Structural element for a single- or dual-track motor vehicle, more particularly for a motorcycle, single- or dual-track motor vehicle, and method for producing such a structural element

Abstract

The invention relates to a structural element (1) for a single- or dual-track motor vehicle, the structural element (1) comprising at least one rheocast component (3) made of a metallic material.

Description

[0001] Structural element for a motorcycle, in particular for a motorcycle, motorcycle and method for producing such a structural element

[0002] The invention relates to a structural element for a motorcycle, in particular for a motorcycle, according to the preamble of patent claim 1. Furthermore, the invention relates to a motorcycle having at least one such structural element. The invention also relates to a method for producing a structural element for a motorcycle, in particular for a motorcycle, according to the preamble of patent claim 10.

[0003] A frame structure for an electric motorcycle is known from US Pat. No. 9,598,132 B2. Furthermore, EP 2,589,528 A1 discloses a motorcycle with a frame and a motor mounted on the frame.

[0004] The object of the present invention is to provide a structural element for a motorcycle, a motorcycle with at least one such structural element and a method for producing such a structural element, so that a particularly low weight and advantageous mechanical properties of the structural element can be realized.

[0005] This object is achieved according to the invention by a structural element having the features of patent claim 1, by a motorcycle having the features of patent claim 9, and by a method having the features of patent claim 10. Advantageous embodiments are the subject of the dependent claims.

[0006] A first aspect of the invention relates to a structural element for a motorcycle. This means that the motorcycle, in its fully manufactured state, comprises the structural element. The motorcycle is preferably a single-track motor vehicle with exactly two vehicle wheels arranged one behind the other, i.e., consecutively, in the longitudinal direction of the motorcycle. Thus, the motorcycle can, for example, be a single-track motorcycle with exactly two vehicle wheels arranged one behind the other, i.e., consecutively, in the longitudinal direction of the motorcycle. Furthermore, it is conceivable for the motorcycle to be a tricycle, in particular a two-track one, thus a motor vehicle, in particular a two-track one, with exactly three vehicle wheels, so that the motorcycle can, for example, be designed as a motorcycle with a sidecar or as a trike.

[0007] In particular, a structural element is understood to be a load-bearing component. The structural element comprises a metallic material. For example, the metallic material is a light metal, i.e., a light metal alloy, in particular an aluminum alloy.

[0008] In order to achieve a particularly low weight and, at the same time, particularly advantageous mechanical properties of the structural element, the invention provides that the structural element has at least one rheocast component made of the metallic material. The rheocast component, also referred to as the first rheocast part, is understood to be a component produced by rheocasting, i.e., by a rheocasting process. Rheocasting is also referred to as rheocasting or rheocasting and is a casting process in which the metallic material, as a cast material, is processed not in a completely liquid, but in a semi-solid or semi-liquid state.In rheocasting, for example, an initially completely solid raw part made of the metallic material is provided, from which, however, no liquid melt is then produced. Instead, the raw part, also referred to as the blank, is electromagnetically kneaded, i.e. processed using electromagnetic waves, so that the blank reaches the aforementioned semi-solid or semi-liquid state, i.e. a state similar to jelly or chilled ice cream. In this state, the blank is pressed into a mold or mould using a piston, for example, as in a die-casting process, and thus formed, whereby the rheocast component is produced from the blank. This makes it possible to achieve particularly thin wall thicknesses of the rheocast component, also referred to as wall thicknesses, and compared to conventional components, the same or even better material properties can be achieved.As a result, the overall weight of the structural element can be kept particularly low, and particularly advantageous mechanical properties of the structural element can be achieved. In particular, wall thicknesses of no more than 3.5 millimeters or even less than 3.5 millimeters can be achieved, while simultaneously achieving particularly advantageous mechanical properties. In order to keep the weight of the structural element particularly low and to be able to achieve particularly advantageous mechanical properties of the structural element, one embodiment of the invention provides that at least 30 percent of a volume and / or a mass of the structural element is formed by the rheocast component.

[0009] A further embodiment is characterized in that the structural element is designed as a frame of the motorcycle. This embodiment is based on the realization that the frame of a motorcycle contributes significantly to the overall weight of the motorcycle, so that by designing the structural element as a frame, the weight of the motorcycle can be kept particularly low.

