Structural component for a vehicle

Abstract

The invention relates to a structural component as a composite component for a vehicle, in particular for a bicycle, which was obtained by injection molding from a thermoplastic material preferably filled with high-tensile short fibers, wherein the structural component comprises, at least in at least one partial region, a further fiber reinforcement, wherein the further fiber reinforcement comprises high-tensile long fibers, wherein the high-tensile long fibers have been overmolded or injection-molded with the filled thermoplastic material as at least one insert in an injection mold, wherein the insert is selected from a group of inserts comprising strips of unidirectional, preferably continuous fibers, semipregs of fiber fabrics or fiber layups, prepregs of fiber layups or fiber fabrics or organic sheets as dimensionally stable semi-finished products with unidirectionally oriented or multidirectionally laid or woven high-tensile long fibers,and wherein at least some of the inserts comprise a thermoplastic as matrix material.,

Description

The invention relates to a structural component as a composite component for a two-wheeler, in particular for a bicycle, which has been obtained from a thermoplastic material, preferably filled with tensile-resistant short fibers, by injection molding. The invention further relates to a method for producing such a structural component.Composite components made of a fiber composite material are generally known from the prior art. It is also known to produce bicycle parts, for example bicycle cranks or bicycle links, from fiber composite materials. In the course of optimizing the weight of bicycles, composite components made in particular of carbon are widely used. As matrix materials, largely temperature-curable plastics, in particular epoxy resin, are used. The fibers used in the prior art are generally glued together as a woven or laid scrim after a predetermined blank and placed into a tool by hand. A plastic based on epoxy resin is introduced into the closed tool, for example, in such a way that the resin penetrates the fiber fabrics or fiber laid scrims. The component is then cured by exposure to temperature. This production method is complicated and requires a high proportion of manual work, both before the component is shaped and in the form of the required reworking.In particular in the case of vehicle frames or bicycle frames for electrically drivable bicycles, the stability of the bicycle frame and of all other structural components is of particular importance, since as a rule an energy store is either fixedly installed in the bicycle frame or is arranged detachably in a correspondingly configured frame compartment. Such a frame compartment means, in particular when it is integrated into the bicycle frame, a structural weakening of the frame profile or a reduction of the area moment of inertia of the relevant cross section. This is critical in particular in the case of bicycle frames for electric vehicles, since these have to absorb a higher weight, greater bending moments and greater drive torques and greater reaction forces during braking.For example, DE 10 2021 126 601 A1 discloses a vehicle frame for an electrically drivable vehicle, in particular for a bicycle having a tube-like frame element, which is formed as a single-piece component and which has at least one layer made of fiber composite material, wherein the vehicle comprises at least one electrical energy store which comprises at least one energy storage cell, wherein the energy store is arranged in the frame element and the energy store is non-detachably fixed to the frame element by means of potting by resin and by means of foaming by a foaming agent. The frame element comprises one or more layers of fiber composite material impregnated and cured with an exchangeable resin. Such a vehicle frame is complicated to produce and does not last from an environmental point of view, since the materials can hardly be separated and can hardly be recycled. This relates in particular to fiber composites which form a composite with cured resins.In the prior art, it is also fundamentally known, in the case of carbon-fiber-reinforced bicycle / carbon frames for bicycles, to additionally provide particularly structurally loaded regions of the frame, such as axle receptacles, dropouts or the like, with inserts or reinforcements made of metal. For example, DE 20 2007 008 86 U1 discloses a receiving device of a bicycle frame for receiving an axle of a wheel, on which at least one reinforcing plate made of metal is arranged.DE 10 2016 015 538 A1 discloses a method for producing a bicycle frame from a plurality of modules, each of which has been obtained by injection molding using the fluid injection technique. The method of fluid injection technology offers a possibility, which is favorable from a process standpoint, of configuring the individual components as hollow bodies in a weight-optimized manner. However, such a method has the disadvantage that the components do not have a constant and defined wall thickness and in particular also no continuously smooth surface within the cavities. This is not advantageous for various reasons. This results in mass differences between components of a series, for example. Also, the passing of cables through the frame may be difficult.The object of the invention is to provide a structural component for a vehicle, in particular for a bicycle, for example for an electric bicycle, which structural component is simple to produce on the one hand and which structural component is designed at least partially in a load-optimized manner on the other hand. In particular, the invention is also based on the object of providing a method for producing such a structural component which enables the component to be produced as easily as possible.The object is achieved by a structural component having the features of claim 1 and by the provision of a method for producing this structural component having the features of claim 18.Advantageous embodiments of the invention are evident from the dependent claims.According to one aspect of the invention, a structural component is provided as a composite component for a vehicle, in particular for a bicycle, which structural component has been obtained by injection molding from a thermoplastic material, preferably filled with tensile strength short fibers, wherein the structural component comprises a further fiber reinforcement at least in a partial region, wherein the further fiber reinforcement comprises tensile strength long