Motor vehicle body and methods for assembling the same

Abstract

Body (10) of a motor vehicle, wherein the body (10) comprises cast components (12) and sheet metal components (11), wherein at least one of the cast components (12) is connected to at least one of the sheet metal components (11), wherein the connection of a respective cast component (12) to a respective sheet metal component (11) is provided via a common plastic coating (13) of the same, at least partially, wherein in the sections where the respective cast component (12) is connected to the respective sheet metal component (11) via the common plastic coating (13) no further joining elements are present, so that in these sections the connection of the cast component (12) to the respective sheet metal component (11) is made exclusively via the common plastic coating.

Description

[0001] The invention relates to a body of a motor vehicle according to the preamble of claim 1 and a method for assembling a body of a motor vehicle according to the preamble of claim 2.

[0002] It is known from practice that a motor vehicle body can comprise both cast components and sheet metal components. Furthermore, it is known to combine at least one cast component with at least one sheet metal component to produce a motor vehicle body.

[0003] To join a cast component to a sheet metal component in a motor vehicle body, welded joints and adhesive joints are commonly used. It is also known to join sheet metal components and cast components of a motor vehicle body using screw connections. These joining methods for sheet metal components and cast components, which are familiar from practice, are problematic when there are large tolerances or dimensional deviations between the components and require additional processes, such as milling, to ensure a high-quality connection between cast components and sheet metal components through bonding, welding, or screwing.

[0004] DE 10 2015 014 361 A1 discloses a method for producing a node structure for a motor vehicle body. The node structure consists of at least two profile parts, with open ends of the profile parts being closed by a closure element. The profile components, closed at their open ends, are positioned in a pressing tool, followed by a pressing process with the addition of fiber-containing plastic compound to produce the profile node. The closure elements prevent the fiber-containing plastic from penetrating the profile components.

[0005] DE 10 2008 032 344 A1 discloses an assembly of a body of a motor vehicle, wherein the assembly is formed by a multi-part component made of carbon fiber reinforced plastic.

[0006] DE 10 2005 056 460 A1 discloses a method for producing a hybrid component made of different materials, wherein a plastic is applied to at least one area of ​​a metal component. A material bond is provided between the partial area of ​​the metal component and the plastic applied thereto.

[0007] DE 199 31 741 A1 discloses a body of a motor vehicle according to the preamble of claim 1.

[0008] DE 10 2006 026 385 A1 discloses a frame element for a motor vehicle body frame. The frame element has hollow profile beams connected by a node. The node thus provides a joining element for connecting the hollow profile beams. The node has an incompressible insert and a surrounding bedding that encompasses the insert.

[0009] EP 2 734 432 B1 and DE 10 2009 010 771 B4 disclose further prior art.

[0010] There is a need for a body and a method for assembling a body in which cast components and sheet metal components can be easily joined with high quality.

[0011] The object of the invention is to provide a novel body of a motor vehicle and a method for assembling and producing the same.

[0012] This object is achieved by a body of a motor vehicle according to patent claim 1 and by a method for assembling a body of a motor vehicle according to patent claim 2.

[0013] According to the invention, the connection of a respective cast component to a respective sheet metal component is provided via a common plastic sheathing of the same, at least in sections.

[0014] In the sections where the cast component is connected to the respective sheet metal component via the common plastic sheath, no further joining elements are present, so that in these sections the connection between the cast component and the respective sheet metal component is made exclusively via the common plastic sheath.

[0015] The invention proposes, for the first time, connecting at least one cast component to at least one sheet metal component in a motor vehicle body, at least in sections, via a common plastic sheath. This allows for a simple and precise connection of cast components and sheet metal components, even if the components have tolerances and thus dimensional deviations.

[0016] Preferably, the plastic coating is carried out using resin transfer molding. Joint coating of the respective cast component and the respective sheet metal component using a resin transfer molding process is particularly preferred.

[0017] Preferably, the respective sheet metal component is provided by punching and forming, and the respective cast component is provided by casting, preferably by die casting, wherein the respective cast component is joined to the respective sheet metal component immediately after the casting of the respective cast component, such that the respective cast component has a defined, casting-dependent component temperature for joining to the respective sheet metal component, namely for the joint encasing of the cast component and the sheet metal component with plastic. This has the advantage that heat stored in the cast component, which originates from the casting process, can be used during plastic encasing, in particular during resin transfer molding, to support the heating of the plastic and thus reduce the energy required for the plastic encasing.

