Body component and manufacturing process

Abstract

The invention relates to a body component (100) of a vehicle body, comprising a composite part (200) which is joined from at least two individual parts (300) made of metallic materials along joining lines (210), wherein the composite part (200) is connected to a reinforcing part (400) which is produced by completely or partially overmolding the composite part (200) with plastic made of a polyamide, wherein the reinforcing part (400) covers the joining lines (210) and has an arrangement of reinforcing ribs (410). The invention further relates to a method for manufacturing a body component (100).

Description

[0001] The invention relates to a body component of a vehicle body according to the preamble of claim 1 and to a manufacturing method according to the preamble of claim 5.

[0002] US 2018 / 001525 A1 aims to provide a high-stiffness joining structure that allows different parts to be securely joined without a complicated manufacturing process and prevents corrosion. The proposed joining structure comprises a first element, a second element made of a different material than the first element, and a separating agent that separates the first and second elements by injecting resin between one end of at least one of the first and second elements and the other element.

[0003] EP 0 995 668 A1 discloses a highly mechanically resilient hollow chamber lightweight component, comprising at least one shell-shaped housing part made of high-strength material, in particular a material other than plastic, and preferably metal, and a support structure made of plastic, in particular thermoplastic plastic, wherein the support structure rests on the inside of the housing part and is in particular connected to the housing part, and at least one cover plate or cover shell made of a high-strength material, in particular metal, which largely covers the cavity formed by the housing part and support structure and is connected in its edge region at least to a part of the rim of the housing part.

[0004] DE 203 10 656 U1 describes a hybrid component for motor vehicles, in particular as a mounting carrier or as part of such a carrier for a front-end module, consisting of a three-dimensionally deformed sheet metal shell with reinforcing ribs made of plastic injection-molded onto it, wherein the sheet metal shell has discrete connection points for the plastic in the form of bumps, cups and / or openings, wherein the connection points are arranged in at least two different planes and there is a connection via the plastic between each connection point of one plane and at least one of the connection points of the other plane.

[0005] DE 10 2012 015 245 A1 discloses a support arrangement for a trailer coupling or a load carrier, comprising a cross member and side carriers connected to the cross member for mounting on a rear of a vehicle body, and at least one bracket arranged on the cross member for a trailer coupling or for a coupling part of a load carrier, wherein the support arrangement has at least one load-bearing component designed as a multi-component component, comprising a base body and a reinforcement body connected to the base body, which has a rib structure and / or a foam body made of a technical foam.

[0006] In a modern aluminum body shell, the rear longitudinal member is manufactured as a cast component. The disadvantage of cast components is the limitation of the minimum rib thickness. In a steel body shell, the rear longitudinal member is assembled from individual sheets. These individual sheets have different material thicknesses and are manufactured using different methods, such as tailor-welded blanks.

[0007] One object of the invention is to provide a body component for a vehicle body, which consists of a composite part made of at least two joined individual parts made of metallic materials, and which exhibits increased strength at a low weight. A further object of the invention is to provide a manufacturing process for such a body component.

[0008] The object is achieved according to the invention by a body part having the features of the characterizing part of claim 1 and a method for its manufacture having the features of the characterizing part of claim 5.

[0009] Advantageous embodiments of the invention are the subject of the dependent claims.

[0010] In the case of a body component of a vehicle body comprising a composite part made of at least two individual parts made of metallic materials joined along joining lines, it is proposed according to the invention that the composite part is connected to a reinforcement part which is produced by completely or partially overmolding the composite part with plastic, in particular PA6 GF50, wherein the reinforcement part covers the joining lines and has an arrangement of reinforcing ribs.

[0011] The composite part can comprise individual components made of various metallic materials, such as different steels, but also non-ferrous metals including aluminum and magnesium and their alloys. The composite part can include components with varying wall thicknesses. It can also include cast components as well as components made from sheet metal, for example, by deep drawing. The individual components can be joined to the composite part in a manner known per se, for example, by spot welding (e.g., resistance spot welding), by clinching, or other conventional joining methods. The joining of the individual components typically occurs along joining lines that correspond, for example, to the course of overlapping edge regions of two joined components.

[0012] According to the invention, the reinforcing element is created by injecting plastic onto or around the composite part, which bonds to the individual parts in a material-bonded and / or form-fit manner, thereby increasing their strength. The reinforcing element has reinforcing structures that cover the joint lines of the composite part. This strengthens the joint lines, resulting in a more secure connection between the individual parts, enabling them to transmit greater forces. Furthermore, it prevents the penetration of corrosive media such as water, salt, and dirt into the joint lines, i.e., the overlapping edge areas of the connected individual parts, thus achieving improved corrosion protection of the body part according to the invention.

[0013] The reinforcement element can, for example, comprise a plastic layer extending over surface areas of one or more individual parts, thereby increasing the component thickness and thus the strength of the individual part(s) and consequently the composite part. Alternatively or additionally, the reinforcement element can include reinforcing structures arranged, for example, extending away from an individual part, such that the body panel consisting of the composite part and the reinforcement element has a greater section modulus than the composite part alone. Polyamide, in particular PA6 GF50, a polyamide 6 reinforced with 50% glass fibers, can be used as the plastic for the reinforcement element. It is characterized by very high stiffness and strength.