fibers, wherein the tensile strength long fibers are injection molded or injection molded as at least one insert in an injection molding tool with a filled thermoplastic material, wherein the insert is selected from a group of insert parts comprising belts of unidirectional, preferably endless fibers, semipregs of fiber fabrics or fiber mats, prepregs of fiber mats or fiber fabrics or organoplates as dimensionally stable semi-finished products with unidirectionally oriented or multidirectionally laid or woven tensile strength long fibers, and wherein at least some of the inserts comprise a thermoplastic as matrix material.A structural component in the sense of the present invention is understood to mean a component on a vehicle, in particular on a bicycle, which, when used as intended, is structurally loaded, i.e. is subjected to operating forces which are generated by the user or to forces resulting from the driving operation. A structural component in this sense will therefore generally be a component which is subject to tensile and / or bending stress. The term vehicle in the sense of the present invention includes primarily, but not exclusively, two-wheelers, in particular bicycles. In principle, the invention can also relate to three-wheelers, reclining wheels or the like.In particular, thermoplastic materials are not suitable without further material-reinforcing measures for absorbing permanent tensile loads or permanent bending loads or greater load cycling loads.A further fiber reinforcement is understood to mean a targeted reinforcement of the structural component by means of tension-resistant long fibers. The further fiber reinforcement is preferably an integral component of the injection-molded component and can be integrated completely not visibly into the injection-molded material. In principle, however, the further fiber reinforcement can also be visibly integrated into the injection-molded material in such a way that the further fiber reinforcement forms an outer side or a part of the lateral surface of the structural component.Although a thermoplastic filled with tensile-resistant short fibers is particularly preferred as the filled thermoplastic according to the invention, other fillers which increase the strength of the thermoplastic are also possible in principle. Here, for example, as an alternative to fiber fillings, so-called beads or mini beads or also flakes can be considered. Suitable fillers are in principle glass fibers and / or carbon fibers.A particular advantage of the structural component according to the invention is that it can be manufactured very easily by injection molding in a single manufacturing cycle.Particularly preferably, the structural component according to the invention was obtained by a conventional injection molding method, in which any cavities provided or at least one cavity in the component were produced, if necessary, by means of at least one slide and / or with at least one core inserted into the tool and / or with at least one dimensionally stable insert inserted into the tool and injection molded around, for example in the form of a dimensionally stable hollow profile inserted into the tool. The term core in the sense of the present application also includes so-called lost cores made of a material that can be released or broken up after completion of the structural component.The structural component according to the invention preferably has a constant wall thickness, in particular in the region of at least one cavity provided in the structural component. A constant wall thickness is understood to mean a uniform wall thickness which also includes a defined wall thickness which changes constantly and which is predefined structurally for reasons of optimizing the mouldability of the tool.Furthermore, the structural component particularly preferably has a smooth and uniform inner surface at least in the region of a cavity. The surface preferably has a roughness depth corresponding to the surface quality produced by electroresistive machining of the cavity of the mold. The surface quality according to standard VDI 3400 may be between 12 and 45, which corresponds to a surface roughness Ra between 0.4 and 18 μm.At least in parts, the structural component according to the invention can have a cross section without continuous cavities, i.e. for example a chambered cross section. In these areas, the structural component according to the invention can have a perforated lateral surface with at least one depression in the cross section of the structural component. This depression can be provided with at least one stiffening rib which can preferably be formed without a slide.The semipregs, prepregs or organoplates provided or used according to the invention are preferably exclusively thermoplastic semipregs, prepregs and organoplates, i.e. with a thermoplastic matrix material which preferably corresponds to the thermoplastic base material of the structural component. The base material used is preferably a grade-free PA6. In principle, recyclates are also suitable as the base material.A semipreg in the sense of the present application is understood to mean a woven fiber fabric or a laid fiber fabric, to which the thermoplastic matrix material used is applied as polymer powder and melted. Prepregs in the sense of the present application are fabrics or laid scrims, optionally multilayers, which are already completely impregnated with the thermoplastic matrix material.Organoplates in the sense of the present invention are understood to mean fully consolidated and impregnated, preferably dimensionally stable, semi-finished products which can likewise optionally be formed in multiple layers.The thermoplastic matrix material of the semipregs, prepregs or organoplates provided according to the application preferably consists of the same base plastic as the base plastic of the injection-molded thermoplastic material used.The term insert in the sense of the present invention means a structure in the form of oriented long fibers, which may be woven or laid, also multilayer. The insert part does not necessarily have to be dimensionally stable or self-supportingly stiff. The term insert part is intended to imply that the relevant structure has been introduced into an injection mold before the injection molding process and has been held or fixed in a specific position therein during the injection molding process, so that the insert part is injection-molded or injection-molded onto the structural component according to the invention.By providing an additional fiber reinforcement made of long fibers, it is possible