[0018] Preferred developments of the invention will become apparent from the dependent claims and the following description. Exemplary embodiments of the invention are explained in more detail, without being limited thereto, with reference to the drawings. Herein: Fig. 1 a section of a motor vehicle body with cast components and sheet metal components before they are joined; Fig. 2 the section of the Fig. 1 after joining cast components and sheet metal components.

[0019] Fig. 1 shows a section of a body 10 of a motor vehicle in the area of ​​several sheet metal components 11 or 11a, 11b, 11c, 11d and 11e as well as a cast component 12. In Fig. 1 shows a partial exploded view of these components, in Fig. 2, the cast component 12 is connected to some of the sheet metal components.

[0020] According to the invention, the connection of a cast component 12 with at least one sheet metal component 11, in Fig. 1, Fig. 2 with the sheet metal component 11c, via an at least partially plastic coating of these components 12, 11c. To connect a cast component 12 to a respective sheet metal component 11, the components are therefore at least partially coated with plastic, preferably using a resin transfer molding process.

[0021] Where the cast component 12 is connected to the respective sheet metal component 11 via a common plastic sheath 13, no further joining elements, such as screws or rivets, are used.

[0022] To manufacture the body 10, the respective sheet metal component 11 or 11a, 11b, 11c, 11d, 11e and the respective cast component 12 are provided. The respective sheet metal component 11 or 11a, 11b, 11c, 11d, 11e is manufactured from sheet metal by stamping and forming. The respective cast component 12 is manufactured using a casting process, in particular by die casting.

[0023] Preferably, the connection of the respective cast component 12 to the respective sheet metal component 11 or 11a, 11b, 11c, 11d, 11e takes place immediately after the casting of the respective cast component 12, in such a way that the respective cast component 12 has a defined component temperature dependent on the casting for the connection to the respective sheet metal component 11 or 11a, 11b, 11c, 11d, 11e.

[0024] This allows heat from the casting process to be used to reduce the energy required to heat the plastic during encapsulation, namely during resin transfer molding.

[0025] Preferably, the components are cleaned before being coated with the plastic using the resin transfer molding process. The components bonded together via the plastic coating can then be further processed to further build the vehicle body.

[0026] The sheathing of the respective cast component 12 and the respective sheet metal component 11 or 11a, 11b, 11c, 11d, 11e for connecting these components provides a positive connection. This can simplify the manufacturing process for the body 10 of a motor vehicle.

Claims

[1] Body (10) of a motor vehicle, wherein the body (10) comprises cast components (12) and sheet metal components (11), wherein at least one of the cast components (12) is connected to at least one of the sheet metal components (11), characterized by , that the connection of a respective cast component (12) to a respective sheet metal component (11) is provided via a common plastic sheath (13) of the same, at least in sections, wherein in the sections where the respective cast component (12) is connected to the respective sheet metal component (11) via the common plastic sheath (13), no further joining elements are present, so that in these sections the connection of the respective cast component (12) to the respective sheet metal component (11) takes place exclusively via the common plastic sheath. [2] Method for assembling a body (10) of a motor vehicle, wherein at least one cast component (12) is connected to at least one sheet metal component (11), characterized by , that in order to connect a respective cast component (2) to a respective sheet metal component (11), the same are at least partially jointly coated with plastic, wherein in the sections where the respective cast component (12) is connected to the respective sheet metal component (11) via the common plastic coating (13), no further joining elements are used, so that in these sections the connection of the respective cast component (12) to the respective sheet metal component (11) takes place exclusively via the common plastic coating. [3] Method according to claim 2, characterized by that the plastic coating is carried out via resin transfer molding. [4] Method according to claim 2 or 3, characterized by following steps: Providing the respective sheet metal component (11) by punching and forming, Providing the respective cast component (12) by casting, Connecting the respective cast component (12) to the respective sheet metal component (11) immediately after the casting of the respective cast component (12), such that the respective cast component (12) has a defined component temperature dependent on the casting for the connection to the respective sheet metal component (11).

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