STRUCTURAL COMPONENT

Description

[0001] The invention relates to a structural component of a motor vehicle and a method for its manufacture, wherein the structural component extends transversely to the vehicle direction and serves to separate the passenger compartment from the front compartment, preferably the engine compartment, wherein the structural component has a firewall, two A-pillars arranged laterally to the firewall and a transverse reinforcement running along the top of the firewall.

[0002] DE 10 2008 062 007 A1 discloses a bulkhead wall that is formed in several parts, namely from a lower crossbeam, a bulkhead element and an upper reinforcing beam, wherein the lower crossbeam is formed as a die-cast light metal component and the bulkhead element as well as the upper reinforcing beam are formed from a light metal sheet. The elements are joined together, for example, by welding, bolting, bonding or clinching.

[0003] A disadvantage here is the considerable effort required to join the individual parts together. DE 10 2008 062 004 A1 discloses a body structure in which the bulkhead has a flange and is connected to the crossmember, which also has a flange. The bulkhead is made of a light alloy sheet and is preferably welded or bonded to the crossmember. Here, too, the disadvantage lies in the significant time required to assemble the individual elements before the body structure component can be installed in the vehicle body.

[0004] DE 10 2014 108 884 A4 and EP 0 836 983 A2 show a one-piece, front hinge column of a vehicle and its manufacturing process.

[0005] The object of the invention is to propose a structural component and an associated method that shortens production time, reduces logistics costs and requires as few manual work steps as possible, thereby increasing the economic efficiency of the part, as well as ensuring that the structural component has the lowest possible weight.

[0006] This problem is solved according to the invention by designing the structural component as a one-piece or single-piece light metal die-cast part.

[0007] The structural component according to the invention for a motor vehicle, which extends transversely to the vehicle direction and serves to separate the passenger compartment from the front compartment, preferably the engine compartment, comprises a firewall, two A-pillars arranged laterally to the firewall, and a transverse reinforcement running along the top of the firewall. The structural component according to the invention is formed in one piece, meaning that the elements such as the firewall, A-pillars, and transverse reinforcement do not require any joining processes to be connected; rather, the structural component according to the invention is formed as a single unit. Furthermore, the structural component according to the invention is formed as a lightweight metal die-cast part, which allows for a thin-walled construction while still achieving the desired stability.

[0008] It has proven advantageous if the firewall has an integrally arranged pedal support. "Integrally arranged" means that a pedal support is directly integrated into the firewall or structural component and is also arranged on the die-cast component according to the invention. Thus, the structural component according to the invention with integrated pedal support is formed in one piece.

[0009] Of course, further or different tabs and brackets can also be integrally arranged on the structural component according to the invention, or further and different tabs and brackets can be integrated into the die-cast light metal component, depending on the vehicle type.

[0010] Preferably, the structural component is thin-walled, with the component wall thickness being between 1 and 8 mm, preferably between 2 and 5 mm. Preferably, the component walls have different thicknesses corresponding to their positioning on the structural component. This varying thickness optimizes the flow behavior within the structural component and / or achieves optimized filling. On the one hand, the individual component walls can have different thicknesses depending on their arrangement; on the other hand, a component wall itself can also have different thicknesses, meaning it can taper or widen to achieve optimized filling, as mentioned above.

[0011] A preferred embodiment has been found in which the A-pillar has ribbing for stiffening. Preferably, the ribbing is arranged on one side of the A-pillar and extends over the entire width and height, or only over a partial area.

[0012] It has proven advantageous if the transverse reinforcement incorporates ribbing for stiffening. The ribbing is preferably arranged between the splash guard and the transverse reinforcement. The ribbing is preferably formed by a regular arrangement of ribs along the top surface of the splash guard.

[0013] Preferably, ribbing is arranged in the transition area between the firewall and the A-pillar. This arrangement of the ribbing increases the stiffness between the individual components of the structural element.

[0014] According to a preferred embodiment, the structural component according to the invention is made of an Al or Mg alloy.

[0015] This problem is solved according to the invention by manufacturing the structural component according to the invention using the die-casting process.

[0016] Manufacturing the structural component according to the invention using the die-casting process enables a complex, thin-walled, yet stable design. Furthermore, various attachments can be integrated directly into the one-piece structural component, thus avoiding additional assembly steps.

[0017] It has proven advantageous to subject the structural component according to the invention to heat treatment after casting. This further enhances the desired properties, such as the strength of the structural component. Heat treatment can be performed on the entire component or only partially.

[0018] All design options can be freely combined with each other.

