Method for manufacturing a vehicle component, vehicle component with a first component and a second component, first component and second component

Abstract

A method for manufacturing a vehicle component (1) is presented and described, the method comprising the following steps: providing a first component (3), providing a second component (5), providing a connecting unit (21), arranging the first component (3), the second component (5) and the connecting unit (21) such that a connecting section (13) and an expandable adhesive section (23) are arranged in a receiving recess (9) such that the expandable adhesive section (23) is arranged between at least one first recess (15) and at least one second recess (17), and expanding the expandable adhesive section (23) such that a first section (31) of the expanded adhesive section (23) extends into the at least one first recess (15) and a second section (33) of the expanded adhesive section (23) extends into the at least one second recess (17).Furthermore, a corresponding vehicle component (1), a first component (3) and a second component (5) are shown and described.

Description

[0001] The present invention relates to a method for producing a vehicle component, a vehicle component having a first component and a second component, and a corresponding first component and a corresponding second component.

[0002] Methods for manufacturing a vehicle component, vehicle components with a first component and a second component, and corresponding first and second components are known from the prior art. Particularly when the vehicle component has a multi-material structure—for example, when the first component is a metal component and the second component is a fiber-reinforced plastic (FRP) component—many areas of application and optimization possibilities arise, as different materials can be specifically combined to meet specific requirements. For example, multi-material structures with a metal component and a fiber-reinforced plastic (FRP) component bonded to the metal component offer significant lightweight construction potential and increasing application possibilities in the automotive industry.For example, to produce a vehicle component with a first component that is a metal component and a second component that is an FRP component, there are situations in which the first component is joined to the second component.

[0003] In general, it is desirable that a first component of a vehicle component and a second component of the vehicle component can be connected to each other in a simple and mechanically robust manner.

[0004] It is therefore the object of the present invention that a first component of a vehicle component and a second component of the vehicle component can be connected to one another in a simple and mechanically robust manner.

[0005] According to a first aspect of the invention, the stated object is achieved by a method having the features of patent claim 1. The method is provided for producing a vehicle component having a first component, a second component, and a connecting unit. The method comprises the following steps: providing the first component with a receiving portion that defines a receiving recess that extends along a first direction of extent and at least one first cutout that extends transversely to the first direction of extent, wherein the first component is either an FRP component, a metal component, or a plastic component. Providing the second component with a connecting portion that defines at least one second cutout that extends transversely to a second direction of extent. If the first component is an FRP component, the second component is a metal component or a plastic component.If the first component is a metal component or a plastic component, the second component is an FRP component. Providing the connecting unit with an expandable adhesive section. Arranging the first component, the second component and the connecting unit such that the connecting section and the expandable adhesive section are arranged in the receiving recess such that the expandable adhesive section is arranged between the at least one first recess and the at least one second recess. Expanding the expandable adhesive section such that a first section of the expanded adhesive section extends into the at least one first recess and a second section of the expanded adhesive section extends into the at least one second recess.

[0006] In the method, the first component is thus provided. The first component has the receiving section, which defines the receiving recess extending along the first direction of extent. With the aid of the receiving recess, the receiving section can receive the connecting section of the second component. The receiving section preferably extends parallel to a straight line along which the first direction of extent runs. The receiving section is preferably arranged, viewed perpendicular to this straight line, between the receiving recess and an area surrounding the first component. The receiving section preferably separates the receiving recess from the area surrounding the first component in all directions perpendicular to the straight line.

[0007] The receiving section defines the at least one first recess, which extends transversely to the first direction of extent. The fact that the receiving section defines the at least one first recess, which extends transversely to the first direction of extent, ensures that the first component and the second component can be connected to one another in a particularly robust mechanical manner, in that the first section of the extended adhesive section can extend into the at least one first recess. In particular, the fact that the at least one first recess extends transversely to the first direction of extent makes it possible to establish a positive connection viewed in the direction of the first direction of extent, which can also be referred to as anchoring viewed in the direction of the first direction of extent.Each first recess preferably extends circumferentially around a straight line along which the first direction of extension runs, such that a particularly robust mechanical connection can be provided between the first component and the second component. Each first recess preferably merges radially inwards, as seen in the direction of this straight line, into the receiving recess, such that the expandable adhesive section can expand particularly easily, at least in sections, into the first recess. Each first recess preferably merges radially inwards, as seen in the direction of this straight line, into the receiving recess along a continuous circular path arranged around the straight line, such that the expandable adhesive section can expand particularly easily, at least in sections, into the first recess.Preferably, each first recess tapers radially inward toward this straight line, so that a positive connection can be provided in the radial direction toward the straight line between the extended adhesive section and the first component. Preferably, each first recess 15 tapers radially inward along a continuous circumferential path arranged around the straight line, so that a positive connection can be provided in the radial direction toward the straight line between the extended adhesive section and the first component.Preferably, each first recess has a cross-sectional area extending perpendicular to the continuous orbit arranged around the straight line, which has the shape of an isosceles trapezoid, the longer base side of which is arranged on a side of the trapezoid facing away from the receiving recess and the shorter base side of which is arranged on a side of the trapezoid facing the receiving recess. Such a trapezoidal shape ensures a particularly robust positive connection between the extended adhesive section and the first component.

[0008] The first component is either an FRP component or a metal component or a plastic component. An FRP component is preferably a fiber-plastic composite component, i.e. a component that is made from a fiber-plastic composite or has a fiber-plastic composite. A fiber-plastic composite is preferably a component that has a plastic matrix and fibers embedded in the plastic matrix. The fibers are preferably carbon fibers and / or glass fibers, in particular long carbon fibers and / or glass fibers. In connection with the present invention, the FRP component can also be referred to as a supporting structure or section of a supporting structure. A metal component is preferably a component that is made from a metal or has a metal. A plastic component is preferably a component that is made from a plastic or has a plastic.