to reinforce critical and particularly structurally stressed regions of the component in a targeted manner and counter to the tensile load or bending load to be expected. Particularly when using thermoplastic materials, the specific reinforcement against tensile loads and / or bending loads to be expected plays a particular role, since the thermoplastic material has a certain tendency to flow. As a result, it is possible in particular to dimension the structural component according to the invention in such a way that excessive mass accumulations of the thermoplastic material are avoided, since such mass accumulations are associated with different shrinkages during the curing or consolidation of the plastic after the injection molding process.The fiber laid scrims provided according to the invention can be formed in one or more layers, wherein the fibers can be oriented in a multi-directional manner and can be oriented in particular with regard to the expected stress on the insert part in the installation position of the structural component.A further particular advantage of the structural component according to the invention is that it can be completely recycled, since it is particularly preferably produced completely without resins that cure under the supply of heat, in particular without the use of epoxy resin. Particularly preferably, the structural component according to the invention comprises only a single type of thermoplastic material.The structural component according to the invention can be selected from a group of structural components comprising frames, frame parts, saddles, seat posts, forks, front steering units, running wheels, spokes, clamping attachments, hub bodies, pedal cranks and the like. In particular, running wheels, their flanks and / or their spokes can be designed in a load-optimized manner according to the invention. In particular spokes which, depending on the configuration of the impeller, are subjected almost exclusively to tension can be reinforced, for example, in the tension direction with unidirectionally oriented continuous fibers.The handlebar clamp of a bicycle handlebar as a structural component can have a fiber reinforcement with tension-resistant continuous fibers at least over a partial length and / or over a partial circumference. This can be reinforced, for example, on an upper side in the region of the neutral fiber of the cross section with unidirectionally oriented continuous fibers. In the following, the terms upper side and lower side and also above or below refer to the component in the installation position on the vehicle and to the perspective of a user who is seated on the vehicle.As a structural component within the meaning of the invention, in particular a profile or a profile section of a bicycle frame can be provided. Particularly stressed areas of a bicycle frame are, for example, the chain struts, in particular, in the case of fully sprung bicycles, the rear swing arm, the head tube, the down tube and the bottom bracket housing, and the transition from the down tube into the bottom bracket housing and the dropouts of the chain struts, in particular, in the area of the axle receptacle. The term "chain braces" selected here does not exclude the corresponding component on a bicycle with toothed belt drive. According to the invention, it can be provided to provide in these regions a fibre reinforcement with long fibres which are oriented in accordance with the loads to be expected.In a variant of the structural component according to the invention, the insert part can have an essentially at least partially closed cross-sectional contour, preferably in the form of a box-shaped or tubular hollow cross-section. Such a contour can be advantageous, for example, in the case of an insert part which reinforces a profile or a profile section of the bicycle frame, for example in the upper tube of the bicycle frame. In some bicycle frames, it is provided that the volume of a bicycle frame configured as an open profile is partially used as a stowage space. This results in the profile cross section of the bicycle frame naturally having a lower area moment of inertia in these regions. In such a case, it is particularly advantageous according to the invention to adapt the contour of the insert part to the partially opened contour of the frame profile, for example in the form of a C profile or a U profile.In a variant of the structural component according to the invention, it can be provided that it comprises at least one insert part which is formed as a woven fiber fabric or laid fiber fabric and which has been injection-molded or injection-molded as an insert part without a matrix material, in such a way that the injection-molded, filled thermoplastic material at least partially penetrates and / or encloses the woven fiber fabric or laid fiber fabric, so that the impregnation of the woven fiber fabric or laid fiber fabric takes place quasi in situ.In this case, it can be provided, for example, that the insert part is provided as a woven stocking or woven hose which is not dimensionally stable before the production of the structural component.In a variant of the structural component according to the invention, in which the structural component is designed as a profile or profile section of a bicycle frame, it is provided that the insert part is arranged in a substantially closed profile chamber of the bicycle frame or is integrated into a wall of the closed profile chamber and / or at least partially encloses the latter, wherein the profile chamber extends in the longitudinal direction of a frame profile and is preferably arranged within the frame profile in the region of an expected tensile stress when the bicycle frame is used as intended.In particular, if the profile section forms an upper tube or a lower tube or a seat tube of the bicycle frame, the profile section can have an open, preferably U-shaped, cross-sectional profile.In a preferred variant of the structural component according to the invention, the structural component is designed as a frame profile of an electric bicycle, wherein in particular the profile section additionally reinforced with long fibers forms a frame compartment and / or at least partially encloses a frame compartment. In such a region of the bicycle frame, the latter is structurally generously dimensioned such that the battery or the electrical energy store can be introduced into the latter. This leads to correspondingly dimensioned frame cross sections so that the energy store can be easily inserted and accommodated. In particular, the frame cross section