FUNCTIONAL COMPONENT, IN PARTICULAR FOR A MOTOR VEHICLE, METHOD FOR MANUFACTURING A FUNCTIONAL COMPONENT AND MOTOR VEHICLE COMPLETING A FUNCTIONAL COMPONENT

Description

[0001] The present invention relates to a functional component, in particular for a motor vehicle, and to a method for producing a functional component. Furthermore, the invention also relates to a motor vehicle comprising at least one functional component.

[0002] Functional components, such as node elements in a motor vehicle, include mounting devices or connection functions for connecting other components, such as handlebars and the like. These mounting devices, including rubber mounts, are screwed, pressed, or bonded to the node elements, which are usually made of a metallic material. Disadvantages of this type of functional component are the relatively high weight, the complex structure of the node element, and the complex manufacturing process.

[0003] DE 10 2011 053 222 A1 discloses a wishbone made of fiber-reinforced plastic for a vehicle wheel suspension, comprising at least two bearing elements and at least one web connecting the bearing elements. The at least one web is produced as a double- or multi-layer web from a fiber-reinforced, flat prepreg by folding, and at least one of the bearing elements is formed as a loop-shaped section in the folding area of ​​the prepreg, with the layers of the at least one web being integrally bonded to one another.

[0004] JP S58 206407 A and JP S59 153607 A teach the manufacture of wishbones using fiber composite materials, such as sheet molding compounds (SMC), wherein the individual elements are bonded together by means of an adhesive.

[0005] Based on this prior art, the object of the present invention is to provide a stable component with high functionality with regard to supporting additional components, while maintaining a simple yet lightweight structure. Furthermore, the object of the invention is to provide a method for producing a functional component that can be implemented simply, without significant technical complexity, and thus also cost-effectively. Furthermore, the object of the present invention is to provide a motor vehicle with high ride comfort and good driving dynamics, which is also characterized by a reduced deadweight.

[0006] The present invention is defined in the appended claims.

[0007] The above object is achieved according to the invention in a functional component, in particular for a motor vehicle, in that the component comprises a hardened fiber composite molding compound, wherein at least one rubber bearing is integrated into the fiber composite molding compound. The hardened fiber composite molding compound, which usually contains at least one reaction resin and fiber material and is also referred to as SMC (sheet molding compound) or BMC (bulk molding compound), among other things, is distinguished from conventional metallic materials by its significantly reduced dead weight and very good mechanical stability. According to the invention, at least one rubber bearing is integrated into the hardened fiber composite molding compound. A rubber bearing within the meaning of the invention is a mounting device or connecting function for further components which are mounted in the functional component in a low-noise and low-vibration manner by the rubber bearing.The rubber bearing is formed in a conventional manner and preferably comprises a bearing core and a layer of rubber or a rubber-like material surrounding the bearing core. The components to be connected, i.e., supported, are inserted, for example, into a recess in the bearing core. By directly integrating the rubber bearing into the cured fiber composite molding compound, additional connecting elements or fastening devices for the arrangement of the rubber bearing are eliminated. This is possible because the rubber bearing is fitted into the fiber structure of the fiber composite molding compound, thus becoming an integral part of the component. This results in a highly functional component with a connecting function or accommodation for additional components to be supported, which, despite its simple structure, is characterized by good stability, very good bearing properties, and, moreover, a low dead weight.Further components can be arranged in a conventional manner on or in the functional component according to the invention.

[0008] The subclaims contain advantageous developments and refinements of the invention.

[0009] According to the invention, the rubber bearing is arranged in a recess in the cured fiber composite molding compound. This contributes to the mechanical stability of the functional component, particularly in the area of ​​the cured fiber composite molding compound into which the rubber bearing is integrated. This is because, for example, when inserting or pressing the rubber bearing into the fiber composite molding compound, the fiber-containing material is essentially not damaged, and a precise connection between the rubber bearing and the fiber composite molding compound is achieved.

[0010] According to the invention, the rubber bearing comprises a metallic or plastic-containing outer ring, wherein the outer ring has a first adhesive structure that prevents the rubber bearing from spontaneously detaching from the cured fiber composite molding compound. By providing an outer ring on the rubber bearing, positioning and stabilization in the cured fiber composite molding compound can be achieved particularly easily. Advantageous adhesive structures include, for example, barbs, ribbing, or other friction-enhancing structures. This increases the stability of the functional component under acting forces such as impact and tensile forces, vibrations, or rotation.