[0009] As already described, the second component is provided. The second component has the connecting section, which defines the at least one second recess extending transversely to the second direction of extent. The fact that the connecting section defines the at least one second recess extending transversely to the second direction of extent ensures that the first component and the second component can be connected to one another in a particularly robust mechanical manner, in that the second section of the extended adhesive section can extend into the at least one second recess. In particular, the fact that the at least one second recess extends transversely to the second direction of extent makes it possible to establish a positive connection viewed in the direction of the second direction of extent, which can also be referred to as anchoring viewed in the direction of the second direction of extent.Preferably, every second recess extends circumferentially around a straight line along which the second direction of extension runs, such that a particularly robust mechanical connection can be provided between the first component and the second component. Preferably, every second recess is open radially outwards in the direction away from this straight line, such that the expandable adhesive section can expand particularly easily, at least in sections, into a corresponding second recess. Preferably, every second recess is open radially outwards along a continuous circumferential path arranged around the straight line, such that the expandable adhesive section can expand particularly easily, at least in sections, into a corresponding second recess.Preferably, every second recess tapers radially inwards in the direction of this straight line, so that the adhesive section can spread particularly quickly in every second recess when expanding. Preferably, every second recess tapers radially inwards along a continuous orbit arranged around the straight line in the direction of this straight line, so that the adhesive section can spread particularly quickly in every second recess when expanding around the straight line. Preferably, every second recess has a cross-sectional area running perpendicular to the continuous orbit arranged around the straight line, which has the shape of an isosceles trapezoid, the longer base side of which is arranged on a side of the trapezoid facing away from the straight line and the shorter base side of which is arranged on a side of the trapezoid facing the straight line.Such a trapezoidal shape ensures particularly easy spreading of the adhesive section in every second recess.

[0010] If the first component is an FRP component, the second component is a metal component or a plastic component. If the first component is a metal component or a plastic component, the second component is an FRP component. The features, technical effects, and / or advantages already described in connection with the first component with regard to the FRP component, the metal component, and the plastic component also apply at least analogously to the second component, so that a corresponding repetition is omitted here. The present invention has proven particularly advantageous for joining components made of different materials.In particular, when either the first component or the second component is an FRP component and the corresponding other component is either a metal component or a plastic component, the first component and the second component can be joined together in an advantageous manner compared to methods known from the prior art.

[0011] As also already described, the connecting unit is provided with the expandable adhesive section. Because the connecting unit has the expandable adhesive section, the connecting unit can expand at least in sections. Preferably, the connecting unit consists of the expandable adhesive section, thereby providing a particularly material-friendly and space-saving alternative. Alternatively, the connecting unit preferably has further components in addition to the expandable adhesive section, so that the connecting unit can provide additional functions with the aid of the further components. The adhesive section is expandable.Because the adhesive section is expandable, the first component and the second component can be connected to one another in a particularly simple manner, since, with the aid of the expandable adhesive section, in order to connect the first component and the second component, only the first component, the second component, and the connecting unit need to be positioned relative to one another and then the adhesive section needs to be expanded. In the context of the present invention, an expandable adhesive section is preferably understood to mean an adhesive section that can be moved from a non-expanded state, in which the adhesive section can be referred to as an expandable adhesive section, into an expanded state, in which the adhesive section can also be referred to as an expanded adhesive section.In particular, the adhesive section occupies a larger volume in its expanded state than in its non-expanded state. Preferably, once brought into the expanded state, the expandable adhesive section can no longer be returned, in particular non-destructively, to another state or the non-expanded state. Preferably, the adhesive section is pressure-sensitively adhesive, so that when the adhesive is in contact with the first component and the second component, it forms a material bond with both the first component and the second component. Preferably, the adhesive section in the expanded state ensures both a positive connection with the first component and the second component as well as a material bond with the first component and the second component.

[0012] The expandable adhesive section preferably comprises a cured epoxy resin. The expandable adhesive section preferably comprises microballoons, which are preferably embedded in the epoxy resin. The expansion of the expandable adhesive section can be ensured with the aid of the microballoons. Preferably, a volume of the adhesive section is increased with the aid of the microballoons. The increase in the volume of the adhesive section preferably occurs during curing of the adhesive section and / or due to heating of the adhesive section. Due to the introduction of sufficiently large thermal energy, the microballoons can expand, so that the volume of the microballoons increases. This simultaneously increases the volume of the adhesive section. Thus, an expansion of the expandable adhesive section can be realized by increasing the volume of the microballoons.Preferably, the microballoons allow an expansion of the expandable adhesive section of up to 650%.

[0013] As also already described, the first component, the second component, and the connecting unit are arranged such that the connecting portion and the expandable adhesive portion are arranged in the receiving recess such that the expandable adhesive portion is arranged between the at least one first recess and the at least one second recess. Arranging the expandable adhesive portion between the at least one first recess and the at least one second recess ensures that the expandable adhesive portion can expand toward the at least one first recess and toward the at least one second recess, and into the at least one first recess and into the at least one second recess.Preferably, the first component and the second component are initially arranged relative to one another such that the first direction of extension and the second direction of extension run along the same straight line. Preferably, the connecting unit is attached to the second component beforehand or afterwards, so that the second component, together with the connecting unit, can be particularly easily inserted into the receiving recess.

[0014] As also already described, the expandable adhesive section is expanded such that the first section of the expanded adhesive section extends into the at least one first recess and the second section of the expanded adhesive section extends into the at least one second recess. Expanding the expandable adhesive section such that the first section of the expanded adhesive section extends into the at least one first recess and the second section of the expanded adhesive section extends into the at least one second recess ensures that the first component and the second component can be mechanically connected to one another in a particularly robust manner.In particular, since the first section of the extended adhesive section extends into the at least one first recess and the second section of the extended adhesive section extends into the at least one second recess, a positive connection can be produced as seen in the direction of the first extension direction and the second extension direction, which can also be referred to as anchoring.