in this region of the bicycle frame cannot be formed closed, which results in particular in structural requirements, in particular if the battery storage device is intended to be removable from the frame by the user of the electric bicycle, i.e. is not a supporting component of the bicycle frame.According to the invention, it can be provided, for example, that the structural component or the profile or the profile section of the bicycle frame forms a continuously closed profile cross section formed as a hollow profile in the region of the frame compartment and, within the same cross section, furthermore forms a partially open profile cross section formed as a frame compartment or forming part of the frame compartment. It is advantageous here, for example, if the insert part extends at least within the continuously closed hollow profile or is integrated into the wall of the closed hollow profile. This region of the frame profile is particularly stressed, in particular by the additional weight of the electrical energy store.In a variant of the structural component according to the invention, in which the latter is designed, for example, as a link or seat post, it can be provided that the insert part has at least one injection-molded or injection-molded continuous fiber-reinforced tape with unidirectionally oriented, tension-resistant long fibers in the form of continuous fibers. The insert part can be designed as a so-called "UD tape".The thermoplastic filled with tensile-resistant short fibers (base material of the structural component) can have a filling degree of 20 to 60 percent by weight, based on the total weight of the structural component.The tensile strength short fibers can have a fiber length of 0.1 to 50 mm, preferably a fiber length of 0.1 to 1 mm.The tensile-resistant long fibers can have a fiber length greater than 50 mm and, for example, a fiber length which approximately corresponds to the largest dimension of the structural component. If the structural component is designed, for example, as a link, the long fibers can have, for example, a length which corresponds to the length or width of the link bow.The thermoplastic or base material of the structural component of the and / or the thermoplastic matrix material is preferably selected from a group of plastics comprising PA, PP, PPA, PS, PE, PE, ABS, PC, POM, PEK, PEEK, PA610, HPPA, PARA, PBT, PK.The tensile strength long fibers are preferably selected from a group of fibers comprising carbon fibers, glass fibers, aramid fibers, Kevlar fibers and basalt fibers.The object on which the invention is based is furthermore achieved by the provision of a method for producing the structural component described above.The method according to the invention comprises the following method steps:providing an injection molding arrangement having at least one injection unit with means for plasticizing and providing a plasticized filled plastic under pressure into a tool having at least one cavity, and wherein the at least one cavity at least partially defines the shape of the structural component and has at least one sprue,inserting and fixing at least one insert part into at least one partial cavity of the tool, wherein the insert part is selected from a group of insert parts comprising belts of unidirectional, preferably endless fibers, semipregs of fiber fabrics or fiber laid scrims, prepregs of fiber laid scrims or fiber fabrics or organoplates as dimensionally stable semi-finished products with unidirectionally oriented or multidirectionally laid or woven tension-resistant long fibers, and wherein at least some of the insert parts comprise a thermoplastic as matrix material,injecting the plasticized plastic under pressure into the closed mold; andopening the tool and removing the finished product.The production of the structural component is preferably carried out in a single injection molding cycle.Particularly preferably, the structural component according to the invention is obtained by a conventional injection molding method, in which any cavities provided or at least one cavity in the component are produced, if necessary, by means of at least one slide and / or with at least one core inserted into the tool and / or with at least one dimensionally stable insert inserted into the tool and injection molded around, for example in the form of a dimensionally stable hollow profile inserted into the tool. The term core in the sense of the present application also includes so-called lost cores made of a material that can be released or broken up after completion of the structural component.The structural component according to the invention is preferably injection-molded with a constant wall thickness, in particular in the region of at least one cavity provided in the structural component. A constant wall thickness is understood to mean a uniform wall thickness which also includes a defined wall thickness which changes constantly and which is predefined structurally for reasons of optimizing the mouldability of the tool.Furthermore, the structural component is produced at least in the region of a cavity with a smooth and uniform inner surface. It is understood that the outer surface or lateral surface of the structural component also has a corresponding surface quality. The surface preferably has a roughness depth corresponding to the surface quality produced by electroresistive machining of the cavity of the mold. The surface quality according to standard VDI 3400 may be between 12 and 45, which corresponds to a surface roughness Ra between 0.4 and 18 μm.The injection molding tool can comprise, for example, at least two partial cavities which define the contour of the structural component in a closed manner. If, for example, at least one strip of unidirectional continuous fibers is provided as an insert, this strip can either be inserted into a partial cavity of the injection molding tool or can be fastened at least temporarily to a wall of the partial cavity by means of adhesive.If the insert is designed, for example, as a dimensionally stable organosheet, it can have been inserted into a partial cavity. A positional fixation can be effected, for example, only when the injection-molding tool is closed, for example, by interaction of two halves of the injection-molding tool.The method can alternatively comprise, for example, a non-dimensionally stable insert, for example in the form of a fabric stocking, fabric tube or the like, being positioned in at least one cavity or partial cavity of the molding tool before the injection molding process.Finally, the method can comprise