[0010] In a further, particularly advantageous embodiment of the invention, the structural element is designed as a rear swing arm for the motorcycle. A rear swing arm of a motorcycle can also contribute significantly to the overall weight of the motorcycle, so that the invention allows the weight of the motorcycle to be kept particularly low. Thus, for example, in the fully manufactured state of the motorcycle, one of the aforementioned vehicle wheels of the motorcycle is designed as a rear wheel, in particular as the sole rear wheel, of the motorcycle and is rotatably mounted on the rear swing arm. In particular, this allows the unsprung masses of the motorcycle to be kept particularly low.

[0011] In order to be able to realize particularly advantageous properties of the rheocast component and thus of the structural element as a whole in a particularly weight-efficient manner, it is provided in a further embodiment of the invention that the rheocast component has at least or exactly one rib for stiffening the rheocast component.

[0012] In a further, particularly advantageous embodiment of the invention, the structural element comprises the first rheocast component and at least or exactly one second rheocast component, provided in addition to the first rheocast component, formed separately from the first rheocast component, and connected, in particular directly, to the first rheocast component. Very preferably, the structural element comprises exactly two rheocast components, namely the first rheocast component and the second rheocast component. This makes it possible to achieve a low weight and particularly advantageous mechanical properties of the structural element. Furthermore, the structural element can be manufactured as needed, quickly and cost-effectively. The previous and following statements regarding the first rheocast component can easily be transferred to the second rheocast component, and vice versa.

[0013] The Rheoguss components are connected to each other, in particular directly, in a form-fitting and / or material-fitting manner and / or in a form-fitting manner.

[0014] It has proven particularly advantageous if the rheocast components are welded together, especially directly, and thus connected to one another. This allows particularly advantageous properties of the structural element to be realized in a particularly lightweight and cost-effective manner.

[0015] It is also conceivable that the Rheoguss components are screwed together.

[0016] It is particularly advantageous if the Rheoguss components are glued together, in particular directly, and are thereby connected to one another, in particular directly.

[0017] Finally, it has proven particularly advantageous if the rheocast components themselves, i.e. considered on their own, form a hollow cross-section, in particular an open one, with at least or exactly one opening, so that the hollow cross-section is open on a side on which the opening is arranged. The opening, in particular designed as a through-opening, is at least predominantly and thus at least more than half, in particular completely, closed by a closing element formed separately from the rheocast components, provided in addition to the rheocast components and, in particular directly, connected to the rheocast components, in particular welded and / or glued and / or screwed. This makes it possible to achieve particularly high rigidity in a particularly weight-effective manner.

[0018] The locking element can be formed in one piece, i.e., from a single piece. This means that the locking element is not composed of multiple, separately formed and interconnected parts, but rather the locking element is formed from a single piece and thus designed as a monoblock or formed by a monoblock. Alternatively, it is conceivable for the locking element to be formed from multiple parts, so that the locking element, for example, has multiple parts, i.e., at least or exactly two parts, which are separately formed and, in particular, directly interconnected, in particular welded and / or glued and / or screwed together, and is formed from the parts.

[0019] In order to be able to realize particularly advantageous mechanical properties of the structural element in a particularly cost-effective and weight-effective manner, it is provided in a further embodiment of the invention that the rheocast components are not mirror-symmetrical to one another.

[0020] The closing element is preferably designed as a component different from a rheocast component, so that the closing element is preferably not produced by rheocasting. The closing element is preferably formed from the aforementioned metallic material or from another, further metallic material, in particular from a steel or a steel alloy. The closing element can be formed from a light metal alloy, in particular an aluminum alloy. For example, the rheocast component is designed as a sheet metal component, in particular different from a rheocast component.

[0021] A second aspect of the invention relates to a motorcycle having at least one structural element according to the first aspect of the invention. Advantages and advantageous embodiments of the first aspect of the invention are to be regarded as advantages and advantageous embodiments of the second aspect of the invention, and vice versa.

[0022] A third aspect of the invention relates to a method for manufacturing a structural element for a motorcycle, which is also simply referred to as a vehicle or motor vehicle. In the method according to the third aspect of the invention, the structural element is manufactured from a metallic material.

[0023] In order to achieve particularly advantageous mechanical properties and a particularly low weight of the structural element, the third aspect of the invention provides for the structural element to be produced by rheocasting. Advantages and advantageous embodiments of the first aspect and the second aspect of the invention are to be regarded as advantages and advantageous embodiments of the third aspect of the invention, and vice versa.