[0015] The present invention is particularly advantageous when joining different materials. Because the connecting unit has the expandable adhesive section, the process effort for joining the first component and the second component can be significantly reduced, since only the first component, the second component and the connecting unit have to be arranged relative to one another and then the expandable adhesive section is expanded. Furthermore, the expanded adhesive section ensures that, when the first component and the second component have materials with different thermal expansion coefficients, its arrangement between the first component and the second component ensures that mechanical stresses in the region of the connection between the first component and the second component can be avoided or at least significantly reduced by deformation of the expanded adhesive section.Furthermore, by arranging the extended adhesive section between the first and second components, inhomogeneous material properties, such as different moduli of elasticity or tensile / compressive strengths of the materials, which could potentially lead to changes in stiffness and strength or stresses in the component, can be compensated for by deforming the extended adhesive section. Furthermore, by arranging the extended adhesive section between the first and second components, the risk of corrosion caused by different electrochemical behaviors of the first and second components can be reduced, thus avoiding additional processing steps and costs.Furthermore, the expansion of the adhesive section prevents unnecessarily tight tolerances, especially when the first or second component is a metal component, which is associated with high costs. Rather, the metal component can be manufactured with a high tolerance, and the expanded adhesive section compensates for the high tolerance, ensuring a mechanically robust connection between the first and second components despite the high tolerance.

[0016] Furthermore, the present invention is particularly advantageous compared to a conventional adhesive bond between the first component and the second component, in which the adhesive bond is created using a liquid, non-expandable adhesive. In the present invention, the geometric tolerances can be larger, since they can be compensated for by the expandable adhesive portion.

[0017] In summary, it can be stated that with the aid of the method, a first component of a vehicle component and a second component of the vehicle component can be connected to one another in a simple and mechanically robust manner.

[0018] In one embodiment, the expandable adhesive portion is a portion of an adhesive film. The fact that the expandable adhesive portion is a portion of an adhesive film ensures reliable, homogeneous, and full-surface adhesive distribution.

[0019] In one embodiment, the expandable adhesive section comprises an adhesive matrix and reinforcing elements embedded in the adhesive matrix. The reinforcing elements can be used to increase the strength and rigidity of the adhesive section. In particular, the expandable property of the adhesive section is achieved by the expandability of the adhesive matrix. The adhesive matrix preferably comprises the microballoons already described. The reinforcing elements preferably comprise carbon fibers and / or glass fibers, in particular short carbon fibers and / or glass fibers.

[0020] In one embodiment, the expandable adhesive portion consists of an adhesive. Because the expandable adhesive portion consists of the adhesive, an embodiment without reinforcing elements in the adhesive portion is provided. Preferably, the adhesive comprises the microballoons already described.

[0021] In one embodiment, the connecting unit has a reinforcing section, wherein the first component, the second component and the connecting unit are arranged such that the connecting section, the expandable adhesive section and the reinforcing section are arranged in the receiving recess such that the expandable adhesive section and the reinforcing section are arranged between the at least one first recess and the at least one second recess.The fact that the connecting unit has the reinforcement section and the first component, the second component and the connecting unit are arranged such that the connecting section, the expandable adhesive section and the reinforcement section are arranged in the receiving recess such that the expandable adhesive section and the reinforcement section are arranged between the at least one first recess and the at least one second recess ensures that when the adhesive section is expanded, the reinforcement section or at least a section of the reinforcement section is also brought into the first recess and / or into the second recess, whereby the first component and the second component can be connected to one another in a particularly robust mechanical manner.The reinforcing section preferably comprises fibers, such as carbon fibers and / or glass fibers, in particular short carbon fibers and / or glass fibers. The reinforcing section is preferably a reinforcing mat. The adhesive preferably impregnates the fibers upon expansion, so that in the manufactured state, the fibers of the reinforcing section are embedded in the expanded adhesive. The composite of adhesive and reinforcing section is preferably expandable, expands during production, and is in an expanded state in the manufactured state. In particular, the expandable property is achieved in that the adhesive is expandable, expands during production, and is in an expanded state in the manufactured state.

[0022] In one embodiment, the receiving portion defines a plurality of first recesses extending transversely to the first direction of extension. Using the plurality of first recesses extending transversely to the first direction of extension, a particularly mechanically robust connection can be established between the first component and the second component.

[0023] In one embodiment, the connecting section defines a plurality of second recesses that extend transversely to the second direction of extension. Using the plurality of second recesses that extend transversely to the second direction of extension, a particularly mechanically robust connection can be established between the first component and the second component.

[0024] According to a second aspect of the invention, the object mentioned at the outset is achieved by a vehicle component having the features of patent claim 8. The vehicle component has a first component, a second component, and a connecting unit. The first component has a receiving portion that defines a receiving recess that extends along a first direction of extent and at least one first cutout that extends transversely to the first direction of extent. The first component is either an FRP component, a metal component, or a plastic component. The second component has a connecting portion that defines at least one second cutout that extends transversely to a second direction of extent. If the first component is an FRP component, the second component is a metal component or a plastic component.If the first component is a metal component or a plastic component, the second component is an FRP component. The connecting unit has an extended adhesive section. The connecting section and the extended adhesive section are arranged in the receiving recess. A first section of the extended adhesive section extends into the at least one first recess and a second section of the extended adhesive section extends into the at least one second recess. Because a first section of the extended adhesive section extends into the at least one first recess and a second section of the extended adhesive section extends into the at least one second recess, a mechanically particularly robust connection is provided between the first component and the second component.This mechanically particularly robust connection can be provided in a particularly simple manner using the extended adhesive section. The features, technical effects, and / or advantages described in connection with the method according to the first aspect of the invention also apply at least analogously to the vehicle component according to the second aspect of the invention, so a corresponding repetition is omitted here.