inserting a laid scrim or fabric into a partial cavity of the mold in contact with the mold wall. Both the laid scrim and the fabric can be designed to be multilayer. The laid scrim can be designed such that the tension-resistant fibers of the laid scrim are oriented in multiple directions.The method can comprise the method step of cutting and aligning the tension-resistant fibers of at least one belt with continuous fibers and / or at least one laid scrim with unidirectionally or multidirectionally oriented tension-resistant fibers as long fibers, before and / or during the insertion into the mold.The method furthermore preferably comprises the alignment of the insert part and / or the tension-resistant long fibers within the molding tool in the main loading direction assumed for the structural component at least in regions.Preferably, as injected thermoplastic or as base material, at least one thermoplastic filled with tensile-resistant short fibers is used.The thermoplastic filled with tensile-resistant short fibers preferably has a filling degree of 20 to 60 percent by weight, based on the total injected mass or based on the total weight of the structural component.The tensile strength short fibers can have a fiber length of 0.1 to 50 mm, preferably a fiber length of 0.1 to 1 mm.The tensile-resistant long fibers used for providing the at least one insert part may have a fiber length greater than 50 mm.In the method according to the invention, it can be provided that the injected thermoplastic and / or the thermoplastic matrix material of at least one insert is selected from a group of plastics comprising PA, PP, PPA, PS, PE, PE, ABS, PC, POM, PEK, PEEK, PA610, HPPA, PARA, PBT, PK.The tensile-resistant long fibers used for providing at least one insert part can be selected from a group of fibers comprising carbon fibers, glass fibers, aramid fibers, Kevlar fibers and basalt fibers.The invention will be explained below with reference to and with reference to an exemplary embodiment illustrated in the attached drawings.The following are shown: FIG. 1 shows a perspective sectional view of a structural component according to the present invention as a bicycle frame of an electric bicycle, FIG. 1A shows an enlarged detail of the detail A in FIG. 1, FIG. 2A shows a first variant of a profile cross section of the frame tube of the bicycle frame according to FIG. 1, FIG. 2B shows a second variant of a profile cross section of the frame tube of the bicycle frame according to FIG. 1, FIG. 3A is a perspective view of the bicycle frame according to FIG. 1 with the frame compartment opened, FIG. 3B is an enlarged view of the opened frame compartment from the direction of the arrow drawn in FIG. 3A , FIG. 4A is an exploded perspective view of the bicycle frame according to FIG. 1 with a fiber reinforcement in the region of the seat tube, FIG. 4B is a perspective view of the bicycle frame shown in FIG. 4A , FIG. 5 is a perspective view of a variant of a bicycle frame as a structural component according to the invention, FIG. 6 is a front perspective view of the bicycle frame shown in FIG. 1 , FIG. 7A is a rear view of the bicycle frame shown in FIG. 1 , FIG. 7B shows a detailed view of the rear swing arm of the bicycle frame shown in FIG. 7A, FIG. 8 is a perspective view of another variant of a bicycle frame as a structural component according to the invention, FIG. 9A shows a further variant of a bicycle frame as a structural component according to the invention, FIG. 9B is a diagram of the detail B in FIG. 9A FIG. 10A is a perspective view of a bicycle frame formed corresponding to the bicycle frame of FIG. 1 , FIG. 10B shows a detail of the dropout of the bicycle frame according to FIG. 10A, FIG. 11 is a perspective view of a fork for a bicycle frame as a structural component according to the invention, FIG. 12 is a view of a seat post as a structural component for a bicycle, FIG. 13 shows a perspective illustration of an impeller as a structural component for a bicycle, FIG. 13A is an enlarged view of the detail A in FIG. 13 , FIG. 14A is a perspective view of an integrated link as a structural component according to the invention, FIG. 14B is a bottom perspective view of the integrated link of FIG. 8A, FIG. 14C is a rear perspective view of the integrated link of FIG. 8A; and FIG. 15 shows a perspective illustration of a crank arm made of thermoplastic material with a partial reinforcement made of long fibers as a structural component in the sense of the present invention.A variant of a structural component according to the invention is embodied, for example, by the bicycle frame 1 shown in partial section in FIG. 1 as a bicycle frame 1 for an electric bicycle. Although the structural members described below in the embodiments, particularly the bicycle frame 1, are described as members particularly suitable for use with an electric bicycle, the invention is not limited to electric bicycles and the members thereof in principle. In principle, however, the design of electric vehicles places the designer with particular requirements with regard to the stability of the bicycle frame 1, since, on the one hand, many frame constructions deviate from the classic framework structure (diamond frame) and, on the other hand, the stability of frame tubes is impaired or particularly stressed by integration of electronic components and / or rechargeable batteries / batteries and / or motor components (motor bracket / motor gear box).The bicycle frame 1 shown in FIG. 1 is predominantly made of thermoplastic material which is filled with tension-resistant short fibers, for example in the form of glass fibers. The bicycle frame 1 can be injection molded in one piece, for example. The bicycle frame 1 comprises the usual frame components, such as a seat tube 2, seat braces 3, chain braces 4, a down tube 5 connected to the seat tube 2 which forms a receptacle 6 for a transmission and / or a motor in a connection region with the seat tube 2. The down tube 5 is designed as a box-shaped profile which is open downward from the perspective of a driver and forms a frame compartment 7 for receiving a removable battery. At the upper end of the down tube 5 facing the driver, a control tube 8 for receiving a headset and a fork stem is formed in a known manner.The bicycle frame 1 shown in the figures is provided according to the invention, at least in partial regions, with a further fiber reinforcement which is integrated into the filled thermoplastic material of the structural component, wherein this fiber reinforcement comprises long fibers which are resistant to