[0024] Further details of the invention will become apparent from the following description of preferred embodiments with the accompanying drawings. Fig. 1 shows a partial schematic perspective view of a first

[0025] Embodiment of a structural element for a motorcycle designed as a rear wheel swing arm;

[0026] Fig. 2 is a further schematic perspective view of the structural element according to the first embodiment;

[0027] Fig. 3 is a further schematic perspective view of the structural element according to the first embodiment; and

[0028] Fig. 4 is a schematic side view of a second embodiment of the

[0029] structural element.

[0030] In the figures, identical or functionally identical elements are provided with the same reference numerals.

[0031] Fig. 1 shows a detail in a schematic perspective view of a first embodiment of a structural element designed as a rear wheel swing arm 1 for a motorcycle. This means that the motorcycle, in its fully manufactured state, has the rear wheel swing arm 1. The motorcycle, also referred to as a vehicle or motor vehicle, is, for example, a land vehicle designed as a single-track motorcycle, so that the motorcycle preferably has exactly two vehicle wheels. The vehicle wheels of the motorcycle are also simply referred to as wheels and are arranged one behind the other, i.e. one after the other, in the longitudinal direction of the motorcycle. The vehicle wheels are ground contact elements by means of which the motorcycle can be or is supported downwards on a ground in the vertical direction of the motorcycle.If the motorcycle is ridden along the ground while being supported on the ground in the vertical direction of the motorcycle via the ground contact elements, the ground contact elements roll, in particular directly, on the ground. The motorcycle has a frame which is designed separately from the rear swing arm 1 and to which, for example, a drive motor of the motorcycle is connected. The rear swing arm 1 is also simply referred to as a swing arm and is mounted on the frame so as to be pivotable about a pivot axis S relative to the frame. Furthermore, the motorcycle has, for example, a fork which is designed separately from the swing arm and separately from the frame and which is mounted on the frame so as to be pivotable about a steering axis relative to the frame. A first of the vehicle wheels is a front wheel of the motorcycle, the front wheel of which is rotatably held on the fork.A second of the vehicle wheels is a rear wheel of the motorcycle, the rear wheel of which is mounted on the swing arm so as to be rotatable about a wheel rotation axis D shown by way of example in Fig. 1 relative to the swing arm. The rear wheel can swing with the swing arm about the pivot axis S relative to the frame, and the front wheel can be pivoted with the fork about the steering axis relative to the frame. By pivoting the fork and the front wheel relative to the frame and about the steering axis, the front wheel and thus the motorcycle can be steered, whereby cornering, changes of direction, and lane changes of the motorcycle can be effected, particularly while the motorcycle is in motion.

[0032] From Fig. 2 it can be seen that the swing arm has, for example, two through-openings 2, which are in particular aligned with one another and through which an axle passes, for example. In this case, the rear wheel, for example, is rotatably mounted on the axle, so that the rear wheel is rotatable about the wheel rotation axis D relative to the axle and relative to the rear wheel swing arm 1 and is thus mounted on the axle and thus on the rear wheel swing arm 1. The respective through-opening 2 is designed as a respective elongated hole, the longitudinal extent of which runs in the longitudinal direction of the motorcycle. As a result, a distance between the vehicle wheels running in the longitudinal direction of the motorcycle and thus a so-called wheelbase of the motorcycle can be adjusted, i.e. varied.

[0033] In order to achieve a particularly low weight and particularly advantageous mechanical properties of the rear swing arm 1, the rear swing arm 1 has precisely two rheocast components, namely a first rheocast component 3 and a second rheocast component 4. The rheocast components 3 and 4 are formed separately from one another and directly connected to one another, in this case such that the rheocast components 3 and 4 are directly welded to one another. The respective rheocast component 3, 4 is formed from a metallic material. The metallic material is preferably a light metal alloy, in particular an aluminum alloy.In the first embodiment, at least 30 percent of the volume and / or mass of the rear wheel swing arm 1 as a whole is formed by the respective rheocast component 3, 4, so that, for example, the rheocast components 3 and 4 in total, i.e. considered together, form at least 60 percent of the volume and / or mass of the rear wheel swing arm 1 as a whole. In the first embodiment, the respective rheocast component 3, 4 is designed as a respective shell element, also simply referred to as a shell, so that the respective rheocast component 3, 4 is designed as a rheocast shell. The respective shell per se, i.e. considered on its own, has a respective open hollow cross-section H, wherein the rheocast components 3 and 4 are assembled, i.e. connected to one another, in such a way that the hollow cross-sections H of the shells face one another.The rheocast components 3 and 4, when viewed individually, form or delimit a hollow cross-section 5, also referred to as the overall hollow cross-section, which has at least one opening 6 designed as a through-opening, whereby the hollow cross-section 5, when viewed individually, is open on a side SE facing rearward in the longitudinal direction of the motor vehicle and thus rearward in the longitudinal direction of the motorcycle. In the fully manufactured state of the motorcycle, the side SE faces the rear wheel, so that the hollow cross-section 5, when viewed individually, is open toward the rear wheel.