[0025] According to a third aspect of the invention, the object mentioned at the outset is achieved by a first component having the features of patent claim 9. The first component is adapted for a vehicle component according to the second aspect. The first component has a receiving portion which defines a receiving recess which extends along a first direction of extent and at least one first recess which extends transversely to the first direction of extent. The first component is either an FRP component or a metal component or a plastic component. The features, technical effects and / or advantages described in connection with the method according to the first aspect of the invention and those described in connection with the vehicle component according to the second aspect of the invention also apply at least analogously to the first component according to the third aspect of the invention, so that a corresponding repetition is omitted here.

[0026] According to a fourth aspect of the invention, the object mentioned above is achieved by a second component having the features of patent claim 10. The second component is adapted for a vehicle component according to the second aspect. The second component has a connecting section that defines at least one second recess that extends transversely to a second extension direction. If the first component according to the third aspect is an FRP component, the second component is a metal component or a plastic component. If the first component according to the third aspect is a metal component or a plastic component, the second component is an FRP component.The features, technical effects and / or advantages described in connection with the method according to the first aspect of the invention, those described in connection with the vehicle component according to the second aspect of the invention and those described in connection with the first component according to the third aspect of the invention also apply at least analogously to the second component according to the fourth aspect of the invention, so that a corresponding repetition is omitted at this point.

[0027] Even if the method steps are described in a specific order, the present invention is not limited to this order. Rather, the individual method steps can be performed in any reasonable order, in particular at least partially in parallel.

[0028] Further features, advantages, and possible applications of the present invention will become apparent from the following description of the exemplary embodiments and the figures. All described and / or illustrated features, individually and in any combination, constitute the subject matter of the invention, regardless of their composition in the individual claims or their references. In the figures, the same reference numerals continue to represent the same or similar objects. Fig. 1a shows a schematic representation of a section of a first embodiment of a vehicle component according to the invention, Fig. 1b shows a schematic representation of a section of a second embodiment of a vehicle component according to the invention, Fig. 2 shows a schematic representation of the Fig. 1a of the first embodiment of the vehicle component according to the invention, wherein in comparison to Fig. 1a more details are visible, Fig. 3a, Fig. 3b and Fig. 3c each show a schematic representation of a section of a corresponding embodiment of a connecting unit of the vehicle component according to the invention, Fig. 4 shows schematic representations of a section of the first embodiment of the vehicle component according to the invention during a method for producing the vehicle component, Fig. 5 shows schematic representations of a section of a third embodiment of the vehicle component according to the invention during a method for producing the vehicle component, Fig. 6 shows schematic representations of a section of a fourth embodiment of the vehicle component according to the invention during a method for producing the vehicle component, Fig. 7 shows a schematic representation of an embodiment of a method according to the invention for producing the vehicle component, and Fig. 8 shows a schematic representation of different method steps of the embodiment of the method according to the invention for producing the vehicle component.

[0029] Fig. 1a shows a schematic representation of a section of a first embodiment of a vehicle component 1 according to the invention and Fig. 1b shows a schematic representation of a section of a second embodiment of a vehicle component 1 according to the invention. The vehicle component 1 has a first component 3 and a second component 5.

[0030] The first component 3 has a receiving section 7. The receiving section 7 defines a receiving recess 9, which extends along a first extension direction 11. In the Fig. In the first embodiment of the vehicle component 1 according to the invention shown in Figure 1a, the first component 3 is a metal component (a component made of a metal) and can also be referred to as a force introduction element. The force introduction element can form a portion of a joint or a bearing, such as a rubber bearing, or have a fastening portion to which a portion of a joint or a bearing can be fastened. In the embodiment shown in Fig. In the second embodiment of the vehicle component 1 according to the invention shown in Figure 1b, the first component 3 is an FRP component (fiber-plastic composite component, i.e. a component made from a fiber-plastic composite, i.e. having fibers embedded in a plastic matrix) and can also be referred to as a supporting structure or section of a supporting structure. The FRP component is preferably a continuous fiber-plastic composite (e-FRP) having continuous fibers embedded in a plastic matrix. The fibers, in particular the continuous fibers, are preferably carbon fibers, and the FRP component is a carbon fiber-reinforced plastic (CFRP). Alternatively, the fibers, in particular the continuous fibers, are preferably glass fibers, and the FRP component is a glass fiber-reinforced plastic (GFRP). The FRP component preferably has a laminate made from several interconnected layers of prepregs.In an alternative embodiment of the vehicle component 1 according to the invention, the first component 3 is a plastic component (a component made of a plastic). The second component 5 has a connecting section 13.

[0031] At the Fig. In the first embodiment of the vehicle component 1 according to the invention shown in Figure 1a, the second component 5 is an FKV component and can also be referred to as a supporting structure or section of a supporting structure. Fig. In the second embodiment of the vehicle component 1 according to the invention shown in Figure 1b, the second component 5 is a metal component and can also be referred to as a force introduction element. The force introduction element can form a section of a joint or a bearing, such as a rubber bearing, or have a fastening section to which a section of a joint or a bearing can be fastened. In an alternative embodiment of the vehicle component 1 according to the invention, the second component 5 is a plastic component. In particular, if the first component 3 is an FRP component, the second component 5 is a metal component or a plastic component. Furthermore, in particular, if the first component 3 is a metal component or a plastic component, the second component 5 is an FRP component. Fig. 1a and Fig. 1b, the vehicle component 1 is shown in a state not yet manufactured, which can also be referred to as a state during manufacture, wherein a large arrow shows a direction of movement of the second component 5 towards the first component 3 ( Fig. 1a) and a direction of movement of the first component 3 towards the second component 5 ( Fig. 1b). After a corresponding movement and further steps described in more detail later, a finished state is achieved in which the connecting section 13 is arranged in the receiving recess 9.