[0014] The body panel according to the invention exhibits high strength at a low weight. At the same time, the freedom in shaping allows for a force-optimized design of the body panel, as reinforcement structures can be oriented according to the expected load paths of the body panel to ensure optimal force distribution. Furthermore, the body panel according to the invention enables improved functional integration by designing the reinforcement element in such a way that additional tasks, such as accommodating mounting points, can be performed.

[0015] In one embodiment, it may be provided that at least one component of the composite part has at least one through-hole through which the plastic of the reinforcement part extends, and / or at least one component of the composite part has an adhesion-promoting layer, in particular a layer made of a copolymer of PA6 and PA6.6.

[0016] Through-holes in the individual components allow the plastic to penetrate the respective component, thus creating a positive connection between the composite part and the reinforcing element. This also results in a stronger bond between the individual components and enables the composite part as a whole to withstand greater forces. If the reinforcing element is designed so that its reinforcing structures are located not only on one side of the composite part but also on the opposite side, the through-holes simultaneously form the material-bonded connection between the reinforcing structures of the reinforcing element on both sides of the composite part.

[0017] The reinforcing structures of the reinforcing element are bonded to the individual components at their surfaces. This bond can be enhanced by applying an adhesion promoter layer to the individual components or the composite part as a whole, thereby achieving a higher force transmission between the composite part and the reinforcing element. For this purpose, an adhesion promoter can be applied to the surface of one or more individual components or the composite part as a whole, for example, by spraying. Alternatively or additionally, an adhesion promoter layer can consist of, for example, a plastic film that is glued, welded, or rolled onto a sheet metal used to manufacture an individual component.If this step is carried out upstream of the production of the individual parts, for example during the rolling of the sheet metal, a blank of this sheet metal can be further processed to produce an individual part together with the foil placed on it, for example by deep drawing.

[0018] In one embodiment, the body component according to the invention can be a body longitudinal member, in particular a rear body longitudinal member. It can be provided, for example, that individual parts of the body longitudinal member comprise a shock absorber bracket, in particular made of CR340 steel, and / or a wheel installation, designed, for example, as a tailored welded blank, in particular made of CR210 and CR340 steel, and / or an upper longitudinal member, in particular made of press-hardened PSC950Y1300T steel, and / or a lower longitudinal member, in particular made of press-hardened PSC950Y1300T steel.

[0019] The concept according to the invention is applicable to aluminum and steel car bodies. The longitudinal member, for example, can be constructed from a few individual sheet metal parts and joined using conventional methods, such as resistance spot welding or clinching. To create a bond between the plastic and the metal, through-holes can be introduced as injection points to achieve a positive fit. Alternatively or additionally, a plastic film can be rolled onto the component, which improves the bond between the plastic and the metal.

[0020] To solve the problem, it is further proposed according to the invention that in a method for manufacturing a body component in which at least two individual parts made of metallic materials are joined along joining lines to form a composite part, the composite part is placed in an injection mold and completely or partially overmolded with a plastic, thereby forming a reinforcing part connected to the composite part, which covers the joining lines and has an arrangement of reinforcing ribs.

[0021] An exemplary application of the method according to the invention relates to a steel body in which a longitudinal body member can be manufactured and joined from a few deep-drawn sheets. In another exemplary application of the method according to the invention, which relates to an aluminum body, similar depths can be achieved with hot-formed aluminum sheets.

[0022] According to the invention, the individual parts can be joined to form a composite part, for example, by resistance spot welding or by clinching. After joining the individual parts, the assembled composite part is placed in an injection mold. The joint lines between the joined individual parts are overmolded, and additional ribbing, i.e., a force-optimized arrangement of reinforcing ribs, is added to achieve a stiffness equivalent to that of current series-produced parts.

[0023] In one embodiment of the method according to the invention, at least one through-hole can be provided in at least one component of the composite part, so that the plastic of the reinforcing part is injected into the at least one through-hole and extends through the through-hole and creates a positive connection between the plastic and the metal.

[0024] In an alternative or additional embodiment of the method according to the invention, at least one component of the composite part can be provided with an adhesion promoter layer, in particular a polyamide layer. For components made of sheet metal, the adhesion promoter layer can be produced by rolling a film, in particular a copolymer of PA6 and PA6.6, onto the surface of the sheet metal. This can be done during the production of the sheet metal in the rolling mill, for example by phosphating the sheet metal and / or by applying an adhesion promoter to the steel or aluminum sheet metal, for example by spraying it on, and / or by rolling on a PA film. The PA film can, for example, consist of a copolymer of PA6 and PA6.6 that possesses extremely high impact strength.

[0025] The individual part can be deep-drawn together with the PA film. Reinforcing structures, such as plastic reinforcing ribs, are then overmolded or injection-molded onto it. These reinforcing structures can be made from PA6 GF50, for example, and injection-molded either on one or both sides.