[0034] From Fig. 2 it can be seen that in the first embodiment the hollow cross-section 5 is closed by a closing element 7 which is formed separately from the rheocast components 3 and 4, provided in addition to the rheocast components 3 and 4 and in this case directly connected to the rheocast components 3 and 4. In the first embodiment the closing element 7 is a closing plate, and thus designed as a sheet metal component. In particular the closing element 7 is made of steel or of the aforementioned light metal alloy, in particular an aluminum alloy, or of another light metal alloy, in particular another aluminum alloy, which is different from the aforementioned light metal alloy. In the first embodiment the closing element 7 is designed in several parts, wherein the closing element 7 has, in particular, exactly two closing parts 8 and 9.The locking parts 8 and 9 are formed separately from one another and are connected, in particular directly, to one another, in particular welded to one another. In particular, the locking element 7 is welded, in particular directly, to the rheocast components 3 and 4 and is thereby connected, in particular directly, to the rheocast components 3 and 4. From Figs. 1 and 2 it can be seen that the rheocast components 3 and 4, which are formed as rheocast shells and whose inner sides face one another, are welded, in particular directly, to one another on their inner sides and are thereby connected, in particular directly, to one another and thereby form the hollow cross-section 5 which is open towards the rear wheel and which is at least predominantly and thus at least more than half, in this case completely, closed by the locking element 7. In particular, this makes it possible to achieve high torsional and flexural rigidity of the rear wheel swing arm 1 in a particularly weight-effective manner.Preferably, the rheocast components 3 and 4 are not mirror-symmetrical to each other.

[0035] The rear swing arm 1 has a first bearing point 10, via which the rear swing arm 1 is mounted or pivotable on the frame about the pivot axis S relative to the frame. The bearing point 10 is formed partially by the rheocast component 3 and partially by the rheocast component 4. Furthermore, the rear swing arm 1 has a first connection device 11, which is formed partially by the rheocast component 3 and partially by the rheocast component 4. By means of the connection device 11, a pressure strut 12, which can be seen in Fig. 3 and is formed separately from the rear swing arm 1, is connected to the rear swing arm 1, in particular in an articulated manner, in the present case, for example, in such a way that the pressure strut 12 is mounted on the rear swing arm 1 so as to be rotatable about a rotation axis relative to the rear swing arm 1. For example, the axis of rotation runs parallel to the pivot axis S. Furthermore, the rear wheel swing arm 1 has a4, which is formed, for example, partly by the rheocast component 3 and partly by the rheocast component 4. By means of the connection device 13, a spring and / or damper element 14 of the motorcycle is connected, in particular in an articulated manner, to the rear wheel swing arm 1, in particular in such a way that the spring and / or damper element 14 is mounted on the rear wheel swing arm 1 so as to be rotatable about a second axis of rotation relative to the rear wheel swing arm 1. For example, the axes of rotation run parallel to one another, wherein the axes of rotation are preferably spaced apart from one another. In addition, the second axis of rotation is spaced apart from the pivot axis S and the wheel axis of rotation D, and the first axis of rotation is spaced apart from the pivot axis S and the wheel axis of rotation D.

[0036] In the embodiment shown in Fig. 3, the spring and / or damper element 14 is a spring strut. The rear swing arm 1 is supported on the frame in a spring-loaded and / or damped manner via the spring and / or damper element 14, such that pivoting movements of the rear swing arm 1 and thus of the rear wheel about the pivot axis S and relative to the frame are spring-loaded and / or damped by means of the spring and / or damper element 14. In particular, compressive forces emanating from the rear swing arm 1, for example, can be transmitted to the spring and / or damper element 14 via the pressure strut 12, whereby the spring and / or damper element 14 can be compressed, for example. Fig. 3 shows a section of the aforementioned frame of the motorcycle, designated 15 in Fig. 3.