[0032] Fig. 2 shows a schematic representation of the Fig. 1a of the first embodiment of the vehicle component 1 according to the invention, wherein in comparison to Fig. 1a more details are visible. The Fig. 2, that the receiving section 7 defines at least one first recess 15 which extends transversely to the first direction of extent 11. The fact that the receiving section 7 defines at least one first recess 15 which extends transversely to the first direction of extent 11 ensures that the first component 3 and the second component 5 can be connected to one another in a particularly robust mechanical manner, which will be discussed in more detail later. In particular, the fact that the at least one first recess 15 extends transversely to the first direction of extent 11 makes it possible to produce a positive connection as seen in the direction of the first direction of extent 11, which can also be referred to as anchoring as seen in the direction of the first direction of extent 11. In addition, the connecting section 13 of the second component 5 defines at least one second recess 17 which extends transversely to a second direction of extent 19.The fact that the connecting section 13 of the second component 5 defines at least one second recess 17, which extends transversely to a second extension direction 19, also ensures that the first component 3 and the second component 5 can be connected to one another in a particularly robust mechanical manner, which, as already mentioned, will be discussed in detail later. In particular, the fact that the at least one second recess 17 extends transversely to the second extension direction 19 makes it possible to establish a positive connection viewed in the direction of the second extension direction 19, which can also be referred to as anchoring viewed in the direction of the second extension direction 19.

[0033] Fig. 3a, Fig. 3b and Fig. 3c each show a schematic representation of a section of a corresponding embodiment of a connecting unit 21 of the vehicle component 1 according to the invention, Fig. 4 shows schematic representations of a section of the first embodiment of the vehicle component 1 according to the invention during a method for producing the vehicle component 1, Fig. 5 shows schematic representations of a section of a third embodiment of the vehicle component 1 according to the invention during a method for producing the vehicle component 1, and Fig. 6 shows schematic representations of a section of a fourth embodiment of the vehicle component 1 according to the invention during a method for producing the vehicle component 1.

[0034] How the vehicle component 1 is manufactured will be described later. An adhesive portion 23 is provided in the manufactured vehicle component 1, which assumes an expanded state in the manufactured vehicle component 1 and can also be referred to as an expanded adhesive portion 23. During the manufacture of the vehicle component 1, the adhesive portion 23 is in a non-expanded state and, in this state, can also be referred to as an expandable adhesive portion 23.

[0035] The connecting unit 21, a section of which is Fig. 3a, consists of an expandable adhesive portion 23, which consists of an adhesive and assumes an expanded state in the manufactured vehicle component 1 and can also be referred to as an expanded adhesive portion 23 in the manufactured vehicle component 1. Before the vehicle component 1 is manufactured, the connecting unit 21 therefore consists of the expandable adhesive portion 23, which consists of the adhesive, and after the vehicle component 1 is manufactured, the connecting unit 21 consists of the expanded adhesive portion 23, which consists of the adhesive. In this exemplary embodiment, the adhesive is expandable, expands during manufacturing, and is in an expanded state in the manufactured state. The adhesive can also be referred to as an expandable adhesive.

[0036] The connecting unit 21, a section of which is Fig. 3b, consists of an expandable adhesive section 23, which has an adhesive matrix 25 and reinforcing elements 27 embedded in the adhesive matrix 25 and assumes an expanded state in the manufactured vehicle component 1 and can also be referred to as an expanded adhesive section 23 in the manufactured vehicle component 1. Before the vehicle component 1 is manufactured, the connecting unit 21 therefore consists of the expandable adhesive section 23, which has the adhesive matrix 25 and the reinforcing elements 27 embedded in the adhesive matrix 25, and after the vehicle component 1 is manufactured, the connecting unit 21 consists of the expanded adhesive section 23, which has the adhesive matrix 25 and the reinforcing elements 27 embedded in the adhesive matrix 25.In this exemplary embodiment, the composite of adhesive matrix 25 and reinforcing elements 27 is expandable, expands during production, and is in an expanded state in the manufactured state. In particular, the expandable property is achieved by the adhesive matrix 25 being expandable, expanding during production, and being in an expanded state in the manufactured state. The adhesive matrix 25 can also be referred to as an expandable adhesive matrix 25. The reinforcing elements 27 preferably comprise carbon fibers and / or glass fibers, in particular short carbon fibers and / or glass fibers.

[0037] The connecting unit 21, a section of which is Fig. 3c, in addition to an expandable adhesive portion 23 made of an adhesive, it has a reinforcing portion 29. In the manufactured vehicle component 1, the expandable adhesive portion 23 assumes an expanded state and can also be referred to as an expanded adhesive portion 23 in the manufactured vehicle component 1. Therefore, before the vehicle component 1 is manufactured, the connecting unit 21 has the reinforcing portion 29 in addition to the expandable adhesive portion 23 made of an adhesive, and after the vehicle component 1 is manufactured, the connecting unit 21 has the reinforcing portion 29 in addition to the expanded adhesive portion 23 made of an adhesive.In this exemplary embodiment, the reinforcing section 29 comprises fibers, such as carbon fibers and / or glass fibers, in particular short carbon fibers and / or glass fibers, and the adhesive impregnates the fibers upon expansion, such that in the manufactured state, the fibers of the reinforcing section 29 are embedded in the expanded adhesive. In this exemplary embodiment, the composite of adhesive and reinforcing section 29 is therefore expandable, expands during production, and is in an expanded state in the manufactured state. In particular, the expandable property is achieved in that the adhesive is expandable, expands during production, and is in an expanded state in the manufactured state. The adhesive can also be referred to as an expandable adhesive.