tension, for example carbon fibers, which are preferably arranged in the component in accordance with the load to be expected of the structural component and are oriented there, wherein the long fibers which are resistant to tension have been injection-molded or injection-molded with the filled thermoplastic material as at least one insert part in an injection molding tool. As already described at the beginning, the long fibers can be oriented in one or more layers, unidirectionally or multidirectionally.In the embodiment of the bicycle frame 1 shown in FIGS. 1A to 2B, the down tube 5 comprises a box-shaped profile which, in the variant shown in cross section in FIG. 2A, is formed as a U-shaped profile which is open on the frame underside and which encloses a closed reinforcing profile 9, for example in the form of a thermoplastic organosheet or a thermoplastic prepreg, which has been injection-molded as an insert part to form the contour shown in FIGS. 2A, B, in such a way that the reinforcing profile 9 has entered a cohesive connection with the profile of the down tube 5. The reinforcing profile 9 integrated into the down tube 5 can comprise a laid fibre or a fibre fabric made of long fibres. The arrangement within the bicycle frame 1 is selected such that, on the one hand, the profile cross section of the down tube 5 is supplemented to form a closed profile with a correspondingly higher area moment of inertia and that this is arranged in the region of the highest expected bending stresses of the bicycle frame 1 (FIG. 2A ).In an alternative embodiment of the cross-sectional profile of the down tube 5 according to FIG. 2B, the frame profile forms a profile chamber 19 which extends over the length of the down tube 5 and within which the reinforcing profile 9 extends.FIG. 1 shows a variant of a partially reinforced structural component according to the invention, wherein, for example, on the bicycle frame 1 according to the invention, various regions of an expected higher structural stress can be correspondingly reinforced with long fibers. In the following, various variants of the bicycle frame 1 will be described, which can be embodied both alternatively and cumulatively in a single embodiment according to the invention.FIGS. 3A and 3B show a variant of the bicycle frame 1, in which the frame compartment 7 is provided in the region of a frame compartment base 10 in the region of feedthroughs 11 in the manner according to the invention with a fiber fabric or a fiber scrim in the form of a flat structural reinforcement 12.FIGS. 4A and 4B show a further variant of a bicycle frame 1 according to the invention, in which the upper portion of the seat tube 2 is correspondingly reinforced. This portion receives the bending forces introduced into the bicycle frame 1 via a seat post 200 (see FIG. 12 ) via the body weight of the user. The fiber reinforcement of the seat tube 2 comprises two reinforcing layers 20A and 20B, which are designed approximately in the shape of a shell and form part of the outer surface of the seat tube 2 or are integrated into the wall of the seat tube 2, in such a way that the seat tube 2 is reinforced in the direction of the main bending stress, i.e. in the forward and rearward direction of travel.FIG. 5 shows a variant of the bicycle frame 1 as a structural component according to the invention, in which the frame geometry is designed differently from the frame geometry of the bicycle frame 1 according to FIG. 1. The bicycle frame 1 according to FIG. 5 comprises an upper tube 13 which forms a force flow with the seat braces 3. The bicycle frame 1 according to FIG. 5 is provided with a junction reinforcement 14 on the underside in the area of the force junction of the connection of the down tube 5 to the head tube 8. As in all exemplary embodiments according to the invention, the node reinforcement 14 is also designed as a fiber fabric or fiber laid scrim made of tension-resistant long fibers.FIG. 6 shows a variant of the bicycle frame 1 according to the invention, which corresponds with respect to the frame geometry to the variant shown in FIG. 1. The bicycle frame 1 according to FIG. 6 is reinforced with a tubular or shell-shaped head tube reinforcement 15 as a fiber fabric or fiber scrim made of tension-resistant long fibers.FIGS. 7A and 7B show a further exemplary embodiment of the invention, wherein FIG. 7 shows a rear view of the bicycle frame 1 with a frame geometry according to FIG. 5, in which the rear structure is provided with a rear structure reinforcement 16 in the region of the connection of the chain struts 4 to the receptacle 6 for the transmission and / or motor, the operating principle of which corresponds to that of the node reinforcement 14.FIG. 8 shows a variant of the bicycle frame 1 according to FIG. 5, in which a junction reinforcement 14 is provided in the region of the connection of the seat tube 2 to the receptacle 6 for the motor and / or transmission in the region facing forward in the direction of travel. In a vehicle which is not designed as an electric vehicle, a corresponding reinforcement of a bottom bracket housing would be provided for receiving a bottom bracket.FIGS. 9A and 9B show a bicycle frame 1 as a structural component, which approximately corresponds to that according to FIGS. 5 and 8, wherein an interface reinforcement 17 is provided there at fastening openings and / or feedthroughs through the wall of the bicycle frame 1, which is formed corresponding to the flat structural reinforcement 12.FIG. 10A shows a variant of the bicycle frame 1 according to FIG. 1, in which the dropouts 18 with feedthroughs for plug-in axles are likewise provided with an interface reinforcement 17, which are designed in accordance with the flat structural reinforcement 12. A further interface reinforcement 12 is provided in the region of mounting bases 21 for brake calipers of a hydraulic disc brake.FIG. 11 shows the fork 300 of a bicycle formed as a structural component according to the invention. The fork 300 is, like all other structural components described in the present application, completely formed from thermoplastic material. The fork 300 comprises, in a known manner, a fork stem 301 which is provided, in the region of its connection to the fork crown 302, with a fork stem reinforcement 303 made of woven or laid long fibers. The design of the fork stem reinforcement 303 corresponds substantially to the design of all other partial reinforcements of the structural component according to the invention. According to the invention, the fork crown 302 can also be correspondingly reinforced.As