[0011] The hardened fiber composite molding compound also features a bushing for accommodating the rubber bearing. The bushing forms the counterpart to the rubber bearing, i.e., the outer ring of the rubber bearing, allowing for a precise and highly stable integration of the rubber bearing into the hardened fiber composite molding compound. The bushing can be made of a metallic or plastic material. The material of the bushing is preferably wear-resistant, which allows the rubber bearing to be inserted and removed from the bushing multiple times without damaging the supporting structures of the fiber composite molding compound.

[0012] According to the invention, the bushing has a second adhesive structure that engages with the first adhesive structure of the outer ring of the rubber bearing. The second adhesive structure thus forms the counterpart to the first adhesive structure and enables particularly good reception, positioning, and stable adhesion of the rubber bearing in the bushing by forming a positive connection.

[0013] Advantageously, the bushing has at least one flat area for arranging a tool for securing the rubber mount in the bushing or for removing the rubber mount from the bushing. This allows for easy integration of the rubber mount into the fiber composite molding compound and also for replacement of the rubber mount, for example, during servicing, without the fiber composite molding compound being subjected to partial deformation or even destruction due to pressure or tensile forces.

[0014] To prevent corrosion damage to the component, especially when using carbon fibers in the fiber composite molding compound, the bushing is preferably designed to be galvanically insulating. This can be achieved by selecting suitable materials for the fiber composite molding compound and, in particular, for the bushing.

[0015] Furthermore, according to the invention, a first method for producing a functional component as described above is also provided, which comprises the steps: Providing a fiber composite molding compound, curing the fiber composite molding compound, wherein the cured fiber composite molding compound comprises a bushing with a second adhesive structure for receiving, positioning, and fixing a rubber bearing in the cured fiber composite molding compound, providing a rubber bearing with a metallic or plastic-containing outer ring, wherein the rubber bearing (1) comprises a first adhesive structure (6), and receiving the rubber bearing (1) in the bushing (5) such that the first adhesive structure (6) and the second adhesive structure (7) of the bushing (5) are positively connected, such that the outer ring of the rubber bearing is integrated into the cured fiber composite molding compound. is characterized. By carrying out this method according to the invention, a highly functional component is obtained in a simple manner using standard processes. This component is very well suited for supporting other components and is characterized by its low dead weight and, due to the lack of fastening means or connecting elements between the rubber bearing and the hardened fiber composite molding compound, by a simple structure. Due to the direct and precise integration of the outer ring of the rubber bearing and thus a stable anchoring of the rubber bearing in the fiber composite molding compound by pressing in the rubber bearing, without the use of conventional fastening means or connecting elements, the technical and logistical effort of the method according to the invention is low and its cost structure is optimized. Furthermore, the rubber bearing can be replaced very easily, for example by pressing the rubber bearing out of the recess.The first method according to the invention is therefore particularly suitable for functional components in which the bearing is subject to high wear due to its design and use and therefore has to be replaced at regular intervals.

[0016] Common process steps, such as shaping the fiber composite molding compound before curing, can complement the process.

[0017] Furthermore, a second method not according to the invention for producing a functional component as described above is described, which comprises the steps: Providing a fiber composite molding compound, introducing the fiber composite molding compound into a tool, inserting at least one rubber bearing comprising a metallic or plastic-containing outer ring into the fiber composite molding compound so that the outer ring of the rubber bearing comes into contact with the fiber composite molding compound, closing the tool, molding the fiber composite molding compound around the rubber bearing and curing the fiber composite molding compound The second method is also characterized by its ease of implementation using standard processes. Furthermore, the second method for integrating the rubber bearing does not require any post-processing of the cured fiber composite molding compound, because the rubber bearing is already formed before the fiber composite molding compound hardens, i.e., during the molding process. This is integrated into the final form of the component during mold closing. This allows the rubber bearing to be even more effectively integrated into the fiber structure of the fiber composite molding compound. The bearing properties and mechanical properties of the functional component are thus very good.