[0038] The Fig. The first embodiment of the vehicle component 1 according to the invention, shown in sections in Figure 4, has the connecting unit 21, a section of which is shown in Fig. 3a and which consists of the adhesive section 23, which in turn consists of the adhesive. Fig. The third embodiment of the vehicle component 1 according to the invention, shown in sections in Figure 5, has the connecting unit 21, a section of which is shown in Fig. 3b and which consists of the adhesive section 23, which has the adhesive matrix 25 and the reinforcing elements 27 embedded in the adhesive matrix 25. The Fig. The fourth embodiment of the vehicle component 1 according to the invention, shown in sections in Fig. 6, has the connecting unit 21, a section of which in Fig. 3c and which, in addition to the adhesive portion 23 consisting of the adhesive, has a reinforcing portion 29.

[0039] For each of the Fig. 4, Fig. 5 and Fig. 6, the connecting section 13 and the expandable adhesive section 23 are arranged in the receiving recess 9 in a state during the manufacture of the vehicle component 1 before the manufactured state (in the Fig. 4, Fig. 5 and Fig. 6 shown on the left). In addition, in the manufactured state, the connecting section 13 and the extended adhesive section 23 are arranged in the receiving recess 9 (in the Fig. 4, Fig. 5 and Fig. 6 (shown on the right). In the manufactured state, a first portion 31 of the extended adhesive portion 23 extends into the at least one first recess 15, and a second portion 33 of the extended adhesive portion 23 extends into the at least one second recess 17.

[0040] The first component 3 is adapted for the vehicle component 1 and is used in each of the Fig. 4, Fig. 5 and Fig. 6, the first component 3 has an identical construction. The first component 3 has the receiving portion 7, which defines the receiving recess 9, which extends along the first extension direction 11, and the at least one first recess 15, which extends transversely to the first extension direction 11. The first component 3 is a metal component.

[0041] The second component 5 is also adapted for the vehicle component 1 and is also used in each of the Fig. 4, Fig. 5 and Fig. 6, the second component 5 has an identical construction. The second component 5 has a connecting section 13 that defines at least one second recess 17 extending transversely to the second extension direction 19. The second component 5 is a composite composite.

[0042] Six first recesses 15 are provided in the first component 3. The receiving section 7 thus defines a plurality of first recesses 15 that extend transversely to the first direction of extension 11. The fact that the receiving section 7 defines the six first recesses 15 that extend transversely to the first direction of extension 11 ensures that the first component 3 and the second component 5 can be connected to one another in a particularly robust mechanical manner. Each first recess 15 extends circumferentially around a straight line along which the first direction of extension 11 runs, so that a particularly robust mechanical connection can be provided between the first component 3 and the second component 5.Each first recess 15 merges radially inwards in the direction of this straight line into the receiving recess 9, so that the expandable adhesive section 23 can expand particularly easily, at least in sections, into the first recess 15. Each first recess 15 merges radially inwards along a continuous circular path arranged around the straight line in the direction of this straight line into the receiving recess 9, so that the expandable adhesive section 23 can expand particularly easily, at least in sections, around the straight line into the first recess 15. In addition, each first recess 15 tapers radially inwards in the direction of this straight line, so that a positive connection can be provided in the radial direction towards the straight line between the expanded adhesive section 23 and the first component 3.Each first recess 15 tapers radially inward along a continuous orbit arranged around the straight line, as viewed toward this straight line, so that a positive connection can be provided in the radial direction toward the straight line between the extended adhesive section 23 and the first component 3. Each first recess 15 has a cross-sectional area running perpendicular to the continuous orbit arranged around the straight line, which has the shape of an isosceles trapezoid, the longer base side of which is arranged on a side of the trapezoid facing away from the receiving recess 9 and the shorter base side of which is arranged on a side of the trapezoid facing the receiving recess 9. Such a trapezoidal shape ensures a particularly robust positive connection between the extended adhesive section 23 and the first component 3.

[0043] Four second recesses 17 are provided in the second component 5. The connecting section 13 of the second component 5 thus defines a plurality of second recesses 17 that extend transversely to the second extension direction 19. The fact that the connecting section 13 defines the four second recesses 17 that extend transversely to the second extension direction 19 ensures that the first component 3 and the second component 5 can be connected to one another in a particularly robust mechanical manner. Each second recess 17 extends circumferentially around a straight line along which the second extension direction 19 runs, so that a particularly robust mechanical connection can be provided between the first component 3 and the second component 5.Each second recess 17 is open radially outward in the direction away from this straight line, so that the expandable adhesive section 23 can particularly easily expand, at least in sections, into a corresponding second recess 17. Each second recess 17 is open radially outward along a continuous circular path arranged around the straight line, so that the expandable adhesive section 23 can particularly easily expand, at least in sections, into a corresponding second recess 17 around the straight line.

[0044] In addition, every second recess 17 tapers radially inwards in the direction of this straight line, so that the adhesive section 23 can spread particularly quickly in every second recess 17 when expanding. Every second recess 17 tapers radially inwards along a continuous orbit arranged around the straight line in the direction of this straight line, so that the adhesive section 23 can spread particularly quickly in every second recess 17 when expanding around the straight line. Every second recess 17 has a cross-sectional area running perpendicular to the continuous orbit arranged around the straight line, which has the shape of an isosceles trapezoid, the longer base side of which is arranged on a side of the trapezoid facing away from the straight line and the shorter base side of which is arranged on a side of the trapezoid facing the straight line.Such a trapezoidal shape ensures particularly easy spreading of the adhesive section 23 in every second recess 17.

[0045] Fig. 7 shows a schematic representation of an embodiment of a method according to the invention for producing the vehicle component 1. The method comprises a first method step 101, a second method step 102, and a third method step 103.