already mentioned above, in FIG. 12 a seat post 200 is designed as a structural component according to the invention. The base body of the seat post 200 is likewise produced from a filled thermoplastic base material by injection molding and additionally reinforced with unidirectionally oriented continuous fibers 201. The continuous fibers 201 can have been inserted into the tool during injection molding, for example, in the form of a so-called UD tape. In addition, the seat post 200 comprises at least one reinforcing patch 202 which is arranged in a highly stressed region of the seat post, for example in that region in which the seat post 200 is enclosed in the installation position by a screw cap or a clamping clamp.FIG. 13 shows a perspective illustration of an impeller 400 which is formed completely from thermoplastic material and in which highly stressed regions, such as for example the rim flanks 401, the spokes 402 and the hub body 403, can be reinforced with long fibers according to the concept according to the invention. As can be seen from the detail in FIG. 13A, provision can be made according to the invention to correspondingly reinforce the spokes 402 in the region of their connection to the rim profile.Figs. 14A to 14C show an integrated link 500 which is entirely formed of thermoplastic resin and partially reinforced with long fibers. The handlebar 500 includes a central portion 501, two handlebar arm portions 502, and two handle portions 503. An integrated link in the sense of the present invention is a link which is provided with a integrally formed front part 504 made of thermoplastic material which is designed for clamping fastening on a fork stem, for example a fork which is likewise completely made of thermoplastic material. The invention is described with reference to the exemplary embodiment by means of an integrated link. The principle of partial fiber reinforcement on the link 500 can, however, be transferred to a link bow of a non-integrated link having a central section designed for clamping fastening.In the case of the link 500 described, a further fiber reinforcement in the form of unidirectional continuous fibers 505 is provided, which were inserted into the injection mold before the injection process, for example, as a so-called "UD tape", and were injection-molded and / or partially encapsulated by injection molding. The continuous fibers 505, for example as carbon fibers or the like, extend continuously from one link end to the other link end and on the outer side of the link bow or in the lateral surface of the link bow. Furthermore, as is shown in FIG. 14A, a further reinforcement with endless fibers 505 can be provided in the central section 501, wherein the endless fibers 505 extend in the region of the central section 501 of the link 500 transversely to those endless fibers 505 which run in the lateral surface of the link bow.FIG. 14B shows a rear view of the link according to FIG. 14A, in which a junction point reinforcement 506 is additionally provided in the region of the connection of the integrated front part 504 to the central section 501 of the link 500.FIG. 14C finally shows a perspective view of the link 500 according to FIG. 1 in the direction of travel, from which it can be seen that the clamping fastening is likewise provided with a junction point reinforcement 506.FIG. 15 finally shows a crank arm 600 of a pedal crank assembly for a bicycle, which crank arm is manufactured integrally from thermoplastic material and is additionally reinforced at least partially with a fiber scrim 601 made of long fibers. In the illustrated embodiment, the long fiber reinforcement forms, for example, the visible side of the crank arm 600, which may be desired for aesthetic reasons. According to the invention, it can be provided that, for example, the feedthroughs for a pedal bearing axle or for receiving a thread for a pedal can also be reinforced, for example, with thermoplastic organoplates in the form of sleeve-shaped inserts injection-molded.List of reference characters1 Bicycle frame 2 seat tube 3 seat braces 4 chain braces 5 down tube 6 receptacle for transmission and / or motor 7 frame compartment 8 head tube 9 reinforcing profile 10 frame compartment base 11 feedthroughs 12 planar structural reinforcement 13 upper tube 14 node reinforcement 15 head tube reinforcement 16 rear reinforcement 17 interface reinforcement 18 dropouts 19 profile chamber 2A, b Reinforcing layers 21 Mounting base 200 Seat post 201 Unidirectional endless fibers 202 Reinforcing patch 300 Fork 301 Fork stem 302 Fork crown 303 Fork stem reinforcement 400 Running wheel 401 Rim flank 402 Spokes 403 Hub body 500 Link 501 Central portion of the link 502 Link arm portions of the link 503 Handle ends of the link 504 Front end 505 Unidirectional endless fiber 506 Node reinforcement of the front end 507 Node reinforcement of the clamping mount 600 Crank arm 601 Fiber web Crank armReferences included in the specificationThis list of documents cited by the applicant has been produced in an automated manner and is only included for the better information of the reader. The list is not part of the German patent application or utility model application. The DPMA does not take any adhesion for any faults or omissions.Patent Literature citedDE 10 2021 126 601 A1

[0004] DE 20 2007 008 86 U1

[0005] DE 10 2016 015 538 A1

[0006]

Claims

Structural component as a composite component for a vehicle, in particular for a bicycle, which has been obtained by injection molding from a thermoplastic material preferably filled with tensile-resistant short fibers, wherein the structural component comprises a further fiber reinforcement at least in at least one partial region, wherein the further fiber reinforcement comprises tensile-resistant long fibers, wherein the tensile-resistant long fibers have been injection molded or injection molded as at least one insert in an injection molding tool with the filled thermoplastic material, wherein the insert is selected from a group of insert parts comprising belts of unidirectional, preferably endless fibers, semipregs of fiber fabrics or fiber mats, prepregs of fiber mats or fiber fabrics or organoplates as dimensionally stable semi-finished products with unidirectionally oriented or multidirectionally laid or woven tensile-resistant long fibers, and wherein at least some of the insert parts comprise a thermoplastic material as matrix material.Structural component according to Claim 1, characterized in that the insert part comprises a stocking-shaped or tubular woven fabric.Structural component according