[0037] From Fig. 1 it can be seen that the respective rheocast component 3, 4, in particular on or on its respective inner side, can have a rib structure 16. In the first embodiment, the rib structure 16 has a plurality of ribs, wherein at least two of the ribs cross each other. In the first embodiment, two first ribs cross each other and two second ribs cross each other, wherein the mutually crossing first ribs are designated 17 and the mutually crossing second ribs are designated 18. The ribs 17 form a first pair of ribs, and the ribs 18 form a second pair of ribs, wherein the rib pairs are arranged successively in the longitudinal direction of the motor vehicle.By means of the ribs 17 and 18 and thus by means of the rib structure 16, the respective Rheoguss component 3, 4 is stiffened, so that a particularly high stiffness of the respective Rheoguss component 3, 4 and thus of the rear wheel swing arm 1 can be ensured in a way that is favorable in terms of weight and installation space.

[0038] Fig. 4 shows a schematic side view of a second embodiment of the rear wheel swing arm 1. Using the example of the rheocast component 3, it can be seen that the second embodiment differs from the first embodiment in particular in that the respective rheocast component 3, 4 has, for example, in particular precisely, a rib 19 on its respective inner side, by means of which the respective rheocast component 3, 4 is stiffened. The rib 19 extends at least substantially in the longitudinal direction of the motorcycle, so that the rib 19 is a longitudinal rib. Overall, it can be seen that the rib 19 or the rib structure 16 is a ribbing or is also referred to as ribbing, wherein the respective rheocast component 3, 4 is stiffened by the respective ribbing. Furthermore, it can be seen that the respective rheocast component 3, 4 is a respective cast shell produced by rheocasting, i.e. by a rheocasting process.This allows advantageously low wall thicknesses of the respective rheocast component 3, 4 to be realized, and particularly advantageous material properties of the respective rheocast component 3, 4 can be realized. List of reference symbols.

[0039] 1 rear swing arm

[0040] 2 passage opening

[0041] 3 Rheocast component

[0042] 4 Rheocast component

[0043] 5 Hollow cross-section

[0044] 6 Opening 7 Closing element

[0045] 8 Locking part

[0046] 9 Locking part 10 Bearing point

[0047] 11 first connection facility

[0048] 12 compression strut 13 second connection device

[0049] 14 Spring and / or damper element

[0050] 15 Frame 16 Rib structure 17 First rib 18 Second rib 19 Rib

[0051] D Wheel rotation axis H Hollow cross section S Swivel axis SE Side

Claims

Patent claims 1. Structural element (1) for a motorcycle, characterized in that the structural element (1) has at least one rheocast component (3) formed from a metallic material.

2. Structural element (1) according to claim 1, characterized in that at least 30% of a volume and / or a mass of the structural element (1) is formed by the rheocast component (3).

3. Structural element (1) according to claim 1 or 2, characterized in that the structural element (1) is designed as a frame (15) for the motorcycle.

4. Structural element (1) according to claim 1 or 2, characterized in that the structural element (1) is designed as a rear wheel swing arm (1) for the motorcycle.

5. Structural element (1) according to one of the preceding claims, characterized in that the rheocast component (3) has at least one rib (17, 18, 19) for stiffening the rheocast component (3).

6. Structural element (1) according to one of the preceding claims, characterized in that the structural element (1) has the rheocast component (3) as the first rheocast component (3) and at least one second rheocast component (4) provided in addition to the first rheocast component (3), formed separately from the first rheocast component (3) and connected to the first rheocast component (3).

7. Structural element (1) according to claim 6, characterized in that the rheocast components (3, 4) are welded and / or glued together and thereby connected to one another.

8. Structural element (1) according to claim 6 or 7, characterized in that the rheocast components (3, 4) have a hollow cross-section (5) with at least one opening (6) which are formed at least predominantly by a closing element formed separately from the rheocast components (3, 4), provided in addition to the rheocast components (3, 4) and connected to the rheocast components (3, 4) (7) is closed.

9. Motorcycle with at least one structural element (1) according to one of the preceding claims.

10. A method for producing a structural element (1) for a motorcycle, in which the structural element (1) is produced from a metallic material, characterized in that the structural element (1) is produced by rheocasting.

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