[0046] In the first method step 101, the first component 3, the second component 5, and the connecting unit 21 are provided. When the connecting unit 21 is provided, the connecting unit 21 has the adhesive section 23 in the non-expanded state, so that the adhesive section 23 in this state can also be referred to as an expandable adhesive section 23. The receiving section 7 of the first component 3 defines a plurality of first recesses 15 that extend transversely to the first extension direction 11. The connecting section 13 of the second component 5 defines a plurality of second recesses 17 that extend transversely to the second extension direction 19.

[0047] To produce the Fig. 4, a connecting unit 21 is provided in which the expandable adhesive portion 23 consists of an adhesive. To produce the Fig. 5, a connecting unit 21 is provided in which the expandable adhesive section 23 has an adhesive matrix 25 and reinforcing elements 27 embedded in the adhesive matrix 25. For producing the Fig. 6, a connecting unit 21 is provided which, in addition to an expandable adhesive portion 23 consisting of an adhesive, has a reinforcing portion 29.

[0048] In the second method step 102, the first component 3, the second component 5 and the connecting unit 21 are arranged such that the connecting section 13 and the expandable adhesive section 23 are arranged in the receiving recess 9 such that the expandable adhesive section 23 is arranged between the at least one first recess 15 and the at least one second recess 17. To produce the Fig. 6, the first component 3, the second component 5 and the connecting unit 21 are arranged such that the connecting section 13, the expandable adhesive section 23 and the reinforcing section 29 are arranged in the receiving recess 9 such that the expandable adhesive section 23 and the reinforcing section 29 are arranged between the at least one first recess 15 and the at least one second recess 17.

[0049] In the third method step 103, the expandable adhesive portion 23 is expanded such that a first portion 31 of the expanded adhesive portion 23 extends into the at least one first recess 15 and a second portion 33 of the expanded adhesive portion 23 extends into the at least one second recess 17.

[0050] Fig. Figure 8 shows a schematic representation of different method steps of the method according to the invention for producing the vehicle component 1. First, an adhesive film 39 wound on a roll core 35 and provided on one side with a protective film 37 is provided. The adhesive film 39 provided with the protective film 37 is unrolled section by section from the roll core 35 and placed on a table 41, on which the adhesive film 39 provided with the protective film 37 is cut into several sections 45 by means of a cutting device 43. Each section of the adhesive film 39 forms an adhesive section 23 as already described and is used as a section of the connecting unit 21 for connecting a corresponding first component 3 and a corresponding second component 5. If a corresponding section is to be used as the adhesive section 23, the protective film 37 is peeled off the corresponding section, which is shown in the Fig. 8 is symbolically represented by arrows, and the adhesive section 23 is laminated circumferentially around the second component 5 onto the second component 5. During lamination, every second recess 17 is preferably covered by the adhesive section 23, but preferably not filled or at least partially filled. After lamination, as already described, in the second method step 102 the first component 3, the second component 5 and the connecting unit 21 are arranged such that the connecting section 13 and the expandable adhesive section 23 are arranged in the receiving recess 9 such that the expandable adhesive section 23 is arranged between the at least one first recess 15 and the at least one second recess 17.

[0051] For each of the Fig. 4, Fig. 5 and Fig. 6, the expandable adhesive section 23 is a section of an adhesive film 39. The fact that the expandable adhesive section 23 is a section of an adhesive film 39 ensures a reliable, homogeneous and full-surface adhesive distribution. In addition, for each of the Fig. 4, Fig. 5 and Fig. 6, the expandable adhesive section 23 is arranged between the at least one first recess 15 and the at least one second recess 17 and is then arranged in the expanded state both in the at least one first recess 15 and in the at least one second recess 17 as well as between the at least one first recess 15 and the at least one second recess 17. The expandable adhesive section 23 encloses the second component 5 circumferentially in a radial direction. In addition, in each of the Fig. 4, Fig. 5 and Fig. 6, a corresponding section of the connecting unit 21 is provided between an end face 47 of the second component 5 and a bottom section 49 of the receiving section 7, which also has a corresponding further expandable adhesive section and in the case of Fig. 6 additionally has a corresponding further reinforcement section. The features, technical effects, and / or advantages described in connection with the expandable adhesive section 23 and those described in connection with the reinforcement section 29 also apply at least analogously to the further expandable adhesive section and the further reinforcement section, so that a corresponding repetition is omitted here.

[0052] To produce the Fig. 4, the first method step 101 is first carried out, wherein in the first method step 101 the expandable adhesive section 23, which consists of the adhesive, is laminated to the second component 5. Subsequently, the second method step 102 is carried out. After the second method step 102, the third method step 103 is carried out, in which the adhesive hardens, expands, and fills the free spaces of the first recesses 15 and the second recesses 17. The adhesive now adheres to the two components and holds the components together in a materially bonded and form-fitting manner.

[0053] To produce the Fig. 5, the first method step 101 is first carried out, wherein in the first method step 101 the expandable adhesive section 23, which consists of the adhesive matrix 25 and the reinforcing elements 27 embedded in the adhesive matrix 25, is laminated to the second component 5. The second method step 102 is then carried out. After the second method step 102, the third method step 103 is carried out, in which the adhesive matrix 25 hardens, expands and fills the free spaces of the first recesses 15 and the second recesses 17. The adhesive matrix 25 now adheres to the two components and holds the components together in a materially bonded and form-fitting manner.With the help of the reinforcing elements 27, the strength and rigidity of the connection can be increased and because the adhesive matrix 25 and the reinforcing elements 27 are arranged in the first recess 15 and in the second recess 17, a mechanically particularly robust connection between the first component 3 and the second component 5 can be provided.

