicated initial shape 164 of the supporting structure element 106 can be formed.

[0172] The Fig. The initial shape 164 of the supporting structure element 106 shown in Figure 7 has an expansion zone 166. A foamed section, e.g., a first foamed section 136, of the plastic material 108 can be created by a volume expansion of the plastic material 108 introduced into the cavity in the expansion zone 166. Fig. 8 shows the state that occurs after the volume expansion of the expansion zone 166. In the Fig. In the foamed section 132 shown in Figure 8, the plastic material 108 has schematically indicated pores 158.

[0173] Such volume expansion can occur simultaneously in other expansion zones, thereby creating further foamed sections.

[0174] The plastic material 108 extends, as shown in particular in Fig. 8, up to the intermediate elements 124. The intermediate elements 124 in the supporting structure element 106 shown in the figures consist of the plastic material 108.

[0175] The tool, not shown in the figures, may be an injection molding tool having a volume expansion device. The volume expansion device may comprise an expansion body 168 extending at least partially into the cavity of the tool. Fig. 9 shows such an expansion body 168.

[0176] The volume expansion of the expansion zone 166 of the plastic material 108 can be achieved by an expansion movement of the expansion body 168. The expansion body optionally has a plurality of expansion elements 170. The expansion elements 170 are spaced apart from one another by intermediate recesses 172, which serve to form the intermediate elements 124, in particular the intermediate wall elements 126.

[0177] When carrying out the method according to the invention, the plastic material melt can extend around the expansion elements 170 such that the expansion elements 170 of the expansion body 168 define the recess 122 of the plastic material 108.

[0178] In the Fig. 10 and Fig. 11 an expansion movement of the expansion body 168 is indicated.

[0179] The expansion movement is carried out such that the foamed section 132 of the plastic material 108 is formed at the bottom 130 of the recess 122. The amplitude of the expansion movement is determined such that the foamed section 132 of the plastic material 108 does not completely fill the recess 122. Compact sections 134 of the plastic material 108 are already pre-formed in the initial mold 164. The plastic material 108 has compact sections 134 wherever no volume expansion of the plastic material 108 occurs.

[0180] Fig. 12 shows a section of an expansion body 168. The complete expansion body 168 is in Fig. 9. The Fig. The section shown in Figure 12 shows only the expansion elements 170 spaced apart from one another by the intermediate recesses 172. The expansion body 168 has expansion body sections 174 on the expansion elements 170. The expansion body sections 174 are shaped such that at least a part of the surfaces 176 of the respective expansion body sections 174 coincides with a lateral surface 178 of a prism 180. In the Fig. 12, the lateral surface 178 of a prism 180 is indicated. The prism edges 182 are dotted on one of the expansion elements.

[0181] When carrying out the method according to the invention with the Fig. 9 shown, based on the Fig. 12 expansion body 168 described in more detail are the Fig. 8 shown recessed sections 128 are formed.

[0182] The deepening section 128, which is in Fig. 8 are surrounded by wall elements 184. A portion of the surfaces of the wall elements 184 coincides with a lateral surface 178 of a prism 180. The prism edges 182 of the prism 180 are in the Fig. 8 indicated by dotted lines.

[0183] The prism 180 is shown incompletely, as it is Fig. 8 shown cutting surface is cut. List of reference symbols 100 structural components 102 carriers 104 cross members 106 supporting structure element 108 plastic material 110 injection-moldable plastic material 112 Longitudinal direction 114 Longitudinal extension 116 Transverse extension 118 first end zone 120 second end zone 122 Deepening 124 intermediate element 126 Partition wall element 128 Advanced Section 130 floor 132 foamed section 134 compact section 136 first foamed section 138 second foamed section 140 additional foamed sections 142 first in-depth section 144 second in-depth section 146 connecting element 148 Reinforcing element 150 sleeve 152 metal sleeve 154 first connection zone 156 second connection zone 158 pores 160 first direction 162 second direction 164 Initial form 166 Expansion Zone 168 expansion bodies 170 Expansion element 172 Intermediate recess 174 Expansion body section 176 Surface 178 lateral surface 180 Prism 182 Prism edge 184 Wall element