[0018] A third method not according to the invention for producing a functional component as described above is also described, which comprises the steps: Providing a fiber composite molding compound, forming a recess in the fiber composite molding compound and producing a rubber bearing in the recess in the fiber composite molding compound by an injection molding process, in particular by an elastomer injection molding process,

[0019] The third method also provides a structurally optimized component with very good bearing properties and thus high functionality with very good mechanical stability. Due to the step of creating a rubber bearing in the recess in the fiber composite molding compound using an injection molding process, the provision of an outer ring on the rubber bearing can be omitted, which reduces the logistical and technical complexity of the process and contributes to a further weight saving of the component according to the invention. In addition, corrosion protection measures are no longer necessary, since the rubber bearing itself ensures galvanic isolation. If necessary, the rubber bearing can be calibrated using a bearing core.According to the third method, the integration of the rubber bearing into the fiber composite molding compound takes place simultaneously with the production of the rubber bearing, so that the production times of the component are shortened and thus a high cycle rate in the manufacturing process is enabled.

[0020] The developments, advantages and effects described for the component according to the invention also apply to the method according to the invention for producing a functional component.

[0021] According to an advantageous development of the third method for producing a functional component, this further comprises at least one of the following steps: Curing the fiber composite molding compound and vulcanizing the rubber bearing.

[0022] The specified process steps, and in particular their combination, stabilize the final shape and structure of the functional component.

[0023] It is advantageously provided that the curing of the fiber composite molding compound and the vulcanization of the rubber bearing, particularly under the influence of heat, take place in a single step. This can accelerate the process and thus shorten processing times.

[0024] The invention further relates to a motor vehicle comprising a functional component as described above. Due to the optimal and low-noise mounting properties of the component according to the invention, the motor vehicle according to the invention is characterized by high ride comfort, very good driving dynamics, and excellent stability at a reduced weight.

[0025] The solutions according to the invention and their further developments result in the following advantages: The component according to the invention is characterized by excellent bearing properties combined with a simple structural design. A functional component and a motor vehicle with reduced dead weight are provided. Due to the integration of the rubber bearing into the fiber composite molding compound, the component is characterized by high stability and excellent mechanical properties. Due to the simplified structure of the component, it can be manufactured easily and cost-effectively using standard processes without significant technical effort. The motor vehicle with the component according to the invention exhibits high driving comfort and excellent driving dynamics.

[0026] Further details, features, and advantages of the invention will become apparent from the following description and the figures. They show: Figure 1 shows a longitudinal section through a rubber bearing for use in a functional component which is not according to the invention, Figure 2 shows a sectional view through a component which is not according to the invention and Figure 3 shows a sectional view through a component according to an advantageous development of the invention.

[0027] The figures show only the relevant parts of the rubber mount and the functional component; all other elements have been omitted for clarity. Furthermore, identical reference numerals refer to identical components.

[0028] In detail, Figure 1A longitudinal section through a rubber bearing 2 suitable for producing a functional component. The rubber bearing comprises an outer ring 3, which can be closed or, for example, slotted, an inner layer made of rubber or a rubber-like material 4, which covers an inner surface of the outer ring 3 at least in sections and preferably essentially completely, and a bearing core 8, for example made of a metallic material. The bearing core 8 is arranged at least in sections on the inside of the layer made of rubber or rubber-like material 4. Additional layers can be present between the bearing core 8 and the layer made of rubber or rubber-like material 4, which are preferably provided to improve the bearing properties and / or damping properties of the rubber bearing.Thus, optional inserts 11 or, alternatively or additionally, chambers, cavities, or additional layers of rubber or rubber-like material can be provided between the bearing core 8 and the layer of rubber or rubber-like material 4, which contribute to improved damping and vibration reduction. These cavities or chambers can be filled with air or a liquid. Furthermore, the bearing core 8 has a bore 9, which serves to accommodate or connect additional components to be mounted, such as a motor vehicle steering rod.

[0029] Figure 2shows a functional component 10, in particular for a motor vehicle, comprising a hardened fiber composite molding compound 1. A rubber bearing 2 is integrated into the hardened fiber composite molding compound 1. In this embodiment, the rubber bearing comprises an outer ring 3 and an inner layer made of rubber or a rubber-like material 4, which in turn has a bore 9. Furthermore, the rubber bearing 2 can also comprise a bearing core, which is arranged at least in sections on the inner side of the layer made of rubber or rubber-like material 4. The rubber bearing 2 in turn provides a connection function or mounting arrangement for a component to be mounted and is intended, for example, to accommodate a motor vehicle handlebar and to mount it in a low-noise and low-vibration manner.