[0054] To produce the Fig.6, the first method step 101 is first carried out, wherein in the first method step 101 the expandable adhesive section 23, which consists of the adhesive, is laminated to the second component 5. Subsequently, in the first method step 101, the reinforcing section 29 is applied to the adhesive section 23. Preferably, the reinforcing section 29 has dry fibers which are applied radially from the outside to the adhesive section 23. Subsequently, the second method step 102 is carried out. After the second method step 102, the third method step 103 is carried out, in which the adhesive hardens, expands, impregnates the reinforcing section 29 and fills the free spaces of the first recesses 15 and the second recesses 17. The adhesive now adheres to the two components and holds the components together in a material-to-material and form-fitting manner.With the help of the reinforcing section 29, the strength and rigidity of the connection can be increased and because the adhesive and sections of the reinforcing section 29 are arranged in the first recess 15 and in the second recess 17, a mechanically particularly robust connection between the first component 3 and the second component 5 can be provided.

[0055] Even if the method steps are described in a specific order, the present invention is not limited to this order. Rather, the individual method steps can be performed in any reasonable order, in particular at least partially in parallel.

[0056] Additionally, it should be noted that "comprising" does not exclude other elements or steps, and "a" or "an" does not exclude a plurality. Furthermore, it should be noted that features described with reference to one of the above embodiments can also be used in combination with other features of other embodiments described above. Reference signs in the claims are not to be considered as limitations. Reference symbol 1 vehicle component 3 first component 5 second component 7 Recording section 9 Recess 11 first extension direction 13 connecting section 15 first recess 17 second recess 19 second extension direction 21 Connection unit 23 Adhesive section 25 Adhesive matrix 27 reinforcement elements 29 Reinforcement section 31 first section of the extended adhesive section 33 second section of the extended adhesive section 35 roll core 37 protective film 39 Adhesive film 41 Table 43 Cutting device 45 sections of the adhesive film with the protective film 47 front side 49 floor section 101 first procedural step 102 second procedural step 103 third procedural step

Claims

[1] Method for producing a vehicle component (1) comprising a first component (3), a second component (5) and a connecting unit (21), the method comprising the following steps: Providing the first component (3) with a receiving portion (7) which defines a receiving recess (9) extending along a first extension direction (11) and at least one first recess (15) extending transversely to the first extension direction (11), wherein the first component (3) is either an FKV component or a metal component or a plastic component, Providing the second component (5) with a connecting portion (13) defining at least one second recess (17) extending transversely to a second extension direction (19), wherein, when the first component (3) is an FKV component, the second component (5) is a metal component or a plastic component, and when the first component (3) is a metal component or a plastic component, the second component (5) is an FKV component, Providing the connecting unit (21) with an expandable adhesive portion (23), Arranging the first component (3), the second component (5) and the connecting unit (21) such that the connecting section (13) and the expandable adhesive section (23) are arranged in the receiving recess (9) such that the expandable adhesive section (23) is arranged between the at least one first recess (15) and the at least one second recess (17), and Expanding the expandable adhesive portion (23) such that a first portion (31) of the expanded adhesive portion (23) extends into the at least one first recess (15) and a second portion (33) of the expanded adhesive portion (23) extends into the at least one second recess (17). [2] A method according to the preceding claim, wherein the expandable adhesive portion (23) is a portion of an adhesive film (39). [3] Method according to one of the preceding claims, wherein the expandable adhesive portion (23) comprises an adhesive matrix (25) and reinforcing elements (27) embedded in the adhesive matrix (25). [4] A method according to any one of claims 1 or 2, wherein the expandable adhesive portion (23) is made of an adhesive. [5] Method according to one of the preceding claims, wherein the connecting unit (21) has a reinforcing section (29), wherein the first component (3), the second component (5) and the connecting unit (21) are arranged such that the connecting section (13), the expandable adhesive section (23) and the reinforcing section (29) are arranged in the receiving recess (9) such that the expandable adhesive section (23) and the reinforcing section (29) are arranged between the at least one first recess (15) and the at least one second recess (17). [6] Method according to one of the preceding claims, wherein the receiving portion (7) defines a plurality of first recesses (15) extending transversely to the first extension direction (11). [7] Method according to one of the preceding claims, wherein the connecting portion (13) defines a plurality of second recesses (17) extending transversely to the second extension direction (19). [8] Vehicle component (1) comprising a first component (3), a second component (5) and a connecting unit (21), wherein the first component (3) has a receiving portion (7) defining a receiving recess (9) extending along a first direction of extent (11) and at least one first recess (15) extending transversely to the first direction of extent (11), wherein the first component (3) is either an FRP component or a metal component or a plastic component, wherein the second component (5) has a connecting portion (13) defining at least one second recess (17) extending transversely to a second direction of extent (19), wherein, if the first component (3) is an FRP component, the second component (5) is a metal component or a plastic component, and if the first component (3) is a metal component or a plastic component, the second component (5) is an FRP component,wherein the connecting unit (21) has an extended adhesive portion (23), wherein the connecting portion (13) and the extended adhesive portion (23) are arranged in the receiving recess (9), and wherein a first portion (31) of the extended adhesive portion (23) extends into the at least one first recess (15) and a second portion (33) of the extended adhesive portion (23) extends into the at least one second recess (17). [9] A first component (3) adapted for a vehicle component (1) according to claim 8, wherein the first component (3) has a receiving portion (7) defining a receiving recess (9) extending along a first extension direction (11) and at least one first recess (15) extending transversely to the first extension direction (11), wherein the first component (3) is either an FRP component or a metal component or a plastic component. [10] Second component (5) adapted for a vehicle component (1) according to claim 8, wherein the second component (5) has a connecting portion (13) defining at least one second recess (17) extending transversely to a second extension direction (19), wherein when the first component (3) according to claim 9 is an FRP component, the second component (5) is a metal component or a plastic component, and when the first component (3) according to claim 9 is a metal component or a plastic component, the second component (5) is an FRP component.

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