Claims

[1] Supporting structure element (106), in particular for a structural component (100), wherein the structural component (100) can preferably be a carrier (102), e.g. a cross member (104), of a transport device, wherein the transport device can be e.g. a vehicle, wherein the supporting structure element (106) contains a plastic material (108), consists of a plastic material (108) and / or is made of a plastic material (108), wherein the plastic material (108) comprises: - a foamed section (132) and - a compact section (134). [2] Supporting structure element (106) according to claim 1, characterized by that the plastic material (108) is injection-moldable and / or the supporting structure element (106) is produced from the plastic material (108) by injection molding. [3] Supporting structure element (106) according to claim 1 or 2, characterized bythat a greatest longitudinal extent (114) of the support structure element (106) measurable in a longitudinal extension direction (112) is at least 250%, e.g. at least 400%, of a greatest transverse extent (116) of the support structure element (106) measurable orthogonally to the longitudinal extension direction (112). [4] Supporting structure element (106) according to one of the preceding claims, characterized by , that the supporting structure element (106) has a recess (122), wherein it is preferred if the recess (122) extends orthogonally to the longitudinal direction (112) into the plastic material (108), wherein the recess (122) can preferably extend into the plastic material (108) down to a bottom (130) of the recess (122). [5] Supporting structure element (106) according to claim 4, characterized by , that the supporting structure element (106) has intermediate elements (124), e.g., intermediate wall elements (126), wherein the intermediate elements (124) divide the recess (122) into a plurality of recess sections (128), wherein it is preferred if the plastic material (108) extends into at least one of the intermediate elements (124), wherein it is particularly preferred if the at least one of the intermediate elements (124) also contains the plastic material (108), consists of the plastic material (108) and / or is manufactured from the plastic material (108). [6] Supporting structure element (106) according to claim 4 or 5, characterized bythat the foamed section (132) of the plastic material (108) is present in the recess (122), e.g. at the bottom (130) of the recess (122), wherein it is preferred if the foamed section (132) of the plastic material (108) is present in at least one of the recess sections (128), e.g. at the bottom (130) of the recess (122) in the at least one recess section (128). [7] Supporting structure element (106) according to one of the preceding claims, characterized by , that the foamed portion (132) is a first foamed portion (136) and the plastic material (108) comprises a second foamed portion (138), wherein it is preferred if the plastic material (108) comprises further foamed sections (140) in addition to the first foamed section (136) and the second foamed section (138). [8] Supporting structure element (106) according to one of claims 4 to 7, characterized bythat the foamed section (132) of the plastic material (108) is present in the recess (122), e.g. at the bottom (130) of the recess (122), wherein it is preferred if the first foamed section (136) of the plastic material (108) is present in at least a first of the recess sections (142), e.g. at the bottom (130) of the recess (122) in the at least one first of the recess sections (142), and the second foamed section (138) of the plastic material (108) is present in at least a second of the recess sections (144), e.g. at the bottom (130) of the recess (122) in the at least one second of the recess sections (144). [9] Supporting structure element (106) according to one of the preceding claims, characterized by , that the support structure element (106) extends from a first end zone (118) to a second end zone (120), wherein it is preferred if the plastic material (108) extends from the first end zone (118) to the second end zone (120), wherein it is particularly preferred if the end zones (118, 120) are connecting zones (154, 156) at which the support structure element (106) can be connected to other support structure elements (106). [10] Supporting structure element (106) according to claim 9, characterized by , that the support structure element (106) does not extend straight from the first end zone (118) to the second end zone (120), wherein it is preferred if the support structure element (106), preferably the recess (122) of the support structure element (106), e.g. the bottom (130) of the recess (122), is deflected in at least one direction, preferably in at least one first direction (160) and in at least one second direction (162), in the course from the first