[0019] An embodiment of the invention is described with reference to the figures, although the invention is not limited to this embodiment. The figures show: Fig. 1 a three-dimensional view of a structural component according to the invention as seen from the passenger compartment, Fig. 2 a three-dimensional view of a structural component according to the invention as seen from the passenger compartment, Fig. 3 a top view of a structural component according to the invention as seen from the passenger compartment, Fig. 4 a side view directed towards an A-pillar, Fig. 5 a three-dimensional view of a structural component according to the invention as seen from the front compartment and Fig. 6 a three-dimensional view of a structural component according to the invention as seen from the front compartment.

[0020] The in Fig. 1The drawing shows a structural component 1 according to the invention for a motor vehicle. In its installed state, the structural component extends transversely to the vehicle interior and separates the passenger compartment from the front compartment, preferably the engine compartment. The structural component 1 includes a firewall 2 and A-pillars 3 molded onto each side of it. The two opposing A-pillars 3 are preferably mirror images of each other. Furthermore, the structural component 1 according to the invention includes a transverse reinforcement 4, which runs along the top surface of the firewall 2. The structural component 1 according to the invention, with its components—A-pillars 3, firewall 2, and transverse reinforcement 4—is formed in one piece. It therefore has no joints or connecting elements. The structural component 1 according to the invention is designed as a die-cast light metal part and can thus be manufactured in a single operation.The die-cast design allows for a thin-walled structure, which, through optional ribbing, provides the necessary stability. As shown in the figures, it is advantageous if a pedal support 4 is also directly integrated into the structural component 1, or if this element is also molded onto the splash guard 2, thus avoiding an additional joining process.

[0021] The figures clearly show that it is advantageous for the A-pillar 3 to have a rib 6 that increases its stability. Preferably, the rib 6 runs along the outer surface of the A-pillar 3. Furthermore, it is preferable for it to be arranged at regular intervals.

[0022] The figures also show that it is advantageous to have a rib 7 between the transverse reinforcement 4 and the upper surface of the firewall 2. This increases the stability of the transverse reinforcement 4. Furthermore, the structural component 1 according to the invention preferably has a rib 8 between the firewall 2 and the respective A-pillar 3.

[0023] Furthermore, the structural component 1 according to the invention preferably has a connection 9 to the sill at the A-pillars 3.

[0024] Furthermore, it is advantageous if the firewall 2 has an integrated passage 10 for the piping of an air conditioning unit. It has also proven advantageous if a passage 11, 12 for the brake pedal and / or steering column is integrated directly into the firewall 2. Likewise, it is advantageous if a service opening 13 for the air conditioning unit is integrated into the firewall 2. Similarly, it is advantageous if attachment points for a cockpit crossmember and / or roof rails are integrated on the A-pillar 3. Reference symbol list

[0025] 1 Structural component 2 Firewall 3 A-pillar 4 Cross reinforcement 5 Pedal carrier 6 A-pillar ribbing 7 Cross reinforcement ribbing 8 A-pillar / firewall ribbing 9 Sill connection 10 Air conditioning access 11 Brake pedal access 12 Steering column access 13 Air conditioning service opening 14 Mounting points

Claims

1. Structural component (1) of a motor vehicle, wherein the structural component (1) extends transversely to the vehicle direction and serves to separate the passenger compartment and the front compartment, preferably the engine compartment, wherein the structural component has a bulkhead (2), two A-pillars (3) arranged in each case laterally with respect to the bulkhead (2), and a transverse reinforcement (4) extending along the top side of the bulkhead (2), characterized in that the structural component is formed as a one-part or one-piece lightweight-metal die-cast part.

2. Structural component (1) according to Claim 1, characterized in that on the bulkhead (2) has a pedal carrier (5) which is arranged integrally thereon.

3. Structural component (1) according to either of Claims 1 and 2, characterized in that the structural component (1) is of thin-walled form, wherein the component wall is between 1 and 8 mm, preferably between 2 and 5 mm.

4. Structural component (1) according to one of Claims 1 to 3, characterized in that the A-pillar (3) has a rib formation (6) for the stiffening thereof.

5. Structural component (1) according to one of Claims 1 to 4, characterized in that the transverse reinforcement (4) has a rib formation (7) for reinforcement.

6. Structural component (1) according to one of Claims 1 to 5, characterized in that a rib formation (8) is arranged in the transition region between bulkhead (2) and A-pillar (3).

7. Structural component (1) according to one of Claims 1 to 6, characterized in that the structural component (1) is produced from an Al or Mg alloy.

8. Method for producing a structural component (1) according to one of Claims 1 to 7, characterized in that the structural component (1) is produced in a die-casting process.

9. Method according to Claim 8, characterized in that the structural component (1) is subjected to heat treatment after casting.