[0026] The body panel manufactured according to the invention, through the complete coverage of the sheet metal by the PA film, advantageously enables its use in humid environments. The complete bonding of the PA film and the improved material adhesion between the plastic and the metal further facilitate higher energy absorption. Another advantage lies in the improved functional integration into the body panel due to the high degree of design freedom afforded by the plastic structure. The reinforcement element with its ribbed structure contributes to a significant weight reduction while maintaining high strength in the body panel. Its strength can be optimized along the load path.

[0027] Exemplary embodiments of the invention are explained in more detail below with reference to drawings.

[0028] This shows: Fig. 1 Schematic representation of individual parts of a composite part for a body panel according to an exemplary embodiment, Fig. 2 schematically a composite part of the exemplary embodiment, and Fig. 3 schematically a body part of the exemplary embodiment produced from the composite part.

[0029] Corresponding parts are marked with the same reference symbols in the figures.

[0030] The exemplary embodiment schematically shows how individual parts 300, which are in Fig. 1 shows a composite part 200, which is in Fig. 2 is shown, and from the composite part 200 a body part 100, which is in Fig. 3 is shown, it is manufactured.

[0031] The in Fig. The individual parts 300 shown in Figure 1 are a shock absorber bracket 301 made of CR340 steel, a wheel assembly 302, designed as a tailored welded blank made of CR210 and CR340 steel, an upper longitudinal member 303 made of press-hardened PSC950Y1300T steel, and a lower longitudinal member 304, also made of press-hardened PSC950Y1300T steel. The wheel assembly 302, the upper longitudinal member 303, and the lower longitudinal member 304 are provided with through holes 310.

[0032] In Fig. Figure 2 also shows that the wheel assembly 302, the upper longitudinal member 303, and the lower longitudinal member 304 are provided with an adhesion-promoting layer 320. It is also evident that the individual parts 300 are joined together along joining lines 210 to form a composite part 200.

[0033] In Fig.Figure 3 shows that the composite part 200 is connected to a reinforcing part 400 to form a body part 100, which in the exemplary embodiment is a longitudinal body member 101. The reinforcing part 400 is formed by injection molding a plastic, the plastic covering the joining lines 210 and being injected into the through holes 310, so that the reinforcing part 400 is positively connected to the composite part 200, and the reinforcing part 400 comprises an arrangement of reinforcing ribs 410 that extend between the through holes 310 and are materially bonded to the composite part 200, thereby giving the body part 100 high rigidity. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] US 2018 / 001525 A1

[0002] EP 0 995 668 A1

[0003] DE 203 10 656 U1

[0004] DE 10 2012 015 245 A1

[0005]

Claims

[1] Body component (100) of a vehicle body, comprising a composite part (200) which is joined from at least two individual parts (300) made of metallic materials along joining lines (210), characterized by , that the composite part (200) is connected to a reinforcing part (400) which is produced by completely or partially overmolding the composite part (200) with plastic made of a polyamide, wherein the reinforcing part (400) covers the joining lines (210) and has an arrangement of reinforcing ribs (410). [2] Body component (100) according to claim 1, characterized by , that at least one individual part (300) of the composite part (200) has at least one through hole (310) through which the plastic of the reinforcing part (400) extends, and / or at least one individual part (300) of the composite part (200) has an adhesion promoter layer (320), in particular a layer of a copolymer of PA6 and PA6.

6. [3] Body component (100) according to claim 1 or 2, characterized by , that it is a body longitudinal member (101), in particular a rear body longitudinal member (101). [4] Body component (100) according to claim 3, characterized by , that individual parts (300) of the body longitudinal member (101) comprise a shock absorber bracket (301), in particular made of CR340 steel, or / and a wheel installation (302), designed for example as a tailored welded blank, in particular made of CR210 and CR340 steel, or / and an upper longitudinal member (303), in particular made of press-hardened PSC950Y1300T steel, or / and a lower longitudinal member (304), in particular made of press-hardened PSC950Y1300T steel. [5] Method for manufacturing a body component (100) in which at least two individual parts (300) made of metallic materials are joined along joining lines (210) to form a composite part (200), characterized by, that the composite part (200) is placed in an injection mold and is completely or partially overmolded with a plastic made of a polyamide, thereby forming a reinforcing part (400) connected to the composite part (200), which covers the joining lines (210) and has an arrangement of reinforcing ribs (410). [6] Method according to claim 5, characterized by , that the individual parts (300) are joined to the composite part (200) by resistance spot welding or clinching. [7] Method according to claim 5 or 6, characterized by , that at least one through hole (310) is provided in at least one individual part (300) of the composite part (200) and the plastic of the reinforcement part (400) is injected into the at least one through hole (310). [8] Method according to any one of claims 5 to 7, characterized by, that at least one individual part (300) of the composite part (200) is provided with an adhesion promoter layer (320), in particular made of a copolymer of PA6 and PA6.

6. [9] Method according to claim 8, characterized by , that at least one individual part (300) is made from a sheet of metal on whose surface a foil is rolled.

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