[0030] The rubber bearing 2 is integrated into the hardened fiber composite molding compound 1 and, for example, pressed into the fiber composite molding compound. This ensures a good bond between the rubber bearing 2 and the hardened fiber composite molding compound 1, and the rubber bearing 2 is fixed in position and stabilized against acting mechanical forces, such as tensile forces, torsional forces, or vibrations. The outer ring 3 of the rubber bearing can be made of a metallic material or a plastic-containing material. The use of a plastic-containing material offers the advantage of additionally providing a material-to-material connection between the rubber bearing 2 and the hardened fiber composite molding compound 1.

[0031] The rubber bearing 2 can advantageously be arranged in a recess in the hardened fiber composite molding compound 1.

[0032] The Figure 3The functional component 20 shown also has a rubber bearing 2 integrated into a hardened fiber composite molding compound 1. In comparison to the functional component 10 from Figure 2 , a bushing 5 is incorporated into the hardened fiber composite molding compound 1, which can be made of metal or a plastic-containing material, for example. The bushing 5 serves to accommodate, position, and fix the rubber bearing 2 in the hardened fiber composite molding compound 1.

[0033] For this purpose, the rubber bearing 1 additionally has a first adhesive structure 6. In this embodiment, the first adhesive structure 6 is designed, by way of example, in the form of a dovetail structure, but can have any shape that supports the friction between the rubber bearing 2 and the hardened fiber composite molding compound 1. The dovetail shape shown here has the additional advantage that a particularly stable, positive-locking connection is formed between the first adhesive structure 6 of the rubber bearing 2, which is arranged on the outer ring 3 of the rubber bearing 2, and a second adhesive structure 7, which is provided on the inside of the bushing 5. The first adhesive structure 6 of the rubber bearing 2 and the second adhesive structure 7 of the bushing 5 form respective counterparts that are precisely matched to one another, so that good integration and anchoring of the rubber bearing 2 in the fiber composite molding compound 1 can be ensured.

[0034] The bushing may further comprise at least one flat area for arranging a tool for fastening the rubber bearing 2 in the bushing 5 or for removing the rubber bearing 2 from the bushing 5.

[0035] The foregoing description of the present invention is for illustrative purposes only and not for the purpose of limiting the invention. Various changes and modifications are possible within the scope of the invention and its equivalents. List of reference symbols:

[0036] 1 hardened fiber composite molding compound 2 rubber bearing 3 outer ring of the rubber bearing 4 layer of rubber or a rubber-like material 5 bushing 6 first adhesive structure 7 second adhesive structure 8 bearing core 9 bore 10, 20 functional component 11 insert

Claims

1. Functional component, in particular for a motor vehicle, wherein the component (10, 20) comprises a cured fibre-composite moulding compound (1), and wherein at least one rubber bearing (2) is integrated into the fibre-composite moulding compound (1), wherein the rubber bearing (2) is pressed into a cutout in the cured fibre-composite moulding compound (1), characterized in that the rubber bearing (2) comprises a metallic or plastics-containing outer ring (3) and the outer ring (3) has a first adhesive structure (7) which prevents autonomous detachment of the rubber bearing (2) from the cured fibre-composite moulding compound (1), wherein the cured fibre-composite moulding compound (1) has a bushing (5) for receiving the rubber bearing (2) and the bushing (2) has a second adhesive structure (7) which comes into form-fitting engagement with the first adhesive structure (6) of the outer ring (3) of the rubber bearing (2).

2. Functional component according to Claim 1, characterized in that the bushing (5) comprises at least one planar region for the arrangement of a tool for fastening the rubber bearing (2) in the bushing (5) or for detaching the rubber bearing (2) from the bushing (5) .

3. Functional component according to Claim 1 or 2, characterized in that the bushing (5) is configured so as to be galvanically isolating.

4. Method for producing a functional component (10, 20) according to one of the preceding claims, characterized by the steps: - providing a fibre-composite moulding compound, - curing the fibre-composite moulding compound, wherein the cured fibre-composite moulding compound comprises a bushing (5) having a second adhesive structure (7) for receiving, positioning, and fixing a rubber bearing (2) in the cured fibre-composite moulding compound (1), - providing a rubber bearing (2) having a metallic or plastics-containing outer ring (3), wherein the rubber bearing (1) comprises a first adhesive structure (6), and - receiving the rubber bearing (1) in the bushing (5), such that the first adhesive structure (6) and the second adhesive structure (7) of the bushing (5) are form-fittingly connected, such that the outer ring (3) of the rubber bearing (2) is integrated in the cured fibre-composite moulding compound (1).

5. Motor vehicle comprising at least one functional component (10, 20) according to one of Claims 1 to 3.