Component connection and manufacturing process

Abstract

The invention relates to a method for producing a component connection between a first component (1) and a second component (2), wherein at least the first component (1) has at least one hollow structure (1.1), wherein an additional component (3) is inserted into at least one hollow structure (1.1) of the first component (1), the shape and dimensions of which are selected such that the additional component (3) at least predominantly fills a cross-section of the hollow structure (1.1), thereby forming a partially planar joining area (3.1, 3.2), on which the second component (2) is arranged in an overlapping arrangement, the first component (1) is joined to the additional component (3), and the second component (2) is joined to the additional component (3) and / or to the first component (1). The invention further relates to a component connection produced according to the method.

Description

[0001] The invention relates to a method for producing a component connection according to the preamble of claim 1 and a component connection produced according to the method according to the preamble of claim 8.

[0002] Structural components optimized for strength and lightweight construction often feature hollow structures, leading to the current use of extruded profiles. However, joining such components is limited, as the hollow surfaces offer only small contact areas and the resulting joints exhibit very low strength. Therefore, current technology allows only overlapping of the closed surface areas, which is disadvantageous due to both complex component forming processes and the loss of installation space.

[0003] DE 10 2021 005 006 A1 discloses a method for welding hollow profiles, wherein at least two hollow profiles, each with a chamfer on a joint face, are provided. The at least two hollow profiles are arranged side by side with their joint faces facing each other such that the two facing chamfers of the hollow profiles form a clearance area in which the hollow profiles do not touch. The clearance area opens towards a welding face, and filler material is placed in this clearance area. The at least two hollow profiles are joined together by means of a fusion welding process from the welding face, whereby the filler material is melted.

[0004] The invention is based on the objective of providing a component connection in which component areas with hollow structures can also be securely and firmly connected to one another.

[0005] The problem is solved according to the invention by a method for producing a component connection with the features of the characterizing part of claim 1 and a component connection produced according to the method with the features of the characterizing part of claim 8.

[0006] Advantageous embodiments of the invention are the subject of the dependent claims.

[0007] In a method for producing a component connection between a first component and a second component, wherein at least the first component has at least one hollow structure, it is proposed according to the invention that an additional component is inserted into at least one hollow structure of the first component, the shape and dimensions of which are selected such that the additional component at least predominantly fills a cross-section of the hollow structure, thereby forming a partially planar joining area, on the joining area the second component is arranged in an overlapping arrangement, the first component is joined with the additional component, and the second component is joined with the additional component and / or with the first component.

[0008] The additional component increases the surface area on which the second component can be positioned and joined. Furthermore, it locally enhances the strength of the first component by being connected to it on at least one side. This connection can advantageously be achieved by welding and / or bonding. The shape and dimensions of the additional component can, for example, have a slight oversize relative to the hollow structure of the first component, allowing it to be pressed into the cavity, thus contributing to increased strength.

[0009] The additional component can be made of the same or a different material than the first component. For example, the first component can be an extruded profile, particularly made of aluminum 6xxx alloy. The additional component can advantageously be made of aluminum 5xxx alloy. If the second component is also made of aluminum 6xxx alloy, the first and second components can then be advantageously joined to the additional component by welding without cracking, since the alloying elements mix in the molten metal. The length of the additional component can be adapted to the load so that the joining areas between the first component and the additional component, and between the second component and the additional component, do not overlap.

[0010] The component arrangement produced by the inventive method enables the reliable joining of hollow profiles at the end face, despite the cavities present there, so that the axes of the components and the joints, for example the welds, are at an angle to each other, in particular at a right angle. Several cavities can be closed by means of several additional components, depending on the requirements of the component connection and the design of the second components.

[0011] The method according to the invention enables the realization of a novel component connection in the area of ​​a right angle between the components, with high strength and low production costs, for example without having to reshape the second component.

[0012] A component joint produced in this way offers new possibilities for lightweight construction with simultaneously high strength, new design options, and is particularly suitable for joining frame components, especially battery housings. The process is especially suitable for joining extruded profiles made of an aluminum 6xxx alloy, as the additional component can have a different alloy. A combination of different materials and / or alloys is possible, particularly through bonding.

[0013] The process can be carried out with current plant technology and exhibits excellent scalability for different component sizes. A reduction in the required installation space can be achieved, as joining on other surfaces is not necessary. The process is also suitable for use with body and structural components.

[0014] Exemplary embodiments of the invention are explained in more detail below with reference to drawings.

[0015] This shows: Fig. 1 schematically a first embodiment, Fig. 2 schematic further views of the first embodiment, Fig. 3 schematically a second embodiment, Fig. 4 schematically a third embodiment, Fig. 5 schematically a fourth embodiment, Fig. 6 schematically a fifth embodiment, and Fig. 7 schematically a sixth embodiment.

[0016] Corresponding parts are marked with the same reference symbols in all figures.