to either of Claims 1 and 2, characterized in that it is selected from a group of structural components comprising bicycle frames (1), frame parts, links (500), seat posts (200), forks (300), link attachments, running wheels (400), spokes, clamping attachments, hub bodies (403), pedal cranks (600) and the like.Structural component according to one of Claims 1 to 3 as a profile or profile section of a bicycle frame 1, characterized in that the insert extends within the profile or profile section over at least one partial cross section of the profile or profile section.Structural component according to one of Claims 1 to 4da, characterized in that the insert part has an essentially at least partially closed cross-sectional contour, preferably in the form of a box-shaped or tubular hollow cross section.Structural component according to one of Claims 1 to 5, characterized in that the structural component has a constant defined wall thickness, in particular in the region of at least one cavity provided in the structural component.Structural component according to one of Claims 1 to 6, characterized in that it comprises at least one insert part which is designed as a fibre fabric or fibre laid scrim and has been injection-moulded or injection-moulded as an insert part without a matrix material in such a way that the injection-moulded filled thermoplastic material at least partially penetrates and / or surrounds the fibre fabric or fibre laid scrim.Structural component according to one of Claims 1 to 7, characterized in that the insert part is designed as a dimensionally stable semifinished product with a thermoplastic matrix material.Structural component as a profile or profile section of a bicycle frame 1 according to one of claims 1 to 8, characterised in that the insert part is arranged in a closed profile chamber 19 of the bicycle frame 1 or is integrated into a wall of the closed profile chamber 19 and / or at least partially encloses the latter, wherein the profile chamber 19 extends in the longitudinal direction of a frame profile and is preferably arranged within the frame profile in the region of an expected tensile stress when the bicycle frame 1 is used as intended.Structural component according to claim 9, characterised in that the profile or the profile section forms an upper tube 13 or a lower tube 5 or a seat tube 2 of the bicycle frame 1 and the profile or the profile section has an open, preferably U-shaped cross-sectional profile, preferably forming a frame compartment 7 or enclosing an at least partially frame compartment 7.Structural component according to either of Claims 9 and 10, characterized in that the insert part forms a frame compartment 7 of the bicycle frame 1 and / or partially encloses the latter.Structural component as a link 500 or seat post according to one of claims 1 to 7, comprising at least one injection-molded or injection-molded continuous fibre-reinforced tape with unidirectionally oriented, tension-resistant long fibres as continuous fibres 505 as an insert.Structural component according to one of Claims 1 to 12, characterized in that the thermoplastic filled with tensile-resistant short fibres has a degree of filling of 20 to 60 percent by weight, based on the total weight of the structural component.Structural component according to one of Claims 1 to 13, characterized in that the tensile-resistant short fibres have a fibre length of from 0.1 to 50 mm, preferably a fibre length of from 0.1 to 1 mm.Structural component according to one of Claims 1 to 14, characterized in that the tensile-resistant long fibres have a fibre length of greater than 50 mm.Structural component according to one of Claims 1 to 15, characterized in that the thermoplastic and / or the thermoplastic matrix material is selected from a group of plastics comprising PA, PP, PPA, PS, PE, PE, ABS, PC, POM, PEK, PEEK, PA610, HPPA, PARA, PBT, PK.Structural component according to one of Claims 1 to 16, characterized in that the tensile-resistant long fibres are selected from a group of fibres comprising carbon fibres, glass fibres, aramid fibres, Kevlar fibres and basalt fibres.Method for producing a structural component made of thermoplastic material having the features of one of the preceding claims 1 to 17, wherein the method comprises the following method steps: - providing an injection-moulding arrangement having at least one injection-moulding unit with means for plasticizing and providing a plasticized filled plastic material under pressure into a tool having at least one cavity, and the at least one cavity at least partially defines the shape of the structural component and has at least one sprue, - inserting and fixing at least one insert part into at least one partial cavity of the tool, wherein the insert part is selected from a group of insert parts comprising belts made of unidirectional, preferably endless, fibers, semipregs made of woven fibers or laid fiber fabrics, Prepregs made of laid fibre structures or woven fibre fabrics or organoplates as dimensionally stable semi-finished products with unidirectionally oriented or multidirectionally laid or woven tension-resistant long fibres, and wherein at least some of the inserts comprise a thermoplastic as matrix material, - injection of the plasticized plastic under pressure into the closed mould and - opening of the mould and removal of the finished product.Method according to claim 18, characterised in that at least one thermoplastic filled with tensile-resistant short fibres is used as the thermoplastic.Method according to claim 19, characterised in that the thermoplastic filled with tensile-resistant short fibres has a filling degree of 20 to 60 percent by weight, based on the total weight of the structural component.Method according to one of Claims 18 to 20, characterized in that the tensile-resistant short fibres have a fibre length of from 0.1 to 50 mm, preferably a fibre length of from 0.1 to 1 mm.Method according to one of Claims 18 to 21 characterised in that the tensile-resistant long fibres have a fibre length greater than 50 mm.Method according to one of Claims 18 to 22da, characterized in that the thermoplastic and / or the thermoplastic matrix material is selected from a group of plastics comprising PA, PP, PPA, PS, PE, PE, ABS, PC, POM, PEK, PEEK, PA610, HPPA, PARA, PBT, PK.Method according to one of Claims 18 to 23da characterized in that the tensile-resistant long fibres are selected from a group of fibres comprising carbon fibres, glass fibres, aramid fibres, Kevlar fibres and basalt fibres.

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