end zone (118) to the second end zone (120) with respect to a straight line connecting the two end zones (118, 120). [11] Supporting structure element (106) according to one of claims 4 to 10, characterized by that the recess (122) and / or at least one recess section (128) is surrounded by wall elements (184), wherein at least a section of the surfaces (176) of the wall elements (184) coincides with a lateral surface (178) of a prism (180). [12] Supporting structure element (106) according to claim 11, characterized bythat at least one foamed section (132, 136, 138, 140) of the plastic material (108), e.g. the foamed section (132), the first foamed section (136), the second foamed section (138) or a further foamed section (140) is surrounded by the at least one section of the surfaces (176) of the wall elements (184) which coincides with the lateral surface (178) of the prism (180). [13] Structural component (100), in particular a support (102), e.g., a cross member (104), for a transport device, wherein the transport device may be, e.g., a vehicle, wherein the structural component (100) comprises: - a supporting structure element (106) according to one of claims 1 to 12 and - at least one connecting element (146) and / or at least one reinforcing element (148), wherein it is preferred if the at least one connecting element (146) and / or the at least one reinforcing element (148) does not consist of the plastic material (108), wherein the at least one connecting element (146) and / or the at least one reinforcing element (148) can preferably be arranged at one of the end zones (118, 120), e.g. at one of the connecting zones (154, 156), wherein the at least one connecting element (146) and / or the at least one reinforcing element (148) is preferably connected to the plastic material (108) in a material-locking and / or form-locking manner. [14] Transport device, e.g. vehicle, wherein the vehicle can preferably be a road vehicle, wherein the transport device comprises a supporting structure element (106) according to one of claims 1 to 12 and / or a structural component (100) according to claim 13. [15] Transport device according to claim 14, characterized by that the structural component (100) is a support (102), e.g. a cross member (104), of the transport device. [16] Road vehicle according to claim 14 or 15, characterized by , that the structural component (100) is a cross member (104) which is arranged between an interior of the road vehicle and a space located in front of or behind the interior in the direction of travel, and / or the structural component (100) is a cross member (104) arranged between an interior and an engine compartment of the road vehicle. [17] Method for producing a supporting structure element (106), wherein the supporting structure element (106) can preferably be a supporting structure element (106) according to one of claims 1 to 12, where - a foamable plastic material is introduced into a cavity of a tool, e.g. a foamable plastic material melt is injected, and - a foamed section (132) of the plastic material (108) is produced by a volume expansion of an expansion zone (166) of the plastic material introduced into the cavity, wherein the tool has a volume expansion device which comprises an expansion body (168) extending at least partially into the cavity of the tool, wherein the volume expansion of the expansion zone (166) of the plastic material (108) is caused or promoted by an expansion movement of the expansion body (168). [18] Method according to claim 17, characterized by , that the supporting structure element (106) is preferably a supporting structure element (106) according to one of claims 4 to 12, wherein the plastic material melt extends around the expansion body (168) or around an expansion element (170) of the expansion body (168) such that the expansion body (168) defines a recess (122) of the plastic material (108) or the expansion element (170) of the expansion body (168) defines a recess portion (128) of the plastic material (108), wherein the expansion movement is carried out such that the foamed portion (132) of the plastic material (108) is formed at the bottom (130) of the recess (122) or the recess portion (128), wherein the amplitude of the expansion movement is determined such that the foamed portion (132) of the plastic material (108) does not completely fill the recess (122) or the recess portion (128). [19] Method according to claim 18, characterized by , that the supporting structure element (106) is preferably a supporting structure element (106) according to one of claims 11 or 12, wherein the expansion body (168) has an expansion body portion (174), wherein at least a portion of the surfaces (176) of the expansion body portion (174) coincides with a lateral surface (178) of a prism (180).

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