[0017] Fig. Figure 1 shows a spatial view of a first embodiment in which a first component 1 is an extruded profile having an open hollow structure 1.1 on its end face. The process is described in Fig. 2 shown in detail.

[0018] First, an exemplary cuboid-shaped additional component 3 is inserted into the hollow structure 1.1, such that the additional component 3 forms a flat surface with the front face of the first component 1, wherein the additional component 3 is cuboid-shaped and has a shape and dimensions that approximately fill the hollow structure 1.1, as shown by way of example with regard to the height h1 and the width b1 of the hollow structure 1.1 and the height h3 and the width b3 of the additional component 3.

[0019] The second component 2 is placed on the front face of the first component 1 and the additional component 3 at an approximately right angle δ and then the additional component 3 is welded to the first component 1 and the second component 2 is welded to the additional component 3 using a laser beam 4.1, so that exemplary weld seams 4 are created.

[0020] The additional component 3 also has a length l3, which is sufficiently large to create two joining areas 3.1 and 3.2. A first joining area 3.1, which serves to connect the additional component 3 to the second component 2, should, for example, have a length l3.1 that is at least twice the thickness d2 of the second component 2 measured in the direction of the length l3 of the additional component 3. A second joining area 3.2, which serves to connect the additional component 3 to the first component 1, adjoins the first joining area 3.1 so that the welds do not negatively affect each other.

[0021] Fig. Figure 3 shows a second embodiment. Here, the additional component 3 is inserted into the hollow structure 1.1 of the first component 1 and secured therein using adhesive 5. The second component 2 is placed on the end face of the first component 1 and the additional component 3 and also secured thereon using adhesive 5.

[0022] Fig. Figure 4 shows a partial view of an embodiment in which an arrangement of battery cells 6 is enclosed by a frame formed from two first components 1 and four second components 2, wherein the two first components 1 are connected to each other on each side by two parallel second components 2. In the selected partial view, only one of the two first components 1 is shown, which has been connected to two second components 2 by means of a weld 4 in the manner described above, wherein an additional component 3, concealed in the selected view by the respective second component 2, is arranged in a hollow structure 1.1, which is also concealed.

[0023] Fig. Figure 5 shows another variant of the embodiment according to Fig. 4, in which the two parallel second components 2 are additionally connected to each other by diagonally arranged struts 2.1 or, depending on the design, together form a component 2.

[0024] In the embodiment according to Fig. 6 are the two first components 1, of which only one is visible in the selected partial view, connected by two plate-shaped second components 2, of which also only one is visible in the selected partial view, but each by several welds 4, each with an additional component 3, which are hidden in the selected representation by the second component 2.

[0025] Fig. Figure 7 finally shows an embodiment which is a variant of the first embodiment as described in the Fig. 1 and Fig.Figure 2 shows the shape of the additional component 3. Here, the shape of the additional component 3 is not cuboid, but prismatic, which saves material and weight compared to the first embodiment. Reference symbol list 1 first component 1.1 Hollow structure 2 second component 2.1 Strut 3 Additional component 3.1 First joining area 3.2 Second joining area 4 weld seam 4.1 Laser beam 5 Adhesive 6 battery cells δ angle l3, l3.1 length b1, b3 width h1, h3 height d2 thickness 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] DE 10 2021 005 006 A1

[0003]

Claims

[1] Method for producing a component connection between a first component (1) and a second component (2), wherein at least the first component (1) has at least one hollow structure (1.1), characterized by , that - an additional component (3) is inserted into at least one hollow structure (1.1) of the first component (1), the shape and dimensions of which are chosen such that the additional component (3) fills at least a majority of a cross-section of the hollow structure (1.1), thereby forming a partially planar joining area (3.1, 3.2), - the second component (2) is arranged in an overlapping arrangement on the joining area (3.1, 3.2), - the first component (1) is joined with the additional component (3), and - the second component (2) is joined with the additional component (3) and / or with the first component (1). [2] Method according to claim 1, characterized by , that the first component (1) is designed as an extruded profile. [3] Method according to claim 1 or 2, characterized by , that the first component (1) and / or the second component (2) is made of an aluminum 6xxx alloy. [4] Method according to any one of claims 1 to 3, characterized by , that the additional component (3) is made of an aluminum 5xxx alloy. [5] Method according to any one of claims 1 to 4, characterized by , that the first component (1) and the second component (2) are joined at an angle (δ), where the angle (δ) preferably is 87.5° ≤ δ ≤ 92.5°. [6] Method according to any one of claims 1 to 5, characterized by that the joining is carried out by fusion welding, in particular by laser beam welding or gas metal arc welding. [7] Method according to any one of claims 1 to 5, characterized by that the joining is done by gluing. [8] Component connection between a first component (1) and a second component (2), wherein at least the first component (1) has at least one hollow structure (1.1), characterized by that the component connection is produced by a method according to one of claims 1 to 7.

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